service LAND ROVER DISCOVERY 1995 User Guide

GENERAL FITTING REMINDERS
1
INFORMATION GENERAL FITTING REMINDERS
WORKSHOP SAFETY IS YOUR RESPONSIBILITY!
The suggestions, cautions and warnings in the
section are intended to serve as reminders for
trained and experienced mechanics. This manual
is not a course in automotive mechanics or
workshop safety.
Shop equipment, shop environment, and the use
and disposal of solvents, fluids, and chemicals
are subject to government regulations which are
intended to provide a level of safety. It is your
responsibility to know and comply with such
regulations.
PRECAUTIONS AGAINST DAMAGE
1.Always fit covers to protect fenders before
commencing work in engine compartment.
2.Cover seats and carpets, wear clean overalls
and wash hands or wear gloves before working
inside vehicle.
3.Avoid spilling hydraulic fluid or battery acid on
paint work. Wash off with water immediately if
this occurs. Use Polythene sheets to protect
carpets and seats.
4.Always use a recommended Service Tool, or a
satisfactory equivalent, where specified.
5.Protect temporarily exposed screw threads by
replacing nuts or fitting plastic caps.SAFETY PRECAUTIONS
1.Whenever possible use a lift or pit when working
beneath vehicle, in preference to jacking. Chock
wheels as well as applying parking brake.
WARNING: Do not use a pit when
removing fuel system components.
2.Never rely on a jack alone to support vehicle.
Use axle stands carefully placed at jacking
points to provide rigid support.
3.Ensure that a suitable form of fire extinguisher is
conveniently located.
4.Check that any lifting equipment used has
adequate capacity and is fully serviceable.
5.Disconnect battery negative lead.
WARNING: Do not disconnect any pipes in
air conditioning refrigeration system,
unless trained and instructed to do so. A
refrigerant is used which can cause blindness if
allowed to contact eyes.
6.Ensure that adequate ventilation is provided
when volatile degreasing agents are being used.
7.Do not apply heat in an attempt to free stiff nuts
or fittings; as well as causing damage to
protective coatings, there is a risk of damage to
electronic equipment and brake linings from
stray heat.

07GENERAL FITTING REMINDERS
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INFORMATION PREPARATION
1.Before removing a component, clean it and its
surrounding areas as thoroughly as possible.
2.Blank off any openings exposed by component
removal, using greaseproof paper and masking
tape.
3.Immediately seal fuel, oil or hydraulic lines when
separated, using plastic caps or plugs, to
prevent loss of fluid and entry of dirt.
4.Close open ends of oilways, exposed by
component removal, with tapered hardwood
plugs or readily visible plastic plugs.
5.Immediately a component is removed, place it in
a suitable container; use a separate container for
each component and its associated parts.
6.Before dismantling a component, clean it
thoroughly with a recommended cleaning agent;
check that agent is suitable for all materials of
component.
7.Clean bench and provide marking materials,
labels, containers and locking wire before
dismantling a component.
DISMANTLING
1.Observe scrupulous cleanliness when
dismantling components, particularly when
brake, fuel or hydraulic system parts are being
worked on. A particle of dirt or a cloth fragment
could cause a dangerous malfunction if trapped
in these systems.
2.Blow out all tapped holes, crevices, oilways and
fluid passages with an air line. Ensure that any
O-rings used for sealing are correctly replaced or
renewed, if disturbed.
3.Use marking ink to identify mating parts, to
ensure correct reassembly. If a centre punch or
scriber is used they may initiate cracks or
distortion of components.
4.Wire together mating parts where necessary to
prevent accidental interchange (e.g. roller
bearing components).
5.Wire labels on to all parts which are to be
renewed, and to parts requiring further
inspection before being passed for reassembly;
place these parts in separate containers from
those containing parts for rebuild.
6.Do not discard a part due for renewal until after
comparing it with a new part, to ensure that its
correct replacement has been obtained.INSPECTION-GENERAL
1.Never inspect a component for wear or
dimensional check unless it is absolutely clean;
a slight smear of grease can conceal an incipient
failure.
2.When a component is to be checked
dimensionally against figures quoted for it, use
correct equipment (surface plates, micrometers,
dial gauges, etc.) in serviceable condition.
Makeshift checking equipment can be
dangerous.
3.Reject a component if its dimensions are outside
limits quoted, or if damage is apparent. A part
may, however, be refitted if its critical dimension
is exactly limit size, and is otherwise satisfactory.
4.Use 'Plastigauge' 12 Type PG-1 for checking
bearing surface clearances. Directions for its
use, and a scale giving bearing clearances in
0,0025 mm steps are provided with it.

