engine LAND ROVER DISCOVERY 1995 User Guide

01INTRODUCTION
14
INFORMATION LOCATION OF IDENTIFICATION NUMBERS
Engine serial number - 300Tdi Engine
The 300Tdi engine number is stamped on the cylinder
block on the right hand side of the engine above the
camshaft front cover plate.
Engine serial number - Mpi engine
Stamped on the R.H. face of the cylinder block
adjacent to the gearbox.
Engine serial number - V8i engine
Stamped on a cast pad on the cylinder block, between
numbers 3 and 5 cylinders.
NOTE: The appropriate engine
compression ratio is stamped above the
serial number.
Main gearbox R380
Stamped on a cast pad on the bottom right hand side
of the gearbox.
Transfer gearbox LT230
The serial number is stamped on the left hand side of
the gearbox casing below the mainshaft rear bearing
housing adjacent to the bottom cover.
Front and rear axles
Serial number is stamped on top of the left hand axle
tube.

01INTRODUCTION
16
INFORMATION FAULT DIAGNOSTIC EQUIPMENT
TESTBOOK
Todays Land Rover Vehicles are equipped with a
large amount of electronics to provide the best
performance of the vehicles systems.
Diagnostic equipment named TESTBOOK is available
to expand the diagnostic abilities of the dealer
workshop. This repair manual is produced with
Testbook in mind.
Features of Testbook include :- Fully upgradable
support for the technician. Structured diagnostics to
accommodate all skill levels. Touch screen operation.
Direct print out of screen information and test results.
ELECTRICAL TROUBLESHOOTING MANUAL
The Electrical Troubleshooting Manual is a separate
publication that is intended for use by trained Land
Rover technicians as an aid to diagnosing electrical
concerns.
It provides circuit diagrams, system diagnosis flow
charts, electrical component location tables, electrical
component location views and circuit operation
details.READING THIS MANUAL
This manual is divided into sections shown on the
contents page, alongside a range of icons, familiar to
service technicians.
Relevant information is contained within each of these
sections. These are further divided into the following
sub-sections which appear at the foot of each page :-
Description and operation.
Fault diagnosis.
Adjustment.
Repair.
Overhaul.
Specifications, Torque.
Service tools.
To avoid repeating information through the sections,
where part of the repair operation impacts on another
section, a cross reference is given to direct the reader
to where the information is sited.
For example:
The maintenance section states the need to renew
V8i drive belt. A cross reference sites this information
in: Section: V8i Engine
- Sub-section: Repairs
- Heading: Drive belt renew.
Sections that contain derivatives such as engines are
further separated within that section.
American terminology.
A few words used in this manual differ to words used
in America. Where this occurs the American word is
placed inside brackets. For example: bonnet [hood],
wing [fender], ramp [hoist].

GENERAL SPECIFICATION DATA
1
INFORMATION ENGINE 3.9 V8i
Type V8i.................................................................................
Number of cylinders Eight, two banks of four.........................................................
Bore 94,00 mm.................................................................................
Stroke 71,12 mm...............................................................................
Capacity 3950 cc...........................................................................
Compression ratio 8.13:1 or 9.35:1............................................................
Valve operation Overhead by push-rod................................................................
Maximum power - 8.13:1 127kW at 4550 rev/min............................
- 9.35:1 134kW at 4750 rev/min............................
Crankshaft
Main journal diameter 58,409-58,422 mm.......................................................
Minimum regrind diameter 57,393-57,406 mm...............................................
Crankpin journal diameter 50,800-50,812 mm................................................
Minimum regrind diameter 49,784-49,797 mm...............................................
Crankshaft end thrust/(end float) Taken on thrust washers of centre main bearing......................................
0,10-0,20 mm
Main bearings
Number and material 5, Lead-indium........................................................
Diametrical clearance 0,010-0,048 mm.......................................................
Undersize bearing shells 0,254 mm, 0,508 mm..................................................
Connecting rods
Type Horizontally split big-end, plain small-end.................................................................................
Length between centres 143,81-143,71 mm...................................................
Big-end bearings
Type and material Lead-indium............................................................
Diametrical clearance 0,015-0,055 mm.......................................................
End-float crankpin 0,15-0,36mm............................................................
Undersize bearing shells 0,254 mm, 0,508 mm..................................................
Piston pins
Length 72,67-72,79 mm..............................................................................
Diameter 22,215-22,220 mm..........................................................................
Fit-in connecting rod Press fit.........................................................
Clearance in piston 0,002-0,007 mm..........................................................

