lock LAND ROVER DISCOVERY 1995 Owners Manual

MFI
3
FAULT DIAGNOSIS FUEL PRESSURE CHECK
In order to check the fuel pressure it is necessary to
first depressurise the fuel system as follows:
WARNING: Under normal operating
conditions the multiport fuel injection
system is pressurised by a high pressure
fuel pump, operating at up to 2.3 to 2.5 bar. When
engine is stationary pressure is maintained within
system. To prevent pressurised fuel escaping and
to avoid personal injury it is necessary to
depressurise multiport fuel injection system
before any service operations are carried out.
If vehicle has not been run there will be a small
amount of residual pressure in fuel line. The
depressurising procedure must still be carried out
before disconnecting any component within the
fuel system.
The spilling of fuel is unavoidable during this
operation. Ensure that all necessary precautions
are taken to prevent fire and explosion.
A Pressure gauge 18G1500
B Fuel tank and pump
C Fuel filter
D Fuel injectors x 8
E Regulator1.Remove fuel pump relay module.
See Repair,
Multiport Fuel Injection Relay
2.Start and run engine.
3.When sufficient fuel has been used to cause fuel
line pressure to drop, injectors will become
inoperative, resulting in engine stall. Switch off
ignition.
4.Disconnect battery negative lead. .
NOTE: Fuel at low pressure will remain in
system. To remove low pressure fuel,
place absorbent cloth around fuel pipe at
the filter during disconnection.
5.Connect the pressure gauge on the outlet from
the filter, located on the chassis under the right
rear wheel arch.
6.Reconnect the battery and turn the ignition to
position II while observing the pressure gauge.
Results
Expected reading 2,39-2,672 kgf/cm
2
Pressure drop-max 0.7 kgf/cm2in one minute.
If pressure is low check that filter is not blocked
and pump is operating satisfactorily. Then
recheck pressure. If pressure is still low renew
regulator.
See Repair, Fuel Pressure
Regulator

19FUEL SYSTEM
8
REPAIR 10.Remove fuel rail and injectors.
11.Remove injector retaining clips, ease injectors
from rail. Remove and discard 'O' rings from
injectors.
12.Remove fuel pressure regulator if required.
Refit
13.FitNEW'O' rings, to injectors. Lightly coat 'O'
rings with silicon grease 300. Insert injectors into
fuel rail, multi-plug connections facing outwards.
14.Refit retaining clips.
CAUTION: Care must be taken when
refitting the fuel rail and injectors to intake
manifold to prevent damage to 'O' rings.
15.Fit aNEW'O' ring to pressure regulator lightly
coat 'O' ring with silicon grease 300 and secure
regulator to the fuel rail.
16.Fit fuel rail and heater pipe assemblies to intake
manifold. Secure rail and pipes in position with
five bolts.
17.Reverse removal procedure. 2 to 7.
18.Pressurise fuel system and check for fuel leaks
around injectors and pressure regulator.PLENUM CHAMBER
Service repair no - 19.22.46
Includes throttle levers and throttle disc
Remove
1.Disconnect battery negative lead.
2.Disconnect electrical multi-plug from bypass air
valve.
3.Disconnect vacuum hose adjacent to bypass air
valve.
4.Mark an identification line on throttle cable outer
to assist re-assembly.
5.Remove clevis pin from throttle cable.
6.Pry adjustment thumb wheel from throttle
bracket. Lay cable aside.
7.Remove retaining clip and clevis pin from kick
down cable (automatic vehicles).
8.Apply adhesive tape behind rear adjustment nut
on kick down cable to prevent nut moving.
9.Remove front lock nut. Remove cable and lay
aside.
10.Remove cruise control vacuum hose.
11.Remove intake hose from neck of plenum
chamber.
12.Disconnect throttle position sensor multi-plug.
13.Remove PCV breather hose.
14.Disconnect two coolant hoses and plug each
hose to prevent excessive loss of coolant.
Identify each hose for re-assembly.

