ECU LAND ROVER DISCOVERY 1995 Service Manual PDF

EMISSION CONTROL
5
REPAIR Rear sensors
9.Release sensor cable from clips.
10.Release multiplug from bracket and disconnect.
11.Unscrew and remove sensor from exhaust pipe
using special tool LRT-12-047 (LST134).Refit
12.Ensure mating faces are clean.
NOTE: New HO2S is supplied pre-treated
with anti-seize compound.
13.If refitting existing HO2S, coat threads with
anti-seize compound.
CAUTION: Do not allow anti-seize
compound to come into contact with HO2S
nose or enter exhaust system.
14.Position HO2S with new sealing washer on
exhaust pipe. Tighten to
20 Nmusing special
tool LRT-12-047 (not RH front sensor).
15.Reconnect multiplug to engine harness and
secure to bracket.
16. RH front sensor only:
Place coil bracket in position and fit nuts. Tighten
to
8 Nm.
CAUTION: Ensure sensor leads are
secured using clips provided. Failure to
correctly secure leads could result in
damage to HO2S.
17.Remove stands. Lower vehicle.

17EMISSION CONTROL
6
REPAIR CATALYTIC CONVERTER/FRONT PIPE - 4.0 V8
Service repair no - 17.50.09
WARNING: The removal of the exhaust
system must only be carried out when the
engine is cold.
Remove
1.Disconnect battery negative lead.
2.Raise vehicle on ramp.
3.Remove oxygen sensors
See Heated Oxygen
Sensor (HO2S) - 4.0 V8
4.Remove 4 nuts/bolts securing front anti-roll bar
brackets.
5.Remove 6 nuts securing front pipe flanges to
manifolds.
6.Remove 2 nuts securing front pipe to
intermediate pipe.
7.With assistance, release front pipe from manifold
flanges.8.With assistance, release front pipe from
intermediate pipe.
9.With assistance, lower anti-roll bar.
10.With assistance, remove exhaust front pipe.
11.Remove flange gaskets and discard.
Refit
12.Reverse removal procedure.

17EMISSION CONTROL
8
REPAIRADD: 09/95 EVAP CANISTER - ADVANCED EVAPS
Service repair no - 17.15.13
Remove
1.Disconnect battery negative lead.
2.Release clip securing vent solenoid hose to
canister and disconnect hose.
3.Release vent and purge line quickfit connections
from canister.
4.Remove nut and bolt securing canister to
mounting bracket, collect fixture clamp.
5.Remove canister.
Refit
6.Fit canister to mounting bracket.
7.Position fixture clamp and secure canister to
mounting bracket with nut and bolt.
8.Connect vent and purge line quickfit connections
to canister.
9.Connect vent solenoid hose to canister and
secure with clip.
10.Reconnect battery negative lead.EVAP CANISTER PURGE VALVE - ADVANCED
EVAPS
Service repair no - 17.15.39
Remove
1.Disconnect battery negative lead.
2.Disconnect multiplug from purge valve.
3.Release purge valve rubber mounting from
bracket.
4.Release quickfit hose connections from throttle
body plenum and EVAP canister.
5.Remove purge valve assembly.
Refit
6.Locate purge valve adjacent to bracket.
7.Connect quickfit hose connections to throttle
body plenum and EVAP canister.
8.Conmnect multiplug to purge valve and secure
purge valve rubber mounting to bracket.
9.Reconnect battery negative lead.

EMISSION CONTROL
9
REPAIR ADD: 09/95 EVAP CANISTER VENT SOLENOID - ADVANCED
EVAPS
Service repair no - 17.15.43
Remove
1.Disconnect battery negative lead.
2.Release clip securing hose to vent solenoid and
disconnect hose.
3.Disconnect multiplug from vent solenoid.
4.Remove vent solenoid from mounting bracket.
Refit
5.Fit vent solenoid to mounting bracket.
6.Connect multiplug to vent solenoid.
7.Connect hose to vent solenoid and secure with
clip.
8.Reconnect battery negative lead.

