clutch LAND ROVER DISCOVERY 1995 Service Repair Manual

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Workshop manual
DISCOVERY
This manual covers vehicles from
1995 model year
01 INTRODUCTION
04 GENERAL SPECIFICATION DATA
05 ENGINE TUNING DATA
07 GENERAL FITTING REMINDERS
09 LUBRICANTS, FLUIDS AND CAPACITIES
10 MAINTENANCE
12 ENGINE Tdi
12 ENGINE 3.9 V8
12 ENGINE 4.0 V8
12 ENGINE Mpi
17 EMISSION CONTROL
19 FUEL SYSTEM Tdi
19 FUEL SYSTEM MFI
19 FUEL SYSTEM SFI
19 FUEL SYSTEM Mpi
19 CRUISE CONTROL
26 COOLING SYSTEM Tdi
26 COOLING SYSTEM V8
26 COOLING SYSTEM Mpi
30 MANIFOLD AND EXHAUST SYSTEM
33 CLUTCH
37 MANUAL GEARBOX
41 TRANSFER GEARBOX
44 AUTOMATIC GEARBOX
47 PROPELLER SHAFTS
51 REAR AXLE AND FINAL DRIVE
54 FRONT AXLE AND FINAL DRIVE
57 STEERING
60 FRONT SUSPENSION
64 REAR SUSPENSION
70 BRAKES
74 WHEELS AND TYRES
75 SUPPLEMENTARY RESTRAINT SYSTEM
76 CHASSIS AND BODY
80 HEATING AND VENTILATION
82 AIR CONDITIONING
84 WIPERS AND WASHERS
86 ELECTRICAL
Published by Rover Technical Communication
Ó1996 Rover Group Limited
Publication Part No. LRL 0079 ENG (2nd Edition)

INTRODUCTION
11
INFORMATION CROSS REFERENCE OF EMISSION SYSTEM
TERMINOLOGY
NEW TERM (ACRONYM)
Accelerator pedal (AP).................................................
Air cleaner (ACL)..........................................................
Air conditioning (AC)....................................................
Battery positive voltage (B+)........................................
Closed loop (CL)..........................................................
Closed throttle position (CTP)......................................
Canister purge valve (CANPV)....................................
Data link connector (DLC)...........................................
Diagnostic trouble code (DTC).....................................
Distributor ignition (DI).................................................
Engine control module (ECM)......................................
Engine coolant level (ECL)...........................................
Engine coolant temperature (ECT)..............................
Engine coolant temperature sensor (ECTS)................
Engine speed (RPM)....................................................
Evaporative emission system (EVAP)..........................
Engine fuel temperature sensor (EFTS)......................
4th gear, 3rd gear etc. (4GR, 3GR)..............................
Fuel pump (FP)............................................................
Fan control module (FCM)...........................................
Generator (GEN)..........................................................
Ground (GND)..............................................................
Heated oxygen sensor (H02S)....................................
Idle air control (IAC)......................................................
Idle air control valve (IACV).........................................
Ignition control module (ICM).......................................
Inertia fuel shutoff (IFS)................................................
Inertia fuel shutoff switch (IFSS)..................................
Intake air temperature (IAT).........................................
Malfunction indicator lamp (MIL)..................................
Manifold vacuum zone (MVZ)......................................
Mass air flow sensor (MAFS).......................................
Multiport fuel injection (MFI)........................................
On board diagnostic (OBD)..........................................
Open loop (OL)............................................................
Park/neutral position (PNP).........................................
Park/neutral position switch (PNPS)............................
Programmable read only memory (PROM)..................
Relay module (RM)......................................................
Service reminder indicator (SRI)..................................
Solid state relay module (SSRM).................................
Three way catalytic converter (TWC)..........................
