ignition LAND ROVER DISCOVERY 1995 User Guide

05ENGINE TUNING DATA
6
INFORMATION ENGINE - Mpi - 2.0 LITRE
Type/Capacity 20 T4/1994 cm
3..................................................................
Firing order 1-3-4-2.......................................................................
Compression ration 10 : 1..........................................................
Idle speed:
Controlled by ECM 875±50 rev/min ...........................................................
Exhaust gas Co content:
- Catalyst 0.5% Max. Not adjustable..................................................................
- Non Catalyst 1,0±25% adjustable using Testbook .........................................................
Ignition
Knock sensor ADU 8229...................................................................
Crankshaft sensor ADU 7340............................................................
Ignition Coils
Type NEC 10049.................................................................................
Primary resistance at 20°C 0.4 to 0.61 ohm..............................................
Consumption - engine idling 0.25 to 0.75 amp.............................................
Spark Plugs
Type/Gap GSP 6662 -0,85 mm.........................................................................
Multipoint Fuel Injection
Type Indirect multipoint injection with engine control module.................................................................................
using speed/density method of air flow measurement.
Fuel pressure regulator MKW 10011....................................................
Fuel pump delivery pressure 2.3 - 2.5 bar............................................
Throttle potentiometer voltage
- Throttle closed 0 - 1 Volt......................................................
- Throttle open 4 - 5 Volts.........................................................
MEMS engine control module MKC 10121..........................................
95 RON minimum -UNLEADEDfuel
CAUTION: Do not use LEADED fuel as it will
damage the catalyst. Serious damage to the
engine may occur if a lower octane number fuel
than that recommended is used.

10MAINTENANCE
4
MAINTENANCE UNDER BONNET [HOOD] MAINTENANCE
CHECK COOLING/HEATER SYSTEMS
Check cooling/heater systems for leaks and hoses for
security and condition.
Cooling system hoses should be changed at first
signs of deterioration.
CHECK CONDITION OF ENGINE MOUNTING
RUBBERS
CHECK BRAKE SERVO HOSE FOR SECURITY
AND CONDITION
CHECK FUEL EVAPORATIVE LOSS CONTROL
SYSTEM FOR LEAKS - V8i CATALYST, Mpi
CHECK FUEL FILLER CAP SEAL FOR LEAKS - V8i
- CATALYST, Mpi
CHECK CONDITION OF HEATER PLUG WIRING
FOR FRAYING, CHAFING AND DETERIORATION -
Tdi
CHECK IGNITION WIRING
Check ignition wiring and high tension leads for
fraying, chafing and deterioration.
CLEAN DISTRIBUTOR CAP - V8i
The electronic ignition employs a Lucas 35DLM8
distributor.
Internal operating parts of distributor are pre-set at
factory and do not normally require resetting.
Adjustments should only be made if unit is known to
be faulty or damaged. Distributor maintenance
consists of following items.
1.Clean outer surfaces of distributor cap to remove
dirt, grease etc.
2.Unclip cap, check cap for cracks.
3.Wipe inside cap with lint free cloth.
4.Check rotor arm, cap and flash shield tracking.
DO NOT DISTURB clear plastic insulating
cover (flash shield) which protects magnetic
pick-up module.
LUBRICATE DISTRIBUTOR ROTOR SPINDLE - V8i
Apply a spot of clean engine oil into rotor spindle after
rotor arm has been removed.
CLEAN/ADJUST SPARK PLUGS - V8i CATALYST
RENEW SPARK PLUGS V8i - V8i CATALYST
Clean, adjust and renew
1.Take great care when fitting spark plugs not to
cross-thread plug, otherwise costly damage to
cylinder head will result.