Tdi
1
ADJUSTMENT THROTTLE CABLE
Adjust
1.Loosen throttle cable adjustment ferrule.
2.Hold throttle lever in fully closed position.
3.Adjust outer cable, by rotating ferrule, to give
1.57 mm (0.062 in) of free play in the inner
cable.
4.Check that throttle opens fully when the throttle
is depressed.EGR THROTTLE POSITION SENSOR
Check
1.Run engine until normal operating temperature is
reached.
2.Switch off engine and disconnect sensor
multiplug.
3.Connect an Ohmmeter across pins 1 and 3 of
multiplug. Ohmmeter should read between 1K
and 1.05K ohms.
4.Connect an Ohmmeter across pins 1 and 2 of
multiplug. Ohmmeter should read between 850
and 900 ohms.
5.If the readings are correct, EGR throttle position
sensor is Ok - reconnect multiplug.
6.Loosen 2 Torx screws securing sensor.
7.Rotate sensor to achieve correct Ohmmeter
readings, then tighten Torx screws.
8.Re-check Ohmmeter readings, then reconnect
multiplug.

Tdi
1
REPAIR TANK SENDER UNIT
Service repair no - 88.25.32
WARNING: Ensure that the WARNINGS
and FUEL HANDLING PRECAUTIONS
given in Section 01 are adhered to before
carrying out the following operations.
Special tool - LST131
Remove
1.Disconnect battery negative lead.
2.Remove the rear carpet retainer.
3.Ease the carpet from under the lower trim panels
at the rear of the fold down seats.
4.Raise the carpet to expose the sound insulation.
5.Fold back the sound insulation to reveal the
access panel.
6.Remove the securing screws and detach the
access panel from the floor.
7.Disconnect the multi-plug from sender unit.8.Disconnect the fuel pipes from the sender unit.
9.Using special tool LST131 remove the locking
ring and withdraw the sender unit from the fuel
tank.
Refit
10.Fit the sender unit to the fuel tank and secure
with the locking ring. Tighten to
45to50 Nm.
11.Connect the fuel pipes to the sender unit.
12.Connect multi-plug to sender unit.
13.Inspect the access panel seal to ensure that it is
satisfactory for further use, renew as necessary.
14.Fit the access panel to the aperture in the floor
and secure with the screws.
15.Reverse removal procedure. 1 to 5. Refit the
sound insulation and carpet.

19FUEL SYSTEM
2
REPAIR THROTTLE CABLE
Service repair no - 19.20.06
Remove
1.Disconnect battery negative lead.
2.Remove pin and clevis pin securing throttle
cable to throttle lever.
3.Pull ferrule from abutment bracket and withdraw
throttle cable.
4.Release throttle cable from clip on bulkhead.
5.Remove pin and clevis pin securing throttle
cable to throttle lever.
6.Release grommet from bulkhead.
7.Withdraw throttle cable from engine
compartment.
Refit
8.Reverse removal procedure. Use new pins to
secure clevis pins.
9.Adjust throttle cable.
See Adjustment,
Throttle Cable
INTAKE HOSE TURBOCHARGER
Service repair no - 19.42.11
Remove
1.Disconnect battery negative lead.
2.Loosen clip and disconnect intake hose from
turbocharger.
3.Loosen clip and disconnect breather hose from
intake hose.
4.Remove clip and disconnect hose from air
cleaner, discard clip.
5.Remove intake hose
Refit
6.Reverse removal procedure. Use a new clip to
secure intake hose to air cleaner.