GENERAL FITTING REMINDERS
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INFORMATION BALL AND ROLLER BEARINGS
CAUTION: Never refit a ball or roller
bearing without first ensuring that it is in a
fully serviceable condition.
1.Remove all traces of lubricant from bearing
under inspection by washing in a suitable
degreaser; maintain absolute cleanliness
throughout operations.
2.Inspect visually for markings of any form on
rolling elements, raceways, outer surface of
outer rings or inner surface of inner rings. Reject
any bearings found to be marked, since any
marking in these areas indicates onset of wear.
3.Holding inner race between finger and thumb of
one hand, spin outer race and check that it
revolves absolutely smoothly. Repeat, holding
outer race and spinning inner race.
4.Rotate outer ring gently with a reciprocating
motion, while holding inner ring; feel for any
check or obstruction to rotation, and reject
bearing if action is not perfectly smooth.
5.Lubricate bearing generously with lubricant
appropriate to installation.
6.Inspect shaft and bearing housing for
discoloration or other marking suggesting that
movement has taken place between bearing and
seatings. (This is particularly to be expected if
related markings were found in operation 2).
7.Ensure that shaft and housing are clean and free
from burrs before fitting bearing.8.If one bearing assembly of a pair shows an
imperfection it is generally advisable to replace
both with new bearings; an exception could be
made if the faulty bearing had covered a low
mileage, and it could be established that
damage was confined to it only.
9.When fitting bearing to shaft, apply force only to
inner ring of bearing, and only to outer ring when
fitting into housing. (Refer to ST1042M).
10.In the case of grease lubricated bearings (e.g.
hub bearings) fill space between bearing and
outer seal with recommended grade of grease
before fitting seal.
11.Always mark components of separable bearings
(e.g. taper roller bearings) in dismantling, to
ensure correct reassembly. Never fit new rollers
in a used outer ring, always fit a complete new
bearing assembly.

07GENERAL FITTING REMINDERS
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INFORMATION OIL SEALS
NOTE: Ensure that the seal running track
is free from pits, scores, corrosion and
general damage prior to fitting
replacement seal.
1.Always fit new oil seals when rebuilding an
assembly.
2.Carefully examine seal before fitting to ensure
that it is clean and undamaged.
3.Coat the sealing lips with clean grease; pack
dust excluder seals with grease, and heavily
grease duplex seals in cavity between sealing
lips.
4.Ensure that seal spring, if provided, is correctly
fitted.
5.Place lip of seal towards fluid to be sealed and
slide into position on shaft, using fitting sleeve
when possible to protect sealing lip from damage
by sharp corners, threads or splines. If fitting
sleeve is not available, use plastic tube or tape
to prevent damage to sealing lip.
6.Grease outside diameter of seal, place square to
housing recess and press into position, using
great care and if possible a 'bell piece' to ensure
that seal is not tilted. (In some cases it may be
preferable to fit seal to housing before fitting to
shaft). Never let weight of unsupported shaft rest
in seal.
7.If correct service tool is not available, use a
suitable drift approximately 0.4mm (0.015 in)
smaller than outside diameter of seal. Use a
hammerVERY GENTLYon drift if a press is not
suitable.
8.Press or drift seal in to depth of housing if
housing is shouldered, or flush with face of
housing where no shoulder is provided. Ensure
that the seal does not enter the housing in a
tilted position.
NOTE: Most cases of failure or leakage of
oil seals are due to careless fitting, and
resulting damage to both seals and
sealing surfaces. Care in fitting is essential if
good results are to be obtained. NEVER use a seal
which has been improperly stored or handled,
such as hung on a hook or nail.

