LAND ROVER DISCOVERY 1995 Workshop Manual

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.

4.0 V8
7
REPAIR 171.Route drive belt around pulleys.
172.Pivot tensioner downwards.
173.Align belt to tensioner and release tensioner.
174.Connect battery positive lead and tighten.
175.Secure terminal cover.
176.Align gearbox breather pipe, clip to engine lifting
eye and fit bolt. Tighten to
9 Nm.
177.Align and secure engine harness brackets to
inlet manifold and fit nuts. Tighten to
9 Nm.
178.Connect injector multiplugs.
179.Connect air intake temperature sensor multiplug.
180.Connect fuel temperature sensor multiplug.
181.Connect coolant temperature multiplug.
182.Connect temperature gauge connector.
183.Connect oil pressure switch Lucar.
184.Connect camshaft sensor multiplug and secure
to bracket.
185.Fit ignition coil bracket.
See FUEL SYSTEM
SFI, Repair, Ignition Coils
186.Position heater hose/pipe assembly.
187.Connect hose to inlet manifold.
188.Align pipe to bracket and fit bolt. Tighten to
9
Nm.
189.Tighten hose clip.
190.Connect heater return hose and tighten clip.
191.Remove plugs from fuel feed and return hose
connections.
192.Clean feed unions.
193.Connect return hose and tighten clip.
194.Connect feed hose union and tighten.
195.Remove cloth.
196.Connect purge hose.
197.Connect leads to generator, tighten terminal nuts
and fit cover.
198.Connect sensing Lucar.
199.Connect servo vacuum hose.
200.Position expansion tank and secure with fixings.
201.Connect hose and tighten clip.
202.Lower ramp.
203.Fit mass air flow sensor.
See FUEL SYSTEM
SFI, Repair, Mass Air Flow Sensor (MAF
Sensor)
204.Fit plenum chamber.See FUEL SYSTEM SFI,
Repair, Plenum Chamber
205.Fit radiator.See COOLING SYSTEM, Repair,
Radiator
206.Fit bonnet.See CHASSIS AND BODY, Repair,
Bonnet [Hood]
207.Reconnect battery negative lead.
208.Bleed power steering system.
See STEERING,
Repair, Power Steering System - Bleed
209.Drain engine oil and refill.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids - USA
Vehicles
210.Start engine. Check for fuel, coolant and oil
leaks.FRONT COVER GASKET
Service repair no - 12.65.04 - Front Cover Gasket
Remove
1.Disconnect battery negative lead.
2.Drain cooling system.
See COOLING SYSTEM
V8, Adjustment, Coolant
3.Remove radiatorSee COOLING SYSTEM,
Repair, Radiator
4.Remove water pump pulley.See COOLING
SYSTEM, Repair, Viscous Coupling, Fan
Blades, Pulley and Fan Cowl
5.Slacken bottom hose clip. Remove hose from
water pump.
6.Raise vehicle on ramp.
7.Disconnect oil cooler hoses from front cover and
position aside. Plug hoses and connections.
8.Disconnect Lucar from oil pressure switch.

12ENGINE
8
REPAIR
9.Disconnect multiplug from camshaft sensor.
See FUEL SYSTEM SFI, Repair, Camshaft
Position Sensor (CMP Sensor)
10.Remove 9 bolts securing front cover.
11.Remove 2 bolts securing sump to front cover.
12.Loosen 4 bolts securing sump adjacent to front
cover (2 each side).
13.Release front cover assembly.
14.Remove oil seal.
15.Remove and discard gasket.Refit
16.Clean sealant from threads of cover bolts.
17.Clean old sealant from front cover and block joint
face.
CAUTION: Use a plastic scraper.
18.Apply Hylosil jointing compound to gasket
position on cover and block.
19.Fit new gasket to block face.
20.Ensure oil seal register in cover is clean.
21.Lubricate outer face of NEW oil seal.
22.Using LRT-12-089, fit seal to cover.
23.Lubricate oil pump drive gear and position in
pump with groove away from engine.
24.Locate alignment tool LRT-12-090 on front cover
and oil pump drive gear.
25.Position front cover over crankshaft.
26.Press and rotate tool to engage drive gear until
drive gear keyway aligns with Woodruff key.
27.Fit cover to cylinder block.

