LAND ROVER DISCOVERY 1995 Workshop Manual

MFI
15
REPAIR 11.Loosen clip and disconnect top hose from
thermostat housing.
12.Disconnect multiplug from distributor amplifier
module.
13.Loosen clip and disconnect hose from heater
valve.
14.Remove injector harnesses from behind fuel rail
and lay to one side.
15.Loosen union and disconnect fuel return hose
from fuel rail.
NOTE: The intake manifold can be
removed from the cylinder block without
removing the fuel rail and injectors.
16.Using the sequence shown, remove 12 bolts
securing the intake manifold to cylinder block.
17.Remove the intake manifold.
18.Noting their fitted position, remove bolts and
clamps securing intake manifold gasket to
cylinder block.
19.Remove and discard gasket.
20.Remove and discard gasket seals.
Do not carry out further dismantling if component
is removed for access only.
21.Remove 5 nuts securing fuel rail support
brackets to intake manifold.
22.Remove fuel rail and injectors.
23.Remove 2 bolts securing thermostat housing to
intake manifold.
24.Remove thermostat housing.
25.Remove bolt securing coolant pipe to intake
manifold. Loosen union and remove coolant
pipe. Remove and discard 'O' ring.
26.Fit new 'O' ring to coolant pipe. Position coolant
pipe to intake manifold. Fit bolt securing coolant
pipe support bracket to intake manifold and
tighten pipe union.
27.Clean mating faces of thermostat housing and
intake manifold.
28.Fit thermostat housing to intake manifold using a
new gasket, fit and tighten bolts.
29.Position fuel rail to intake manifold, fit and
tighten retaining bolts.

19FUEL SYSTEM
16
REPAIR Refit
1.Clean mating faces of cylinder heads, cylinder
block and intake manifold.
2.Locate NEW seals in position with ends
engaged in notches formed between the cylinder
heads and block.
3.Apply RTV sealant between ends of seals,
cylinder head and block.
4.Fit intake manifold gasket with the word
'FRONT'to the front and open bolts hole to the
front RH side.
5.Fit gasket clamps and tighten bolts finger tight.
6.Locate intake manifold onto cylinder heads,
clean threads of manifold securing bolts.
7.Allow 10 minutes for RTV sealant to cure.
8.Fit manifold bolts finger tight. Working in the
sequence shown tighten the bolts to
38 Nm.
9.Tighten the gasket clamp bolts to18 Nm.
10.Reverse removal procedure.
11.Fill cooling system.
See COOLING SYSTEM,
Repair, Radiator
12.Start engine check for water and fuel leaks.

MFI
17
REPAIR FUEL FILTER
Service repair no - 19.25.02
Remove
WARNING: Spilling of fuel is unavoidable
during this operation. Ensure all
necessary precautions are taken to
prevent fire and explosion.
WARNING: Ensure fuel handling
precautions given in Section 01 -
Introduction are strictly adhered to when
carrying out following instructions.
1.Depressurise fuel system.
See Depressurising
Fuel System
2.Access to filter is gained through right hand rear
wheel arch.
3.Clean area around hose connections to prevent
ingress of foreign matter into fuel system. Clamp
inlet and outlet hoses to prevent fuel spillage
when disconnecting hoses.
4.Loosen two fuel line unions and remove hoses.
Plug ends of hoses to prevent ingress of dirt.
5.Release securing bolt and bracket and remove
filter from chassis side member.
Refit
6.Fit a new filter observing direction of flow arrows
stamped on canister.
7.Tighten securing nut and bolt.
8.Fit inlet and outlet hoses. Tighten to
30Nm.
9.Refit fuel pump relay module, reconnect battery.
10.Start engine and inspect for fuel leaks around
hose connections.

19FUEL SYSTEM
18
REPAIR FUEL PIPES
Service repair no - 19.40.92
WARNING: Depressurise fuel system.See
Depressurise Fuel System
before
disconnecting any fuel pipes ensure that
all necessary precautions are taken against fuel
spillage
WARNING: Ensure fuel handling
precautions given in Section 01 -
introduction are strictly adhered to when
carrying out following instructions.
KEY
1. Fuel feed hose to fuel rail.
2. Fuel return hose to fuel tank.
3. Rigid fuel feed pipe.
4. Rigid fuel return pipe.
5. Fuel filter.6. Rigid fuel feed pipe to filter.
7. Breather hose.
8. In-tank fuel pump.
9. Fuel filler neck.
10. Fuel tank.

MFI
19
REPAIR THROTTLE CABLE
Service repair no - 19.20.06
Remove
1.Remove clevis pin securing cable to lever.
2.Carefully pry throttle cable adjustment nut out of
mounting bracket.
3.Remove cable from mounting bracket.
4.Release outer cable from retaining clips in
engine compartment.
5.Remove lower dash panel.
6.Disconnect cable from accelerator pedal and
release cable locknut.
7.Feed cable through bulkhead grommet into
engine compartment.
Refit
8.Feed new cable from engine compartment
through bulkhead grommet.
9.Connect cable to accelerator pedal.
10.Connect cable to throttle linkage, using a new
cotter pin.
11.Clip outer cable adjustment nut into mounting
bracket.
12.Adjust outer cable to give 1.57 mm free play in
inner cable. Check throttle operation.

