bonnet LAND ROVER DISCOVERY 1995 Service Repair Manual

01INTRODUCTION
12
INFORMATION VEHICLE IDENTIFICATION NUMBER (VIN)
The Vehicle Identification Number and the
recommended maximum vehicle weights are stamped
on a plate located under the bonnet [hood] riveted to
the front of the engine compartment.
Vehicle Identification Number Plate (UK, Australia,
R.O.W., Europe)
A.Build date (Australia). Type approval
B.VIN (17 digits)
C.Maximum permitted laden weight for vehicle
D.Maximum vehicle and trailer weight
E.Maximum road weight-front axle
F.Maximum road weight-rear axle
The number is also stamped on the right side of the
chassis forward of the spring mounting turret.
Vehicle Identification Number Plate (Saudi Arabia)
A.Year of manufacture
B.Month of manufacture
C.Maximum vehicle weight
D.Maximum road weight-front axle
E.Maximum road weight-rear axle
F.VIN (17 digits)
The vehicle identification number identifies the
manufacturer, model range, wheel base, body type,
engine, steering, transmission, model year and place
of manufacture. The following example shows the
coding process.
SALWorld manufacturer identifier
LHRange Rover or
LJDiscovery
GClass 100 inch
B2 door
F300 Tdi or
VV8i Petrol
85 speed LHD or
75 speed RHD
M1995 MY
ASolihull site

01INTRODUCTION
16
INFORMATION FAULT DIAGNOSTIC EQUIPMENT
TESTBOOK
Todays Land Rover Vehicles are equipped with a
large amount of electronics to provide the best
performance of the vehicles systems.
Diagnostic equipment named TESTBOOK is available
to expand the diagnostic abilities of the dealer
workshop. This repair manual is produced with
Testbook in mind.
Features of Testbook include :- Fully upgradable
support for the technician. Structured diagnostics to
accommodate all skill levels. Touch screen operation.
Direct print out of screen information and test results.
ELECTRICAL TROUBLESHOOTING MANUAL
The Electrical Troubleshooting Manual is a separate
publication that is intended for use by trained Land
Rover technicians as an aid to diagnosing electrical
concerns.
It provides circuit diagrams, system diagnosis flow
charts, electrical component location tables, electrical
component location views and circuit operation
details.READING THIS MANUAL
This manual is divided into sections shown on the
contents page, alongside a range of icons, familiar to
service technicians.
Relevant information is contained within each of these
sections. These are further divided into the following
sub-sections which appear at the foot of each page :-
Description and operation.
Fault diagnosis.
Adjustment.
Repair.
Overhaul.
Specifications, Torque.
Service tools.
To avoid repeating information through the sections,
where part of the repair operation impacts on another
section, a cross reference is given to direct the reader
to where the information is sited.
For example:
The maintenance section states the need to renew
V8i drive belt. A cross reference sites this information
in: Section: V8i Engine
- Sub-section: Repairs
- Heading: Drive belt renew.
Sections that contain derivatives such as engines are
further separated within that section.
American terminology.
A few words used in this manual differ to words used
in America. Where this occurs the American word is
placed inside brackets. For example: bonnet [hood],
wing [fender], ramp [hoist].

MAINTENANCE
3
MAINTENANCE VEHICLE EXTERIOR
CHECK/ADJUST HEADLAMP ALIGNMENT
Check/adjust headlamp and auxiliary alignment.
CHECK FRONT WHEEL ALIGNMENT
Use recognised wheel alignment equipment to
perform this check and adjustment.
See STEERING,
Adjustment, Front Wheel Alignment
REMOVE WHEELS, CHECK TYRES
Check tyres (including spare) for compliance with
manufacturers' specification.
Check visually for cuts, lumps, bulges, uneven tread
wear and tread depth. Check road wheels for
damage.
Check/adjust tyre pressures.
CHECK/TIGHTEN TOWING BRACKET FITTINGSINSPECT BRAKE PADS FOR WEAR, CALIPERS
FOR LEAKS AND CONDITION
Check thickness of brake pads, fit new pads if
minimum thickness is less than 3,0mm. Check brake
pads for oil contamination. If new brake pads required.
See BRAKES, Repair, Front Brake Pads
or.See BRAKES, Repair, Rear Brake Pads
WARNING: When renewing brake pads, it
is essential that only genuine components
with correct grade of lining are used.
Always fit new pads as complete axle sets, NEVER
individually or as a single wheel set. Serious
consequences could result from out of balance
braking due to mixing of linings.
Refit road wheels
Fit road wheels in original hub position. Secure in
position with wheel nuts, do not fully tighten wheel
nuts at this stage, lower vehicle and finally tighten
wheel nuts to correct torque.
Alloy wheels:
130 Nm.
Steel wheels:130 Nm.
LUBRICATE ALL HINGES, DOOR CHECK
MECHANISMS, BONNET [HOOD] CATCHES AND
FUEL FILLER FLAP