LUBRICANTS, FLUIDS AND CAPACITIES
1
INFORMATION RECOMMENDED LUBRICANTS AND FLUIDS -
USA VEHICLES
AMBIENT TEMPERATURE°C
COMPONENT SPECIFICATION VISCOSITY -30 -20 -10 0 10 20 30 40 50
Engine Use oils to API 5W/20 )
service level
SGSH 5W/30 )
or 5W/40 )
RES.22.OL.G4
or
CCMC G4 10W/30
10W/40 )
10W/50 )
15W/40 )
15W/50 )
20W/40 )
20W/50 )
Automatic gearbox ATF Dexron IID
Final drive units API or GL5 90 EP
Swivel pin housings MIL - L - 2105 or
MIL - L - 2105B, C
or D 80W EP
Power steering ATF Dexron IID
LT 230T API GL4 or GL5
transfer gearbox MIL - L - 2105 or
MIL - L - 2105B
Brake reservoir Brake fluid must have a minimum
boiling point of 260°C (500ÊF) and
comply with FMVSS/116/DOT 4
Lubrication nipples
(hubs, ball joints,
etc.)NLGI-2 multipurpose lithium based
grease
See table on page 3 for remaining vehicle components

LUBRICANTS, FLUIDS AND CAPACITIES
3
INFORMATION Propeller shaft Front
and RearNLGI - 2 Multi-purpose Lithium based GREASE
Lubrication nipples
(hubs, ball joints
etc.)
Seat slides
Door lock striker
Brake and clutch
reservoirsBrake fluids having a minimum boiling point of 260°C (500°F) and complying with
FMVSS 116 DOT4
Engine coolant Use an ethylene glycol based anti-freeze (containing no methanol)
V8i, Tdi, Mpi with non-phosphate corrosion inhibitors suitable for use in aluminium engines to ensure
the protection of the cooling system against frost and corrosion in all seasons. Use one
part anti-freeze to one part water for protection down to -36°C (-33°F).
IMPORTANT: Coolant solution must not fall below proportions one part
anti-freeze to three parts water, i.e. minimum 25% anti-freeze in coolant otherwise
damage to engine is liable to occur. Or a maximum of 60%.
Battery lugs, Petroleum jelly.
Earthing surfacesNOTE: Do not use Silicone Grease
where paint has
been removed
Air Conditioning
System Refrigerant Use only refrigerant R134a
Compressor Oil Nippon Denso ND-oil8 Unipart ND-oil8
ABS Sensor Silicone grease: Staborags NBU - Wabco 830 502,0634
bush-rear Wacker chemie 704 - Wabco 830 502,0164
Kluber GL301
LUBRICATION PRACTICE
Use a high quality oil of the correct viscosity range and service classification in the engine during maintenance and
when topping up. The use of oil not to the correct specification can lead to high oil and fuel consumption and
ultimately to damaged components.
Oil to the correct specification contains additives which disperse the corrosive acids formed by combustion and
prevent the formation of sludge which can block the oilways. Additional oil additives should not be used. Always
adhere to the recommended servicing intervals.
WARNING: Many liquids and other substances used in motor vehicles are poisonous. They must
not be consumed and must be kept away from open wounds. These substances, among others,
include anti-freeze windscreen washer additives, lubricants and various adhesives.

MAINTENANCE
1
MAINTENANCE SERVICE SCHEDULE
This section gives information on the range of service
procedures.
Where required, instructions are given for carrying out
each service procedure, or a cross reference is given,
where the procedure can be found in this manual.
Service Schedule sheets are published separately to
reflect the maintenance needs and intervals for each
vehicle variant and model year. The procedures given
must be used in conjunction with the Service
Schedule sheets.
The Service Schedule sheets are available from:-
Land Rover Merchandising
PO Box 534
Erdington
Birmingham B24 0QS.
England.VEHICLE INTERIOR
CHECK SEATS & BELTS
Check condition and security of seats, seat belt
mountings, seat belts, buckles and opertion of inertia
seat belts. Lubricate seat tilt pivots.
CHECK OPERATION OF FOOT BRAKE AND
CLUTCH
If pedal feels 'spongy' bleed system.See BRAKES,
Repair, Brake System Bleed
or.See CLUTCH,
Repair, Bleed hydraulic system
Check all hoses and pipes for security, fractures and
leaks. Fit new hoses and pipes as necessary.
CHECK OPERATION OF LAMPS
Check operation of all lamps, horns and warning
indicators.
CHECK OPERATION OF WIPERS
Check operation of front/rear screen wipers and
washers and condition of wiper blades.
AIR BAG MODULE(S)
Check air bag module covers.
Check visually for signs of damage.
Renew every ten years.