19FUEL SYSTEM
20
REPAIR ACCELERATOR PEDAL
Service repair no - 18.30.35
Remove
1.Remove lower dash panel.
2.Remove clevis pin securing throttle cable to
accelerator pedal.
3.Release tension from pedal return spring.
4.Remove circlip from pedal pivot pin.
5.Withdraw pivot pin.
NOTE: It may be necessary to lower
steering column to gain access to pivot
pin circlip.
6.Remove accelerator pedal.
Refit
7.Lightly grease pivot and clevis pins.
8.Fit clevis pin using aNEWcotter pin.
9.Reverse removal procedure.FUEL PUMP AND SENDER UNIT
Service repair no - 19.45.03
A plastic fuel tank with a combined fuel pump/sender
unit is fitted. The fuel pump/sender unit is accessed
through a panel in the load space floor.
Fuel pump/sender unit
WARNING: Ensure that fuel handling
precautions given in Section 01 -
Introduction are strictly adhered to when
carrying out following instructions.
CAUTION: Before disconnecting any part
of fuel system, it is imperative that all dust,
dirt and debris is removed from around
components to prevent ingress of foreign matter
into fuel system.
Service Tools:
LRT-19-001 wrench - pump retaining ring
LRT-19-002 'Speedfit' disconnector
Remove
1.Depressurise fuel system.
See Depressurising
Fuel System
2.Disconnect battery negative lead.
3.Syphon at least 9 litres (2 gallons) of fuel from
fuel tank into a suitable container that can be
sealed.
4.Remove carpet from loadspace floor and
tailgate.
5.Fold back loadspace sound insulation to reveal
access panel.

MFI
21
REPAIR 6.Remove access panel from floor.
7.Disconnect multi-plug from fuel sender unit.
8.Disconnect two fuel line unions from fuel pump.
9.Using service tool no. LRT-19-001, remove
pump unit retaining ring. Withdraw unit from fuel
tank.
WARNING: A quantity of fuel will be
retained in body of unit, care must be
taken to prevent fuel spillage when unit is
removed.
Refit
10.Insert fuel pump into tank. Fit retaining ring.
Tighten to
48 Nm.
11.Connect fuel lines to pump.
12.Connect multi-plug to sender unit.
13.After assembly, check all fuel pipes, sealing
rings and hose connections are secure.
14.Run engine to check for fuel leaks.
15.Inspect access panel seal, fit a new seal if
necessary.
16.Fit access panel and tighten screws.
17.Reverse removal procedure. 4 - 5. Fit insulation
and carpet.

19FUEL SYSTEM
22
REPAIR FUEL TANK
Service repair no - 19.55.01
WARNING: Ensure that fuel handling
precautions given in Section 01 -
introduction are strictly adhered to when
carrying out following instructions.
CAUTION: Before disconnecting any part
of fuel system, it is imperative that all dust,
dirt and debris is removed from around
components to prevent ingress of foreign matter
into fuel system.
Remove
1.Depressurise fuel system. Disconnect battery
negative lead.
2.Syphon fuel tank into a suitable container that
can be sealed afterwards.
ENSURE TANK IS DRAINED COMPLETELY.
(refer to Warning concerning fuel vapour and
spillage at start of procedure).
3.Remove carpet loadspace floor and tailgate.
4.Fold back sound insulation to reveal access
panel.
5.Remove access panel.
6.Disconnect electrical multi-plug.
7.Disconnect two fuel line unions from fuel pump.
8.Working underneath vehicle mark location of
anti-roll [sway] bar straps.
9.Remove rear anti-roll [sway] bar straps, and
allow bar to swing down clear of tank.
10.Remove tank filler and vent hoses at fuel tank.
11.Remove nut and bolt securing right hand side
fuel tank strap.
12.Disconnect evaporative control pipe at green
end of 'speedfit' connector.
NOTE: To disconnect 'speedfit' connector,
insert forked end of LRT-19-002 into slots
of connector see illustration. Press down
on collet and simultaneously pull pipe from
connector.

MFI
23
REPAIR
13.Remove back two bolts and nut plates securing
fuel tank cradle.
14.Remove front nuts, bolts and washers. Remove
fuel tank cradle.
15.With assistance, tilt right hand side of tank
upwards and manoeuvre tank through chassis to
remove.
Refit
16.Reverse removal procedure. Ensuring sealing
ring, fuel pipe and hose connections are secure.
17.Run engine, check all connections for fuel leaks.

MFI
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Air-Bypass valve (stepper motor) 20...............................................................
All flexible hose securing clamps 1,3...............................................................
Fuel feed pipe - hose to fuel rail 22.................................................................
Fuel filter 31....................................................................................................
EVAPORATIVE LOSS CONTROL SYSTEM
All flexible hose securing clamps 1,7...............................................................
METRIC Nm
M5 6...........................................................................
M6 9...........................................................................
M8 25...........................................................................
M10 45.........................................................................
M12 90.........................................................................
M14 105.........................................................................
M16 180.........................................................................
UNC / UNF
1/4 9...........................................................................
5/16 24.........................................................................
3/8 39...........................................................................
7/16 78.........................................................................
1/2 90...........................................................................
5/8 136...........................................................................
NOTE: Torque values above are for all screws and bolts used except for those specified.