10MAINTENANCE
4
MAINTENANCE UNDER BONNET [HOOD] MAINTENANCE
CHECK COOLING/HEATER SYSTEMS
Check cooling/heater systems for leaks and hoses for
security and condition.
Cooling system hoses should be changed at first
signs of deterioration.
CHECK CONDITION OF ENGINE MOUNTING
RUBBERS
CHECK BRAKE SERVO HOSE FOR SECURITY
AND CONDITION
CHECK FUEL EVAPORATIVE LOSS CONTROL
SYSTEM FOR LEAKS - V8i CATALYST, Mpi
CHECK FUEL FILLER CAP SEAL FOR LEAKS - V8i
- CATALYST, Mpi
CHECK CONDITION OF HEATER PLUG WIRING
FOR FRAYING, CHAFING AND DETERIORATION -
Tdi
CHECK IGNITION WIRING
Check ignition wiring and high tension leads for
fraying, chafing and deterioration.
CLEAN DISTRIBUTOR CAP - V8i
The electronic ignition employs a Lucas 35DLM8
distributor.
Internal operating parts of distributor are pre-set at
factory and do not normally require resetting.
Adjustments should only be made if unit is known to
be faulty or damaged. Distributor maintenance
consists of following items.
1.Clean outer surfaces of distributor cap to remove
dirt, grease etc.
2.Unclip cap, check cap for cracks.
3.Wipe inside cap with lint free cloth.
4.Check rotor arm, cap and flash shield tracking.
DO NOT DISTURB clear plastic insulating
cover (flash shield) which protects magnetic
pick-up module.
LUBRICATE DISTRIBUTOR ROTOR SPINDLE - V8i
Apply a spot of clean engine oil into rotor spindle after
rotor arm has been removed.
CLEAN/ADJUST SPARK PLUGS - V8i CATALYST
RENEW SPARK PLUGS V8i - V8i CATALYST
Clean, adjust and renew
1.Take great care when fitting spark plugs not to
cross-thread plug, otherwise costly damage to
cylinder head will result.

Tdi
3
REPAIR ENGINE
Service repair no - 12.41.01
Remove
CAUTION: Seal all exposed pipe ends
against ingress of dirt after disconnection.
1.Park vehicle on level ground and apply park
brake.
2.Disconnect battery negative lead.
3.Remove bonnet [hood].
See CHASSIS AND
BODY, Repair, Bonnet [Hood]
4.If air conditioning is fitted, remove RH footwell
side trim panel and disconnect harness multiplug
from relay.
5.Disconnect the two engine harness multiplugs
on LH side of footwell.
6.Remove engine harness grommet from
bulkhead and move harness into engine bay.
7.Release battery positive lead from retaining clip
at base of suspension turret.
8.Remove Radiator Assembly.
See COOLING
SYSTEM, Repair, Radiator
9.Discharge air conditioning system.See AIR
CONDITIONING, Adjustment, Refrigerant
Recovery Recycling Recharging
Remove retaining bolts and disconnect both pipe
adaptors from rear of compressor.
10.Remove rocker cover insulation.
11.Disconnect cyclone hose from air cleaner hose.
12.Remove air cleaner hose from turbocharger.
13.Remove feed pipe/hose from turbocharger and
intercooler.
14.Disconnect heater hoses from cylinder head and
heater rails.
15.Remove bolt securing transmission breather
pipe clip to cylinder head; move breather pipes
aside.
16.Disconnect inlet and outlet hoses from power
steering pump.
17.Disconnect bypass hose from thermostat
housing.
18.Release bypass hose from retaining clips on
front timing cover.
19.Remove split pin securing inner throttle cable to
injector pump.
20.Depress tags on outer cable adjusting nut,
remove cable from mounting bracket, and move
aside.
21.If automatic transmission is fitted, release
kickdown cable from injector pump and mounting
bracket.

