ignition system LAND ROVER DISCOVERY 1995 User Guide

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.

17EMISSION CONTROL
4
REPAIR HEATED OXYGEN SENSOR (HO2S) - 4.0 V8
WARNING: Do not attempt HO2S removal
when the exhaust is hot.
Remove
For all sensors:
1.Raise and support front of vehicle.
2.Release sensor lead from clips.
RH front sensor only
3.Remove nuts retaining coil bracket and position
bracket aside.
See FUEL SYSTEM SFI, Repair,
Ignition Coils
4.Release multiplug from bracket behind cylinder
head.
5.Disconnect multiplug and release sensor lead
from clip.
6.Unscrew and remove sensor from exhaust pipe.LH front sensor
7.Disconnect multiplug and release from bracket.
8.Unscrew and remove sensor from exhaust pipe
using special tool LRT-12-047 (LST134).

19FUEL SYSTEM
4
DESCRIPTION AND OPERATION OPERATION
Diesel engines operate by compression ignition. The
rapid compression of air in the cylinder during the
compression cycle heats the injected fuel, causing it
to self ignite. During cold starting, automatically
controlled glow plugs assist in raising the temperature
of the compressed air to ignition point.
A cold start advance unit advances the injection timing
to further assist starting. Idle quality is improved by
the high idle setting.
The engine is supplied with pre-compressed air by a
single stage turbocharger.
Exhaust gases passing over a turbine cause it to
rotate, driving a compressor mounted on the turbine
shaft. Air drawn from the cold air intake passes, via
the air cleaner, to the turbocharger where it is
compressed. The compressed air passes to the
cylinders via an intercooler, which reduces the
temperature of the compressed air, increasing its
density.
Fuel is drawn from the tank by a mechanical lift pump
and passes to the injection pump via a filter. In
addition to removing particle contamination from the
fuel, the filter incorporates a water separator, which
removes and stores both bound and unbound water.
The injection pump meters a precisely timed, exact
quantity of fuel to the injectors in response to throttle
variations, injection timing varying with engine speed.
Any excess fuel delivered to the injection pump is not
injected, passing back to the tank via the fuel return
line.
Fuel is injected in a finely atomised form into a
pre-combustion chamber in the cylinder head where it
ignites. The burning fuel expands rapidly into the main
combustion chamber, creating extreme turbulence
which mixes the burning fuel thoroughly with the
compressed air, providing complete combustion.
Cold Starting is assisted by glow plugs, a cold start
advance unit and a high idle setting.Glow plugs
Glow plug operation is controlled by a timer unit, start
relay and resistor. When the ignition is turned on the
timer unit is energised, the glow plugs start to operate
and a warning light on the dashboard illuminates,
remaining illuminated until the glow plugs are
automatically switched off.
The length of time the glow plugs will operate is
dependent on under bonnet temperature, which is
monitored by a sensor located in the timer unit.
Starting the engine results in the power supply to the
glow plugs passing through the resistor, which
reduces their operating temperature. The glow plugs
are cut out either by the temperature sensor in the
timer, or by a microswitch on the injection pump which
operates when the throttle is depressed.
Cold start advance
The cold start advance unit is connected to the engine
cooling system via hoses. It contains a temperature
sensitive element which is retracted when cold and
pulls the advance lever, via cable, towards the rear of
the pump against spring pressure. As coolant
temperature rises, the cold start element expands
releasing tension on the cable and allowing spring
pressure to move the advance lever forwards.

MFI
1
DESCRIPTION AND OPERATION DESCRIPTION
Hot Wire Multiport Fuel Injection
The 'Hot Wire' Multiport fuel injection system derives
its name from the mass air flow sensor which uses
one cold wire and one electrically heated wire to
measure the volume of air entering the engine.
The function of the system is to supply the exact
amount of fuel directly into the intake manifold
according to the prevailing engine operating
conditions.
To monitor these conditions, various sensors are fitted
to the engine to measure engine parameters. Data
from the sensors is received by the Engine control
module (ECM), the ECM will then determine the exact
amount of fuel required at any condition.
The ECM having received data from the sensors
produces pulses, the length of which will determine
the simultaneous open time of each bank of injectors
in turn, which will govern the amount of fuel injected.
Engine control module - ECM
The Multiport fuel injection system is controlled by the
14 CUX Engine Control Module comprising of a
microprocessor with integrated circuits and
components mounted on printed circuit boards. The
ECM is connected to the main harness by a 40 pin
plug.
Injectors
The eight fuel injectors are fitted between the
pressurized fuel rail and inlet manifold. Each injector
comprises a solenoid operated needle valve with a
movable plunger rigidly attached to the nozzle valve.
When the solenoid is energized the plunger is
attracted off its seat and allows pressurized fuel into
the intake manifold.Engine coolant temperature sensor
The engine coolant temperature sensor is located in
the front of the thermostat housing. The sensor
provides engine coolant information to the ECM. The
ECM increases the injector opening time when cold to
provide improved driveability, and reduces the
opening time as the engine reaches normal operating
temperature.
Engine fuel temperature sensor
The engine fuel temperature sensor is located in the
rail on the RH side of the ram housing. The sensor
sends fuel temperature data to the ECM, the ECM on
receiving the data will adjust the injector open time
accordingly to produce good hot starting in high
ambient temperatures.
Idle air control valve
The idle air control valve is screwed into a housing
attached to the rear of the plenum chamber, between
the plenum chamber and bulkhead. The idle air
control valve has two windings which enable the
motor to be energised in both directions thus opening
or closing the air valve as required by the ECM.
The idle air control valve will open and allow extra air
into the plenum chamber to maintain engine idle
speed when the engine is under increased (Electrical
and Mechanical) loads.
The idle air control valve will control engine idle speed
when the vehicle is stationary.
Heated oxygen sensors (0
2sensors) - Catalyst
vehicles
The two heated oxygen sensors are located forward
of the catalysts mounted in the exhaust downpipes.
The sensors monitor the oxygen content of the
exhaust gases and provide feedback information of
the air/fuel ratio to the ECM. Each sensor is heated by
an electrical element to improve its response time
when the ignition is switched on.