04GENERAL SPECIFICATION DATA
2
INFORMATION Pistons
Clearance in bore, measured at bottom
of skirt at right angles to piston pin 0,018-0,041 mm...................................
Piston rings
Number of compression rings 2..........................................
Number of control rings 1....................................................
No 1 compression ring Molybdenum barrel faced.....................................................
No 2 compression ring Tapered and marked 'T' or 'TOP'.....................................................
Width of compression rings 1,478-1,49 mm..............................................
Compression ring gap 0,40-0,65 mm......................................................
Oil control ring width 3,0 mm.........................................................
Oil control ring rail gap 0,38-1,40 mm.....................................................
Camshaft
Location Central...........................................................................
Bearings Tin - aluminium...........................................................................
Number of bearings 5..........................................................
Drive Chain 9,52 mm pitch x 54 pitches..................................................................................
TappetsHydraulic-self-adjusting ...........................................................................
Valves
Length: Inlet 116,59-117,35 mm..................................
Exhaust 116,59-117,35 mm...........................
Seat angle: Inlet 45°to 45 1/2° ..................................
Exhaust 45°to 45 1/2° ...........................
Head diameter: Inlet 39,75-40,00 mm..................................
Exhaust 34,226-34,480 mm...........................
Stem diameter: Inlet 8,664-8,679 mm..................................
Exhaust 8,651-8,666 mm...........................
Stem to guide clearance: Inlet 0,025-0,066 mm..................................
Exhaust 0,038-0,078 mm...........................
Valve lift (Inlet and Exhaust) 9,49 mm............................................
Valve spring length fitted 40,4 mm at pressure of 29,5 kg..................................................
Lubrication
System type Wet sump, pressure fed.....................................................................
Oil pump type Eccentric rotor...................................................................
Oil pressure 2.75 bar (40 lb/in
2) at 2500 rev/min with engine at ......................................................................
running temperature
Oil filter-internal Wire screen, pump intake filter.................................................................
Oil filter-external Full flow, self-contained cartridge...............................................................

GENERAL SPECIFICATION DATA
3
INFORMATION ENGINE 4.0 V8
Type 4.0 litre V8.................................................................................
Number of cylinders Eight, two banks of four.........................................................
Bore 94.00 mm................................................................................. 3.70 in
Stroke 71.12 mm............................................................................... 2.80 in
Capacity 3950 cm
3........................................................................... 241 cu in
Valve operation Overhead by push-rod................................................................
High Compression Low Compression
Compression ratio 9.35:1............................................................ 8.2:1
Valve operation Overhead by push-rod................................................................
Maximum power: 9.35:1 140kW at 4750 rev/min..............................
8.2:1 132kW at 4750 rev/min................................
Crankshaft
Main journal diameter 63.500 - 63.487 mm....................................................... 2.50 - 2.4995 in
Crankpin journal diameter 55.513 - 55.500 mm................................................ 2.1855 - 2.1850 in
Crankshaft end thrust/end float Taken on thrust washers of centre main bearing........................................
0.10 - 0.20 mm 0.004 - 0.008 in
Main bearings
Number and type 5, Vandervell shells..............................................................
Material Lead bronze with lead-indium overlay............................................................................
Diametrical clearance 0.015 - 0.060 mm....................................................... 0.0006 - 0.0024 in
Connecting rods
Type Horizontally split big-end, plain small-end.................................................................................
Length between centres 155.12 - 155.22 mm................................................... 6.1071 - 6.1110 in
Big-end bearings
Type and material Vandervell VP3 Lead bronze with lead-indium overlay............................................................
Diametrical clearance 0.015 - 0.016 mm....................................................... 0.0006 - 0.0024 in
Piston pins
Length 60.00 - 60.50 mm.............................................................................. 2.3622 - 2.3819 in
Diameter 23.995 - 24.000 mm.......................................................................... 0.9447 - 0.9449 in
Fit-in connecting rod Press fit.........................................................
Clearance in piston 0.015 - 0.006 mm.......................................................... 0.0006 - 0.0002 in
Pistons
Clearance in bore, measured at bottom
of skirt at right angles to piston pin 0.020 - 0.050 mm................................... 0.0008 - 0.0020 in

