fuel LAND ROVER DISCOVERY 1995 Workshop Manual

19FUEL SYSTEM
4
REPAIR
NOTE: If rotary coupler is to be re-used a
piece of adhesive tape should be placed
around the moulding in position A to
prevent rotation. Failure to do this may result in
damage to the wires inside the coupler.
6.Release clips securing rotary coupler to column
stalk assembly.
7.Remove rotary coupler from column stalk
assembly.
CAUTION: Ensure front wheels are in the
straight ahead position before removal
and refitting. Store in a plastic bag. DO
NOT rotate mechanism whilst removed.
Refit
8.Reverse removal procedure. Ensuring that the
column harnesses are not trapped by the
column shroud.
NOTE: If original rotary coupler is to be
fitted and there is evidence of tampering, it
is imperative that the coupler is
centralised.
See SUPPLEMENTARY RESTRAINT
SYSTEM, Repair, Rotary Coupler
NOTE: If a new rotary coupler is to be
fitted and the sealing tape is broken it
MUST NOT be used. Ensure rotary coupler
lugs are correctly engaged in the rear of the
steering wheel.ACTUATOR - V8i
Service repair no - 19.75.12
NOTE: The actuator is non serviceable, fit
a new unit if failure or damage occurs.
Remove
1.Disconnect battery negative lead.
2.Disconnect vacuum hose from actuator.
3.Remove nut securing actuator to throttle bracket.
4.Remove actuator, and manoeuvre actuator
operating link off throttle lever.
5.Withdraw actuator.
Refit
6.Inspect rubber diaphragm. Fit a new actuator
assembly if diaphragm is damaged.
7.Reverse removal procedure. Fitting the hook
uppermost.

19FUEL SYSTEM
6
REPAIR VACUUM PUMP - TDI
Service repair no - 19.75.06
NOTE: The vacuum pump is non
serviceable, fit a new unit if failure or
damage occurs.
Remove
1.Release turnbuckle securing wheel chock and
remove.
2.Release strap securing jack and remove.
3.Release 3 pump mounting rubbers from vehicle
body.
4.Manoeuvre pump out of box section.
5.Release multiplug cover and disconnect
multiplug from pump.
6.Disconnect vacuum hose from pump.
7.Remove pump.
Refit
8.Reverse removal procedure. Ensure all hose
and electrical connections are secure.

CRUISE CONTROL
7
REPAIR CRUISE CONTROL ECU - V8i
Service repair no - 19.75.49
Remove
1.Remove lower dash panel.
2.Disconnect ECU multi-plug.
3.Remove ECU fixing.
4.Remove ECU.
5.Reverse removal procedure. Ensuring that
electrical multi-plug is securely reconnected.
SPEED TRIP ECU - MANUAL V8i
NOTE: The neutral lock out relay
module/speed trip ECU is mounted in the
right hand side footwell. To identify
components.
See Electrical Trouble Shooting
Manual.
VEHICLE SPEED SENSOR
Service repair no - 18.30.22
For Tdi
See FUEL SYSTEM Tdi, Repair, Vehicle
Speed Sensor
For V8iSee FUEL SYSTEM MFI, Repair, Vehicle
Speed Sensor
NEUTRAL LOCK OUT RELAY
Service repair no - 19.75.28
1.Remove 3 studs securing fascia right hand side
closing panel.
2.Release and move closing panel aside.
3.Remove 2 studs securing right hand side 'A' post
lower trim casing.
4.Remove casing.
5.Locate relay (neutral coloured base) and release
base from bracket.
6.Remove relay.
NOTE: For further information.See
Electrical Trouble Shooting Manual.
Refit
7.Reverse removal procedure.