12ENGINE
20
REPAIR CYLINDER HEAD GASKET
Service repair no - 12.29.02
Remove
1.Disconnect battery negative lead.
2.Remove bonnet [Hood].
See CHASSIS AND
BODY, Repair, Bonnet [Hood]
3.Drain coolant.
4.Remove air cleaner assembly.
See FUEL
SYSTEM, Repair, Air Cleaner
5.Detach crankcase ventilation valve and side
breather hose from rocker cover and move to
one side.
6.Remove injection pipes.
7.Disconnect spill rail from fuel injectors.
8.Remove fuel injectors and sealing washers.
Identify each injector to the location from which it
is removed.
See FUEL SYSTEM, Repair,
Injectors
9.Remove inter-connecting harness from glow
plugs.
10.Remove glow plugs.
See FUEL SYSTEM,
Repair, Glow Plugs
11.Remove top hose, radiator to thermostat.
12.Disconnect by-pass hose from thermostat.
13.Disconnect hose, thermostat to water pump.
14.Disconnect water temperature sensor lead.
15.Remove hose inter-cooler to induction manifold.
16.Remove induction manifold.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
Manifold - Tdi
17.Remove exhaust manifold and turbocharger
assembly.
See MANIFOLD AND EXHAUST
SYSTEM, Repair, Exhaust Manifold - Tdi
18.Disconnect heater hose from water pump and
move heater rail aside.
19.Disconnect heater hose from rear of cylinder
head.
20.Remove bolt securing air cleaner mounting
bracket to support strut.
21.Remove bolt securing harness bracket to
cylinder head.
22.Remove rear lifting bracket, this will also release
clips securing transmission and engine breather
pipes and multiplug. Note loose spacer under
clip securing engine breather pipe and multiplug.

12ENGINE
12
REPAIR
12.Ensure service tools LRT-12-010 and
LRT-12-091 are scrupulously clean. Coat seal
guide and oil seal journal with clean engine oil.
CAUTION: Do not handle oilseal lip, check
it is not damaged. Ensure outside diameter
remains clean and dry.
13.Position oil seal guide LRT-12-010 on crankshaft
flange.
NOTE: Lubricant coating must cover seal
guide outer surface completely to ensure
that oil seal lip is not turned back during
assembly. Position oil seal, lipped side towards
engine, on seal guide. Seal outside diameter
MUST be clean and dry.
14.Fit oil seal using tool LRT-12-091. Remove seal
guide.
15.Tighten rear main bearing cap to
90 Nm.
16.Fit sump.
17.Fit flywheel or flexible drive plate and ring gear.ENGINE
Service repair no - 12.41.01
Remove
1.Park vehicle on level ground and apply park
brake.
2.De-pressurise fuel system.
See FUEL
SYSTEM, Repair, Depressurising Fuel
System
3.Remove bonnet [hood].See CHASSIS AND
BODY, Repair, Bonnet [Hood]
4.Remove battery.See ELECTRICAL, Repair,
Battery
5.Remove radiator/oil coolers.See COOLING
SYSTEM, Repair, Radiator/Oil Coolers
6.Place an absorbent cloth around fuel feed hose
at fuel rail and release compression nut.
Remove feed hose from rail, seal end of pipes
with masking tape to prevent ingress of dirt.
7.Release fuel return hose clamp and remove
hose from pressure regulator, seal both
openings with masking tape to prevent ingress of
dirt.
8.Remove vacuum hose from rear of regulator.
9.Manual vehicles: Disconnect throttle cable from
bracket. Automatic vehicles: Detach throttle
bracket from plenum chamber and lay assembly
to one side.
See FUEL SYSTEM, Repair,
Plenum Chamber DO NOT DISTURB KICK
DOWN CABLE SETTING.
10.Remove ram housing.See FUEL SYSTEM,
Repair, Ram Housing
11.Remove air flow sensor.See FUEL SYSTEM,
Repair, Air Flow Sensor
12.Remove air cleaner assembly.See FUEL
SYSTEM, Repair, Air Cleaner Assembly
13.Remove Generator.See ELECTRICAL,
Description and operation, Generator
14.Release air conditioning compressor from its
mounting and lay to one side. DO NOT
discharge air conditioning system.
See AIR
CONDITIONING, Repair, Compressor

4.0 V8
3
REPAIR ENGINE ASSEMBLY
Service repair no - 12.41.01/99
Remove
1.Position vehicle on ramp.
2.Remove bonnet.
See CHASSIS AND BODY,Repair, Bonnet [Hood]
3.Remove radiator.See COOLING SYSTEM,
Repair, Radiator
4.Remove plenum chamber.See FUEL SYSTEM
SFI, Repair, Plenum Chamber
5.Remove mass air flow sensor.See FUEL
SYSTEM SFI, Repair, Mass Air Flow Sensor
(MAF Sensor)
6.Slacken hose clip securing bottom hose to
expansion tank.
7.Disconnect hose.
8.Remove 2 nuts securing expansion tank.
9.Remove nut and bolt securing expansion tank.
10.Remove expansion tank.
11.Disconnect servo vacuum hose from ram
housing.
12.Disconnect battery sensing lead Lucar from
generator.
13.Remove generator terminal cover.
14.Remove 2 terminal nuts and release leads from
terminals.
15.Release purge hose from ram pipe housing.
16.Position cloth to absorb fuel spillage.
17.Slacken clip securing fuel return hose to fuel rail.
18.Disconnect hose.
19.Plug connections.
20.Disconnect fuel feed hose union.
21.Plug connections. Position hoses aside.
22.Slacken clip securing heater return hose to pipe.
23.Disconnect hose.24.Slacken clip securing heater feed adaptor hose
to inlet manifold.
25.Remove bolt securing pipe bracket.
26.Disconnect feed hose from inlet manifold.
27.Disconnect hose/pipe assembly.
28.Disconnect leads from spark plugs and remove
ignition coils.
See FUEL SYSTEM SFI, Repair,
Ignition Coils
29.Disconnect fuel temperature sensor multiplug.
30.Disconnect coolant sensor multiplug.
31.Disconnect temperature gauge sensor lead.
32.Release camshaft sensor multiplug from bracket
and disconnect multiplug.
33.Disconnect oil pressure switch Lucar.
34.Disconnect air intake temperature sensor
multiplug.
35.Disconnect 8 injector multiplugs.
36.Remove 4 nuts securing harness brackets to
inlet manifold.
37.Release harness brackets.
38.Remove bolts securing gearbox breather pipes
to engine lifting bracket.

