LAND ROVER DISCOVERY 1995 Workshop Manual

12ENGINE
20
REPAIR CYLINDER HEAD GASKET
Service repair no - 12.29.02
Remove
1.Disconnect battery negative lead.
2.Remove bonnet [Hood].
See CHASSIS AND
BODY, Repair, Bonnet [Hood]
3.Drain coolant.
4.Remove air cleaner assembly.
See FUEL
SYSTEM, Repair, Air Cleaner
5.Detach crankcase ventilation valve and side
breather hose from rocker cover and move to
one side.
6.Remove injection pipes.
7.Disconnect spill rail from fuel injectors.
8.Remove fuel injectors and sealing washers.
Identify each injector to the location from which it
is removed.
See FUEL SYSTEM, Repair,
Injectors
9.Remove inter-connecting harness from glow
plugs.
10.Remove glow plugs.
See FUEL SYSTEM,
Repair, Glow Plugs
11.Remove top hose, radiator to thermostat.
12.Disconnect by-pass hose from thermostat.
13.Disconnect hose, thermostat to water pump.
14.Disconnect water temperature sensor lead.
15.Remove hose inter-cooler to induction manifold.
16.Remove induction manifold.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
Manifold - Tdi
17.Remove exhaust manifold and turbocharger
assembly.
See MANIFOLD AND EXHAUST
SYSTEM, Repair, Exhaust Manifold - Tdi
18.Disconnect heater hose from water pump and
move heater rail aside.
19.Disconnect heater hose from rear of cylinder
head.
20.Remove bolt securing air cleaner mounting
bracket to support strut.
21.Remove bolt securing harness bracket to
cylinder head.
22.Remove rear lifting bracket, this will also release
clips securing transmission and engine breather
pipes and multiplug. Note loose spacer under
clip securing engine breather pipe and multiplug.

Tdi
21
REPAIR 23.Remove rocker cover.
24.Remove nuts and bolts and withdraw rocker
shaft assembly.
25.Remove push rods, store as an identified set to
allow refitment to same location.
26.Remove valve stem caps.
27.Evenly slacken, then remove, bolts retaining
cylinder head to block. Two of the bolts also
secure the air cleaner mounting bracket.
28.Lift off cylinder head and remove gasket.
Refit
29.Ensure face of cylinder block is thoroughly clean.
30.Select new gasket of correct thickness.
CAUTION: Three thicknesses of gasket are
available, different thicknesses are
identified by the number of small holes
punched in the right hand side of the gasket. One
hole identifies the thinnest gasket and three holes
the thickest. When renewing gaskets the gasket
being fitted must be of the same thickness as the
one removed. Therefore if the removed gasket had
two holes punched in the side the replacement
gasket must also have two holes punched in the
side.
31.Place gasket on cylinder block with identification
holes positioned towards rear on right hand side
and side marked TOP uppermost.
32.Clean mating face of cylinder head.
33.Lower cylinder head onto block ensuring correct
location with dowels.

12ENGINE
22
REPAIR
NOTE: Cylinder head retaining bolts can
be used up to a maximum of five times.
34.Lubricate threads of bolts with light oil and fit to
positions illustrated.
Bolt sizes:
M10 x 117mm locations 3, 5, 12, and 13.
M12 x 140mm locations 1, 2, 7, 8, 9, 10, 15, 16, 17,
and 18.
M12 x 100mm locations 4, 6, 11, 14.
35.Tighten bolts so that underside of heads just
make contact with cylinder head.
36.Following the sequence illustrated tighten all
bolts to
40 Nm.
37.Attach degree disc special tool LRT-12-007 to a
power bar.
38.Make a suitable pointer from welding rod and
attach to a bolt screwed into a rocker shaft
securing bolt hole.
39.Tighten all bolts through 60°strictly in sequence
illustrated.
40.Repeat 60°tightening procedure, again strictly in
sequence illustrated.
41.Tighten the ten longer bolts (M12 x 140mm) a
further 20°, again following the sequence
illustrated.
NOTE: Repositioning of the pointer will be
necessary to reach all bolts, the pointer
can be fitted to the rocker shaft securing
studs using two nuts.
CAUTION: The double tightening
procedure must be carried out, on no
account should tightening be performed in
one operation, otherwise damage to the cylinder
head may occur.
42.Fit valve stem caps.
43.Fit push rods to locations from which they were
removed.
44.Fit rocker shaft assembly evenly tightening
securing nuts and bolts to correct torque.
45.Fit rocker cover ensuring oil seal is satisfactory
for continued use.
NOTE: Rocker cover seals can be re-used
up to a maximum of five times.
46.Secure rocker cover with special seal washers
and nuts tightened to correct torque.
47.Refit remainder of items by reversing operations
1 to 22 tightening securing bolts to correct torque
where applicable.