Throttle body (TB)........................................................
Throttle position sensor (TPS)......................................
Torque converter clutch (TCC)....................................
Transmission range (TR)..............................................
Transmission range selector (TRS).............................
Vehicle speed sensor (VSS)........................................
Wide open throttle (WOT)............................................OLD TERM (ACRONYM)
Throttle pedal (-)..........................................................
Air cleaner (-)...............................................................
Air conditioning (AC)....................................................
Battery plus, bat +, bat feed (B+).................................
Closed loop (-).............................................................
Closed throttle, idle position (-)....................................
Charcoal canister purge valve (-).................................
Serial link (-)................................................................
Fault code (-)...............................................................
Electronic ignition (-)....................................................
Electronic control unit (ECU)........................................
Coolant level (-)...........................................................
Coolant temperature (temp).........................................
Coolant temperature thermistor (-)..............................
Engine speed (rev/min)................................................
Evaporative loss system (ELC)...................................
Fuel temperature thermistor (-)....................................
Fourth gear, 3rd gear (-)..............................................
Fuel pump (-)...............................................................
Condenser fan timer (-)................................................
Alternator (-)................................................................
Ground, earth (B-)........................................................
Lambda (02) sensor (-)................................................
Idle speed control (ISC)................................................
Stepper motor (-).........................................................
Ignition module (-)........................................................
Inertia switch (-)...........................................................
Inertia switch (-)...........................................................
Intake temperature/ambient temperature (-)................
EFI warning lamp (-)....................................................
Manifold depression, vacuum (-).................................
Air flow meter (-)..........................................................
Electronic fuel injection (EFI).......................................
Fault code display unit (-)............................................
Open loop (-)...............................................................
Park or neutral (-).........................................................
Start inhibit switch (-)...................................................
Chip, PROM (PROM)...................................................
Relay (-).......................................................................
Check engine light (-)...................................................
Control unit (-)..............................................................
Catalyst, catalytic converter (CAT)..............................
Throttle housing (-)......................................................
Throttle potentiometer (-).............................................
Direct drive clutch (DDC)..............................................
Transmission gear (-)...................................................
Shift lever, shifter (-)....................................................
Road speed transducer (-)...........................................
Full throttle, wide open throttle (WOT).........................