Tdi
3
REPAIR TURBOCHARGER OIL FEED PIPE
Service repair no - 19.42.14
Remove
1.Disconnect battery negative lead.
2.Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Manifold
and Exhaust System - Tdi
3.Remove banjo bolt securing oil feed pipe to
turbocharger, discard 2 sealing washers.
4.Unscrew union, disconnect oil feed pipe from
cylinder block.
CAUTION: Plug the connections.
5.Move oil feed pipe from behind turbocharger and
remove.
Refit
6.Reverse removal procedure. use new sealing
washers.
7.Tighten banjo bolt to
20 Nm.
8.Check/top-up engine oil level.TURBOCHARGER OIL DRAIN PIPE
Service repair no - 19.42.12
Remove
1.Disconnect battery negative lead.
2.Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Manifold
and Exhaust System - Tdi
3.Unscrew union and disconnect oil drain pipe
from cylinder lock.
4.Remove 2 bolts securing oil drain pipe to
turbocharger.
5.Remove oil drain pipe, remove and discard
gasket.
CAUTION: Plug the connection.
Refit
6.Ensure mating surfaces of oil pipe, turbocharger
and engine block are clean.
7.Reverse removal procedure. Use a new gasket.
8.Tighten oil drain pipe to turbocharger bolts to
25
Nm.
9.Check/top-up engine oil level.

19FUEL SYSTEM
4
REPAIR TURBOCHARGER ACTUATOR
Service repair no - 19.42.31
Remove
1.Remove exhaust manifold and turbocharger.
See MANIFOLD AND EXHAUST SYSTEM,
Repair, Exhaust Manifold - Tdi
2.Remove 2 nuts securing the actuator to the
turbocharger bracket.
3.Release clip and disconnect hose from actuator.
4.Remove and discard clip securing control lever
to wastegate spindle.
5.Remove turbocharger actuator.
Refit
6.Fit the replacement actuator and secure with
nuts.
7.Push the control lever as far as possible towards
the actuator and apply pressure to keep the
lever in this position.
8.Pressurise the actuator to 57 - 62 cm Hg and
hold this pressure.
CAUTION: Use only the threaded end of
the lever to make adjustments. Forcing the
complete lever in or out will change the
calibration with the possibility of damaging engine
boost.
9.Screw the lever in either direction until the eye
on the end will locate easily over the wastegate
spindle and secure with a new clip.
10.Release the pressure and tighten the locknut.
11.Refit exhaust manifold and turbocharger.
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust Manifold - Tdi
TURBOCHARGER AND GASKET
Service repair no - Turbocharger - 19.42.01
Service repair no - Gasket - 19.42.25
Remove
1.Disconnect battery negative lead.
2.Remove air cleaner assembly.
See Air Cleaner
3.Remove exhaust manifold assembly.See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust Manifold - Tdi
4.Remove and discard clip securing control lever
to wastegate spindle.
5.Remove 4 bolts and 2 clamp plates securing
turbocharger to exhaust manifold.
6.Remove turbocharger and discard gaskets.
Refit
7.Clean mating faces of turbocharger and exhaust
manifold.
8.Reverse removal procedure. Use new clip to
secure control lever to wastegate spindle.
Tighten to
45 Nm.
9.Check/top-up engine oil level.

Tdi
5
REPAIR FUEL LIFT PUMP
Service repair no - 19.45.09
Remove
1.Loosen unions securing fuel injection pipes to
injectors and injector pump. Remove injection
pipes.
2.Plug the connections to prevent the ingress of
foreign material.
3.Loosen unions and disconnect fuel supply and
feed hoses from fuel lift pump.
4.Plug the connections to prevent the ingress of
foreign material.
5.Remove 2 bolts securing lift pump to engine
block.
6.Remove fuel lift pump and discard gasket.Refit
7.Clean mating faces of fuel lift pump and engine
block.
8.Using a new gasket, fit fuel pump, ensure correct
location of lever with camshaft. Fit securing
bolts. Tighten to
25 Nm.
9.Connect fuel hoses to pump and secure unions.
Tighten to
33 Nm.
10.Fit injector pipes to injectors and injection pump,
and secure unions. Tighten to
28 Nm.