ECU LAND ROVER DISCOVERY 1995 Service Repair Manual

ELECTRICAL
49
REPAIR Refit
8.Fit bulb to lens.
9.Secure bulb retaining clip.
10.Connect 2 Lucars to bulb.
11.Position lamp lens to shroud.
12.Position lamp to bracket and secure fog lamp
adjustment ball joint to bracket.
13.Position spacers, align lamp to bracket and
secure with Torx screws.
14.Fit front fog lamp.
See fog lamp - front; Refit
CLOCK
Service repair no - 88.15.07
Remove
1.Remove drinks tray.
See CHASSIS AND
BODY, Repair, drinks tray
2.Release 4 clock panel securing tags.
3.Release clock panel from louvre panel.
4.Disconnect 2 multiplugs from clock.
5.Remove clock.
Refit
6.Position clock.
7.Connect multiplugs to clock and secure clock to
louvre panel.
8.Fit drinks tray.
See CHASSIS AND BODY,
Repair, drinks tray; Refit
REAR SPEAKER
Service repair no - 88.15.12
Remove
1.Remove 4 screws securing speaker.
2.Release speaker and disconnect 2 Lucars.
3.Remove speaker.
Refit
4.Position speaker, connect Lucars and secure
with screws.

86ELECTRICAL
50
REPAIR DIGITAL DIESEL SHUT-OFF VALVE (DDS) - 97 MY
Service repair no - 86.77.00
Remove
1.Remove fuel injection pump.
See FUEL
SYSTEM, Repair, fuel injection pump and
timing
2.Drill into 2 break-off screws to a depth of
approximately 5 mm using a 3.2 mm drill.
CAUTION: Use a drill bushing to guide the
drill during the above.
3.Using an 'Easy-out' remove 2 valve retaining
screws and discard.
4.Release DDS valve from fuel shut-off solenoid.
5.Remove protective cap from fuel shut-off
solenoid electrical connection.
6.Remove fuel shut-off solenoid terminal nut and
remove DDS valve.
Refit
7.Position DDS terminal lead to fuel shut-off
solenoid and secure with nut tightened to
2Nm.
8.Position DDS valve to fuel shut-off solenoid .
9.Position clamping plate to DDS valve and tighten
shear bolts simultaneously until heads shear.
10.Fit fuel injection pump.
See FUEL SYSTEM,
Repair, fuel injection pump and timing; Refit
ANTENNA AMPLIFIER - 97 MY
Service repair no - 86.50.29
Remove
1.Remove RH alpine light trim casing.
See
CHASSIS AND BODY, Repair, alpine light
trim casing
2.Release amplifier to sixth light connector and
seal finisher.
3.Remove screw securing amplifier to body and
release from location.
4.Disconnect co-axial cable from amplifier.
5.Disconnect Lucar from amplifier.
6.Remove amplifier.
Refit
7.Fit amplifier, connect co-axial cable and Lucar to
amplifier.
8.Position amplifier to location and secure with
screw.
9.Secure amplifier lead through seal finisher and
connect to sixth light.
10.Fit RH alpine light trim casing.
See CHASSIS
AND BODY, Repair, alpine light trim casing;
Refit