GENERAL SPECIFICATION DATA
9
INFORMATION TRANSMISSION 3.9 V8i
Manual gearbox
Type R380 Single helical constant mesh.......................................................................
Speeds 5 forward 1 reverse all synchromesh.............................................................................
Clutch
Make and type Borg and beck diaphram type..................................................................
Clutch plate diameter 266.5mm........................................................
Automatic gearbox
Type ZF4HP Four speed and reverse with fluid torque converter.....................................................................
Transfer box
Type LT230T Two speed reduction on main gearbox output, front....................................................................
and rear drive permanently engaged via a lockable
differential.
Propeller shafts
Type
Front Tubular 51mm diameter.................................................................................
Front - Catalyst vehicles Solid bar 28.6mm diameter...................................................
Rear Tubular 51mm diameter.................................................................................
Universal joints Open type Hookes O3EHD.................................................................
Rear axle
Type Spiral bevel, fully floating shafts.................................................................................
Ratio 3.54:1.................................................................................
Front axle
Type Spiral bevel, enclosed constant velocity joints, fully.................................................................................
floating shafts
Angularity of universal joint on full lock 32° ............................
Ratio 3.54:1.................................................................................

04GENERAL SPECIFICATION DATA
20
INFORMATION Lubrication
System Wet sump, pressure fed.............................................................................
Pressure, engine warm at normal operating speeds 25 - 55lbf/in
2= 1,76 - 3,87Kgf cm2........
Oil pump:
- Type G-rotor integral with front cover.......................................................................
- Drive off crankshaft nose.....................................................................
Oil pressure relief valve Non-adjustable....................................................
Relief valve spring:
- Full length 51,6mm......................................................................
- Compressed length at 7.71Kg load 31mm................................
Oil filter Screw-on disposable canister.............................................................................
Engine oil cooler Combined with coolant radiator and intercooler...............................................................
FUEL SYSTEM - 300 Tdi
Fuel lift pump type Mechanical with hand primer............................................................
Fuel lift pump pressure 42 - 55 kpa at 1800 rpm.....................................................
Fuel filter Paper element in disposable canister..........................................................................
Air cleaner Paper element type........................................................................
COOLING SYSTEM - 300 Tdi
System type Pressurised, spill return, thermostatically controlled.....................................................................
water and anti freeze mixture. Pump assisted thermo
syphon. Coolant radiator combined with oil cooler and
turbo intercooler.
Cooling fan 11 blade axial flow 433 mm diameter. 1.29:1 drive.......................................................................
ratio. Viscous coupling.
Pump type Centrifugal, impellor, belt driven.........................................................................
Thermostat opening 88° .........................................................
Expansion tank cap pressure 15lbf/in
2= 1,06Kgf cm2(system pressure) ...........................................
CLUTCH - 300 Tdi
Type Valeo diaphragm spring.................................................................................
Centre plate diameter 235 mm.......................................................
Facing material Verto F202 grooved.................................................................
Release bearing Ball journal...............................................................

04GENERAL SPECIFICATION DATA
24
INFORMATION FUEL SYSTEM - Mpi
Electronic fuel injection data
See ENGINE TUNING DATA, Information, Engine............................................
- Mpi - 2.0 Litre
Fuel Pump:
Make/Type A.C. Rochester/Electric immersible.......................................................................
Pump pressure 3.2 bar.................................................................
Delivery at 3 bar pressure & 12V (min) 64 litre/h............................
Regulated pressure range 3.0 ñ 0.2 bar................................................
Fuel pump delivery pressure 2.3 - 2.5 kgf/cm
2............................................
Fuel filter Bosch in-line filter 'canister' type..........................................................................
COOLING SYSTEM - Mpi
Pressure cap 15lbf/in
2(1.03 bar) (system pressure) ....................................................................
Thermostat 88 ÊC.......................................................................
CLUTCH - Mpi
Type Diaphragm spring, hydraulically operated.................................................................................
Adjustment Self adjusting.......................................................................
Clutch plate diameter 215.13 mm.......................................................
TRANSMISSION - Mpi
Manual gearbox
Type R380 Single helical constant mesh.......................................................................
Speeds 5 forward 1 reverse all synchromesh.............................................................................
Transfer box
Type LT230T Two speed reduction on main gearbox output. Front....................................................................
and rear drive permanently engaged via a lockable
differential
Overall ratios (final drive): In high transfer In low transfer
Fifth 4.146:1.................................................................................. 9.761:1
Fourth 4.989:1............................................................................... 11.746:1
Third 7.518:1................................................................................. 17.701:1
Second 11.479:1............................................................................. 27.109:1
First 17.884:1.................................................................................. 42.109:1
Reverse 18.463:1............................................................................ 43.472:1