10MAINTENANCE
10
MAINTENANCE
CHECK/TOP UP COOLING SYSTEM
1.To prevent corrosion of aluminium alloy engine
parts it is imperative that cooling system is filled
with a solution of water and phosphate free
anti-freeze, winter or summer. Never fill or top up
with plain water.
WARNING: Do not remove filler cap when
engine is hot because cooling system is
pressurised and personal scalding could
result.
2.When removing filler cap, turn cap slowly
anti-clockwise, pause and allow all pressure to
escape.
3.Continue to turn until cap is removed.
4.When engine is cold expansion tank coolant
should be level with top of indicator post, visible
inside tank through filler hole.
5.If necessary, top up cooling system with
premixed coolant. Use soft water whenever
possible, if local water supply is hard, rainwater
should be used.
6.When replacing filler cap it is important that it is
tightened down fully. Failure to tighten filler cap
properly may result in water loss, with possible
damage to engine
The cooling system should be drained and flushed at
2 year intervals or at onset of second winter. Refer to
Coolant Requirements.
See COOLING SYSTEM,
Adjustment, Coolant RequirementsCHECK/ TOP UP POWER STEERING FLUID
RESERVOIR
1.Remove fluid reservoir cap. Check that fluid is
up to high mark on dipstick.
CHECK/ TOP UP CLUTCH AND BRAKE FLUID
RESERVOIRS
CAUTION: Brake fluid can damage
paintwork. If spillage occurs, wash
affected area IMMEDIATELY with a large
quantity of water.
CHECK/TOP UP WASHER RESERVOIR
Top up washer reservoir to within 25 mm of filler neck.
Use a screen washer solvent/anti-freeze solution to
assist removing mud, flies and road film and protect
against freezing.
LUBRICATE ACCELERATOR AND CRUISE
CONTROL LINKAGES
CHECK/ADJUST IGNITION TIMING - V8i
CATALYST
Check ignition timing.See ENGINE TUNING
DATA, Information, Engine 3.9 V8i

V8i
1
DESCRIPTION AND OPERATION DESCRIPTION
The V8i engine has cast aluminium cylinder heads
and cylinder block. The two banks of steel cylinder
liners which are pressed down to stops in the block,
are set at 90°to one another. The three ringed
aluminium pistons transmit the power through the
connecting rods to a cast iron five bearing crankshaft,
which drives the centrally located camshaft via a
duplex type chain.
The electronic ignition distributor is driven by a gear
off the front of the camshaft and the lubrication oil
pump is driven by a gear off the front of the
crankshaft. The overhead inlet and exhaust valves are
operated by rocker shafts, pushrods and self adjusting
hydraulic tappets.
Multiport fuel injection ensures that engine
performance, economy and exhaust emissions are
automatically correct for the demands of highway and
off road operation.

12ENGINE
2
FAULT DIAGNOSIS ENGINE NOISES
Excessive or obtrusive noise from the engine
compartment originates from three main sources:
A. The exhaust system, which makes an
unmistakable and easy to diagnose noise.
B. External components emit the greatest variety of
noises, but are also easy to diagnose by simply
removing the drive belt.
C. Engine internal mechanical noises which can
vary in volume and pitch and may be a
combination of, tapping - knocking or rumbling,
are the most difficult to diagnose. The following
is therefore a guide to diagnosis of engine
internal mechanical noises only.
Engine internal mechanical noises.
Single or multiple, light tapping noise, particularly
when engine is cold.
See Description and
operation, Description
1.Is engine oil level correct?
NO - Top up to correct level.
See
LUBRICANTS, FLUIDS AND
CAPACITIES, Information,
Recommended Lubricants and Fluids
YES - Continue.
2.Is the lubricating pressure correct?
NO -
See Engine Oil Pressure Test
YES - Suspect valve operating mechanism.
3.To confirm diagnosis, remove the rocker covers
and with the engine idling, insert a feeler gauge
of 0,015mm between each rocker and valve
stem. A faulty valve operating mechanism will
emit a different noise when the feeler gauge is
inserted.
See Repair, Rocker Shaft Renew
Heavy knocking noise (particularly on load and
when engine is hot).
See Description and
operation, Description
1.Is engine oil level correct?
NO - Top up to correct level.
See
LUBRICANTS, FLUIDS AND
CAPACITIES, Information,
Recommended Lubricants and Fluids
YES - Continue.
2.Is the lubricating pressure correct?
NO -
See Engine Oil Pressure Test
YES - Drain engine oil and filter, and examine
for metallic contamination.
3.Is the oil contaminated with metal particles?
YES - Suspect faulty big end bearings. To
confirm diagnosis, short out the ignition to
each spark plug in turn. The noise will
disappear or be reduced when the
cylinder with the faulty big end is shorted
out.
4.If noise is not conclusively diagnosed, check the
security of the flywheel and crankshaft front
pulley. Temporarily release the drive belt to
reduce general noise level and use a
stethoscope to locate source of noise.
Heavy rumbling noise (particularly during hard
acceleration).
See Description and operation,
Description
1.Is engine oil level correct?
NO - Top up to correct level.
See
LUBRICANTS, FLUIDS AND
CAPACITIES, Information,
Recommended Lubricants and Fluids
YES - Continue.
2.Is the lubricating pressure correct?
NO -
See Engine Oil Pressure Test
YES - Drain engine oil and filter, and examine
for metallic contamination.
3.Is the oil contaminated with metal particles?
YES - Suspect faulty main bearings. If noise is
not conclusively diagnosed, check the
security of the flywheel and crankshaft
front pulley. Temporarily release the drive
belt to reduce general noise level and use
a stethoscope to locate source of noise.