ELECTRICAL
1
OVERHAUL DISTRIBUTOR-LUCAS 35DLM8
Overhaul
DISTRIBUTOR CAP
Service repair no - 86.35.10
1.Unclip and remove cap
2.Fit a new cap if faulty.
3.Clean cap and HT brush with a lint free cloth.
ROTOR ARM
Service repair no - 86.35.16
1.Pull rotor arm from shaft.
2.Fit a new rotor arm if faulty.
INSULATION COVER (FLASH SHIELD)
Service repair no - 86.35.40
1.Remove cover secured by three screws.
2.Fit a new cover if faulty.
VACUUM UNIT
Service repair no - 86.35.21
1.Remove two screws from vacuum unit securing
bracket. Disengage vacuum unit connecting rod
from pick-up base plate connecting peg.
Withdraw vacuum unit from distributor body.AMPLIFIER MODULE
Service repair no - 86.35.30
1.Remove two screws and withdraw module.
2.Remove gasket.
3.Remove two screws and cast heatsink.
WARNING: Amplifier module is a sealed
unit containing Beryllia. This substance is
extremely dangerous if handled. DO NOT
attempt to open or crush module.
PICK-UP AND BASE PLATE ASSEMBLY
Service repair no - 86.35.42
1.Use circlip pliers to remove circlip retaining
reluctor on rotor shaft.
2.Remove flat washer, and 'O' ring recessed in top
of reluctor.
3.Gently withdraw reluctor from shaft, taking care
not to damage teeth.
NOTE: Coupling ring fitted beneath
reluctor.
4.Remove three support pillars and cable
grommet. Lift out pick-up and base plate
assembly.
NOTE: Do not disturb two barrel nuts
securing pick-up module, otherwise air
gap will need re-adjustment.
5.Fit a new pick-up and base plate assembly if
module is known to be faulty, otherwise check
pick-up winding resistance (2k-5k ohm).
Reassemble
6.This is mainly a reversal of dismantling
procedure, noting following points:

ENGINE
DESCRIPTION AND OPERATION15
OPERATION
The 300 TDi is a 4 cylinder, water cooled,
turbocharged diesel engine with a capacity of 2.5
litres.
The cast iron cylinder block is integral with the
crankcase and incorporates direct bored cylinders.
The crankshaft is carried in 5 main bearings,
end-float being controlled by thrust washers which
are positioned on both sides of the centre main
bearing.
The flywheel/drive plate housing is an aluminium
alloy casting secured to the rear of the cylinder
block, it also forms the mounting for the starter
motor. A plugged aperture in the housing allows
access for the insertion of the timing pin.
The aluminium alloy cylinder head carries a
conventional rocker shaft and rockers, operating 2
valves per cylinder via camshaft followers and push
rods from a single camshaft, supported in the
cylinder block by 4 bearings and driven by a gear
and toothed belt from the crankshaft. A lobe formed
between the 2 inner bearing journals provides drive
for the fuel lift pump and another lobe, between the 2
drive end journals provides drive for the brake servo
pump. Camshaft end-float is controlled by a thrust
plate bolted to the cylinder block.
Graphite coated, aluminium alloy pistons are fitted
with 2 compression and an oil control ring and are
secured to the connecting rods by semi-floating
gudgeon pins which are an interference fit in the
small end bush. A swirl chamber is incorporated in
the piston crown to facilitate combustion.
The timing case consists of cast aluminium alloy
front and rear covers which house the oil pump,
crankshaft and camshaft front oil seals and which
also carry the fuel injection pump and drive belt idler
pulley. Housed within the timing case housing is the
crankshaft gear which provides drive for the
camshaft and fuel injection pump gears via a rubber
toothed belt.

ENGINE
OVERHAUL1
TIMING BELT, TENSIONER AND GEARS
Timing belt - remove
1.Position toolLRT-12-080to crankshaft pulley,
retain with 4 bolts.
2.Restrain crankshaft using toolLRT-12-080
and remove crankshaft pulley flange head bolt.
NOTE: Bolt and washer fitted to early
engines.
3.Remove toolLRT-12-080 .
4.Position toolLRT-12-049and thrust button,
part of toolLRT-12-031to crankshaft pulley,
remove pulley, recover Woodruff key.
5.Using sequence shown, progressively slacken
then remove 14 bolts securing timing belt front
cover.