LUBRICANTS, FLUIDS AND CAPACITIES
3
INFORMATION Propeller shaft Front
and RearNLGI - 2 Multi-purpose Lithium based GREASE
Lubrication nipples
(hubs, ball joints
etc.)
Seat slides
Door lock striker
Brake and clutch
reservoirsBrake fluids having a minimum boiling point of 260°C (500°F) and complying with
FMVSS 116 DOT4
Engine coolant Use an ethylene glycol based anti-freeze (containing no methanol)
V8i, Tdi, Mpi with non-phosphate corrosion inhibitors suitable for use in aluminium engines to ensure
the protection of the cooling system against frost and corrosion in all seasons. Use one
part anti-freeze to one part water for protection down to -36°C (-33°F).
IMPORTANT: Coolant solution must not fall below proportions one part
anti-freeze to three parts water, i.e. minimum 25% anti-freeze in coolant otherwise
damage to engine is liable to occur. Or a maximum of 60%.
Battery lugs, Petroleum jelly.
Earthing surfacesNOTE: Do not use Silicone Grease
where paint has
been removed
Air Conditioning
System Refrigerant Use only refrigerant R134a
Compressor Oil Nippon Denso ND-oil8 Unipart ND-oil8
ABS Sensor Silicone grease: Staborags NBU - Wabco 830 502,0634
bush-rear Wacker chemie 704 - Wabco 830 502,0164
Kluber GL301
LUBRICATION PRACTICE
Use a high quality oil of the correct viscosity range and service classification in the engine during maintenance and
when topping up. The use of oil not to the correct specification can lead to high oil and fuel consumption and
ultimately to damaged components.
Oil to the correct specification contains additives which disperse the corrosive acids formed by combustion and
prevent the formation of sludge which can block the oilways. Additional oil additives should not be used. Always
adhere to the recommended servicing intervals.
WARNING: Many liquids and other substances used in motor vehicles are poisonous. They must
not be consumed and must be kept away from open wounds. These substances, among others,
include anti-freeze windscreen washer additives, lubricants and various adhesives.

MAINTENANCE
1
MAINTENANCE SERVICE SCHEDULE
This section gives information on the range of service
procedures.
Where required, instructions are given for carrying out
each service procedure, or a cross reference is given,
where the procedure can be found in this manual.
Service Schedule sheets are published separately to
reflect the maintenance needs and intervals for each
vehicle variant and model year. The procedures given
must be used in conjunction with the Service
Schedule sheets.
The Service Schedule sheets are available from:-
Land Rover Merchandising
PO Box 534
Erdington
Birmingham B24 0QS.
England.VEHICLE INTERIOR
CHECK SEATS & BELTS
Check condition and security of seats, seat belt
mountings, seat belts, buckles and opertion of inertia
seat belts. Lubricate seat tilt pivots.
CHECK OPERATION OF FOOT BRAKE AND
CLUTCH
If pedal feels 'spongy' bleed system.See BRAKES,
Repair, Brake System Bleed
or.See CLUTCH,
Repair, Bleed hydraulic system
Check all hoses and pipes for security, fractures and
leaks. Fit new hoses and pipes as necessary.
CHECK OPERATION OF LAMPS
Check operation of all lamps, horns and warning
indicators.
CHECK OPERATION OF WIPERS
Check operation of front/rear screen wipers and
washers and condition of wiper blades.
AIR BAG MODULE(S)
Check air bag module covers.
Check visually for signs of damage.
Renew every ten years.

10MAINTENANCE
10
MAINTENANCE
CHECK/TOP UP COOLING SYSTEM
1.To prevent corrosion of aluminium alloy engine
parts it is imperative that cooling system is filled
with a solution of water and phosphate free
anti-freeze, winter or summer. Never fill or top up
with plain water.
WARNING: Do not remove filler cap when
engine is hot because cooling system is
pressurised and personal scalding could
result.
2.When removing filler cap, turn cap slowly
anti-clockwise, pause and allow all pressure to
escape.
3.Continue to turn until cap is removed.
4.When engine is cold expansion tank coolant
should be level with top of indicator post, visible
inside tank through filler hole.
5.If necessary, top up cooling system with
premixed coolant. Use soft water whenever
possible, if local water supply is hard, rainwater
should be used.
6.When replacing filler cap it is important that it is
tightened down fully. Failure to tighten filler cap
properly may result in water loss, with possible
damage to engine
The cooling system should be drained and flushed at
2 year intervals or at onset of second winter. Refer to
Coolant Requirements.
See COOLING SYSTEM,
Adjustment, Coolant RequirementsCHECK/ TOP UP POWER STEERING FLUID
RESERVOIR
1.Remove fluid reservoir cap. Check that fluid is
up to high mark on dipstick.
CHECK/ TOP UP CLUTCH AND BRAKE FLUID
RESERVOIRS
CAUTION: Brake fluid can damage
paintwork. If spillage occurs, wash
affected area IMMEDIATELY with a large
quantity of water.
CHECK/TOP UP WASHER RESERVOIR
Top up washer reservoir to within 25 mm of filler neck.
Use a screen washer solvent/anti-freeze solution to
assist removing mud, flies and road film and protect
against freezing.
LUBRICATE ACCELERATOR AND CRUISE
CONTROL LINKAGES
CHECK/ADJUST IGNITION TIMING - V8i
CATALYST
Check ignition timing.See ENGINE TUNING
DATA, Information, Engine 3.9 V8i

