height LAND ROVER DISCOVERY 1995 Service Repair Manual

04GENERAL SPECIFICATION DATA
18
INFORMATION 300 Tdi ENGINE
Type Direct injection, turbocharged, intercooled.................................................................................
Number of cylinders 4.........................................................
Bore 90,47 mm.................................................................................
Stroke 97,00 mm...............................................................................
Capacity 2495 cc...........................................................................
Compression ratio 19.5:1±0.5:1 ............................................................
Valve operation O.H.V. pushrod operated................................................................
Crankshaft
Main bearing journal diameter 63,475 - 63,487 mm..........................................
Regrind dimensions 63,2333 - 63,246 mm.........................................................
Use 0.010 in U/S bearings
Crankpin journal diameter 58,725 - 58,744 mm................................................
Regrind dimensions 58,4708 - 58,48985 mm.........................................................
Use 0.010 in U/S bearings
Crankshaft end thrust Taken on thrust washers at centre main bearing.......................................................
Crankshaft end float 0,05 - 0,15 mm.........................................................
Main bearings
Number and type 5 halved shells with oil grooves..............................................................
Diametrical clearance 0,0792 - 0,0307 mm.......................................................
Connecting rods
Length between centres 175,38 - 175,43 mm...................................................
Diametrical clearance (big-end bearings) 0,025 - 0,075 mm........................
End float on crankpin 0,15 - 0,356 mm.......................................................
Pistons
Type Aluminium alloy, combustion chamber in crown..................................................................................
Graphite coating on sidewalls.
Skirt diametrical clearance
(at right angle to gudgeon pin) 0,025 - 0,05 mm.........................................
Maximum height above combustion face 0,8 mm.........................
Gudgeon pins
Type Floating.................................................................................
Fit in piston Hand push fit.......................................................................
Diameter 30,1564 - 30,1625 mm..........................................................................
Clearance in connecting rod 0,0025 - 0,0163 mm............................................

04GENERAL SPECIFICATION DATA
22
INFORMATION ENGINE - Mpi - 2.0 LITRE
Type 20 T4 - 16 valve twin overhead camshaft.................................................................................
Cylinder arrangement 4 in line.......................................................
Bore 84.45 mm.................................................................................
3.325 in
Stroke 89.00 mm...............................................................................
3.504 in
Capacity 1994 cm
3...........................................................................
121.68 in3
Firing order 1-3-4-2.......................................................................
Compression ratio 10 : 1............................................................
Oil pump
Outer rotor to body clearance 0.05 to 0.10 mm..........................................
Inner rotor tip clearance 0.025 to 0.12 mm...................................................
Outer rotor end float 0.03 to 0.08 mm.........................................................
Oil pressure relief valve
Spring free length 42.0 mm.............................................................
Cooling system
Starts to open 82 to 86°C ...................................................................
Thermostat fully open 88°C .......................................................
Open travel A 9 mm...................................................................
Camshaft
Camshaft end-float 0.06 to 0.25 mm...........................................................
Bearing clearance 0.060 to 0.094 mm............................................................
Service limit 0.15 mm.............................................................
Timing belt tensioner
Spring free length 57.5 to 58.5 mm.............................................................
Cylinder head
Longitudinal warp - maximum 0.1 mm.................................
Transverse warp - maximum 0.1 mm...................................
Diagonal warp - maximum 0.1 mm......................................
Cylinder head height 135.0 to 135.1 mm...............................................
Valve springs
Free length 46.25 mm.......................................................................
Fitted length 37.0 mm.....................................................................
Load at fitted length 255±12 N ..........................................................
Load at valve open length 560±22.5 N ................................................