4.0 V8
7
REPAIR 171.Route drive belt around pulleys.
172.Pivot tensioner downwards.
173.Align belt to tensioner and release tensioner.
174.Connect battery positive lead and tighten.
175.Secure terminal cover.
176.Align gearbox breather pipe, clip to engine lifting
eye and fit bolt. Tighten to
9 Nm.
177.Align and secure engine harness brackets to
inlet manifold and fit nuts. Tighten to
9 Nm.
178.Connect injector multiplugs.
179.Connect air intake temperature sensor multiplug.
180.Connect fuel temperature sensor multiplug.
181.Connect coolant temperature multiplug.
182.Connect temperature gauge connector.
183.Connect oil pressure switch Lucar.
184.Connect camshaft sensor multiplug and secure
to bracket.
185.Fit ignition coil bracket.
See FUEL SYSTEM
SFI, Repair, Ignition Coils
186.Position heater hose/pipe assembly.
187.Connect hose to inlet manifold.
188.Align pipe to bracket and fit bolt. Tighten to
9
Nm.
189.Tighten hose clip.
190.Connect heater return hose and tighten clip.
191.Remove plugs from fuel feed and return hose
connections.
192.Clean feed unions.
193.Connect return hose and tighten clip.
194.Connect feed hose union and tighten.
195.Remove cloth.
196.Connect purge hose.
197.Connect leads to generator, tighten terminal nuts
and fit cover.
198.Connect sensing Lucar.
199.Connect servo vacuum hose.
200.Position expansion tank and secure with fixings.
201.Connect hose and tighten clip.
202.Lower ramp.
203.Fit mass air flow sensor.
See FUEL SYSTEM
SFI, Repair, Mass Air Flow Sensor (MAF
Sensor)
204.Fit plenum chamber.See FUEL SYSTEM SFI,
Repair, Plenum Chamber
205.Fit radiator.See COOLING SYSTEM, Repair,
Radiator
206.Fit bonnet.See CHASSIS AND BODY, Repair,
Bonnet [Hood]
207.Reconnect battery negative lead.
208.Bleed power steering system.
See STEERING,
Repair, Power Steering System - Bleed
209.Drain engine oil and refill.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids - USA
Vehicles
210.Start engine. Check for fuel, coolant and oil
leaks.FRONT COVER GASKET
Service repair no - 12.65.04 - Front Cover Gasket
Remove
1.Disconnect battery negative lead.
2.Drain cooling system.
See COOLING SYSTEM
V8, Adjustment, Coolant
3.Remove radiatorSee COOLING SYSTEM,
Repair, Radiator
4.Remove water pump pulley.See COOLING
SYSTEM, Repair, Viscous Coupling, Fan
Blades, Pulley and Fan Cowl
5.Slacken bottom hose clip. Remove hose from
water pump.
6.Raise vehicle on ramp.
7.Disconnect oil cooler hoses from front cover and
position aside. Plug hoses and connections.
8.Disconnect Lucar from oil pressure switch.

Mpi
1
REPAIR CAMSHAFT FRONT OIL SEAL
Service repair no - 12.13.07 - Exhaust
Service repair no - 12.13.09 - Inlet
Remove
1.Disconnect battery negative lead.
2.Remove drive belt.
See SECTION 10,
Maintenance, Under Bonnet [Hood]
Maintenance
3.Remove 5 bolts, timing belt upper cover.
4.Remove timing belt upper cover.
5.Remove 5 bolts, timing belt centre cover.
6.Remove timing belt centre cover.
7.Rotate crankshaft to align camshaft gear timing
marks - 90°B.T.D.C.
8.Fit tool LRT-12-058 to lock flywheel.
9.Fit tool LRT-12-060 to lock camshaft gears.
10.Loosen camshaft belt tensioner bolt.
11.Move tensioner away from belt and tighten
tensioner bolt.
12.Remove belt from camshaft gears.