MFI
3
DESCRIPTION AND OPERATION Tune select resistor -
To suit individual market requirements a tune select
resistor is connected across pins 5 and 27 of the
ECM.
It is located adjacent to the ECM, and strapped to the
MFI cable assembly. The value of the resistor is
dependent on the market application:
Red wire, 180 ohms, Australia, Rest of world.
Green wire, 470 Ohms, UK and Europe - non catalyst.
Yellow wire 910 Ohms, Saudi non catalyst.
White wire, 3K9 Ohms, European catalyst
Condenser fans
It should be noted that under high coolant
temperatures, when the engine is switched off, the
condenser fans will be activated and will run for
approximately ten minutes.Vehicle speed sensor
The vehicle speed sensor is located on the side of the
Transfer box adjacent to the parking brake. The
sensor provides road speed data to the ECM. The
ECM in turn detects vehicle movement from the road
speed input and ensures that idle air control mode is
disengaged. Should the vehicle speed sensor fail in
service the ECM idle air control would become erratic.
The sensor also provides road speed data to the
electric speedometer and cruise control ECU.
Inertia fuel shutoff switch
The inertia fuel shutoff switch is a mechanically
operated switch, located on the bulkhead adjacent to
the washer reservoir under bonnet [hood].
The switch is normally closed and is in line with the
fuel pump. In the event of a sudden impact the switch
opens, and disconnects the electrical feed to the fuel
pump. The switch is reset by pressing down the
button.
WARNING: Check the integrity of the fuel
system before the inertia switch is reset.
Relay modules
The two multiport fuel injection relays are located in
the RH footwell area behind the 'A' post panel. The
main relay module is energized via the ECM when the
ignition is switched on and supplies current to the
multiport fuel injection system. The fuel pump relay
module is energized by the ECM which in turn
operates the fuel pump to pressurize the fuel system.

19FUEL SYSTEM
6
DESCRIPTION AND OPERATION BODY MOUNTED COMPONENTS
1. Engine control module (ECM).
2. Main relay and fuel pump relay.
3. Inertia switch.
4. Ignition coil.
5. Charcoal canister.
6. Purge control valve.

MFI
7
DESCRIPTION AND OPERATION MICRO PROCESSOR POWER CHECK
(Instrument binnacle - Service use only)
As part of the engine starting procedure, this symbol
will illuminate momentarily.
FUEL INJECTION SYSTEM
CAUTION: The fuel system incorporates
fine metering components that would be
affected by any dirt in the system;
therefore it is essential that working conditions
are scrupulously clean. If it is necessary to
disconnect any part of the fuel injection system,
the system MUST be depressurized. All openings
left open after the removal of any component from
the fuel system, MUST be sealed off to prevent
ingress of dirt.ENGINE SETTING PROCEDURE
If a major overhaul has been undertaken of the fuel
injection/engine system, the following check and
adjustments must be carried out before attempting to
start the engine.
1.Spark plug gaps.
See ENGINE TUNING DATA,
Information, Engine 3.9 V8i
2.Ignition timing.See ELECTRICAL,
Adjustment, Ignition Timing
CAUTION: Catalyst vehicle - if the engine
is misfiring, it should be immediately shut
down and the cause rectified. Failure to do
so will result in irreparable damage to the
catalysts.
NOTE: If the previous checks and
adjustments are satisfactory but the
engine will not start, the ignition and fuel
injection electrical circuits must be checked using
the appropriate recommended equipment.

MFI
1
FAULT DIAGNOSIS ENGINE TUNING
Circuit fault diagnosis may be carried out on all V8i
vehicles, using Testbook. Testbook will guide the
operator by visual prompts through a series of
diagnostic checks.
Before commencing any fault diagnosis, the following
preminary checks must be carried out.
Preliminary checks
CAUTION: Catalyst exhaust: If engine is
misfiring or fails to start within 12 seconds
the cause must be rectified. Failure to do
so will result in irreparable damage to the
catalysts. After rectification the engine must be
run at 1500 rev/min (no load) for 3 minutes to
purge any accumulation of fuel in the system.
1.Check that the inertia fuel shut off switch is not
tripped.
2.Check fuse in main fuse panel.
3.Check for ample fuel in tank.
4.Check air inlet system for possible leaks into the
intake manifold.
5.Check HT cables for correct firing order and
routing.
6.Check ignition timing.
Only when the above checks have been carried out,
should circuit diagnosis begin.
See Electrical
Trouble Shooting Manual.
INJECTOR TESTS
NOTE: Before removing any of the
injectors, remove and examine the spark
plugs, check for consistent colouration of
plugs. A leaking injector will result in the
appropriate spark plug being 'sooted up'.
The following test may only be carried out using
suitable injector test equipment.
Leak Test
Leak test with the injectors closed but pressurise to
2.54 Kgf/cm
2. No injector should leak more than 2
drops of fuel per minute.
Fuel Delivery Test
Fuel delivery test with the injector open and
pressurised as above, fuel delivery from each injector
should be 160-175cc per minute using white spirit, or
180-195cc per minute using petrol at 20°C±2°C.