GENERAL SPECIFICATION DATA
23
INFORMATION Valves
Valve stem diameter:
Inlet 7.09 to 7.10 mm.........................................................................
Exhaust 7.07 to 7.09 mm...................................................................
Valve head diameter:
Inlet 31.7 to 31.95 mm.........................................................................
Exhaust 29.2 to 29.43 mm...................................................................
Valve installed height - maximum 43.4 mm....................................
Valve stem to guide clearance:
Inlet 0.04 to 0.06 mm.........................................................................
Service limit 0.09 mm.............................................................
Exhaust 0.06 to 0.07 mm...................................................................
Service limit 0.10 mm.............................................................
Valve guides
Internal diameter - Inlet and Exhaust 7.137 to 7.162 mm...............................
Overall length:
Inlet 48.5 mm.........................................................................
Exhaust 52.9 mm...................................................................
Valve seats
Valve seat angle - Inlet and Exhaust 45° ................................
Valve seat width - Inlet and Exhaust 1.5 to 2.0 mm................................
Valve face angle:
Inlet and Exhaust 45°to 45°15' .............................................................
Crankshaft
End-float 0.03 to 0.2 mm...........................................................................
Thrust washer halves thickness 2.31 to 2.36 mm.......................................
Main journal diameter 54.005 to 54.026 mm.......................................................
Maximum out of round 0.010 mm............................................
Main bearing diametric clearance 0.03 to 0.07 mm....................................
Big-end journal diameter 47.648 to 47.661 mm..................................................
Maximum out of round 0.010 mm............................................
Big-end bearing diametric clearance 0.04 to 0.08 mm................................
Piston rings
New ring to groove clearance:
Top compression 0.06 to 0.09 mm.............................................................
2nd compression 0.05 to 0.07 mm..............................................................
Oil control rails - expander fitted 0.03 to 0.05 mm......................................
Ring fitted gap:
Top compression 0.25 to 0.35 mm.............................................................
2nd compression 0.3 to 0.5 mm..............................................................
Oil control rails 0.38 to 1.14 mm.................................................................
Pistons
Piston diameter:
Grade A 84.409 to 84.422 mm...................................................................
Grade B 84.423 to 84.436 mm...................................................................
Clearance in bore 0.01 to 0.03 mm.............................................................
Cylinder bore
Grade A 84.442 to 84.455 mm...................................................................
Grade B 84.456 to 84.469 mm...................................................................

GENERAL SPECIFICATION DATA
25
INFORMATION VEHICLE DIMENSIONS
Dimensions
Overall length (including spare wheel) 4538 mm.............................
Overall length (including tow hitch) 4581 mm..................................
Overall width 2189 mm....................................................................
Overall height 1914 mm...................................................................
Wheelbase 2540 mm.......................................................................
Track front/rear 1486 mm.................................................................
Width between wheel boxes 1080 mm............................................
Seating capacity 5 to 7...............................................................
Performance
Tyre size fitted 205 R16 radial..................................................................
Tyre size fitted 235/70 R16 radial..................................................................
Max. gradient (EEC kerb weight) 45° .....................................
Approach angle (EEC kerb weight) 35° ..................................
Departure angle with tow hitch (EEC kerb weight) 20° ...........
Departure angle without tow hitch
(EEC kerb weight) 29° ............................................................
Ramp break over angle 33° ....................................................
Min. ground clearance (unladen) 204 mm.....................................
Wading depth 500 mm...................................................................
Towing weights
On road Off road
Unbraked trailers 750 kg.............................................................. 500 kg
Trailers with overrun brakes - Mpi 2750 kg.................................... 1000 kg
Trailers with overrun brakes - V8i & Tdi 3500 kg........................... 1000 kg
4 wheel trailers with coupled brakes
(FULLY BRAKED)* 4000 kg.......................................................... 1000 kg
NOTE: * Only applies to vehicles modified to accept coupled brakes.
NOTE: All weight figures are subject to local restrictions.

