ignition LAND ROVER DISCOVERY 1995 Service Repair Manual

01INTRODUCTION
2
INFORMATION FUEL HANDLING PRECAUTIONS
The following information provides basic precautions
which must be observed if fuel is to be handled safely.
It also outlines the other areas of risk which must not
be ignored.
This information is issued for basic guidance only, and
in any case of doubt, appropriate enquiries should be
made of your local Fire Officer or Fire Department.
Fuel vapour is highly flammable and in confined
spaces is also very explosive and toxic.
When fuel evaporates it produces 150 times its own
volume in vapour, which when diluted with air
becomes a readily ignitable mixture. The vapour is
heavier than air and will always fall to the lowest level.
It can readily be distributed throughout a workshop by
air current, consequently, even a small spillage of fuel
is very dangerous.
Always have a fire extinguisher containingFOAM CO
2
GAS,orPOWDERclose at hand when handling fuel,
or when dismantling fuel systems and in areas where
fuel containers are stored.
WARNING: lt is imperative that the battery
is not disconnected during fuel system
repairs as arcing at the battery terminal
could ignite fuel vapour in the atmosphere.
Always disconnect the vehicle battery BEFORE
carrying out work on the fuel system.
Whenever fuel is being handled, transferred or
stored, or when fuel systems are being dismantled
all forms of ignition must be extinguished or
removed, any leadlamps used must be flame proof
and kept clear of spillage.
No one should be permitted to repair components
associated with fuel without first having had fuel
system training.Hot fuel handling precautions
WARNING: Before commencing any
operation requiring fuel to be drained from
the fuel tank, the following procedure must
be adhered to:
1.Allow sufficient time for the fuel to cool, thus
avoiding contact with hot fuels.
2.Vent the system by removing the fuel filler cap in
a well ventilated area. Refit the filler cap until the
commencement of fuel drainage.
Fuel transfer
WARNING: Fuel must not be extracted or
drained from any vehicle while it is
standing over a pit.
The transfer of fuel from the vehicle fuel tank must be
carried out in a well ventilated area. An approved
transfer tank must be used according to the transfer
tank manufacturer's instructions and local regulations,
including attention to grounding of tanks.
Fuel tank removal
AFUEL VAPOURwarning label must be attached to
the fuel tank upon removal from the vehicle.
Fuel tank repair
Under no circumstances should a repair to any tank
be attempted.

01INTRODUCTION
4
INFORMATION ACCESSORIES AND CONVERSIONS
DO NOT FITunapproved accessories or conversions,
as they could affect the safety of the vehicle.
Land Rover will not accept liability for death, personal
injury, or damage to property which may occur as a
direct result of the fitting of non-approved conversions
to the vehicle.
WHEELS AND TYRES
WARNING: DO NOT replace the road
wheels with any type other than genuine
Land Rover wheels which are designed for
multi-purpose on and off road use and have very
important relationships with the proper operation
of the suspension system and vehicle handling.
Replacement tyres must be of the make and sizes
recommended for the vehicle, and all tyres must
be the same make, ply rating and tread pattern.
STEAM CLEANING
To prevent consequential rusting, any steam cleaning
within the engine bayMUSTbe followed by careful
re-waxing of the metallic components affected.
Particular attention must be given to the steering
column, engine water pipes, hose clips and ignition
coil clamp.
SPECIFICATION
The specification details and instructions set out in
this Manual apply only to a range of vehicles and not
to any one. For the specification of a particular vehicle
purchasers should consult their Dealer
The Manufacturer reserve the right to vary their
specifications with or without notice, and at such times
and in such manner as they think fit. Major as well as
minor changes may be involved in accordance with
the Manufacturer's policy of constant product
improvement.
Whilst every effort is made to ensure the accuracy of
the particulars contained in this Manual, neither the
Manufacturer or Dealer, by whom this Manual is
supplied, shall in any circumstances be held liable for
any inaccuracy or the consequences thereof.SPECIAL SERVICE TOOLS
The use of approved special service tools is
important. They are essential if service operations are
to be carried out efficiently, and safely. Where special
tools are specified,only these tools should be used
to avoid the possibility of personal injury or
damage to the components.Also the amount of time
which they save can be considerable.
Every special tool is designed with the close
co-operation of Land Rover, and no tool is put into
production which has not been tested and approved
by us. New tools are only introduced where an
operation cannot be satisfactorily carried out using
existing tools or standard equipment. The user is
therefore assured that the tool is necessary and that it
will perform accurately, efficiently and safely.
Special tools bulletins will be issued periodically giving
details of new tools as they are introduced.
All orders and enquiries from the United Kingdom
should be sent direct to V. L. Churchill. Overseas
orders should be placed with the local V. L. Churchill
distributor, where one exists. Countries where there is
no distributor may order direct from:
V. L. Churchill Limited,
PO Box 3,
Daventry, Northants,
England, NN11 4NF.
The tools recommended in this Workshop Manual are
listed in a multi-language illustrated catalogue,
obtainable from:
Messers. V. L. Churchill at the above address,
or from:
Land Rover Merchandising Service,
PO Box 534,
Erdington,
Birmingham, B24 0Q5,
COPYRIGHT
ÓLand Rover 1996
All rights reserved. No part of this publication may be
produced, stored in a retrieval system or transmitted
in any form, electronic, mechanical, recording or other
means without prior written permission of Land Rover.

