engine LAND ROVER DISCOVERY 1995 Workshop Manual

STEERING
1
ADJUSTMENT POWER STEERING BOX
Service repair no - 57.10.13
WARNING: Adjustments of steering box
should not be required while in warranty
period. If box is stiff or tight and within
warranty, it must be returned to manufacturer. No
attempt must be made to introduce backlash.
1.Apply park brake, select 'P' in automatic
transmission and chock wheels. Support chassis
front on axle stands.
2.Remove engine undertray.
3.Disconnect drag link from steering drop arm.
4.Check torque to turn.
See Fault diagnosis,
Stiff Steering Checklist
5.Centralise steering box.See Centralise
Steering Box
NOTE: Only check for no backlash when
steering box is in central position.
NOTE: If steering wheel is not straight, it
should be repositioned.
See Repair,
Steering Wheel
The adjustment of the steering box ensures
any preload or end float present on centre is
removed.
6.The adjustment is obtained by rocking the drop
arm about centre whilst an assistant slowly
tightens the steering box adjuster screw.
7.Tighten the locknut when all backlash has been
removed.
8.Repeat the check for backlash. If backlash exists
loosen locknut and repeat adjustment
procedure.
9.Turn steering wheel lock to lock and check no
tightness exists.
10.Ensure front wheels are aligned and in straight
ahead position.
See Front Wheel Alignment
11.Adjust drag link 924 mm between ball joint
centres.
12.Connect drag link. Tighten to
40 Nm.
13.Lower vehicle to ground level and remove
chocks.
14.Road test vehicle.
See Fault diagnosis, Road
Test Procedure
NOTE: If steering wheel is not in straight
ahead position when vehicle is travelling
in a straight line, drag link length is
incorrect and is pushing drop arm away from
central position.
Drag link adjust
15.Right hand drive vehicles - if steering wheel is to
right, drag link is too long. If steering wheel is to
left drag link is too short.
Left hand drive vehicles - if steering wheel is to
right, drag link is too short. If steering wheel is to
left drag link is too long.
16.Adjust drag link until steering wheel points
straight ahead when vehicle is travelling in a
straight line.
CENTRALISE STEERING BOX
1.To centralise the box, insert a suitable peg (hole
size 8.06 mm) into the rear of the drop arm and
into the steering box casing to enable rapid and
accurate setting on centre.

STEERING
3
ADJUSTMENT FRONT WHEEL ALIGNMENT
Service repair no - 57.65.01
Checking Toe-out dimensions
NOTE: No Adjustment is provided for
castor, camber or swivel pin inclinations.
1.Set vehicle on level ground with road wheels
positioned straight ahead.
2.Push vehicle back and forwards to settle linkage.
3.Measure toe-out at horizontal centre-line of
wheels.
4.Check tightness of clamp bolt fixings. Tighten to
14 Nm.
Adjust
5.Loosen adjuster sleeve clamp.
6.Rotate adjuster to lengthen or shorten track rod.
7.Check toe-out setting as instructions 1 to 4.
When toe-out is correct, tap steering linkage ball
joint, in directions of arrows shown, to maximum
of their travel. This ensures full unrestricted
working travel.
8.Tighten clamp bolts to
14 Nm.
POWER STEERING PUMP DRIVE BELT
Service repair no - 57.20.01
Adjust
NOTE: For details of drive belt adjust
procedure
See ENGINE, Repair, Drive
Belt