4.0 V8
9
REPAIR 28.Remove alignment tool LRT-12-090.
29.Apply a small amount of Loctite 242 to threads
and refit front cover bolts. Tighten to
22 Nm.
30.Fit sump bolts. Tighten to23 Nm.
31.Connect camshaft sensor multiplug.
32.Connect Lucar to oil pressure switch terminal.
33.Remove plugs from oil cooler pipes and cover.
34.Fit new 'O' ring seals, reconnect oil cooler pipes.
Tighten to
15 Nm.
CAUTION: Over tightening of oil cooler
pipe unions can crack front cover.
35.Refit bottom hose to water pump. Tighten clip.
36.Refit water pump pulley.
See COOLING
SYSTEM, Repair, Viscous Coupling, Fan
Blades, Pulley and Fan Cowl
37.Refit radiator assembly.See COOLING
SYSTEM, Repair, Radiator
38.Refill cooling system.See COOLING SYSTEM
V8, Adjustment, Coolant
39.Check/top-up engine oil.
40.Lower ramp.
41.Reconnect battery negative lead.

12ENGINE
10
REPAIR ROCKER COVER GASKET - LEFT HAND
Service repair no - 12.29.40 - LH Cover Gasket
Service repair no - 12.29.41 - RH Cover Gasket
Remove
1.Disconnect battery negative lead.
2.Remove plenum chamber.
See FUEL SYSTEM
SFI, Repair, Plenum Chamber
3.Remove screw securing dipstick tube to rocker
cover.
4.Release plug leads from guide clips and
disconnect from 4 spark plugs.
5.Remove 4 bolts securing rocker cover to cylinder
head.
6.Remove rocker cover.
7.Remove and discard rocker cover gasket.
Refit
8.Clean mating faces between rocker cover and
cylinder head using Bostick cleaner 6001 or
equivalent. Allow to dry.
NOTE: Gasket fits one way round only. It
must be fitted accurately, first time.
Subsequent movement will destroy
bonding.
9.Apply a thin coating of impact adhesive (Bostick
1775 or equivalent) to mating faces of rocker
cover seal face and new gasket. Use a brush to
ensure an even film. Allow adhesive to become
touch dry.
10.Place one end of gasket into cover recess with
edge firmly against recess wall, holding
remainder of gasket clear. Work around cover,
pressing gasket into place ensuring edge firmly
contacts recess wall.
CAUTION: Allow cover to stand for thirty
minutes before fitting.
11.Fit rocker cover to cylinder head, ensure short
screws are inboard. Tighten to
9 Nm.
12.Connect leads to spark plugs and secure to
guide clips on rocker cover.
13.Secure dipstick tube to rocker cover.
14.Refit plenum chamber.
See FUEL SYSTEM
SFI, Repair, Plenum Chamber
15.Reconnect battery negative lead.

4.0 V8
11
REPAIR ROCKER COVER GASKET - RIGHT HAND
Service repair no - 12.29.41 - RH Cover Gasket
1.Depressurise fuel system.
See FUEL SYSTEM
SFI, Repair, Fuel System - Depressurise
2.Disconnect battery negative lead.3.Drain cooling system.
See COOLING SYSTEM
V8, Adjustment, Coolant
NOTE: Leave hose disconnected.
4.Disconnect purge pipe from plenum chamber
hose.
5.Disconnect breather pipe from rocker cover.
6.Remove bolt securing coolant pipe brackets and
nut securing bracket to manifold.
7.Loosen hose clip and disconnect coolant return
hose from pipe.
CAUTION: Plug connection.
8.Loosen clip and disconnect fuel return hose from
pipe.
9.Disconnect fuel hose from injector pipe.
CAUTION: Use 2 spanners.10.Remove 2 nuts securing engine harness
brackets to manifold.
11.Release 4 ht leads from 2 brackets on rocker
cover.