10MAINTENANCE
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MAINTENANCE
ABS VEHICLES - CHECK ROAD WHEEL SPEED
SENSOR ELECTRICAL HARNESS FOR DAMAGE
RENEW OXYGEN SENSORS
See EMISSION CONTROL, Repair, Heated
Oxygen Sensor (HO2S)
RENEW CATALYTIC CONVERTERS
See MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust System Complete
REPORT ANY UNUSUAL FEATURES OF VEHICLE
CONDITION AND ADDITIONAL WORK REQUIREDCARRY OUT ROAD TEST
For details of dynamometer testing.See
INTRODUCTION, Information, Dynamometer
Testing - Non Anti-lock brake vehicles See
INTRODUCTION, Information, Dynamometer
Testing - Vehicles with Anti-lock brakes (ABS)
Check following items:
1.Inhibitor switch only operates in P and N.
2.Engine for excessive noise.
3.Clutch for slip, judder or spin.
4.Automatic gear selection/shift speeds.
5.Gear selection/noise - high/low range.
6.Steering for abnormal noise/effort.
7.Steering for free play.
8.All instruments, gauges and warning indicators.
9.Heater and air conditioning systems.
10.Heated rear screen.
11.Shock absorbers - ride irregularities.
12.Foot brake, on emergency stop, pulling to one
side, binding, pedal effort.
13.Parkbrake efficiency.
14.Seat reclining and latching.
15.Fully extend seat belt, check operation of
retraction and latching. Inertia belts lock when
snatched or vehicle on slope.
16.Road wheel balance.
17.Transmission for vibrations.
18.Body noises, squeaks and rattles.
19.Excessive exhaust smoke.
20.Engine idle speed.
21.Endorse service record.
22.Report any unusual features of vehicle condition
and additional work required.
ENDORSE SERVICE RECORD

MAINTENANCE
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MAINTENANCE
RESET EMISSION MAINTENANCE REMINDER -
USA
The emission maintenance reminder is designed to
activate at 52,500 and 105,000 miles respectively and
will illuminate a 'Service Engine' red warning light in
instrument binnacle.
The emission maintenance reminder must be reset
after required maintenance has been carried out and
a new tamperproof label fitted by a Land Rover of
North America dealer. This emission maintenance
reminder is part of the Emission Control System
Reset
1.The control unit is located in the passenger
footwell.
2.Identify control unit and remove from plug.
3.Remove tamperproof label to reveal access hole
for resetting.
4.Place a thin metallic probe into access hole and
momentarily electrically short between reset pins
inside unit.RECOMMENDED SERVICE ITEMS
Refer Service Schedule sheets for intervals.
Clean sunroof drain tubes, clean and lubricate guide
rails and slides.
Renew the hydraulic brake fluid.
See BRAKES,
Repair, Brake System Bleed
Renew all hydraulic brake fluid, seals, brake servo
filter and flexible hoses.
All working surfaces of the master cylinder and caliper
cylinders should be examined and renewed where
necessary.
ABS vehicles only - renew hydraulic brake fluid and
flexible hoses examine the working surfaces of the
caliper cylinders and renew the seals or cylinders
where necessary.
Air cleaner - When the vehicle is used in dusty or field
conditions or deep wading, frequent attention to the
air cleaner may be required.
ABS vehicles used extensively in arduous off-road
conditions - check the rear wheel road speed sensor
for abrasive wear.

Tdi
1
REPAIR DRIVE BELT INFORMATION
A single 'serpentine drive belt' drives all the
ancilliaries bar the air conditioning compressor, which
has a separate drive belt. It is essential that the belts
are fitted exactly as shown. It should also be noted
that the water pump/viscous fan is driven in a
clockwise direction.
A drive belt tensioner automatically tensions the drive
belt, eliminating the need for tensioning individual
drive belts. Turning the tensioner pulley in a clockwise
direction will release drive belt tension.
Under normal highway use the belt must be changed
at 160,000 kilometres, 96,000 miles or eight years
whichever occurs first.
The drive belt must be examined at every service and
replaced if necessary.Off road driving
Regular examination of the drive belt is essential if the
vehicle is used off road. The vehicle driver should be
requested to identify the type of mileage the vehicle
has covered.
After every off road session the owner should inspect
the belt for cuts and possible damage caused by
stones. If belt has jumped, reposition belt correctly. A
new belt must be fitted at the next service or before,
dependant on the type of damage sustained.
Fan cowl
To ensure easy access to the drive belt the top portion
of the fan cowl is detachable.
Check condition
Check condition of drive belt. Renew a belt that shows
signs of wear, splitting or oil contamination.