57STEERING
2
REPAIR POWER STEERING BOX
Service repair no - 57.10.01
General precautions
1.Whenever any part of system, is removed or
disconnected, utmost cleanliness must be
observed.
2.Disconnected ports and hoses must be plugged
to prevent ingress of dirt. If metal sediment is
found in system, establish cause rectify and
flush system.
3.Do not start engine until reservoir is full as pump
will be damaged.
4.Metric pipe fittings are used with 'O' ring pipe
ends on fittings to steering box.
5.Follow normal 'O' ring replacement procedure
whenever pipes are disconnected.
6.Ensure compatible metric components when
fitting replacement pipes.
CAUTION: Before removing any parts of
steering linkage, it is imperative that road
wheels are positioned straight ahead.
Then steering wheel removed to prevent rotary
coupler being wound up or damaged.
CAUTION: After refitting steering linkage
parts follow correct procedure to ensure
that road wheels, steering box and
steering wheel are correctly positioned relative to
each other when in straight ahead condition. If
steering wheel requires repositioning, ensure that
drive pegs on rotary coupler are correctly
positioned before steering wheel is replaced.
This ensures drive pegs locate in their holes in
rear of steering wheel.
After final alignment connect rotary coupler
multiplug, tighten steering wheel securing nut and
fit air bag - if fitted or steering wheel trim pad.
NOTE: When drag link is disconnected
from steering box, travel available at
steering wheel to each full lock is not
equal.
Remove
1.Site vehicle on level surface.
2.Open bonnet[hood].
3.Remove filler cap from power steering fluid
reservoir.
4.Clean steering box.
5.Disconnect feed and return pipes from steering
box.
6.Plug open pipes and steering box ports to
prevent ingress of dirt.
7.Support chassis front on axle stands. Or raise
vehicle on a hoist.
WARNING: Ensure wheels are chocked,
parking brake is applied, and low range
selected.

57STEERING
4
REPAIR
Refit
15.Position steering box to chassis side member,
ensuring locating peg is engaged. Tighten bolts
to
81 Nm.
16.Fit pinch bolt and nut securing universal joint to
power steering box. Tighten to
25 Nm.
17.Position tie bar, tighten bolts and nut to81 Nm,
starting with tie bar to mounting nut, then
loosen nut and bolts by one complete turn.
18.Check steering box, adjust if necessary.See
Adjustment, Power Steering Box
19.Refit drag link to drop arm tighten nut to40 Nm.
20.Fit undertray.
21.Lower vehicle to ground.
22.Remove plugs and refit pipes to steering box.
Tighten 16mm thread to
20 Nm.
14mm thread to15 Nm.
23.Remove filler cap. Fill reservoir to oil level mark
on dipstick. Use recommended fluid.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids
and bleed power steering system.See
Power Steering System - Bleed
24.Recheck fluid level and replace cap.
25.With engine running, test steering system for
leaks by holding steering in both full lock
directions.
CAUTION: Do not maintain this pressure
for more than 30 seconds in any one
minute, to avoid oil overheating and
possible seal damage.
26.Test drive vehicle: using both full lock directions,
to settle steering components. If possible, drive
vehicle over speed bumps and include harsh
braking.
WARNING: Do not test drive vehicle on
public highway.
27.Drive vehicle in a straight line on level ground
and stop.
28.Tighten tie bar to mounting nut to
110 Nm.
29.Tighten bolts securing tie bar to81 Nm.
30.Ensure steering wheel is correctly aligned when
wheels are positioned straight ahead.
31.If necessary reposition steering wheel.
See
Steering Wheel
32.Road test vehicle.

STEERING
5
REPAIR POWER STEERING SYSTEM - BLEED
Service repair no - 57.15.02
1.Ensure fluid in reservoir reaches dipstick
maximum.
2.Run engine to normal operating temperature.
3.Recheck and correct reservoir fluid level.
NOTE: During instructions 4 to 6, maintain
maximum fluid level in reservoir. Do not
increase engine speed or move steering
wheel.
4.With engine at idle speed, loosen bleed screw.
When fluid seeps past bleed screw retighten
screw.
5.Check fluid level.
6.Clean away fluid around bleed screw.
7.Check hose connections, pump and steering box
for fluid leaks by holding steering on full lock in
both directions.
CAUTION: Do not maintain this pressure
for more than 30 seconds in any one
minute to avoid overheating fluid and
possibly damaging seals.
8.Carry out road test.POWER STEERING FLUID RESERVOIR
Service repair no - 57.15.08
Remove
1.Remove undertray.
2.Position drain tin beneath reservoir.
3.Loosen mounting bracket clamp bolt, raise
reservoir to gain access to pipe clamps.
4.Loosen clamps, disconnect feed and return
hoses from reservoir, allow fluid to drain.
CAUTION: Plug the connections.
5.Remove reservoir.
CAUTION: Discard fluid drained from
system. Do not allow fluid to contact
paintwork, if spilled, remove fluid and
clean area with warm water.

