battery LAND ROVER DISCOVERY 1995 Workshop Manual

Tdi
1
REPAIR VISCOUS COUPLING, FAN BLADES, PULLEY AND
FAN COWL
Service repair no - 26.25.03/05
Viscous coupling -Remove1to3
Fan blades -Remove1to4
Fan cowl -Remove1to3
Fan pulley -Remove1to6
Remove
WARNING: Disconnect battery negative
terminal to prevent engine being started
before removing or adjusting drive belt.
1.Slacken nut securing viscous coupling/fan blade
assembly to pulley.
NOTE: Nut securing viscous unit to pulley
has a left hand thread. Release by turning
clockwise when viewed from front of
viscous unit.
2.Drop viscous unit and fan assembly into bottom
of cowling
3.Remove two fixings clips from top of cowling and
lift cowling complete with viscous unit and fan
out of lower mountings.
4.Remove fan blades from viscous coupling if
necessary.
5.Remove serpentine drive belt and, if fitted, air
conditioning compressor belt.
6.Remove pulley fixings, remove pulley.
NOTE: The serpentine belt is removed by
using a hexagonal socket and tommy bar
on the auto-tensioning pulley nut. Whilst
tensioning the device the belt can be removed.
7.Reverse removal procedure. Ensure fan blades
are fitted correctly. Fan is marked 'front' and
should be fitted with word 'front' closest to
radiator. Tighten to
30 Nm.
8.Refit drive belt.See ENGINE, Repair, Drive
Belt
THERMOSTAT
Service repair no - 26.45.01
Remove
1.Partially drain cooling system, until coolant level
is below thermostat housing.
2.Disconnect hose from thermostat housing.
3.Disconnect electrical connections to water
temperature switch.
4.Remove outlet elbow.
5.Withdraw thermostat.
Test
6.Note rating of thermostat is 88°C. Place
thermostat in a container half full of water. Heat
water, observe temperature at which thermostat
begins to open. Thermostat is satisfactory if its
open between 85°C and 89°C.
Refit
7.Insert thermostat with jiggle pin/vent hole upper
most (12 o'clock position) .
8.Fit the outlet elbow and new joint washer.
Tighten to
28 Nm.
9.Reverse removal procedure. 1 to 3.
10.Check for coolant leaks around all connections
and joint faces.

26COOLING SYSTEM
2
REPAIR WATER PUMP
Service repair no - 26.50.01
Remove
WARNING: Disconnect battery negative
terminal to prevent engine being started
before removing drive belts.
1.Drain engine cooling system.
See Adjustment,
Coolant
2.Remove top hose radiator to thermostat.
3.Remove top hose intercooler to induction
manifold.
4.Slacken water pump and power steering pump
pully retaining bolts.
5.Remove drive belt.
6.Remove centre nut from belt tensioner.
7.Manoeuvre pulley upwards and withdraw
tensioner from retaining stud.
8.Disconnect hose thermostat to bottom hose,
release hose from clip on water pump and move
aside.
9.Remove water pump pulley.
10.Remove power steering pump pulley.
11.Remove 8 bolts securing water pump, noting
location of 3 through bolts.
12.Withdraw pump and gasket, clean all gasket
material from mating surfaces.
Refit
13.Refit water pump in reverse order to removal
using new gasket.RADIATOR
Service repair no - 26.40.01
Remove
1.Drain cooling system.
See Adjustment,
Coolant
2.Disconnect radiator top hose.
3.Remove fan blade assembly.
4.Remove cowl.
5.Disconnect engine oil cooler connections and
turbo intercooler connections from radiator ends.
NOTE: Oil spillage will occur when
connections are loosened. Blank off
exposed oil connections.
6.Disconnect expansion tank bleed hose from
radiator.
7.Remove radiator securing brackets from each
side.
8.Remove radiator unit by lifting from its location.
Check condition of rubber mounting pads.
Refit
9.Check radiator sealing strips are securely
located.
10.Transfer oil cooler adaptors if fitting new radiator.
11.Reverse removal procedure. Tighten oil cooler
connections to
30 Nmbefore fitting fan blades
and cowl.
12.Check all connections for leaks.