04GENERAL SPECIFICATION DATA
4
INFORMATION Piston rings
Number of compression rings 2..........................................
Number of control rings 1....................................................
No 1 compression ring Nitrided steel barrel faced.....................................................
No 2 compression ring Tapered spherical barrel marked 'TOP'.....................................................
Width of compression rings 1.478 - 1.49 mm.............................................. 0.0582 - 0.0587 in
(Top) 1.21 - 1.23 mm................................ 0.0476 - 0.0484 in
Compression ring gap 0.40-0.65 mm...................................................... 0.0157 - 0.0256 in
(Top) 0.3 - 0.5 mm................................ 0.0118 - 0.0197 in
Oil control ring type Aclonoform..........................................................
Oil control ring width 3.0 mm......................................................... 0.1181 in
Oil control ring rail gap 0.38-1.40 mm..................................................... 0.0150 - 0.0551 in
Camshaft
Location Central...........................................................................
Bearings Non serviceable...........................................................................
Number of bearings 5..........................................................
Drive Chain 9.52 mm pitch x 54 pitches..................................................................................
Camshaft End Float 0.076 - 0.355 mm......................................................... 0.003 - 0.014 in
TappetsHydraulic self-adjusting ...........................................................................
Valves
Length: Inlet 116.59 - 117.35 mm.................................. 4.590 - 4.620 in
Exhaust 116.59 - 117.35 mm........................... 4.590 - 4.620 in
Seat angle: Inlet 46°-46°25' ..................................
Exhaust 46°-46°25' ...........................
Head diameter: Inlet 39.75 - 40.00 mm.................................. 1.565 - 1.575 in
Exhaust 34.227 - 34.48 mm........................... 1.3475 - 1.3575 in
Stem diameter: Inlet 8.664 - 8.679 mm.................................. 0.3411 - 0.3417 in
Exhaust 8.651 - 8.666 mm........................... 0.3406 - 0.3412 in
Stem to guide clearance: Inlet 0.025 - 0.066 mm.................................. 0.0010 - 0.0026 in
Exhaust 0.038 - 0.078 mm........................... 0.0015 - 0.0031 in
Valve lift (Inlet and Exhaust) 9.94 mm............................................ 0.3913 in
Valve spring length fitted 40.4 mm (1.59 in) at pressure of 29.5 kg (65 lb)..................................................
Lubrication
System type Wet sump, pressure fed.....................................................................
Oil pump type Rotor...................................................................
Oil pressure 2.11 to 2.81 kg/cm
2(30 to 40 psi) at 2400 rev/min with ......................................................................
engine warm
Oil filter-internal Wire screen, pump intake filter in sump................................................................
Oil filter-external Full flow, self-contained cartridge...............................................................

04GENERAL SPECIFICATION DATA
6
INFORMATION FUEL SYSTEM (GEMS) 4.0 V8 ENGINE
Type Sagem - Lucas Gems 8 hot wire system electronically.................................................................................
controlled
Fuel pump-make/type High pressure electrical, immersed in the fuel tank......................................................
Fuel pump delivery pressure 2.4-2.6 bar (34-37 lbf/in
2) ............................................
Fuel filter Bosch in-line filter 'canister' type..........................................................................
Mass airflow sensor
Make and type Lucas 'Hot Wire' 20AM.................................................................
Injectors
Make and type Lucas D1000.................................................................
Electronic Control Module
Make and type Lucas GEMS 8.3.................................................................
Fuel pressure regulator
Make and type Lucas 8RV.................................................................
Coolant temperature sensor
Make and type Lucas 8TT.................................................................
Bypass Air valve (Stepper motor)
Make and type Lucas 3ACM.................................................................
Throttle position sensor
Make and type Lucas 3TP.................................................................
Heated oxygen sensor - catalyst vehicles
Make and type Lucas 4LS.................................................................
Camshaft position sensor
Make and Land Rover part no. Lucas ERR6170.........................................
Crankshaft position sensor
Make and type Lucas 3VRS, Honeywell ERR6049.................................................................
Knock sensor
Make and type Lucas 2KS.................................................................
Intake air temperature sensor
Make and type Lucas 10TT.................................................................
Ignition coils
Make and type Lucas 2DIS2.................................................................
Fuel temperature sensor
Make and type Lucas 6TT.................................................................