MFI
9
REPAIR
15.Remove distributor vacuum hose.
16.Release two screws and remove throttle position
sensor.
17.Remove six screws securing plenum chamber.
Remove plenum chamber.
18.Remove air idle air control valve hose.Throttle lever assembly - remove
19.If fitted - unclip cruise control actuator link. Hold
throttle fully open, release link from countershaft
assembly. Carefully return lever assembly to
close throttle.
20.Release tension on inboard throttle spring.
21.Bend back lock washer tabs.
22.Hold throttle stop lever in closed position,
release nut from throttle shaft.
23.Release tension on outboard throttle spring.
24.Remove overtravel spring.

MFI
13
REPAIR 44.Grease new air seal with Admax L3 or
Energrease LS3. Push seal down shaft, into
counterbore until seal is 6.0 mm (0.236 in) below
face of plenum.
Throttle levers and bracket - assemble
45.Fit stop lever to throttle shaft, a new tab washer
and secure with throttle shaft nut.
46.Holding stop lever on stop, tighten throttle shaft
nut securely, bend over tabs to lock nut in
position.
47.Fit inboard throttle return spring noting that small
hooked end of spring is nearest plenum.
48.Locate hooked end of inboard spring on stop
lever. Wind up straight end one full turn and
locate in appropriate slot.
49.Fit countershaft to interconnecting nut of throttle
valve shaft.
50.Secure throttle bracket assembly to plenum.
Secure with three retaining bolts.
51.Ensure hooked end of outboard spring is
retained by lever, wind spring up one full turn
and locate free end in appropriate slot.
52.Fit overtravel spring.
Lightly grease throttle return and overtravel
springs with Admax L3 or Energrease LS3.
NOTE: If new throttle levers have been
fitted, minimum throttle setting of disc
must be checked to ensure it is 90Ê to
bore.53.Using a depth vernier or depth micrometer,
check dimension from mouth of bore to top and
bottom of valve disc. Dimension must be within
0.5 mm (0.019 in) total indicator reading across
diameter of disc.
54.If dimension is out of limits, adjust small set
screw below stop lever.
Refit
55.Reconnect and adjust cruise control actuator
link.
See Actuator Link Setting
56.Clean joint faces of plenum and ram housing.
Apply 'Hylomar' sealant, refit plenum chamber.
Tighten bolts to
26 Nm.
57.Reverse removal procedure.

MFI
15
REPAIR 11.Loosen clip and disconnect top hose from
thermostat housing.
12.Disconnect multiplug from distributor amplifier
module.
13.Loosen clip and disconnect hose from heater
valve.
14.Remove injector harnesses from behind fuel rail
and lay to one side.
15.Loosen union and disconnect fuel return hose
from fuel rail.
NOTE: The intake manifold can be
removed from the cylinder block without
removing the fuel rail and injectors.
16.Using the sequence shown, remove 12 bolts
securing the intake manifold to cylinder block.
17.Remove the intake manifold.
18.Noting their fitted position, remove bolts and
clamps securing intake manifold gasket to
cylinder block.
19.Remove and discard gasket.
20.Remove and discard gasket seals.
Do not carry out further dismantling if component
is removed for access only.
21.Remove 5 nuts securing fuel rail support
brackets to intake manifold.
22.Remove fuel rail and injectors.
23.Remove 2 bolts securing thermostat housing to
intake manifold.
24.Remove thermostat housing.
25.Remove bolt securing coolant pipe to intake
manifold. Loosen union and remove coolant
pipe. Remove and discard 'O' ring.
26.Fit new 'O' ring to coolant pipe. Position coolant
pipe to intake manifold. Fit bolt securing coolant
pipe support bracket to intake manifold and
tighten pipe union.
27.Clean mating faces of thermostat housing and
intake manifold.
28.Fit thermostat housing to intake manifold using a
new gasket, fit and tighten bolts.
29.Position fuel rail to intake manifold, fit and
tighten retaining bolts.

19FUEL SYSTEM
16
REPAIR Refit
1.Clean mating faces of cylinder heads, cylinder
block and intake manifold.
2.Locate NEW seals in position with ends
engaged in notches formed between the cylinder
heads and block.
3.Apply RTV sealant between ends of seals,
cylinder head and block.
4.Fit intake manifold gasket with the word
'FRONT'to the front and open bolts hole to the
front RH side.
5.Fit gasket clamps and tighten bolts finger tight.
6.Locate intake manifold onto cylinder heads,
clean threads of manifold securing bolts.
7.Allow 10 minutes for RTV sealant to cure.
8.Fit manifold bolts finger tight. Working in the
sequence shown tighten the bolts to
38 Nm.
9.Tighten the gasket clamp bolts to18 Nm.
10.Reverse removal procedure.
11.Fill cooling system.
See COOLING SYSTEM,
Repair, Radiator
12.Start engine check for water and fuel leaks.