V8i
3
FAULT DIAGNOSIS ENGINE STARTING PROBLEMS
Engine fails to crank in park or neutral (Automatic
Transmission)
1.Is battery in good state of charge?
NO -
See INTRODUCTION, Information,
Jump Starting
YES - Continue.
2.Is automatic transmission inhibitor switch faulty
or gear selection linkage incorrectly adjusted?
YES -
See AUTOMATIC GEARBOX, Repair,
Inhibitor Switch
,
NO -
See Electrical Trouble Shooting
Manual.
If problem is not diagnosed repeat tests, starting
at 1.
Engine fails to crank (Manual Transmission)
1.Is battery in good state of charge?
NO -
See INTRODUCTION, Information,
Jump Starting
YES -See Electrical Trouble Shooting
Manual.
If problem is not diagnosed repeat tests, starting
at 1.
Engine cranks but fails to start
1.Is the cranking speed fast enough (120 rpm)?
NO -
See INTRODUCTION, Information,
Jump Starting
If necessary also.See Electrical Trouble
Shooting Manual.
YES - Continue.
2.Is there combustion in any cylinder?
NO -
See ELECTRICAL, Fault diagnosis,
Lucas Constant Energy Ignition
System - V8i See Electrical Trouble
Shooting Manual.
YES - Continue.
3.Are the fuel supply, tank, pump, ventilation and
emission control systems in correct working
order or the fuel contaminated?
NO -
See FUEL SYSTEM, Repair, Fuel
Filter See FUEL SYSTEM, Repair,
Fuel Tank See FUEL SYSTEM, Repair,
Fuel pump and Sender Unit See
EMISSION CONTROL, Description and
operation, Emission control
If problem is not diagnosed repeat tests, starting
at 2.ENGINE RUNNING PROBLEMS
Engine runs at high speed but will not idle (stops)
Engine idle speed erratic Engine starts but stops
immediately
Engine stalls Engine misfires/hesitation
1.Multiport fuel injection.
See Electrical Trouble
Shooting Manual. See ELECTRICAL, Fault
diagnosis, Lucas Constant Energy Ignition
System - V8i
Check brake vacuum connections.See
BRAKES, Description and operation, Brake
Servo Unit
Check heater/ventilation unit vacuum
connections.
See HEATING AND
VENTILATION, Description and operation,
Heating and Ventilation Unit
If problem is not diagnosed continue.
2.Are HT leads correctly routed and clipped?
NO -
See ELECTRICAL, Repair, Distributor
- V8i
YES - Continue.
3.Is fuel supply, tank, pump, ventilation and
emission control systems in correct working
order or the fuel contaminated?
NO -
See FUEL SYSTEM, Repair, Fuel
Filter See FUEL SYSTEM, Repair,
Fuel Tank See FUEL SYSTEM, Repair,
Fuel Pump and Sender Unit See
EMISSION CONTROL, Description and
operation, Emission Control
If problem is not diagnosed repeat tests, starting
at 1.
Engine lacks power/poor performance
1.Is throttle travel restricted or cable incorrectly
adjusted?
YES - Check thickness of carpets.
See FUEL
SYSTEM, Repair, Throttle Cable See
FUEL SYSTEM, Repair, Accelerator
Pedal
NO - Continue.
2.Are the Ignition and Multiport Fuel Injection
systems in order?
NO -
See Electrical Trouble Shooting
Manual.A1 See ELECTRICAL, Fault
diagnosis, Lucas Constant Energy
Ignition System - V8i See
ELECTRICAL, Repair, Distributor - V8i
YES - Continue.

