service LAND ROVER DISCOVERY 1995 Workshop Manual

Mpi
1
REPAIR COOLANT PUMP
Service repair no - 26.50.01
Remove
1.Position drain tin below coolant pump hose.
WARNING: Do not carry out the next
instruction until the coolant is cool to
avoid personal injury from scalding.
2.Release clip and disconnect hose from coolant
pump housing cover.
3.Remove 5 bolts securing housing cover.
4.Remove housing cover.
5.Remove coolant pump from housing.
6.Discard 3 sealing rings.
Refit
7.Clean coolant pump housing and mating faces.
8.Lubricate new sealing rings with Loctite 405 and
fit to coolant pump.
9.Fit coolant pump to housing.
10.Position housing cover, fit 5 bolts. Tighten to
25Nm
11.Connect hose to housing cover and tighten clip.
12.Refill cooling system.

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.

26COOLING SYSTEM
4
REPAIR THERMOSTATIC SENSOR
Service repair no - 19.22.18
Remove
1.Disconnect Lucar connector from sensor.
2.Remove sensor.
Refit
3.Clean sensor.
4.Apply Loctite 405 to threads of sensor.
5.Fit sensor and tighten to
15Nm
6.Connect Lucar to sensor.
7.Top-up cooling system.THERMOSTAT
Service repair no - 26.45.01
Remove
1.Position suitable container to collect coolant.
2.Slacken 2 clips and release radiator top hose.
3.Release bypass hose from securing bracket.
4.Release top hose from securing bracket.
5.Remove top hose.

MANIFOLD AND EXHAUST SYSTEM
1
REPAIR EXHAUST SYSTEM COMPLETE
Service repair no - 30.11.01
To improve sealing and accuracy of assembly, a two
piece exhaust system is fitted.
NOTE: Ensure no exhaust leaks are
evident in either a new or old exhaust
system, as this will affect vehicle
performance.
WARNING: To prevent personal injury
occurring from a hot exhaust system, DO
NOT attempt to disconnect any
components until exhaust system has cooled
down.

30MANIFOLD AND EXHAUST SYSTEM
2
REPAIR Remove
Catalysts - remove and refit 1 to 5
1.Raise vehicle on a ramp [hoist].
2. Catalyst vehicles only:Disconnect two heated
oxygen sensor wiring connectors.
NOTE: NAS models have four heated
oxygen sensors fitted.
3.Remove two nuts securing rear exhaust
assembly to front exhaust assembly.
4.Remove nuts and release front downpipes from
manifolds. Discard gaskets.
5.Lower front exhaust assembly with catalysts (if
fitted), retain olive.
NOTE: Assistance is required for removing
and refitting rear exhaust assembly.
6.Remove bolts securing three hanger brackets to
chassis. Lower exhaust assembly onto rear axle.
Detach rubbers from hanging brackets.
7.Place extended axle stands underneath chassis,
in front of chassis mounted rear towing brackets.
8.Lower ramp[hoist] until vehicle weight is
supported securely on stands.
9.Lower ramp [hoist] until rear shock absorbers
are ALMOST fully extended.
10.Move rear exhaust to a diagonal position, centre
silencer to right of vehicle.
11.Facing rear of vehicle, twist assembly
anti-clockwise clear of rear axle.
12.Remove rear exhaust assembly from vehicle.
Refit
13.Position rear exhaust assembly over rear axle in
a diagonal position, as for removing.
14.Twist assembly clockwise until it is in mounting
position.
15.Reverse removal procedure. 1. to 9. using new
manifold gaskets and applying exhaust sealer to
system joint.
16.Examine system for leaks, ensuring that system
does not foul underbody components. Rectify if
necessary.EXHAUST MANIFOLD - V8i
Service repair no - Left hand - 30.15.10
Service repair no - Right hand - 30.15.11
Remove
1.Disconnect front exhaust pipe(s) from
manifold(s).
2.Tap back bolt locking tabs and remove eight
bolts, lock tabs and washers.
3.Remove manifold(s) and old gaskets.
Refit
4.Ensure that mating surfaces of cylinder head
and exhaust manifold are clean and smooth.
5.Coat threads of each bolt with anti-seize
compound.
6.Place manifold and new gaskets in position on
cylinder head and fit securing bolts, new
lockplates and plain washers. Plain washers are
fitted between manifold and lockplates.
7.Evenly tighten manifold bolts to
20Nmbend
over lockplate tabs.
8.Reconnect front exhaust pipe, using new
exhaust flange gaskets.

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.

MANIFOLD AND EXHAUST SYSTEM
9
REPAIR MANIFOLD CHAMBER GASKET - Mpi
Service repair no - 30.15.37
Remove
1.Disconnect battery negative lead.
2.Position absorbent cloth around fuel pipe to fuel
rail union. Loosen union to relieve pressure.
Re-tighten union.
3.Release clip and remove air cleaner to throttle
housing hose.
4.Disconnect stepper motor and throttle
potentiometer multiplugs.
5.Release clip and disconnect breather hose from
throttle housing.
6.Release throttle cable from abutment bracket.
7.Release throttle cable from cam. Remove
coolant bypass hose from throttle housing.
8.Disconnect fuel temperature sensor multiplug.
9.Release clip and disconnect brake servo hose
from manifold.

CLUTCH
1
REPAIR CLUTCH ASSEMBLY
Service repair no - 33.10.01
Clutch pressure plate
Renew pressure plate if diaphragm spring fingers are
worn or if pressure plate shows signs of wear, cracks
or burning.
Clutch driven plate
Renew driven plate if centre hub splines are worn or if
lining is contaminated, burned or unevenly worn.
Service tools:
Clutch centralising tool
LRT-12-001 - V8
LRT-12-040 - Tdi
LRT-12-057 - Mpi
Remove
1.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
2.Mark position of clutch cover to flywheel for
reassembly.
3.Remove clutch cover securing bolts, working
evenly and diagonally.
4.Do not disturb three bolts in clutch cover.
5.Remove clutch assembly.
6.Withdraw clutch driven plate.
Refit
NOTE: To prevent clutch plate sticking,
lubricate splines using Rocol MV 3 or
Rocol MTS 1000 grease.
7.Renew/refit clutch driver plate and clutch
assembly using centralising tool, where
applicable, align assembly marks.
8.Secure clutch assembly cover fixings evenly,
working in a diagonal sequence. Tighten to
28
Nm.
9.Fit gearbox to engine.