Tdi
23
REPAIR VACUUM PUMP
Service repair no - 70.50.19
Remove
NOTE: To ease pump removal set engine
to T.D.C. on No.1 cylinder.
1.Disconnect battery negative lead.
2.Detach servo hose from vacuum pump.
3.Remove six bolts securing vacuum pump.
4.Detach pump complete with harness bracket.
Note location of bracket for refitting.
Refit
5.Clean mating faces of pump and block.
6.Loosely assemble pump to block with a new
gasket and with harness bracket located under
head of bolt noted during removal.
7.Evenly tighten bolts, to depress pump plunger,
finally tightening to
25 Nm.
8.Connect vacuum hose and secure with clip.
9.Reconnect battery negative lead.GENERATOR
Service repair no - 86.10.02
Remove
1.Disconnect battery negative lead.
2.Remove drive belt.
See Drive Belt Renew
3.Disconnect electrical leads from rear of
generator.
4.Remove securing bolt from bottom of generator.
5.Remove long through bolt from top fixing and
withdraw generator.
Refit
6.Reverse removal procedure.

Tdi
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 block
Bearing cap 133...............................................................................................
Blanking plug, oil gallery, rear 37....................................................................
Oil squirt jet assembly 17................................................................................
Drain plug, cylinder block 25...........................................................................
Oil squirt jet, vacuum pump cam 7.................................................................
Connecting rod to cap 59................................................................................
Oil pick up assembly to bearing cap 9...........................................................
Oil pick up assembly to front cover 25............................................................
Camshaft thrust plate 9..................................................................................
Oil drain pipe to block (internal) 25.................................................................
Oil drain pipe to block (external) 25................................................................
Sump to cylinder block and front cover 25......................................................
Drain plug, oil sump 35...................................................................................
Tappet guide 14..............................................................................................
Breather side cover assembly 25....................................................................
Baffle plate to breather side cover 4..............................................................
Vacuum pump 25............................................................................................
Fuel lift pump 25.............................................................................................
Flywheel housing 45.......................................................................................
Flywheel housing clutch cover stud 10...........................................................
Plug, flywheel housing 12...............................................................................
Rear oil seal assembly 25...............................................................................
Oil filter adaptor 45..........................................................................................
Waxstat adaptor to oil filter adaptor 9............................................................
Oil pressure switch 17.....................................................................................
Oil filter, spin on 13.........................................................................................
Oil cooler unions to filter adaptor 45...............................................................
Oil level tube 25..............................................................................................
Engine mounting foot to cylinder block 85......................................................
Engine mounting foot to flywheel housing 45.................................................
Engine mounting foot rubber to mounting foot (bolt and nut) 85.....................
Flywheel to crankshaft 146..............................................................................
Clutch cover plate to flywheel 34....................................................................
Flex drive plate to crankshaft (auto) 146..........................................................
Flex drive plate to ring gear (auto) 25.............................................................
Flex drive plate to torque converter (auto) 45.................................................

12ENGINE
2
SPECIFICATIONS, TORQUECylinder head
Cylinder head to cylinder block See repair section......................................................
Stub pipe heater feed 22.................................................................................
Water temperature sensor 14.........................................................................
Blanking plug cylinder head 14.......................................................................
Engine lifting brackets 25................................................................................
Electrical harness clip bracket 25...................................................................
Exhaust manifold stud 10................................................................................
Exhaust manifold nut 45.................................................................................
Inlet manifold stud 8.......................................................................................
Inlet manifold nut and bolt 25..........................................................................
Air temperature sensor, inlet manifold 14.......................................................
Blanking plug, inlet manifold 14......................................................................
Heatshield to inlet manifold 6.........................................................................
Glow plug 20...................................................................................................
Glow plug terminal nut 2................................................................................
Injector clamp (stud) 8...................................................................................
Injector clamp (nut) 25....................................................................................
Thermostat housing 25...................................................................................
Water outlet elbow to thermostat housing 25..................................................
Water temperature switch, thermostat housing 11..........................................
Plug thermostat housing 6.............................................................................
Rocker shaft pedestal bolt 5 + 50° .....................................................................
Rocker cover (stud) 8.....................................................................................
Rocker cover (fixing nut) 10............................................................................
Breather cyclone to rocker cover 9................................................................
Tappet adjusting nut 16..................................................................................
Front cover to cylinder block 25......................................................................
Front cover plate to front cover 25..................................................................
Static idler - timing belt (stud) 10.....................................................................
Static idler - timing belt (nut) 45......................................................................
Tensioner (timing belt) 45...............................................................................
Camshaft hub bolt 80......................................................................................
Timing pulley to camshaft hub 25...................................................................
Fuel injection pump (stud) 8...........................................................................
Fuel injection pump (nut) 25...........................................................................
Abutment bracket to injection pump 25...........................................................
Support bracket injection pump to cylinder block 25.......................................
Fuel injection pump access plte to front cover plate 25..................................
Timing pulley to injection pump hub 25...........................................................
TV Damper pulley bolt to crankshaft 80 + 90° .....................................................
Fan pulley to hub 25.......................................................................................
Fan and viscous coupling to hub 45...............................................................
Auto tensioner, auxiliary drive (stud) 14..........................................................
Auto tensioner, auxiliary drive (nut) 45...........................................................
Auxiliary mounting bracket to cylinder block (stud) 8.....................................
Auxiliary mounting bracket to cylinder block (bolt and nut) 25........................
Water pump to block and mounting plate 25..................................................
Water pump pulley to hub 25..........................................................................