51REAR AXLE AND FINAL DRIVE
4
OVERHAUL 35.Fit pinion outer bearing track to pinion housing.
Use service tools LRT-54-505 and LRT-54-507.
36.Fit pinion head bearing to pinion. Use service
tool LRT-54-502.
37.Fit pinion into its location without shims for
bearing pre-load.
38.Fit outer bearing, and spacer (front axle
differential only).
39.Fit driving flange, washer and nut.
40.Do not fit oil seal at this stage.
41.Tighten pinion flange nut until force required to
rotate pinion is
3Nmif new bearings are fitted.
This will pre-load bearings to check pinion height
dimension.
NOTE: If using original bearings, pre-load
figure is 1.5 Nm.
Drive pinion markings
NOTE: Markings on end face adjacent to
serial number are of no relevance to
servicing.
42.Figures marked on end face opposite to serial
number show in thousandths of an inch,
deviation from nominal, required to set pinion.
Pinions marked plus (+) must be set below
nominal. Pinions marked minus (-) must be set
above nominal. Unmarked pinions must be set at
nominal.

REAR AXLE AND FINAL DRIVE
5
OVERHAUL
43.Nominal setting dimension is represented by
setting gauge block LRT-54-503. Referenced
from pinion end face to bottom radius of
differential bearing bore.
Drive pinion adjustment
44.Ensure pinion end face is free of burrs around
etched markings.
45.Remove keep disc from magnetized base of dial
gauge tool.
46.Place dial gauge and setting block on surface
plate. Zero dial gauge trace pin on setting block.
NOTE: Setting block has three height
settings heights.
Use 39.50mm setting mark for this differential.
Pinion height shims
PART No. INCH MM
FTC3853 .061 1.548
FTC3854 .060 1.523
FTC3855 .059 1.498
FTC3856 .058 1.473
FTC3857 .057 1.448
FTC3858 .056 1.423
FTC3859 .055 1.398
FTC3860 .054 1.373
FTC3861 .053 1.348
FTC3862 .052 1.323
FTC3863 .051 1.298
FTC3864 .050 1.273
FTC3865 .049 1.248
FTC3866 .048 1.223
FTC3867 .047 1.198
FTC3868 .046 1.173
47.Position dial gauge centrally on pinion end face,
register on lowest point on one differential
bearing bore. Note dial gauge measurement
from zeroed setting.

51REAR AXLE AND FINAL DRIVE
6
OVERHAUL 48.Repeat on other bearing bore. Add readings
then halve sum to obtain mean reading. Note
whether trace pin has moved up or down from
zero.
A. Where trace pin moves down, reading is
equal to thickness of shims to remove, to
bring pinion to nominal.
B. Where trace pin moves up, reading is
equal to thickness of shims to add, to bring
pinion to nominal.
49.Before adjusting shim thickness: check pinion
face marking. If a plus (+) figure, subtract in
thousandths of an inch from shim thickness
figure.
50.If pinion has a minus (-) figure, add amount to
shim thickness figure.
Adjust shim thickness under pinion head bearing
track as necessary.
INCH MM
.001 = .025
.002 = .05
.003 = .075
.004 = .10
.005 = .125
.006 = .15
.007 = .175
.008 = .20
.009 = .225
.010 = .25
NOTE: Where dial indicator is metric
conversion must be made to inches when
measuring and selecting shims.
51.Recheck pinion height setting. If setting is
correct, mean reading of dial gauge will agree
with figure marked on pinion end face.
For example, with end face marking of +3, dial
gauge reading should indicate pinion is +0.003
in.Bearing pre-load adjustment
52.Remove the pinion flange, pinion, outer bearing
and spacer.
53.Slide new shim, of same thickness as original
(bearing pre-load) into position on pinion shaft. If
fitting a new shim use thickest shim 2.155 mm.
54.Fit pinion to pinion housing and fit outer bearing
and spacer (front differential only).
55.Fit driving flange, washer and nut.
56.Do not fit oil seal at this stage.
57.Tighten pinion flange nut to130 Nm.Force to
rotate pinion shaft is 3Nm using new bearings.
Change shim as necessary to obtain reading.
Thicker shim will reduce pre-load. Thinner shim
will increase pre-load.
NOTE: If using original bedded in
bearings, pre-load figure is 1.5 Nm.
58.Remove pinion flange.