V8i
9
REPAIR FRONT COVER GASKET
Service repair no - 12.65.04
1.Remove crankshaft pulley.
See Crankshaft
Pulley Assembly. Do not remove pulleys
2.Remove water pump pulley.
3.Release distributor cap clips.
4.Release plug leads from plugs and clips.
5.Place cap and leads to one side.
6.Turn engine until No. 1 piston is at T.D.C.
7.Check position of rotor arm.
8.Remove fixings securing power steering pump
bracket to water pump bracket.
9.Remove power steering pump bracket from
water pump.
10.Remove clips securing wiring to generator
tensioner.
11.Disconnect distributor feed wire.
12.Pivot power steering pump away from front
cover, tighten pivot to retain in position.
13.Disconnect vacuum pipe from distributor.
14.Remove water pump bottom hose.
15.Disconnect oil pressure switch.
16.Disconnect heater hose at water pump.
17.Remove generator tensioner from water pump,
move tensioner aside.
18.Mark distributor position to front cover.
19.Remove distributor clamp, remove distributor.
See ELECTRICAL, Repair, Distributor - V8i
20.Remove fixings sump to front cover.
21.Loosen four adjacent sump fixings.
22.Remove generator support strut from front cover,
move strut aside.
23.Loosen remaining front cover fixings and remove
front cover.
24.Remove front cover gasket.Refit
25.Clean timing cover, clean block face.
26.Lightly grease gasket faces.
27.Fit new gasket to block face.
28.Apply hylosil to sump gasket.
29.Clean threads of cover fixing bolts, apply Loctite
372 to threads.
30.Fit timing cover, fit fixing bolts. Tighten to
28
Nm.
31.Fit generator support strut to front cover.
32.Tighten sump to timing cover fixings to
10 Nm.
33.Tighten sump fixings to10 Nm.
34.Lubricate distributor O ring.
35.Fit distributor in position marked.
36.Align oil pump drive, if distributor does not seat
correctly.
37.Fit distributor clamp. Tighten to
20 Nm.
38.Locate generator tensioner on water pump
bracket.
39.Connect heater hose, tighten clip.
40.Connect oil pressure switch.
41.Connect bottom hose, tighten clip.
42.Connect vacuum pipe to distributor.
43.Loosen power steering pump pivot, lower pump.
44.Connect distributor feed wire.
45.Connect wire ties to generator tensioner.
46.Fit power steering pump bracket to water pump.
Tighten to
28 Nm.
47.Fit power steering pump to bracket.
48.Position distributor cap. Fit plug leads to plugs
and clips.
49.Clip distributor cap in position.
50.Fit water pump pulley. Tighten to
10 Nm.
51.Fit crankshaft pulley.See Crankshaft Pulley
Assembly
52.Tension drive belts correctly.
53.Check ignition timing.
54.Refill cooling system.

4.0 V8
3
REPAIR ENGINE ASSEMBLY
Service repair no - 12.41.01/99
Remove
1.Position vehicle on ramp.
2.Remove bonnet.
See CHASSIS AND BODY,Repair, Bonnet [Hood]
3.Remove radiator.See COOLING SYSTEM,
Repair, Radiator
4.Remove plenum chamber.See FUEL SYSTEM
SFI, Repair, Plenum Chamber
5.Remove mass air flow sensor.See FUEL
SYSTEM SFI, Repair, Mass Air Flow Sensor
(MAF Sensor)
6.Slacken hose clip securing bottom hose to
expansion tank.
7.Disconnect hose.
8.Remove 2 nuts securing expansion tank.
9.Remove nut and bolt securing expansion tank.
10.Remove expansion tank.
11.Disconnect servo vacuum hose from ram
housing.
12.Disconnect battery sensing lead Lucar from
generator.
13.Remove generator terminal cover.
14.Remove 2 terminal nuts and release leads from
terminals.
15.Release purge hose from ram pipe housing.
16.Position cloth to absorb fuel spillage.
17.Slacken clip securing fuel return hose to fuel rail.
18.Disconnect hose.
19.Plug connections.
20.Disconnect fuel feed hose union.
21.Plug connections. Position hoses aside.
22.Slacken clip securing heater return hose to pipe.
23.Disconnect hose.24.Slacken clip securing heater feed adaptor hose
to inlet manifold.
25.Remove bolt securing pipe bracket.
26.Disconnect feed hose from inlet manifold.
27.Disconnect hose/pipe assembly.
28.Disconnect leads from spark plugs and remove
ignition coils.
See FUEL SYSTEM SFI, Repair,
Ignition Coils
29.Disconnect fuel temperature sensor multiplug.
30.Disconnect coolant sensor multiplug.
31.Disconnect temperature gauge sensor lead.
32.Release camshaft sensor multiplug from bracket
and disconnect multiplug.
33.Disconnect oil pressure switch Lucar.
34.Disconnect air intake temperature sensor
multiplug.
35.Disconnect 8 injector multiplugs.
36.Remove 4 nuts securing harness brackets to
inlet manifold.
37.Release harness brackets.
38.Remove bolts securing gearbox breather pipes
to engine lifting bracket.

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
10
REPAIR
38.Disconnect 2 ignition coil multiplugs.
39.Disconnect 3 vacuum hoses from manifold.
40.Release cover and remove bolt securing earth
lead to cylinder block.
41.Move earth lead aside.
42.Remove 4 bolts securing air conditioning
compressor, move compressor aside.