wipers LAND ROVER DISCOVERY 1995 Service Repair Manual

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04
05
07
09
10
12
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19
26
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44
47
51
54
57
60
64
74
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76
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84
86
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)

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.

19FUEL SYSTEM
4
REPAIR ENGINE CONTROL MODULE (ECM)
Service repair no - 18.30.01
Remove
1.Disconnect battery negative lead.
2.Release and move washer reservoir aside.See
WIPERS AND WASHERS, Repair, Washer
Reservoir
3.Remove 2 studs securing ECM cover.
4.Remove cover.
5.Disconnect 3 ECM multiplugs.
6.Remove 2 bolts securing ECM.
7.Release ECM from 2 lower retainers.
8.Remove ECM.
Refit
9.Reverse removal procedure.
NOTE: Ensure ECM is correctly located by
lower retainers.MASS AIR FLOW SENSOR (MAF SENSOR)
Service repair no - 19.22.25
Remove
1.Disconnect battery negative lead.
2.Loosen clip and disconnect intake hose from
MAF sensor.
3.Disconnect multiplug from MAF sensor.
4.Release 2 clips and remove MAF sensor from air
cleaner.
5.Collect 'O' ring seal.
Refit
6.Ensure mating faces of air cleaner, MAF sensor
and intake hose are clean.
7.Fit 'O' ring to MAF sensor.
8.Fit MAF sensor to air cleaner and secure with
clips.
9.Connect multiplug to MAF sensor.
10.Connect intake hose and secure with clip.
CAUTION: Failure to connect intake hose
securely will allow unmetered air to enter
the engine, causing running problems.
11.Reconnect battery negative lead.

CHASSIS AND BODY
21
REPAIR REAR DOOR GLASS
Service repair no - 76.31.21
Remove
1.Remove the spare wheel from the rear door.
2.Remove the rear door wiper arm.
See WIPERS
AND WASHERS, Repair, wiper arm - rear
window.
3.If the glass is fitted, disconnect the heater leads
from the terminals, push out the glass and
remove the mounting rubber.Refit
4.Thoroughly clean the opening to be glazed.
5.Clean the glass and fit the mounting rubber,
ensuring that the glass sits correctly in the
groove.
6.Fit a draw cord around the exterior of the
mounting rubber with the tails of the cord
situated on the top corner of the bend at the
bottom of the glass.
7.To aid assembly, coat the glass opening in the
door with liquid soap.
8.Position the assembled glass and rubber
mounting to the opening, with the tails of the
draw cord fed into the interior of the vehicle.
9.With assistance from a second operator, pushing
the glass and mounting rubber into the opening,
pull the draw cord from the mounting rubber
enabling the seal to ride up over the retaining
flange.
10.Connect the heater leads to the terminals on the
glass.

76CHASSIS AND BODY
50
REPAIR
NOTE: If heated front screen: 2 electrical
multiplug connectors are located under
the decker [cowl] panel. To access release
decker panel.
Remove
1.Remove windscreen wiper arms.
See WIPERS
AND WASHERS, Repair, wiper arms -
windscreen.
2.Remove rear view mirror and stickers from
glass.
3.Remove'A'post finishers.
4.Fit protective cover over dash panel and apply
masking tape to protect'A'posts.
5.Ease one end of bottom finisher away from
glass, pull to disengage finisher flange and
remove.
6.Lift lip of LH'A'post finisher and release sealing
strip along its length, pull to disengage finisher
flange from glass and remove.7.Remove RH'A'post finisher.
8.Remove header finisher.
9.Apply masking tape to protect paint finish around
glass.
10.Prepare cutting wire in handle'A'.Bend end of
wire to handle and tape over end.
11.Force cutting wire through sealer from inside and
100mm (3 7/8 in) from a top corner. Use a
needle if necessary to make a pilot hole.
12.Attach handle'B'.Allow 200mm (7 7/8 in) of wire
between handles, tape over end of wire.
13. With an assistant on the inside:Wedge the
tube of the handle'A'between glass and body
flange 100mm (3 7/8 in) ahead of hole in sealer.
14. From the outside:Carefully cut sealer from
flange using a straight pull away from the glass.
Continue in 100mm (3 7/8 in) steps around the
glass, use a sawing action at the corners.
CAUTION: Along the bottom edge, great
care must be taken to cut up to the 2
supports, positions indicated on the
obscuration band (See item 18).
15.Remove handle'B', withdraw the cutting wire
and insert it through the sealer between the
supports. Refit handle'B'.

