starter removal LAND ROVER DISCOVERY 1995 Service Repair Manual

Tdi
5
REPAIR
37.Remove nuts and plain washers securing front
engine mountings to chassis,and lift both engine
mounting bracket assemblies from vehicle.
38.Remove engine to bell housing fixings. Leave
starter motor attached.
39.Raise engine to separate from transmission.
40.Check all connections to engine have been
disconnected.
41.Remove engine.Refit
42.Apply Hylomar to mating faces of bell housing.
Lubricate splines of gearbox primary pinion with
Rocol MV 3.
If automatic transmission, coat the four drive
plate to torque convertor bolts with Loctite 290.
Tighten to
39 Nm.
43.Lower engine and locate with transmission.
If manual transmission locate primary pinion into
clutch and engage bell housing dowels. Fit
engine to bell housing fixings. Tighten to
40 Nm.
If automatic transmission fixings. Tighten to46
Nm.
44.Raise engine, refit front engine mounting
brackets to cylinder block and bell housing.
45.Remove gearbox support and lower engine.
46.Tighten front engine mountings to chassis
fixings. Tighten to
45 Nm.
47.Reverse removal procedure. 1 to 37.

ZF
7
REPAIR Accessories removal/fitting
If fitting a replacement transmission assembly to the
vehicle, remove the following items from the existing
assembly and fit to the replacement.
CAUTION: It is important to remove the
spacer from the extension shaft and fit
onto the replacement unit.
50.Breather pipe union and washers from main
gearbox.
51.Breather pipe, union and washers from transfer
gearbox.
52.Main gearbox selector lever.
53.RH mounting bracket assembly.
54.Oil cooler pipe unions.
55.Fit blanks to all apertures where unions have
been removed and blank off pipe ends.
Refit
1.Fit transmission to cradle and hoist.
2.Locate hoist under vehicle and remove torque
convertor retaining strap.
3.Ensure low range gear is engaged.
4.Apply approved sealant to bell housing face.
5.Carefully raise assembly, align bell housing with
flywheel housing and bring mating faces
together.
6.Fit nuts and bolts to secure transmission to
engine.
7.Locate electrical wiring and breather pipes to
position.
8.Secure kick down cable clip to bell housing.
9.Raise hoist sufficiently to take weight.
10.Remove block and jack from engine sump.
11.Fit filler/dipstick tube to gearbox sump and
secure bracket to bell housing.
12.Apply Loctite to torque convertor bolts
13.Working through starter aperture refit the four
torque convertor to flexible drive securing bolts,
rotating crankshaft to gain access to bolt
locations.
14.Refit starter and heatshield.
15.Secure breather pipes and harness with ties.
16.Fit left hand mounting bracket assembly to
gearbox.
17.Raise transmission and support with a suitable
ramp [hoist] jack.
18.Remove two bolts securing transmission to
cradle, lower hoist and remove from under
vehicle.
19.Apply Loctite to above bolts and fit to transfer
gearbox input bearing support plate.
20.Fit chassis cross member.21.Secure gearbox mounting brackets to chassis
cross member.
22.Remove ramp [hoist] jack.
23.Connect electrical leads to differential lock
switch.
24.Connect inhibitor switch multi-plug.
25.Connect selector cable to lever on side of
gearbox.
26.Connect oil cooler pipes to gearbox and secure
retaining bracket to gearbox sump.
27.Secure silencer to chassis and refit exhaust front
pipe.
28.Refit front propeller shaft to transfer gearbox.
29.Refit rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
30.Connect speedometer cable to transfer gearbox.
31.Refill transfer gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
32.Lower ramp [hoist] to ground level.
33.Reconnect turbo-charger hose to inter-cooler.
34.Reconnect top hose to radiator.
35.Refill cooling system with correct mixture of
coolant.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
36.Reconnect kick down cable to fuel injection
pump.
37.Secure breather pipe clip to rear of cylinder
head.
38.Engage harness with clips along top of
bulkhead.
39.On left hand drive vehicles only, connect
multi-plug to top of brake fluid reservoir.
40.Refit insulation pad to rocker cover and inlet
manifold, secure with oil filler cap.
41.Refit gaiter and knob to transfer gear lever.
42.Select high range gear.
43.Reconnect battery terminals.
44.Refill main gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids

75SUPPLEMENTARY RESTRAINT SYSTEM
4
DESCRIPTION AND OPERATION GENERAL PRECAUTIONS
Impacts which do not deploy airbags
CAUTION: Check for structural damage in
the area of the impact, paying particular
attention to bumper armatures,
longitudinals, crash cans and bracketry.
1.Carefully inspect any airbag part before
installing. Do not install any part that shows
signs of being dropped or improperly handled,
such as dents, cracks or deformation.
2.Always remove the key from the starter switch
before beginning work.
3.Always disconnect both the negative '-' cable
and positive '+' cable at the battery before
removal of driver or passenger airbag modules.
Disconnect the negative cable first.
CAUTION: The airbag system has
sufficient stored energy to deploy airbags
for up to 20 minutes.
4.To continue work immediately, disconnect the
driver's airbag and passenger's airbag (where
fitted).
5.Do not try to dismantle the airbag module. There
are NO separately serviceable parts. Once an
airbag has been deployed, it cannot be repaired
or reused.
6.Do not install used airbag parts from another
vehicle. When repairing, use only new airbag
parts.