57STEERING
6
REPAIR Refit
6.Position reservoir, connect feed and return
hoses and tighten clamps to
3 Nm.
7.Fit reservoir in clamp, tighten clamp bolt.
8.Fill reservoir to 'MAX' mark on dipstick with
power steering fluid.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids
9.Fit undertray.
10.Bleed power steering system.
See Power
Steering System - Bleed
POWER STEERING PUMP DRIVE BELT
Service repair no - 57.20.02
NOTE: For details of drive belt remove and
refit.
See ENGINE, Repair, Drive Belt
POWER STEERING PUMP - V8i
Service repair no - 57.20.14
NOTE: The power steering pump is not
serviceable. Fit new pump if worn or
damaged.
Remove
1.Disconnect battery negative lead.
2.Remove drive belt from steering pump.
See
ENGINE, Repair, Drive Belt
3.Remove undertray.
4.Remove fan blades and viscous coupling.
See
COOLING SYSTEM, Repair, Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
5.Position drain tin beneath steering pump.
6.Using a 9 mm Allen key to restrain steering
pump pulley, remove 3 bolts securing pulley to
pump; remove pulley.

STEERING
7
REPAIR 7.Loosen clamp securing reservoir hose to
steering pump; disconnect hose.
8.Disconnect high pressure pipe from steering
pump.
CAUTION: Plug the connections.
9.Release ht lead from clip
10.Remove 3 bolts securing steering pump.
Remove pump and recover engine lifting
bracket.
NOTE:Do not carry out further
dismantling if component is removed for
access only.
11.Remove 5 bolts securing front mounting plate.
12.Fit front mounting plate to replacement steering
pump. Tighten bolts to
9 Nm.
Refit
13.Position steering pump and engine lifting plate,
fit bolts. Tighten to
35 Nm.Secure ht lead in
clip.
14.Connect high pressure pipe to steering pump,
tighten union to
20 Nm.
15.Connect reservoir hose to steering pump.
Tighten clamp to
3 Nm.
16.Position pulley to pump, coat threads of bolts
with Loctite 242.
17.Restrain pulley using a 9 mm Allen key, fit bolts.
Tighten to
10 Nm.
18.Fit drive belt.See ENGINE, Repair, Drive Belt
19.Fit fan blades and viscous coupling.See
COOLING SYSTEM, Repair, Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
20.Fit undertray.
21.Reconnect battery negative lead.
22.Bleed power steering system.
See Power
Steering System - Bleed
POWER STEERING PUMP - Tdi
Service repair no - 57.20.14
Remove
1.Remove fan blades and viscous coupling.
See
COOLING SYSTEM, Repair, Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
2.Restrain steering pump pulley, loosen but do not
remove 3 bolts securing pulley.
3.Remove drive belt.
See ENGINE, Repair,
Drive Belt
4.Remove 3 bolts securing steering pump pulley,
remove pulley.
5.Remove undertray.
6.Position drain tin beneath steering pump.

57STEERING
8
REPAIR 7.Loosen clamp securing reservoir hose to
steering pump, disconnect hose.
8.Disconnect high pressure pipe from steering
pump.
CAUTION: Plug the connections.
9.Remove 4 bolts securing steering pump to
mounting bracket, remove pump.
NOTE:Do not carry out further
dismantling if component is removed for
access only.
10.Remove 3 bolts securing mounting plate to
pump, remove plate.
11.Fit mounting plate to replacement steering
pump. Tighten bolts to
9 Nm.
Refit
12.Position steering pump, fit 3 bolts. Tighten to
35
Nm.
13.Connect high pressure pipe to steering pump.
Tighten to
20 Nm.
14.Connect reservoir hose to steering pump.
Tighten clamp to
3 Nm.
15.Position pulley to steering pump, coat threads of
bolts with Loctite 242; fit but do not fully tighten 3
bolts.
16.Fit drive belt.
See ENGINE, Repair, Drive Belt
17.Restrain steering pump pulley, tighten bolts to10
Nm.
18.Fit fan blades and viscous coupling.See
COOLING SYSTEM, Repair, Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
19.Fit undertray.
20.Bleed power steering system.
See Power
Steering System - Bleed