WIPERS AND WASHERS
1
DESCRIPTION AND OPERATION WINDSCREEN WIPER AND WASHER OPERATION
The illustration below locates and identifies the main
components of the windscreen and washer system
which is operated by a multi-switch on the right hand
side of the steering column.
All functions of the system are described in the
following paragraphs.
1. Multi-switch
2. Wiper motor
3. Wiper arm/blade
4. Washer reservoir
5. Windscreen washer motor/pump
6. Non return valve
7. Washer jet
8. Rear window washer motor pump
9. Non return valve10. Headlamp power wash motor/pump
11. Headlamp power washer jet
12. Non return valve
13. Rear window wiper switch
14. Rear window washer switch
15. Rear window wiper motor, arm and blade
16. Washer jet

84WIPERS AND WASHERS
2
DESCRIPTION AND OPERATION Wash wipe function
With the ignition switched on, power is supplied via a
fuse to the multi-switch, a control unit and a park
switch which is driven by the wiper motor.
Single wipe A
Pull the lever down and release immediately.
NOTE: With the lever held down, the
wipers will continue operating at high
speed until it is released.
Intermittent wipe B
Turn switch to second position.
Normal speed wipe C
Turn switch to second position.
Fast speed wide D
Turn switch to third position.
Variable delay (intermittent wipe)
Rotate the switch to vary the delay between wipes.
Windscreen washer E
Pull the lever towards the steering wheel. The
windscreen washers will operate in conjunction with
the wipers for as long as the lever is held in this
position.
Headlamp washers
The headlamp washers operate automatically
whenever the windscreen washers are operated,
provided the headlamps are illuminated and switched
to dipped beam. For continuous washing, hold the
windscreen washer control in the washposition E.
REAR WINDOW WIPER AND WASHER
OPERATION
The illustration J5375 also locates and identifies the
main components of the rear window wiper and
washer system which is operated by two switches
mounted on the right hand side of the instrument
binnacle.
Rear window wipe A
Press the switch to operate: after continuously wiping
3 or 4 times, the wiper operates intermittently (approx
once every 6 seconds) until switched off.
Rear window washer B
Press and hold the switch for the required duration of
rear screen washing. The wiper operates
automatically during washing and continues for a
further 3 wipes after the switch is released.

WIPERS AND WASHERS
1
FAULT DIAGNOSIS WIPER MOTOR CHECKING
NOTE: These instructions apply to
windscreen and rear window wiper motor.
If unsatisfactory operation of wiping equipment is
experienced, a systematic check to determine fault
should be carried out:
1.Check blades for signs of excessive friction. This
reduces wiping speed of motor and cause
increased current draw which may damage
armature. Check by substitution.
2.Check windscreen wiper motor light running
current and speed with motor coupling link
disconnected from wiper shaft transmission
linkage.
Check rear window glass wiper motor with wiper
connected and glass wet. Connect an ammeter in
series with motor supply. Measure current
consumption when motor is switched on. Check
operating speed by timing speed of rotation of motor
coupling link. The results should compare with figures
given in 'General Specification Data'.
NOTE: If vehicle wiring connections are
disconnected and an alternative supply
source is applied it is essential that
correct polarity is observed. Failure to observe
this will cause motor to rotate in reverse direction,
which may result in limit switch contacts being
damaged.
3.If motor does not run satisfactorily or takes
higher than normal current, a fault exists and
must be remedied.
4.If current consumption and speed of motor are
satisfactory. A check should be carried out for
proper functioning of transmission linkage and
wiper arm shafts.
NOTE: Service parts are not available for
windscreen and rear window wiper motors
with exception of windscreen wiper rotary
connecting link.

WIPERS AND WASHERS
1
REPAIR WASHER RESERVOIR
Service repair no - 84.10.03.
Remove
1.Remove two bolts securing top of reservoir.
2.From underneath the wheelarch remove two
bolts securing base of reservoir.
3.Withdraw reservoir and disconnect tubing from
washer pumps and power wash.
4.Disconnect electrical leads from pumps.
Refit
5.Reverse removal procedure. 1 to 4.WASHER PUMP - WINDSCREEN, REAR WINDOW
OR POWER WASH
Service repair no - 84.20.21.
Remove
1.Remove washer reservoir.See Washer
reservoir
2.Disconnect washer tubing from pump.
3.Disconnect electrical leads from pump.
4.Pull top of pump away from its location in
reservoir and remove pump.
Note position of sealing gasket in reservoir.
Refit
5.Reverse removal procedure. 1 to 4.

84WIPERS AND WASHERS
2
REPAIR WINDSCREEN WASHER JETS
Service repair no - 84.10.09.
Remove
1.Disconnect washer tube from jet.
2.Remove nut and washer securing washer jet to
air intake cowl.
3.Remove jet.
Refit
4.Reverse removal procedure. 1 to 3.WINDSCREEN WASHER TUBES
Service repair no - 84.10.15.
Remove
1.Disconnect tubing from reservoir pump.
2.Disconnect tubing from washer jets.
3.Disconnect tubing from three-way tee piece.
4.Release tubing from retaining clip and withdraw.
Refit
5.Reverse removal procedure. 1 to 4. Ensuring the
tubing is not pinched or restricted.