INTRODUCTION
7
INFORMATION DYNAMOMETER TESTING - VEHICLES WITH
ANTI-LOCK BRAKES (ABS)
WARNING: Do not attempt to test ABS
function on a dynamometer
Four wheel dynamometers
NOTE: Before testing a vehicle on a four
wheel dynamometer disconnect the valve
relay.
See Electrical Trouble Shooting
Manual.
The ABS function will not work, the ABS warning
light will illuminate. Normal braking will be
available.
Provided that front and rear rollers are rotating at
identical speeds and that normal workshop safety
standards are applied, there is no speed restriction
during testing except any that may apply to the tyres.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
NOTE: ABS will not function on a two
wheel dynamometer. The ABS light will
illuminate during testing. Normal braking
will be available.
If brake testing on a single rig is necessary it must be
carried out with propeller shaft to the rear axle
removed, AND neutral selected in BOTH main and
transfer boxes.
If checking engine performance, the transfer box must
be in high range and drive shaft to stationary axle
removed.
TOWING
CAUTION: The vehicle has permanent
four-wheel drive. The following towing
instructions must be adhered to:
Towing the vehicle on all four wheels with driver
operating steering and brakes.
1.Turn ignition key turn to position '1' to release
steering lock.
2.Select neutral in main gearbox and transfer
gearbox.
3.Secure tow rope, chain or cable to towing eye.
4.Release the parking brake.
CAUTION: The brake servo and power
assisted steering system will not be
functional without the engine running.
Greater pedal pressure will be required to apply
the brakes, the steering system will require
greater effort to turn the front road wheels.
The vehicle tow connection should be used only
in normal road conditions, 'snatch' recovery
should be avoided.
Suspended tow by breakdown vehicle
CAUTION: To prevent vehicle damage,
front or rear propeller shaft MUST BE
removed, dependent upon which axle is
being trailed.
1.Mark propeller shaft drive flanges at transfer
gearbox and axles with identification lines to
enable the propeller shaft to be refitted in its
original position.
2.Remove the propeller shaft fixings, remove the
shaft from the vehicle.
3.If the front axle is to be trailed turn ignition key to
position '1' to release steering lock.
CAUTION: The steering wheel and/or
linkage must be secured in a straight
ahead position. DO NOT use the steering
lock mechanism for this purpose.

01INTRODUCTION
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INFORMATION TRANSPORTING THE VEHICLE BY TRAILER
Lashing eyes are provided on front and rear of the
chassis side members, to facilitate the securing of the
vehicle to a trailer or other means of transportation.
CAUTION: Underbody components must
not be used as lashing points.
Install vehicle on trailer and apply park brake. Select
neutral in main gearbox. Selecting 'N' will prevent
damage to parking pawl of the automatic gearbox.
FRONT OF CHASSIS
REAR OF CHASSIS
JUMP STARTING
WARNING: Hydrogen and oxygen gases
are produced during normal battery
operation. This gas mixture can explode if
flames, sparks or lighted tobacco are brought
near battery. When charging or using a battery in
an enclosed space, always provide ventilation and
shield your eyes.
Keep out of reach of children. Batteries contain
sulphuric acid. Avoid contact with skin, eyes, or
clothing. Also, shield eyes when working near
battery to protect against possible splashing of
acid solution. In case of acid contact with skin,
eyes, or clothing, flush immediately with water for
a minimum of fifteen minutes. If acid is swallowed,
drink large quantities of milk or water, followed by
milk of magnesia, a beaten egg, or vegetable oil.
SEEK MEDICAL AID IMMEDIATELY.
To Jump Start - Negative Ground Battery
WARNING: To avoid any possibility of
injury use particular care when connecting
a booster battery to a discharged battery.
1.Position vehicles so that jump leads will reach,
ensuring that vehiclesDO NOT TOUCH,
alternatively a fully charged slave battery may be
positioned on floor adjacent to vehicle.
2.Ensuring that ignition and all electrical
accessories are switched off, that parking brake
is applied and neutral is selected on a manual
gearbox, with an automatic gearbox select
neutral (N) or park (P) and then connect the
jump leads as follows;
A.Connect one end of first jumper cable to positive
(+) terminal of booster battery.
B.Connect other end of first jumper cable to
positive (+) terminal of discharged battery.
C.Connect one end of second jumper cable to
negative terminal of booster battery.

