engine LAND ROVER DISCOVERY 1995 Owners Manual

V8i
15
REPAIR OIL SUMP
Service repair no - 12.60.44
Remove
1.Drain engine oil
See SECTION 10,
Maintenance, Under Vehicle Maintenance
2.Fit drain plug. Tighten to40 Nm.
3.If fitted, disconnect low oil level sensor multiplug.
4.Remove bolt securing dipstick tube to rocker
cover.
5.Working form the centre outwards, progressively
loosen and remove 17 bolts securing sump.
Remove sump.
6.Remove all traces of sealant from mating
surfaces of sump, cylinder block and front cover,
using a suitable solvent or plastic scraper.
7.Degrease mating surfaces of sump, cylinder
block and front cover.Refit
8.Apply RTV Hylosil White sealant to mating
surface of sump.
9.Position sump, tighten bolts finger tight.
10.Tighten bolts progressively in sequence shown.
Tighten to
18 Nm.
11.Fit bolt securing dipstick tube to rocker cover.
12.If fitted, connect low oil level sensor multiplug.

V8i
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Engine
Adaptor plate to crankshaft 84........................................................................
Generator and power steering mounting bracket to cylinder head 30............
Cylinder head:
Stage 1: 20.............................................................................................
Stage 2: - Further 180°±5°
Drive plate to converter 39..............................................................................
Engine mountings to engine and chassis 55..................................................
Engine mounting rubbers to brackets 30........................................................
Flexible drive plate to crankshaft adaptor plate 41.......................................... **
Flywheel to crankshaft bolts 78....................................................................... **
Lifting eye to cylinder heads 39......................................................................
Main bearing cap rear bolts 92....................................................................... *
Oil sump drain plug 40....................................................................................
Oil sump to cylinder block 18..........................................................................
Rocker cover to cylinder head 9....................................................................
Rocker shaft bracket to cylinder head 38........................................................
Spark plug 21..................................................................................................
Starter motor attachment 44...........................................................................
* These bolts must have threads coated in lubricant EXP16A before assembly.
** These bolts must have threads coated in sealant Loctite 270
METRIC Nm
M5 6......................................................................................................
M6 9......................................................................................................
M8 25.....................................................................................................
M10 45...................................................................................................
M12 90...................................................................................................
M14 105..................................................................................................
M16 180..................................................................................................
UNC / UNF
1/4 9......................................................................................................
5/16 24...................................................................................................
3/8 39.....................................................................................................
7/16 78...................................................................................................
1/2 90.....................................................................................................
5/8 136....................................................................................................
NOTE: Torque values above are for all screws and bolts used except for those specified.

V8i
1
SERVICE TOOLS ENGINE
LRT-12-034 Spring compressor
MS1519A
LRT-12-010 Crankshaft rear seal guide
RO1014
LRT-12-052 Oil pressure test kit

4.0 V8
1
DESCRIPTION AND OPERATION DESCRIPTION
For description and operation refer to overhaul
manual 4.0/4.6 V8 engine.
CONTENT OF THIS SECTION
Only service repair operations not covered in engine
section V8i or unique to 4.0 V8 engines appear in the
repair sub-section of this section.

4.0 V8
1
REPAIR CRANKSHAFT PULLEY
Service repair no - 12.21.01 - Crankshaft Pulley
Remove
1.Disconnect battery negative lead.
2.Remove cooling fan.
See COOLING SYSTEM,
Repair, Viscous Coupling, Fan Blades,
Pulley and Fan Cowl
3.Slacken 3 water pump pulley securing bolts.
4.Remove drive belt.
See ENGINE 3.9 V8,
Repair, Drive Belt Renew
5.Remove water pump pulley bolts. Remove water
pump pulley.
6.Raise and support front of vehicle.
7.Remove 9 bolts securing bell housing access
cover (2 dowel bolts).
8.Remove access plate.
NOTE: It will be necessary to have an
assistant position a large flat ended
screwdriver between ring gear and adaptor
plate to prevent ring gear rotating.
9.Remove crankshaft pulley bolt. Collect pulley
and tool.
Refit
10.Clean seal running surface on pulley.
11.Clean key and keyway.
12.Fit crankshaft pulley.
NOTE: It will be necessary to have an
assistant position a large flat ended
screwdriver between ring gear and adaptor
plate to prevent ring gear rotating.
13.Refit crankshaft pulley bolt. Tighten to
270 Nm.
14.Ensure mating faces between bell housing
access cover and mating face are clean.
15.Fit access cover.
16.Fit cover bolts. Tighten to
10 Nm.
17.Remove supports and lower vehicle.
18.Ensure mating faces between water pump pulley
and pump are clean.
19.Refit water pump pulley. Fit bolts finger tight.
20.Fit drive belt.
See ENGINE 3.9 V8, Repair,
Drive Belt Renew
21.Tighten water pump pulley bolts to Tighten to24
Nm.
22.Refit cooling fan.See COOLING SYSTEM,
Repair, Viscous Coupling, Fan Blades,
Pulley and Fan Cowl
23.Reconnect battery negative lead.