V8i
1
REPAIR EXPANSION TANK
Service repair no - 26.15.01
Remove
WARNING: Do not remove expansion tank
filler cap when engine is hot. The cooling
system is pressurised and personal
scalding could result.
1.Remove expansion tank filler cap by first turning
it slowly anti-clockwise, pause to allow pressure
to escape. Continue turning in same direction
and lift off.
2.Disconnect two hoses from bottom of expansion
tank, allowing coolant to drain into a suitable
container.
3.Remove three fixing bolts, remove expansion
tank.
Refit
4.Reverse removal procedure.
5.Replenish cooling system.
6.Check for leaks around all hose connections.VISCOUS COUPLING, FAN BLADES, PULLEY AND
COWL
Service repair no - 26.25.19 - Viscous coupling
and fan assembly
Service repair no - 26.25.03 - Water pump pulley
Service repair no - 26.25.05 - Fan blades
Special tools:
LRT-12-093
LRT-12-094 - Viscous coupling removal
Remove
1.Disconnect battery negative lead.
NOTE: 4.0 V8 only:
Release coolant hose from cooling fan upper
cowl.
2.Release 2 clips securing cooling fan upper cowl.
Remove cowl.

26COOLING SYSTEM
2
REPAIR
3.Use LRT-12-093 to prevent coolant pump pulley
from turning and using LRT-12-094, unscrew
viscous coupling from water pump.
NOTE: Nut securing viscous unit to water
pump has a right hand thread. Release by
turning anti-clockwise when viewed from
front of viscous unit.
4.Remove fan and coupling assembly.
Do not carry out further dismantling if component
is removed for access only.
NOTE: Mark fan with reference to assist
refitting.
5.Remove 4 Allen screws securing blades to
coupling. Remove coupling.
6.Remove serpentine drive belt.
7.Remove pulley fixings, remove pulley.Refit
8.Clean fan blades and mating faces.
9.Fit fan blades to coupling. Secure with screws.
Tighten to
24 Nm.
10.Using LRT-12-093 and LRT-12-094, fit fan
assembly to pump. Tighten to
56 Nm.
11.Fit cooling fan upper cowl. Secure with clips.
12. 4.0 V8 only:Fit coolant hose to cooling fan upper
cowl.
13.Fit serpentine drive belt.
14.Fit pulley fixings, remove pulley.
15.Reconnect battery negative lead.

26COOLING SYSTEM
6
REPAIR WATER PUMP
Service repair no - 26.50.01
Remove
WARNING: Disconnect battery negative
terminal to prevent engine being started
before removing or adjusting drive belts.
1.Drain engine cooling system.
See Adjustment,
Coolant
2.Remove fan blades and pulley.See Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
3.Disconnect inlet hose from water pump.
4.Remove water pump bolts.
5.Remove water pump and joint washer.
Refit
6.Lightly grease new joint washer, position on
timing cover.
7.Clean threads of all long bolts and coat with
Loctite 572 thread lubricant-sealant.
8.Locate water pump in position. Tighten
remaining water pump housing bolts evenly to
28 Nm.
9.Reverse removal procedure. 1 to 3.
10.Check for coolant leaks around all hose
connections and joint faces.

26COOLING SYSTEM
2
REPAIR RADIATOR
Service repair no - 26.40.01
Remove
1.Disconnect battery negative lead.
WARNING: Do not carry out the next
instruction until the coolant is cool to
avoid personal injury from scalding.
2.Slacken clip and release bottom hose from
radiator, allow coolant to drain into a suitable
container
3.Slacken clip and release bottom hose from
radiator rail.
4.Slacken clip and release top hose from radiator.
5.Release air cleaner to throttle housing hose from
securing brackets.
6.Slacken clip and release bypass hose from
radiator.
7.Slacken clip and release top expansion hose
from radiator.
8.Remove 2 bolts securing radiator side support
brackets.
9.Collect L.H. support bracket and position R.H.
support bracket aside.
10.Slacken clip and release heater hose from
radiator rail.
11.Disconnect 2 multiplugs from cooling fan
assemblies.