BRAKES
3
DESCRIPTION AND OPERATION Description of components
1. ABS Modulator unit
To provide the ABS function a Modulator is positioned
within the system between the master cylinder and the
calipers. On both LHD and RHD vehicles it is sited on
the left inner wing [fender]. The Modulator has 8
solenoid valves, 2 for each wheel, 2 expanders and a
recirculation pump. It is non serviceable.
2. Servo/master cylinder
Actuation of the system is provided by a combined
master cylinder and servo assembly attached to the
pedal box, this provides pressure to opposed piston
calipers at each brake pad Twin piston at the front
axle, single piston at the rear.
3. Pressure reducing valve
To maintain the braking balance, pressure to the rear
axle is regulated by a Pressure Reducing Valve (PRV)
This PRV is of the failure bypass type, allowing full
system pressure to the rear axle in the event of a front
circuit failure. It is sited on the left inner wing [fender].
4. Electronic control unit - ECU
ABS control is provided by an electronic control unit
which is positioned on the passenger side of the
vehicle behind the dash panel/glove box.
The ECU, which is non-serviceable, is connected to
the ABS harness by a 35 way connector. non
serviceable.
The ECU continually monitors the brake system,
providing diagnostics in the event of a system
malfunction. Details of how to access the ECU
diagnostics are provided in the Electrical
Troubleshooting Manual.
5.& 6. Front and rear sensors/exciter rings - 4 off
A sensor is sited at each wheel, sensing a 60 tooth
exciter ring. When vehicle is in motion inductive
sensors send signals to ECU. Front exciter ring is
fitted to outside diameter of constant velocity joint
inside each front hub assembly. The rear exciter ring
is bolted to the rear of each brake disc bell.7. Diagnostic plug connection
A diagnostic plug is located behind the dash. To the
left of the steering column on LHD vehicles. To the
right of the steering column on RHD vehicles. It is a 5
way blue connector.
The location and identification of ABS electrical relays
are given in the Electrical Troubleshooting Manual.
For location and identification of ABS electrical fuses.
See ELECTRICAL, Repair, Fuse Box - Interioror.
See ELECTRICAL, Repair, Fuse Box - Engine
Compartment
ANTI-LOCK BRAKE SYSTEM - ABS
Manufactured by WABCO
Introduction
The purpose of ABS is to prevent vehicle wheels
locking during brake application, thus maintaining
vehicle steerability and stability. This allows vehicle to
be steered whilst brakes are applied, even under
emergency conditions, and to avoid obstacles where
there is sufficient space to redirect the vehicle.
WARNING: ABS is an aid to retaining
steering control and stability while
braking.
·ABS cannot defy the natural laws of physics
acting on the vehicle.
·ABS will not prevent accidents resulting from
excessive cornering speeds, following
another vehicle too closely or aquaplaning,
i.e. where a layer of water prevents adequate
contact between tyre and road surface.
·The additional control provided by ABS must
never be exploited in a dangerous or
reckless manner which could jeopardise the
safety of driver or other road users.
·The fitting of ABS does not imply that the
vehicle will always stop in a shorter stopping
distance.

BRAKES
7
DESCRIPTION AND OPERATION BRAKE SERVO UNIT
Description
The power assistance for the brake system is
provided by a twin diaphragm suspended vacuum
servo.
A 'Suspended Vacuum' servo is one where, with the
engine running vacuum is present both sides of the
diaphragm or diaphragms when the brakes are fully
released or partially applied. The principal of having
vacuum both sides of the diaphragm has two main
advantages. First, it ensures instantaneous servo
response to the brake being applied or released and
second, it provides very accurate control of the
position of the diaphragm and therefore, the degree of
partial brake application.At full pedal depression, vacuum is present in front of
the diaphragm with atmospheric pressure on the rear.
Operation
Brakes released
With the brakes released depression is present both
sides of the diaphragms, in chambers 1,2,3 and 4.
The chambers comunicate by ports A, B, D via the
valve C which is shown fully released in RR3640M.