12ENGINE
2
REPAIR CRANKSHAFT FRONT OIL SEAL
Service repair no - 12.21.14 - Crankshaft Front Oil
Seal
Remove
1.Remove crankshaft pulley.
See ENGINE 3.9 V8,
Repair, Crankshaft Pulley Assembly
2.Screw tool LRT-12-088 into oil seal.
3.Turn centre bolt of tool to extract oil seal.
4.Remove oil seal from tool.
Refit
5.Clean seal seating and pulley seal register.
6.Lubricate seal with oil.
7.Locate oil seal in housing and drive into place
using LRT-12-089.
8.Lubricate oil seal lip.
9.Locate seat in front cover.
10.Drift seat into position using tool LRT-12-089.
11.Refit crankshaft pulley.
See ENGINE 3.9 V8,
Repair, Crankshaft Pulley Assembly; Refit

4.0 V8
3
REPAIR ENGINE ASSEMBLY
Service repair no - 12.41.01/99
Remove
1.Position vehicle on ramp.
2.Remove bonnet.
See CHASSIS AND BODY,Repair, Bonnet [Hood]
3.Remove radiator.See COOLING SYSTEM,
Repair, Radiator
4.Remove plenum chamber.See FUEL SYSTEM
SFI, Repair, Plenum Chamber
5.Remove mass air flow sensor.See FUEL
SYSTEM SFI, Repair, Mass Air Flow Sensor
(MAF Sensor)
6.Slacken hose clip securing bottom hose to
expansion tank.
7.Disconnect hose.
8.Remove 2 nuts securing expansion tank.
9.Remove nut and bolt securing expansion tank.
10.Remove expansion tank.
11.Disconnect servo vacuum hose from ram
housing.
12.Disconnect battery sensing lead Lucar from
generator.
13.Remove generator terminal cover.
14.Remove 2 terminal nuts and release leads from
terminals.
15.Release purge hose from ram pipe housing.
16.Position cloth to absorb fuel spillage.
17.Slacken clip securing fuel return hose to fuel rail.
18.Disconnect hose.
19.Plug connections.
20.Disconnect fuel feed hose union.
21.Plug connections. Position hoses aside.
22.Slacken clip securing heater return hose to pipe.
23.Disconnect hose.24.Slacken clip securing heater feed adaptor hose
to inlet manifold.
25.Remove bolt securing pipe bracket.
26.Disconnect feed hose from inlet manifold.
27.Disconnect hose/pipe assembly.
28.Disconnect leads from spark plugs and remove
ignition coils.
See FUEL SYSTEM SFI, Repair,
Ignition Coils
29.Disconnect fuel temperature sensor multiplug.
30.Disconnect coolant sensor multiplug.
31.Disconnect temperature gauge sensor lead.
32.Release camshaft sensor multiplug from bracket
and disconnect multiplug.
33.Disconnect oil pressure switch Lucar.
34.Disconnect air intake temperature sensor
multiplug.
35.Disconnect 8 injector multiplugs.
36.Remove 4 nuts securing harness brackets to
inlet manifold.
37.Release harness brackets.
38.Remove bolts securing gearbox breather pipes
to engine lifting bracket.

12ENGINE
4
REPAIR 39.Release battery positive lead terminal cover.
40.Remove terminal nut
41.Release terminal from battery.
42.Release fusebox main feed lead.
43.Position battery cable over engine.
44.Pivot jockey pulley downwards to release drive
belt tension.
45.Release belt from pulleys.
46.Remove drive belt.
47.Disconnect compressor multiplug
48.Remove 4 bolts securing compressor.
49.Remove heatshield.
50.Release compressor from bracket and tie aside.
51.Slacken clip securing PAS hose to pump.
52.Disconnect hose.
53.Plug hose and pump.
54.Disconnect PAS hose connection at pump and
steering box.
55.Release unions and remove hose.
56.Remove and discard 'O' rings.
57.Plug pump and steering box.
58.Remove LH and RH engine mounting nuts.
59.Position lifting chains and attach hooks to engine
lifting eyes.
60.Raise engine sufficiently to release engine
mountings.
61.Release engine mountings and remove.
62.Lower engine until it just rests on engine
mounting brackets.
63.Disconnect chains.
64.Raise ramp.
65.Remove catalytic converter/front pipe assembly.
See EMISSION CONTROL, Repair, Catalytic
Converter/Front Pipe - 4.0 V8
66.Remove 9 bolts securing bell housing bottom
cover. Note position of 2 dowel bolts.
67.Remove cover.
68.Remove locknut securing transfer box tie bar.
69.Remove 2 bolts securing tie bar to tranmission.
70.Remove tie bar.
71.Remove 2 and slacken 1 bolt, securing bell
housing access plate and position aside.
72.Mark drive plate to torque converter relationship.
73.With assistance, rotate crankshaft for access to
first bolt (torque converter to drive plate).
74.Remove first bolt.
75.Repeat steps for the remaining 3 bolts.
76.Remove 2 bolts securing crankshaft sensor
shield to engine backplate.
See FUEL SYSTEM
SFI, Repair, Crankshaft Position Sensor
(CKP Sensor)