Mpi
3
REPAIR
12.With assistance lift out radiator assembly.
Do not carry out further dismantling if component
is removed for access only.
13.Remove 2 bolts securing radiator rail to radiator.
14.Remove radiator rail.
15.Remove 8 nuts securing fan assemblies to
radiator.
NOTE: Vehicles without air conditioning
have one cooling fan fitted.
Refit
16.Position fan assemblies to radiator and tighten
nuts to
6Nm
17.Position radiator rail to radiator and secure with
bolts.
18.Position radiator to vehicle.
19.Secure radiator to body with the side support
brackets and retaining bolts.
20.Connect multiplugs to cooling fans.
21.Fit and secure 6 hoses to radiator.
22.Secure air cleaner to throttle housing to
brackets.
23.Refill cooling system.
24.Reconnect battery negative lead.

30MANIFOLD AND EXHAUST SYSTEM
4
REPAIR EXHAUST MANIFOLD - Tdi
Service repair no - 30.15.10
Remove
1.Disconnect battery negative lead.
2.Remove heat shield from rear of air intake
manifold.
3.Release dip stick tube from cylinder block.
4.Disconnect the intake hose from the manifold.
5.Remove the two bolts and two nuts securing the
intake manifold to the cylinder head and
withdraw the inlet manifold.
6.Remove air filter inlet pipe to turbo unit.
7.Remove intercooler pipe from turbo to
intercooler.
8.Disconnect the EGR pipe from the inlet manifold
hose.
9.Remove the three fixings at the exhaust pipe
flange.
10.Release the turbo charger oil pipes from the
cylinder block.
11.Remove the turbo boost pipes.
12.Remove seven bolts securing the exhaust
manifold, release the heater rail and remove the
manifold gasket, complete with turbo unit.
13.Remove four bolts and disconnect diaphragm
rod from manifold, and remove turbo charger if
necessary.
Refit
14.Reverse removal procedure. 1 to 12. Use a new
manifold and exhaust flange gaskets.
15.Reconnect battery negative lead. Start engine
and check for leaks.

MANIFOLD AND EXHAUST SYSTEM
5
REPAIR INLET MANIFOLD GASKET - Mpi
Service repair no - 30.15.08
Remove
1.Disconnect battery negative lead.
2.Position absorbent cloth around fuel pipe to fuel
rail union. Unscrew union to relieve fuel
pressure. Re-tighten union.
CAUTION: Plug connections.
3.Release clip and remove air cleaner to throttle
housing hose.
4.Disconnect stepper motor multiplug.
5.Disconnect throttle potentiometer multiplug.
6.Release throttle cable from abutment bracket.
7.Release throttle cable from cam. Remove
coolant bypass hose.
8.Disconnect fuel temperature sensor multiplug.
9.Release clip and disconnect brake servo hose
from manifold.

MANIFOLD AND EXHAUST SYSTEM
7
REPAIR Refit
19.Ensure mating faces of inlet manifold and
cylinder head are clean.
20.Fit a new gasket, position inlet manifold to
cylinder head.
21.Fit nuts and bolts, tighten in the order shown to
the correct torque
25Nm
22.Position engine breather hose to manifold and
secure with bolts.
23.Connect fuel injector harness and intake air
temperature sensor multiplug.
24.Connect fuel hose to pressure regulator and
secure with clip.
25.Fit fuel pipe to fuel rail, tighten union to
10Nm
26.Connect vacuum hoses to manifold.
27.Position engine harness and cam cover brackets
to manifold, secure with bolts.
28.Connect breather hose and brake servo hose to
manifold, secure with clips.
29.Connect multiplug to fuel temperature sensor.
30.Connect breather hose to throttle housing and
secure with clip.
31.Connect throttle cable to cam and secure to
abutment bracket.
32.Connect coolant bypass hose to throttle housing.
33.Connect stepper motor and throttle
potentiometer multiplugs.
34.Connect air cleaner hose to throttle housing and
secure with clip.
35.Connect battery negative lead.
36.Adjust throttle cable.EXHAUST MANIFOLD GASKET - Mpi
Service repair no - 30.15.12
Remove
1.Raise vehicle.
2.Loosen 2 nuts securing downpipe to silencer
box.
3.Remove 4 nuts securing downpipe to exhaust
manifold.
4.Release downpipe from exhaust manifold.
5.Discard gasket.