MFI
19
REPAIR THROTTLE CABLE
Service repair no - 19.20.06
Remove
1.Remove clevis pin securing cable to lever.
2.Carefully pry throttle cable adjustment nut out of
mounting bracket.
3.Remove cable from mounting bracket.
4.Release outer cable from retaining clips in
engine compartment.
5.Remove lower dash panel.
6.Disconnect cable from accelerator pedal and
release cable locknut.
7.Feed cable through bulkhead grommet into
engine compartment.
Refit
8.Feed new cable from engine compartment
through bulkhead grommet.
9.Connect cable to accelerator pedal.
10.Connect cable to throttle linkage, using a new
cotter pin.
11.Clip outer cable adjustment nut into mounting
bracket.
12.Adjust outer cable to give 1.57 mm free play in
inner cable. Check throttle operation.

19FUEL SYSTEM
10
DESCRIPTION AND OPERATION ADD: 09/95 DESCRIPTION AND OPERATION - ADVANCED
EVAPS
1.Fuel filter
2.Fuel pump and gauge sender unit
3.Fuel feed hose
4.Fuel return hose
5.Fuel filler neck assembly
Fuel Tank Assembly
The fuel tank consists of a moulded High Density
Polyethylene (HDPE) fuel cell into which is fitted an
electric fuel pump and four roll-over valves. The pump
is a self priming ñwet" type where the motor is
immersed in fuel. The pump assembly is sealed to the
tank with a rubber seal and secured in place using a
coated steel locking ring. The pump also incorporates
a fuel tank pressure sensor in the top flange.
NOTE: If the pump is removed, a new seal
must always be fitted.

SFI
5
REPAIR FUEL RAIL AND INJECTORS
Service repair no - 19.60.04 - Fuel Rail
Service repair no - 19.60.12 - Injectors
Remove
1.Disconnect battery negative lead.
2.Depressurise fuel system.
See Fuel System -
Depressurise
3.Release plenum chamber and place aside.See
Plenum Chamber
4.Disconnect purge hose, crankcase breather
hose, servo vacuum hose and fuel regulator
hose from ram housing.
5.Remove 6 bolts securing ram housing to inlet
manifold.6.Place small packing block on inlet manifold.
Lever between packing block and ram pipe
housing to break seal.
CAUTION: Do not lever against fuel rail.
7.Remove ram housing.
8.Place cloth over inlet manifold to prevent ingress
of foreign matter.
9.Disconnect 8 injector multiplugs.
10.Disconnect fuel temperature sensor multiplug.
11.Position cloth around fuel feed pipe union to
absorb fuel spillage.
12.Disconnect fuel feed pipe from fuel rail.
13.Plug fuel pipe and rail.
14.Slacken clip securing fuel return hose.

SFI
13
REPAIR PLENUM CHAMBER
Service repair no - 19.22.46
Remove
1.Disconnect battery negative lead.
2.Slacken clip securing intake hose to plenum
chamber and release hose.
3.Remove split pin from throttle cable clevis pin.
4.Remove clevis pin.
5.Release and remove kick down cable clevis pin.
6.Disconnect vacuum hose from cruise actuator.
7.Release throttle cable from abutment bracket.
8.Remove front locknut from kick down cable.9.Release cable from bracket.
10.Disconnect breather hose from plenum.
11.Release clip and disconnect multiplug from
throttle position sensor (TP Sensor).
12.Disconnect multiplug from idle air control (IAC).
13.Remove 6 bolts securing plenum chamber.
14.Release plenum chamber from ram pipe
housing.
15.Fit approved hose clamp to water jacket coolant
hoses.
16.Tighten clamp.
17.Position cloth to absorb coolant spillage.
Do not carry out further dismantling if
component is removed for access only.
18.Slacken clips securing coolant hoses to plenum.