INTRODUCTION
9
INFORMATION
D.Connect other end of second jumper cable to a
good earth point on the engine,NOT TO
NEGATIVE TERMINAL OF DISCHARGED
BATTERY.Keep jumper lead away from moving
parts, pulleys, drive belts and fan blade
assembly.
WARNING: Making final cable connection
could cause an electrical arc which if
made near battery could cause an
explosion.
3.If booster battery is installed in another vehicle,
start engine and allow to idle.
4.Start engine of vehicle with discharged battery,
following starting procedure in Owners' Manual.
CAUTION: If vehicle fails to start within a
maximum time of 12 seconds, switch
ignition off and investigate cause. Failing
to follow this instruction could result in
irrepairable damage to catalysts.
5.Remove negative (-) jumper cable from the
engine and then terminal of booster battery.
6.Remove positive (+) jumper cable from positive
terminals of booster battery and discharged
battery.

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).........................

04GENERAL SPECIFICATION DATA
6
INFORMATION FUEL SYSTEM (GEMS) 4.0 V8 ENGINE
Type Sagem - Lucas Gems 8 hot wire system electronically.................................................................................
controlled
Fuel pump-make/type High pressure electrical, immersed in the fuel tank......................................................
Fuel pump delivery pressure 2.4-2.6 bar (34-37 lbf/in
2) ............................................
Fuel filter Bosch in-line filter 'canister' type..........................................................................
Mass airflow sensor
Make and type Lucas 'Hot Wire' 20AM.................................................................
Injectors
Make and type Lucas D1000.................................................................
Electronic Control Module
Make and type Lucas GEMS 8.3.................................................................
Fuel pressure regulator
Make and type Lucas 8RV.................................................................
Coolant temperature sensor
Make and type Lucas 8TT.................................................................
Bypass Air valve (Stepper motor)
Make and type Lucas 3ACM.................................................................
Throttle position sensor
Make and type Lucas 3TP.................................................................
Heated oxygen sensor - catalyst vehicles
Make and type Lucas 4LS.................................................................
Camshaft position sensor
Make and Land Rover part no. Lucas ERR6170.........................................
Crankshaft position sensor
Make and type Lucas 3VRS, Honeywell ERR6049.................................................................
Knock sensor
Make and type Lucas 2KS.................................................................
Intake air temperature sensor
Make and type Lucas 10TT.................................................................
Ignition coils
Make and type Lucas 2DIS2.................................................................
Fuel temperature sensor
Make and type Lucas 6TT.................................................................

GENERAL SPECIFICATION DATA
15
INFORMATION BULBS
REPLACEMENT BULBS TYPE
Exterior lights
Headlamps 12V 60/55W (Halogen)
Headlamps - France amber 12V 60/55W (Halogen)
Auxiliary driving lamps 12V 55W H3 (Halogen)
Sidelamps 12V 5W bayonet
Tail lamps 12V 5/21W bayonet
Reverse lamps 12V 21W bayonet
Stop lamps 12V 21W bayonet
Direction indicator lamps 12V 21W bayonet
Rear side marker lamps 12V 5W capless
Number plate lamps 12V 5W capless
Interior lights
Instrument panel lamps and warning lamps 12V 1.2W bulb/holder unit
Ignition warning lamp (Instrument panel) 12V 2W capless
Interior roof lamps 12V 10W 'Festoon'
Clock illumination 12V 1.2 capless
Cigar lighter illumination 12V 1.2W capless
Door shut face/puddle lamps 12V 5W capless
Auxiliary switch panel illumination (green) 12V 1.2W capless
Heated rear screen warning lamp (amber) 12V 1.2W capless
Hazard warning lamp 12V 1.2W capless
Automatic graphics illumination 12V 5W capless
Heater/air conditioning graphics illumination 12V 1.2W bulb/holder unit
Differential lock warning lamp 12V 1.2W bulb/holder unit
Column switch illumination 12V 1.2W capless
CAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damage
to vehicle wiring and switches.