GENERAL SPECIFICATION DATA
7
INFORMATION SHIFT SPEED AUTOMATIC ZF ON 3.9 V8i
OPERATION SELECTOR VEHICLE SPEED ENGINE SPEED
POSITON APPROX APPROX (RPM)
KICKDOWN
MPH KPH
KD4 - 3 D 84 - 92 136 - 150
KD3 - 2 3(D) 57 - 62 91 - 99
KD2 - 1 2(D,3) 27 - 34 44 - 56
KD3 - 4 D N/A N/A
KD2 - 3 D(3) 60 - 63 96 - 104 4750 - 5200
KD1 - 2 D(3,2) 34 - 40 56 - 64 4600 - 5250
FULL THROTTLE
FT4 - 3 D 61 - 67 98 - 108
FT3 - 2 3(D) 40 - 46 64 - 73
FT3 - 4 D 74 - 80 119 - 129 3980 - 4330
FT2 - 3 D(3) 55 - 60 88 - 96 4350 - 4800
FT1 - 2 D(3,2) 29 - 34 48 - 56 3950 - 4650
PART THROTTLE
PT4 - 3 D 47 - 54 75 - 86
PT3 - 2 D(3) 29 - 37 48 - 59
PT2 - 1 D(3,2) 10 - 12 16 - 19
LIGHT THROTTLE
LT3 - 4 D 26 - 30 43 - 49 1430 - 1650
LT2 - 3 D(3) 18 - 22 29 - 35 1420 - 1820
LT1 - 2 D(3,2) 9 - 10 14 - 16 1180 - 1220
ZERO THROTTLE
ZT4 - 3 D 19 - 25 31 - 41
ZT3 - 2 D(3) 12 - 15 19 - 24
ZT2 - 1 D(3,2) 6 - 7 10 - 11
TORQUE CONVERTER
Lock up (IN) D 51 - 54 81 - 86 1875 - 2000
Unlock (OUT) D 49 - 52 78 - 83 1825 - 1930
NOTE: The speeds given in the above chart are approximate and only intended as a guide. Maximum shift
changes should take place within these tolerance parameters.

04GENERAL SPECIFICATION DATA
8
INFORMATION SHIFT SPEED AUTOMATIC ZF ON Tdi ENGINE
OPERATION SELECTOR VEHICLE SPEED ENGINE SPEED
POSITON APPROX APPROX (RPM)
KICKDOWN
MPH KPH
KD4 - 3 D 62 - 72 99 - 115
KD3 - 2 3(D) 43 - 49 69 - 78
KD2 - 1 2(D,3) 23 - 36 37 - 58
KD3 - 4 D 64 - 76 102 - 122 3400 - 4000
KD2 - 3 D(3) 46 - 51 74 - 82 3600 - 3900
KD1 - 2 D(3,2) 26 - 29 42 - 46 3500 - 3800
PART THROTTLE
PT4 - 3 D 39 - 45 62 - 72
PT3 - 2 D(3) 24 - 30 38 - 48
PT2 - 1 D(3,2) 18 - 20 29 - 32
LIGHT THROTTLE
LT3 - 4 D 24 - 28 38 - 45 1300 - 1400
LT2 - 3 D(3) 21 - 23 34 - 37 1700 - 1800
LT1 - 2 D(3,2) 13 - 14 21 - 22 1700 - 1900
ZERO THROTTLE
ZT4 - 3 D 22 - 27 35 - 43
ZT3 - 2 D(3) 18 - 22 29 - 35
ZT2 - 1 D(3,2) 9 - 11 14 - 18
TORQUE CONVERTER
Lock up (IN) D 46 - 49 74 - 78 1600 - 1850
Unlock (OUT) D 45 - 48 72 - 77 1700 - 1800
NOTE: The speeds given in the above chart are approximate and only intended as a guide. Maximum shift
changes should take place within these tolerance parameters.

04GENERAL SPECIFICATION DATA
18
INFORMATION 300 Tdi ENGINE
Type Direct injection, turbocharged, intercooled.................................................................................
Number of cylinders 4.........................................................
Bore 90,47 mm.................................................................................
Stroke 97,00 mm...............................................................................
Capacity 2495 cc...........................................................................
Compression ratio 19.5:1±0.5:1 ............................................................
Valve operation O.H.V. pushrod operated................................................................
Crankshaft
Main bearing journal diameter 63,475 - 63,487 mm..........................................
Regrind dimensions 63,2333 - 63,246 mm.........................................................
Use 0.010 in U/S bearings
Crankpin journal diameter 58,725 - 58,744 mm................................................
Regrind dimensions 58,4708 - 58,48985 mm.........................................................
Use 0.010 in U/S bearings
Crankshaft end thrust Taken on thrust washers at centre main bearing.......................................................
Crankshaft end float 0,05 - 0,15 mm.........................................................
Main bearings
Number and type 5 halved shells with oil grooves..............................................................
Diametrical clearance 0,0792 - 0,0307 mm.......................................................
Connecting rods
Length between centres 175,38 - 175,43 mm...................................................
Diametrical clearance (big-end bearings) 0,025 - 0,075 mm........................
End float on crankpin 0,15 - 0,356 mm.......................................................
Pistons
Type Aluminium alloy, combustion chamber in crown..................................................................................
Graphite coating on sidewalls.
Skirt diametrical clearance
(at right angle to gudgeon pin) 0,025 - 0,05 mm.........................................
Maximum height above combustion face 0,8 mm.........................
Gudgeon pins
Type Floating.................................................................................
Fit in piston Hand push fit.......................................................................
Diameter 30,1564 - 30,1625 mm..........................................................................
Clearance in connecting rod 0,0025 - 0,0163 mm............................................