4.0 V8
5
REPAIR 77.Release sensor/shield and remove.
78.Disconnect sensor multiplug.
79.Remove sensor.
80.Remove starter motor heatshield.
See
ELECTRICAL, Repair, Starter Motor
Heatshield - 4.0 V8
81.Disconnect solenoid Lucar.
82.Disconnect RH and LH knock sensor multiplugs.
See FUEL SYSTEM SFI, Repair, Knock
Sensor
83.Release harness from engine.
84.Remove nut securing handbrake cable
heatshield.
85.Release speed sensor lead from clip on
heatshield.
86.Remove heatshield.
87.Disconnect top oil cooler pipe union from
transmission.
88.Release union.
89.Remove 'O' ring and discard.
90.Plug pipe and transmission.
91.Remove bolt securing oil cooler pipe bracket tosump. Collect spacer.
92.Remove 3 bolts from top of bell housing.
93.Collect 2 harness brackets.
94.Remove 2 bolts, LH and RH side of bell housing.
95.Remove centre LH bell housing bolt using long
extension.
96.Remove 2 lower bolts from bell housing.
97.Fit suitable wooden block in access plate hole to
retain torque converter.
98.Secure block with cover plate and tighten one
cover plate bolt.
99.Support gearbox on a jack.
100.Lower ramp.
101.Position lifting chains and attach hooks to engine
lifting eyes.
102.Raise engine.
103.Raise jack.
104.Break engine to gearbox joint.
105.Raise engine.

12ENGINE
6
REPAIR
106.Remove top starter bolt securing engine earth
cable.
107.Remove nut securing kick-down cable clip to LH
cylinder head.
108.With assistance, raise engine, move aside all
pipes and wires. Move engine clear of vehicle.
109.Lower engine onto bench.
Refit
110.Clean engine and gearbox mating faces.
111.Clean dowel and dowel holes.
112.With assistance raise engine off bench. Lower
and guide engine into engine compartment
ensuring no wires or pipes become trapped.
113.Position clip securing kick-down cable to LH
cylinder head.
114.Fit and tighten nut.
115.Position engine earth cable and secure to starter
with top bolt. Tighten to
45 Nm.
116.Lower engine.
117.With assistance, engage engine with gearbox.
118.Fit 3 bottom bell housing bolts. Tighten to
46
Nm.
119.Lower jack supporting gearbox.
120.Lower engine onto mounting brackets.
121.Fit centre RH bell housing bolt.
122.Fit centre LH bell housing bolt.
123.Fit harness brackets to 2 top bell housing bolts.
124.Fit bolts. Tighten to
46 Nm.
125.Remove plugs from tranmission and oil cooler
pipe.
126.Clean pipe, lubricate NEW 'O' ring and fit to
pipe.
127.Connect pipe to transmission and secure with
union. Tighten to
30 Nm.
128.Align pipe bracket to sump, position spacer and
fit bolt. Tighten to
18 Nm.
129.Fit heatshield and secure with nut.
130.Secure transducer lead to clip on heatshield.131.Slacken bell housing access plate bolt.
132.Move plate aside.
133.Remove block.
134.Align drive plate and torque converter.
135.Fit 2 torque converter bolts.
136.Rotate engine and fit second 2 bolts. Tighten to
45 Nm.
137.Rotate engine and tighten first 2 bolts to Tighten
to
45 Nm.
138.Clean cover plate and mating face.
139.Position cover plate and fit bolts. Tighten to
45
Nm.
140.Position access plate.
141.Fit 2 remaining bolts and tighten all bolts to
Tighten to
9 Nm.
142.Position engine harness around engine.
143.Connect knock sensor multiplug.
144.Connect starter solenoid Lucar.
145.Position starter motor heatshield and secure clip
to solenoid.
146.Align shield bracket to engine mounting bracket
and fit bolt. Tighten to
9 Nm.
147.Clean crankshaft sensor mating faces.
148.Position sensor and connect multiplug.
149.Position/align sensor and shield to backplate. Fit
bolts. Tighten to
6 Nm.
150.Fit tie bar, align to transmission and fit bolts.
Tighten to
25 Nm.
151.Fit tie bar securing nut. Tighten to45 Nm.
152.Fit catalytic converter/front pipe assembly.See
EMISSION CONTROL, Repair, Catalytic
Converter/Front Pipe - 4.0 V8
153.Raise engine.
154.Fit RH mounting rubber.
155.Move engine over.
156.Fit LH mounting rubber.
157.Lower engine.
158.Disconnect hoist.
159.Fit engine mounting nuts. Tighten to
55 Nm.
160.Remove plugs from steering pump and steering
box.
161.Clean PAS hose unions.
162.Lubricate 'O' rings and fit to hose unions.
163.Position hose.
164.Align unions to pump and steering box. Tighten
14mm thread to
15 Nm, 16mm thread to
Tighten to
20 Nm.
165.Remove plugs from feed hose and PAS pump.
166.Connect hose to pump and tighten clip.
167.Untie compressor and position to engine
bracket.
168.Position heatshield and fit bolts. Tighten to
25
Nm.
169.Connect compressor multiplug.
170.Position drive belt.