ENGINE TUNING DATA
1
INFORMATION ENGINE 3.9 V8i
Type3.9 Litre V8i .................................................................................
Firing order1-8-4-3-6-5-7-2 .....................................................................
Cylinder Numbers
Left bank 1-3-5-7..........................................................................
Right bank 2-4-6-8........................................................................
No 1 Cylinder locationPulley end of left bank ...................................................
Timing marksOn crankshaft vibration damper ..................................................................
Spark plugs
Make/type(8.13:1 Compression) Champion RN11YCC......................................
Gap 0.84-0.96mm..................................................................................
Make/type(9.35:1 Compression) Champion RN11YCC......................................
Gap 0.84-0.96mm..................................................................................
Coil
Make/type Bosch 0-221-122-392,........................................................................
Compression ratio8.13:1 or 9.35:1 .........................................................
Fuel injection systemLucas 14 CUX Hot-wire air flow sensor system .....................................................
electronically controlled
Valve Timing Inlet Exhaust
Opens 32°BTDC .............................................................................. 70°BBDC
Closes 73°ABDC .............................................................................. 35°ATDC
Duration 285° ........................................................................... 285°
Valve peak 104°ATDC ....................................................................... 114°BTDC
Idle speed - controlled by MFI system
- all loads off in neutral 665 to 735 rev/min.....................................................
- auto gearbox in gear, air con operating 650±28 rev/min .........................
- auto gearbox in gear, air con off 600±28 rev/min ....................................
- manual gearbox 700±28 rev/min .............................................................
- manual gearbox, air con operating 750±28 rev/min ................................
Base idle speed525±25 rev/min
See FUEL SYSTEM, Fault..............................................................
diagnosis, Base idle speed setting.
Ignition Timing - dynamic at 800 rev/min max,
vacuum disconnected
8.13:1 compression, non catalyst 2°BTDC±1° .....................................
9.35:1 compression, non catalyst 4°BTDC±1° .....................................
9.35:1 compression, catalyst 5°BTDC±1° ............................................
Exhaust gas
CO content at idle 0.5 to 1.0% max.............................................................

05ENGINE TUNING DATA
2
INFORMATION Distributor
Make/type Lucas 35DLM8 electronic........................................................................
Rotation Clockwise............................................................................
Air gap 0.20-0.35mm..............................................................................
Part number Lucas Rover
8.13:1, non catalyst 42584A.......................................................... ERR 4753
9.35:1, non catalyst 42582A.......................................................... ERR 4754
9.35:1, catalyst 42583A................................................................. ERR 4755
Centrifugal Advance
Decelerating check-vacuum hose disconnected
Distributor rpm decelerating speeds
8.13:1 non catalyst
2000 Distributor advance................................................................................. 5°30' to 8°30'
1400 ................................................................................. 6°18' to 8°30'
800 ................................................................................... 2°to 4°
9.35:1 non catalyst
2200 Distributor advance................................................................................. 7°to 10°
1400 ................................................................................. 7°48' to 10°
650 ................................................................................... 1°to 3°
9.35:1 catalyst
2200 Distributor advance................................................................................. 5°30' to 8°30'
1400 ................................................................................. 6°18' to 8°30'
800 ................................................................................... 2°to 4°
Fuel
8.13:1, non catalyst 91 RON minimum unleaded..........................................................
9.35:1, non catalyst 95 RON minimum unleaded..........................................................
9.35:1, catalyst 95 RON minimum unleaded.................................................................
USA-Premium unleaded (PUG) CLC or AKI 90 octane minimum.......................................
95 RON minimum
Australian market variations
Fuel 91 RON minimum unleaded..................................................................................
Compression ratio 8.13:1............................................................
Spark plug Champion RN12YC........................................................................
Spark plug gap 0.84-0.96mm (0.033-0.038 in).................................................................
Ignition Timing at 800 rev/min max
(vacuum pipe disconnected) 2°BTDC±1° ............................................
Exhaust gas idle CO 1% max (hot)........................................................