ELECTRICAL
3
REPAIR BATTERY
Service repair no - 86.15.01
NOTE: Some vehicles are fitted with a
battery backed-up sounder. Disconnecting
the vehicle battery will cause the alarm to
sound unless the following procedure is followed:
1.Turn starter switch 'ON' then 'OFF'.
2.Disconnect battery WITHIN 15 SECONDS (see
WARNING).
If alarm is accidentally activated, ensure sounder is
connected and silence by turning the starter switch to
position II.
Remove
WARNING: During battery removal or
before carrying out any repairs or
maintenance to electrical components
always disconnect battery negative lead first. If
positive lead is disconnected with negative lead in
place, accidental contact of wrench to any
grounded metal part could cause a severe spark,
possibly resulting in personal injury. Upon
installation of battery connect positive lead first.
3.Disconnect both battery leads, negative first.
4.Release four nuts securing battery bracket in
position.
5.Remove bracket.
6.Remove battery.
Refit
7.Reverse removal procedure.
NOTE: Coat battery clamps and terminals
with petroleum jelly before refitting.DISTRIBUTOR-LUCAS 35 DLM8 - V8i
Service parts
1. Cap
2. HT brush and spring
3. Rotor arm
4. Insulation cover
5. Pick-up module and base plate assembly
6. Vacuum unit
7. Amplifier module
8. 'O'-ring oil seal
9. Gasket

ELECTRICAL
43
REPAIR ANTI-THEFT ALARM ECU (96 MODELS)
Service repair no - 86.55.85
Remove
1.Remove 4 studs securing fascia left hand
closing panel.
2.Remove closing panel.
3.Disconnect 2 multiplugs from ECU.
4.Remove nut securing ECU/relay bracket.
5.Lower bracket.
6.Remove 2 nuts securing ECU to bracket.
7.Remove ECU.
NOTE: A new ECU must be initialised
using TestBook.
Refit
8.Reverse removal procedure.HANDSET (96 MODELS)
If vehicle does not respond to handset immediately, it
may have lost synchronisation. To re-synchronise,
press either button, 4 times in quick succession. If
handset still fails to respond, check batteries, refer to
Owner's handbook. If batteries are okay, it may be
necessary to use emergency key access, refer to
Owner's handbook.
NOTE: New handsets must be initialised
using TestBook.
PASSIVE COIL (96 MODELS)
Service repair no - 86.77.35
Remove
1.Remove steering column shroud.
See
STEERING, Repair, Steering column shroud
2.Release multiplug from harness clip and
disconnect.
3.Release passive coil from starter switch.
4.Remove bulb holder/starter switch shroud.
5.Remove coil.
Refit
6.Fit coil, ensuring switch illumination bulb harness
passes through large cut-out.
7.Secure coil with cable tie.
8.Position bulb holder/starter switch shroud and
locate bulb.
9.Locate bulb holder/starter switch shroud,
ensuring cut-out in shroud aligns with lug on
starter switch.
10.Connect multiplug and secure to clip.
11.Fit column shroud.

ELECTRICAL
45
REPAIR SOUNDER (96 MODELS)
Service repair no - 86.55.87
Remove
NOTE: Failure to follow steps 1 and 2 will
result in sounder being activated.
1.Turn starter switch 'ON' then 'OFF'.
2.WITHIN 15 SECONDS, depress release clip on
multiplug and detach from sounder.
3.Remove 2 securing bolts and remove sounder
complete with bracket.
Refit
4.Reverse removal procedure.
NOTE: If sounder is accidentally activated,
it can be silenced, provided it is
reconnected, by turning starter switch to
position II.SWITCH - ELECTRIC SEAT
Service repair no - 86.75.03
Remove
1.Release switch panel from centre console.
2.Disconnect 2 switch multiplugs
3.Remove switch panel.
Refit
4.Reverse removal procedure.

ELECTRICAL
47
REPAIR
10.From above, remove top bolt securing starter
motor and position earth lead aside.
NOTE: To assist removal, use 230 mm
extension bar positioned between engine
mounting bracket and exhaust manifold.
11.Remove bottom bolt securing starter motor.
12.Remove starter motor.Refit
13.Ensure mating faces are clean.
14.Locate starter motor in fitted position and fit
bottom bolt finger tight.
15.Fit top bolt. Tighten to
42 Nm.
16.Bottom bolt. Tighten to42 Nm.
17.Connect feed wires to solenoid terminal. Secure
with nut.
18.Connect Lucar to starter solenoid.
19.Manoeuvre heat shield down and forward to
position bracket against engine mounting.
Engage clip on solenoid.
20.Align bracket to hole using suitable tool and fit
retaining bolt.
21.Clean flange mating surfaces, locate propeller
shaft and align reference marks.
22.Fit bolts and NEW nyloc nuts. Tighten to
48 Nm.
NOTE: Fit bolts with head towards transfer
box and away from differential.
23.Lower vehicle.
24.Reconnect battery negative lead.

86ELECTRICAL
48
REPAIR STARTER MOTOR HEAT SHIELD - 4.0 V8
Service repair no - 86.60.12
Remove
1.Disconnect battery negative lead.
2.Raise vehicle on ramp.
3.Remove heated oxygen sensor from RH exhaust
front pipe.
See EMISSION CONTROL, Repair,
Heated Oxygen Sensor (HO2S) - 4.0 V8
4.Remove bolt securing heat shield to RH engine
mounting bracket.
5.Release heat shield clip from starter solenoid.
6.Manoeuvre heat shield rearwards and around
starter motor.
Refit
7.Reverse removal procedure.BULB - FRONT FOG LAMP
Service repair no - 86.40.94
Remove
1.Remove front fog lamp.
See fog lamp - front
2.Remove 2 Torx screws securing fog lamp to
bracket and collect 2 spacers.
3.Release fog lamp adjustment ball joint from
bracket and remove lamp.
4.Release lamp lens from shroud.
5.Disconnect 2 Lucars from bulb.
6.Release bulb retaining clip.
7.Remove bulb from lens.