Tdi
3
SPECIFICATIONS, TORQUE Turbo charger oil drain adaptor to block 42....................................................
Oil drain pipe to turbocharger 25....................................................................
Turbocharger oil drain pipe to adaptor 38.......................................................
Turbocharger oil feed pipe adaptor to block 25...............................................
Turbocharger oil feed pipe to adaptor 25........................................................
Oil feed pipe to turbocharger 19.....................................................................
Turbocharger to cylinder head (stud) 10.........................................................
Turbocharger to cylinder head (nut) 45...........................................................
Turbocharger to blanking plate 25..................................................................
Turbocharger to EGR valve 25.......................................................................
EGR delivery tube to valve 25........................................................................
EGR delivery tube to mixing tube 25..............................................................
Fuel lift pump to filter (union) 15.....................................................................
Fuel filter from lift pump (banjo bolt) 33...........................................................
Fuel filter to fuel injection pump (banjo bolt) 33..............................................
Fuel injection pump from fuel filter (banjo bolt) 25..........................................
Injector pipes to injectors and fuel injection pump 29.....................................
Spill rail to injectors (banjo bolt) 10.................................................................
Spill rail to injection pump (banjo bolt) 25.......................................................
Boost pipe injection pump (banjo bolt) 10.......................................................
Plug, rear of injection pump 29.......................................................................
PAS pump to mounting plate 25.....................................................................
PAS pump mounting plate to auxiliaries mounting bracket 25........................
PAS pump pulley to hub 25............................................................................
Generator to auxiliaries mounting bracket 25.................................................
Starter motor (bolt and nut) 45........................................................................
Tachometer electrical connection 4...............................................................
Air conditioning compressor
Compressor mounting bracket to front cover 45.............................................
Compressor to mounting bracket (stud) 8......................................................
Compressor to mounting bracket (nut) 25......................................................
Belt tensioner pulley to tensioner arm 45........................................................
Belt tensioner assembly to front cover plate 25..............................................
Idler pulley to front cover plate 45...................................................................
Compressor belt guard (nut) 25......................................................................
Sensors to water outlet elbow (air/con) 25......................................................
Blanking plug, water outlet elbow (air/con) 25................................................
Generator mounting bracket to front cover 45................................................
Generator to mounting bracket 85..................................................................
Generator pulley to hub 95.............................................................................
Generator belt guard 25..................................................................................

12ENGINE
4
SPECIFICATIONS, TORQUEMETRIC 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
DESCRIPTION AND OPERATION DESCRIPTION
The V8i engine has cast aluminium cylinder heads
and cylinder block. The two banks of steel cylinder
liners which are pressed down to stops in the block,
are set at 90°to one another. The three ringed
aluminium pistons transmit the power through the
connecting rods to a cast iron five bearing crankshaft,
which drives the centrally located camshaft via a
duplex type chain.
The electronic ignition distributor is driven by a gear
off the front of the camshaft and the lubrication oil
pump is driven by a gear off the front of the
crankshaft. The overhead inlet and exhaust valves are
operated by rocker shafts, pushrods and self adjusting
hydraulic tappets.
Multiport fuel injection ensures that engine
performance, economy and exhaust emissions are
automatically correct for the demands of highway and
off road operation.

12ENGINE
2
DESCRIPTION AND OPERATION
1. Cylinder block
2. Pistons and gudgeon pins (8)
3. Connecting rods (8)
4. Core plugs
5. Camshaft
6. Dipstick
7. Camshaft key
8. Timing chain
9. Camshaft sprocket
10. Distance piece
11. Distributor drive gear
12. Distributor
13. Front cover
14. Front cover oil seal
15. Coolant pump
16. Crankshaft damper / pulley17. Crankshaft sprocket
18. Crankshaft sprocket key
19. Crankshaft
20. Centre main bearing shells (2)
21. Crankshaft rear oil seal
22. Spacer
23. Adaptor plate
24. Rear main bearing cap, shell and side seals
25. Connecting rod caps
26. Main bearing caps and shell bearings
27. Oil filter
28. Oil pump suction pipe/strainer
29. Oil sump
30. Oil sump drain plug
31. Oil pump drive key