57STEERING
12
FAULT DIAGNOSIS Steering column alignment
1.Place vehicle on level ground. Measure the
angle of lower steering shaft using a Pernumeter
placed on the shaft between the universal joints.
The angle should measure a minimum of 12Ê.
2.If necessary, realign the shaft. Release the five
fixings securing the steering column. Position
column as required. Tighten the fixings evenly,
27 Nm.
3.Loosen the three screws securing lower steering
column shroud to upper shroud ensure lower
shroud is clipped to upper shroud. Reposition
shroud, tighten screws.
4.Recheck steering column angle.
Steering box adjustment
1.Check steering box adjustment.
See
Adjustment, Power Steering Box
Steering damper check
1.Check condition of steering damper
See
Steering Damper
VISUAL CHECK AND BASIC ADJUSTMENTS
NOTE: It is important that the following
instructions are carried out in the
sequence shown and the results recorded.
1.Road springs - check that road springs are
correctly seated and are to correct specification
for vehicle. For spring specification.
See
GENERAL SPECIFICATION DATA,
Information, Road Springs Data
2.Ride height - measure trim height from wheel
centre to wheelarch eyebrow. Record results on
data sheet.
3.Check/top up power steering fluid
See Repair,
Power Steering Fluid Reservoir
4.Check tension and condition of drive belt.See
ENGINE, Repair, Drive Belt
5.Track rod/drag link - check condition of track rod,
drag link and ball joints.
See Repair, Drag Link
and Drag Link Ends
If either component is damaged, check operation
of steering damper and steering box for
smoothness. Replace all damaged or worn
components that impair the operation of the
steering system.
6.Suspension bushes - examine all steering and
suspension bushes for signs of wear and
deterioration. Also check all fixings for torque
relaxation. Tighten to correct torque value.
See
FRONT SUSPENSION, Specifications, torque,
Torque Values
7.Oil leaks - check front and rear axle hubs for
leak and repair as necessary.
8.Brake system - check brake system for leaks,
pipe condition, pad wear/contamination, disc
wear/condition and ABS sensors for correct
fitting.
9.Hub end float - check movement in the hubs by
rocking the wheels.
10.Check front wheel alignment. Vehicles displaying
a tendency to veer more than considered
allowable, it is permissible to set the front track
to parallel.
11.Having completed all the above checks and
adjustments, road test vehicle.
See Road Test
Procedure
Attempting to reproduce the symptoms
established earlier. If symptoms still exist refer to
relevant Diagnostic Chart.

ENGINE
DATA, TORQUE & TOOLS1
ENGINE DATA
Rocker shaft
Rocker shaft wear - maximum 0.025 mm..................
Rocker arm shaft to bush clearance - maximum 0.12 mm....
Valve clearance - inlet and exhaust 0.20 mm..............
Oil pump
Outer rotor to housing clearance 0.025 to 0.075 mm................
Inner to outer rotor clearance 0.025 to 0.075 mm..................
Outer rotor end-float 0.026 to 0.135 mm.........................
Relief valve spring free length 68.0 mm..................
Cylinder head
Cylinder head maximum warpage 0.08 mm...............
Maximum movement of valve to guide 0.15 mm...........
Valve stem diameter:
Inlet 7.96 mm......................................
Exhaust 7.94 mm...................................
Valve head stand down:
Inlet 0.81 to 1.09 mm......................................
Exhaust 0.86 to 1.14 mm...................................
Valve seat insert face angle:
Inlet 60° ......................................
Exhaust 45° ...................................
Valve face angle:
Inlet 60°00' to 60°30' ......................................
Exhaust 45°00' to 45°30' ...................................
Valve spring free length 46.28 mm.......................
Timing belt tension on torque wrench
Used belt 12 Nm..................................
New belt 15 Nm...................................
Drive plate - automatic gearbox
Setting height 12.4 mm...............................