10MAINTENANCE
16
MAINTENANCE
LUBRICATE PROPELLER SHAFT SLIDING , AND
UNIVERSAL JOINTS
1.Clean all grease nipples on front and rear
propeller shafts.
2.Using a low pressure hand grease gun, apply
recommended grease, to grease nipples at front
and rear propeller shaft universal and sliding
joints.
NOTE: The rear propeller shaft flexible
coupling is not fitted with a grease nipple.
CHECK VISUALLY BRAKE, FUEL, CLUTCH
PIPES/UNIONS FOR CHAFING LEAKS AND
CORROSION
CHECK EXHAUST SYSTEM FOR LEAKS,
SECURITY AND DAMAGE
CHECK FOR FLUID LEAKS FROM POWER
STEERING AND SUSPENSION SYSTEMS,
HYDRAULIC PIPES AND UNIONS FOR CHAFING
AND CORROSION
CHECK/TIGHTEN STEERING UNIT AND STEERING
ROD BALL JOINT FIXINGS, CHECK CONDITION
OF OF BALL JOINTS AND DUST COVERS
Ball joints are lubricated for their normal life during
manufacture and require no further lubrication. This
applies ONLY if rubber boot has not been dislodged
or damaged. Joints should be checked at specified
mileage intervals but more frequently if vehicle is used
under arduous conditions.
1.Check for wear in joints by moving ball joint up
and down vigorously. If free movement is
apparent fit a new joint assembly.

10MAINTENANCE
18
MAINTENANCE
ABS VEHICLES - CHECK ROAD WHEEL SPEED
SENSOR ELECTRICAL HARNESS FOR DAMAGE
RENEW OXYGEN SENSORS
See EMISSION CONTROL, Repair, Heated
Oxygen Sensor (HO2S)
RENEW CATALYTIC CONVERTERS
See MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust System Complete
REPORT ANY UNUSUAL FEATURES OF VEHICLE
CONDITION AND ADDITIONAL WORK REQUIREDCARRY OUT ROAD TEST
For details of dynamometer testing.See
INTRODUCTION, Information, Dynamometer
Testing - Non Anti-lock brake vehicles See
INTRODUCTION, Information, Dynamometer
Testing - Vehicles with Anti-lock brakes (ABS)
Check following items:
1.Inhibitor switch only operates in P and N.
2.Engine for excessive noise.
3.Clutch for slip, judder or spin.
4.Automatic gear selection/shift speeds.
5.Gear selection/noise - high/low range.
6.Steering for abnormal noise/effort.
7.Steering for free play.
8.All instruments, gauges and warning indicators.
9.Heater and air conditioning systems.
10.Heated rear screen.
11.Shock absorbers - ride irregularities.
12.Foot brake, on emergency stop, pulling to one
side, binding, pedal effort.
13.Parkbrake efficiency.
14.Seat reclining and latching.
15.Fully extend seat belt, check operation of
retraction and latching. Inertia belts lock when
snatched or vehicle on slope.
16.Road wheel balance.
17.Transmission for vibrations.
18.Body noises, squeaks and rattles.
19.Excessive exhaust smoke.
20.Engine idle speed.
21.Endorse service record.
22.Report any unusual features of vehicle condition
and additional work required.
ENDORSE SERVICE RECORD