19FUEL SYSTEM
8
REPAIR ACTUATOR - Tdi
Service repair no - 19.75.05
NOTE: The actuator is non serviceable, fit
a new unit if failure or damage occurs.
Remove
1.Disconnect battery negative lead.
2.Remove split pin, withdraw clevis pin and
disconnect cable from lever.
3.Disconnect link ball end from cable lever.
4.Disconnect vacuum hose from actuator.
5.Remove nut securing actuator to bracket and
remove actuator.
6.Inspect rubber diaphragm. Fit a new actuator
assembly if diaphragm is damaged.Refit
7.Check that link setting distance (dimension 'A')
equals 16 mm and that the retainer is locked in
position. If correct, proceed to paragraph 9.
8.If dimension 'A' is not correct, proceed as
follows:
·Measure 16 mm from diaphragm collar and
mark the position.
·Position link and retainer to the mark and
rotate retainer half a turn to secure.
·Check measurement 'A' is still 16 mm, then
turn retainer a further quarter turn to lock.
9.Fit actuator and secure to bracket with nut.
10.Connect vacuum hose.
11.Connect link ball end to cable lever.
12.Connect cable to lever and secure with clevis pin
and split pin.
13.Adjust cable position to remove any free play
from link, setting dimension 'B' should be 103
mm.

MANIFOLD AND EXHAUST SYSTEM
1
DESCRIPTION AND OPERATION CATALYTIC CONVERTERS - V8i
Description
Catalytic converters which form part of the engine
emission control system, are designed to 'clean' the
exhaust gases, by closely controlling the fuel air ratio
delivered to the engine and converting the residual
exhaust compounds into products more acceptable to
the environment.
The front section of the exhaust system to each
cylinder bank contain the ceramic elements of the
catalytic converters. The oxygen sensors which
transmit information to the fuel ECU for control of the
mixture, are located in the exhaust down pipes.
The Hydrocarbons (HC), Nitogen oxides (NO
x) and
Carbon monoxide (CO) emitted by the engine react
with the catalytic element and exhaust temperature to
convert the toxic gas, into Nitrogen (N), Carbon
dioxide (CO
2) and water vapour.Should the engine be supplied with a rich mixture
causing high CO in the exhaust gas, the ceramic
element will become coated and the useful life of the
catalyst reduced. If the mixture is too weak, excess
oxygen in the exhaust gas will cause the catalysts to
burn out.
1. Catalysts
2. Lambda oxygen sensors

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.

30MANIFOLD AND EXHAUST SYSTEM
6
REPAIR 10.Release clip and disconnect breather hose from
manifold.
11.Release 2 bolts securing cam cover brackets to
manifold.
12.Remove 3 bolts securing engine harness to
manifold.
13.Disconnect 3 vacuum hoses from manifold.
14.Release clip and disconnect fuel hose from
pressure regulator.
CAUTION: Plug the connections.
15.Disconnect intake air temperature sensor
multiplug.
16.Disconnect fuel injector harness multiplug.
17.Remove 2 nuts and 7 bolts securing manifold to
cylinder head
18.Remove manifold assembly and collect gaskets.

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.

30MANIFOLD AND EXHAUST SYSTEM
10
REPAIR 10.Release clip and disconnect breather hose from
manifold.
11.Release 2 bolts securing camshaft cover
brackets to manifold.
12.Disconnect 4 vacuum hoses from manifold.
13.Remove 6 bolts securing manifold chamber to
lower manifold.
14.Remove manifold chamber and collect gaskets.
Refit
NOTE: For torque values.See
Specifications, torque, Torque Values
15.Ensure mating faces of manifold chamber and
lower manifold are clean.
16.Fit a new gasket, position manifold chamber to
lower manifold.
17.Fit bolts, tighten to the correct torque.
18.Connect vacuum hoses to manifold.
19.Position camshaft cover brackets to manifold,
secure with bolts.
20.Connect breather hose and brake servo hose to
manifold, secure with clips.
21.Connect multiplug to fuel temperature sensor.
22.Connect breather hose to throttle housing and
secure with clip.
23.Connect throttle cable to cam and secure to
abutment bracket.
24.Connect coolant bypass hose to throttle housing.
25.Connect stepper motor and throttle
potentiometer multiplugs.
26.Connect air cleaner hose to throttle housing and
secure with clip.
27.Reconnect battery negative lead.
28.Adjust throttle cable.