12ENGINE
12
REPAIR
12.Remove 4 bolts securing rocker cover to cylinder
head.
13.Remove rocker cover.
14.Remove and discard rocker cover gasket.Refit
15.Clean mating faces between rocker cover and
cylinder head using Bostick cleaner 6001 or
equivalent. Allow to dry.
NOTE: Gasket fits one way round only. It
must be fitted accurately, first time.
Subsequent movement will destroy
bonding.
16.Apply a thin coating of impact adhesive (Bostick
1775 or equivalent) to mating faces of rocker
cover seal face and new gasket. Use a brush to
ensure an even film. Allow adhesive to become
touch dry.
17.Place one end of gasket into cover recess with
edge firmly against recess wall, holding
remainder of gasket clear. Work around cover,
pressing gasket into place ensuring edge firmly
contacts recess wall.
CAUTION: Allow cover to stand for thirty
minutes before fitting.
18.Fit rocker cover to cylinder head, ensure short
screws are inboard. Tighten to
9 Nm.
19.Connect fuel feed and return hoses.
20.Refit ht leads into retaining brackets.
21.Secure engine harness to brackets.
22.Connect coolant pipes to hoses and secure
brackets.
23.Connect breather hose to rocker cover.
24.Connect purge hose to plenum chamber.
25.Connect bottom hose to radiator.
26.Refill cooling system.
See COOLING SYSTEM
V8, Adjustment, Coolant
27.Reconnect battery negative lead.

4.0 V8
13
REPAIR CRANKSHAFT REAR OIL SEAL
Service repair no - 12.21.20
Remove
1. Manual vehicles:Remove flywheel.
See
ENGINE 3.9 V8, Repair, Flywheel
2. Automatic vehicles:Remove drive plate.See
ENGINE 4.0 V8, Repair, Drive Plate -
Automatic
3.Remove oil seal from location.
CAUTION: Do not damage seal location or
running surface on crankshaft.
Refit
4.Ensure both seal location and running surface
on crankshaft are clean.
5.Ensure mating faces of flywheel and crankshaft
are clean.
6.Lubricate seal guide LRT-12-095 with clean
engine oil. Position over crankshaft boss.
7.Lubricate oil seal lip.
8.Position seal squarely. Remove guide.
9.Drift seal into location using LRT-12-091.
10. Manual vehicles:Fit flywheel.
See ENGINE 3.9
V8, Repair, Flywheel
11. Automatic vehicles:Fit drive plate.See
ENGINE 4.0 V8, Repair, Drive Plate -
Automatic

12ENGINE
14
REPAIR DRIVE PLATE - AUTOMATIC
Service repair no - 12.53.13
Remove
1.Remove automatic gearbox and torque
converter.
See AUTOMATIC GEARBOX,
Repair, LT230T Transfer Gearbox with
Automatic Gearbox Assembly - V8i
2.Remove 4 clamp ring bolts. Collect clamp ring.
3.Remove flexible drive plate/starter ring gear
assembly from hub aligner.
4.Remove 6 screws from hub aligner. Remove hub
aligner from crankshaft. Collect shim.
5.Check drive plate for distortion or cracks. Check
starter ring gear for chipped or broken teeth. If
either component shows signs of damage, fit a
new assembly.Refit
6.Ensure all mating surfaces are clean.
7.Fit shim and hub aligner to crankshaft.
8.Fit hub aligner screws. Tighten to
85 Nm.
9.Fit drive plate and clamp ring.
10.Fit clamp ring bolts. Tighten to
45 Nm.
NOTE: It is only necessary to reshim the
drive plate when a new crankshaft or hub
aligner is fitted.
11.Fit automatic gearbox and converter assembly.
See AUTOMATIC GEARBOX, Repair, LT230T
Transfer Gearbox with Automatic Gearbox
Assembly - V8i
ROCKER SHAFT - OVERHAUL
Service repair no - 12.29.29 - Rocker shaft -
overhaul
See Overhaul Manual 4.0/4.6 V8 Engine
TAPPETS - ENGINE SET
Service repair no - 12.29.57 - Tappets - engine set
See Overhaul Manual 4.0/4.6 V8 Engine