ENGINE
OVERHAUL3
All engines
13.Check that timing mark on camshaft pulley is
aligned with mark on timing belt rear cover and
the crankshaft Woodruff key is aligned with the
arrow cast on the rear cover.
14.Remove crankshaft pulley bolt.
15.Insert timing pinLRT-12-045into fuel injection
pump gear hub plate and injection pump hub.
16.Slacken but do not remove centre bolt securing
camshaft drive gear to camshaft.
17.If timing belt is to be refitted, mark direction of
rotation on outside surface of belt with chalk or
similar soft material.
18.Slacken but do not remove bolt securing timing
belt tensioner pulley, move pulley until tension
is removed from belt.
19.Remove nut and washer securing idler pulley.
20.Release idler pulley from timing belt, remove
pulley.
21.Release timing belt from gears, discard belt.

ENGINE
4
OVERHAUL Timing belt tensioner and timing gears - remove
1.Remove crankshaft gear using tools
LRT-12-031andLRT-12-078,recover
Woodruff key from crankshaft.
2.Remove and discard 'O' ring.
3.Remove bolt and slotted washer securing
timing belt tensioner pulley, remove pulley
together with tensioner bracket.
4.Recover flanged spacer from idler pulley stud.
5.Remove centre bolt and washer securing
camshaft timing gear, remove gear and hub
plate as an assembly.
NOTE: Later engines are fitted with a
flange head bolt.
CAUTION: Do not remove 3 bolts securing
hub plate to gear.

ENGINE
OVERHAUL5
6.Remove 3 bolts securing fuel injection pump
gear and hub plate to pump hub.
CAUTION: Do not remove nut securing
hub to fuel injection pump.
7.Remove timing pinLRT-12-045.
8.Remove fuel injection pump gear and hub
plate.Inspecting components
1.Check timing gear teeth for burrs.
2.Remove all traces of gasket from timing belt
front and rear covers using suitable gasket
removal spray and a plastic scraper.

ENGINE
OVERHAUL9
5.Check that timing pinLRT-12-045moves
freely in and out of injection pump hub, if pin
does not move freely, slacken 3 bolts, move
gear slightly and re-check.
6.When timing pin moves freely, tighten 3 bolts
to 25 Nm.
7.Remove timing pinLRT-12-045and
flywheel/drive plate locking toolLRT-12-044.
8.Rotate crankshaft twice in a clockwise direction
using crankshaft pulley bolt until flywheel/drive
plate locking toolLRT-12-044can be refitted.
9.Slacken timing belt tensioner securing bolt and
re-tension timing belt.
10.Tighten tensioner bolt to 45 Nm.
11.Fit timing pinLRT-12-045into fuel injection
pump gear hub plate and pump hub. If timing
pin cannot be inserted, slacken injection pump
gear bolts, rotate pump shaft using shaft nut
until pin slides easily into pump hub, Tighten
bolts to 25 Nm.
12.Tighten camshaft gear bolt to 80 Nm.
13.Remove timing pin and flywheel/drive plate
locking tools.
14.Fit plug to flywheel housing, tighten to 12 Nm.
15.Remove crankshaft pulley bolt.
16.Support timing belt front cover on suitable
blocks of wood.
17.Smear a new crankshaft oil seal with engine
oil.
18.Using toolLRT-12-077,fit oil seal from inside
face of front cover.
19.Fit a dry, new gasket to timing belt rear cover.
20.Position timing belt front cover to rear cover.
21.Fit bolts of the correct length in positions
shown.

ENGINE
OVERHAUL11
ROCKER SHAFT
Remove
1.Disconnect breather hoses from crankcase
breather cyclone unit.
2.Remove bolt securing cyclone unit to rocker
cover.
3.Remove cyclone unit, remove and discard 'O'
ring.
4.Disconnect breather hoses from cylinder block
and rocker cover.
5.Remove 3 flange nuts securing rocker cover,
recover sealing washers.
6.Remove rocker cover, remove and discard
gasket.
7.Slacken locknut on each tappet adjusting
screw, slacken adjusting screws until they are
clear of push rods.
8.Working from the centre outwards,
progressively slacken then remove 3 nuts and
2 bolts securing rocker shaft pedestals to
cylinder head.
CAUTION: Insert a slave bolt into
pedestals 1 and 5 to prevent components
sliding off shaft.
9.Remove rocker shaft assembly.