gearbox LAND ROVER DISCOVERY 1995 Owner's Manual

12ENGINE
4
REPAIR 22.Disconnect feed pipe and spill return pipe from
injector pump.
23.Disconnect both pipes from fuel lift pump.
24.Disconnect servo hose from vacuum pump.
25.Remove three retaining nuts and disconnect
exhaust down pipe.
26.Remove oil cooler pipes from oil filter adaptor.
27.If automatic transmission is fitted, disconnect
feed and return pipes at gearbox oil cooler.
Remove retaining bracket from LH side of
cylinder block and release both oil cooler pipes.
28.Support gearbox.
29.Disconnect ground strap from starter motor.
30.On vehicles with automatic transmission, remove
fixings and detach drive plate housing access
panel and gasket.31.Working through drive plate housing aperture
mark the torque convertor and drive plate to
facilitate reassembly.
32.Remove the four convertor to flexible drive
securing bolts, rotating crankshaft to gain access
to each individual bolt.
33.Fit engine lifting bracket to the two RH rear
cylinder head fixing bolts.
34.Using suitable hoist, fit lifting chains to engine.
35.Remove four bolts, from both sides, securing
front engine mounting brackets to cylinder block.
36.Remove two bolts, from both sides, securing
front engine mounting bracket to bell housing.

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5
REPAIR
37.Remove nuts and plain washers securing front
engine mountings to chassis,and lift both engine
mounting bracket assemblies from vehicle.
38.Remove engine to bell housing fixings. Leave
starter motor attached.
39.Raise engine to separate from transmission.
40.Check all connections to engine have been
disconnected.
41.Remove engine.Refit
42.Apply Hylomar to mating faces of bell housing.
Lubricate splines of gearbox primary pinion with
Rocol MV 3.
If automatic transmission, coat the four drive
plate to torque convertor bolts with Loctite 290.
Tighten to
39 Nm.
43.Lower engine and locate with transmission.
If manual transmission locate primary pinion into
clutch and engage bell housing dowels. Fit
engine to bell housing fixings. Tighten to
40 Nm.
If automatic transmission fixings. Tighten to46
Nm.
44.Raise engine, refit front engine mounting
brackets to cylinder block and bell housing.
45.Remove gearbox support and lower engine.
46.Tighten front engine mountings to chassis
fixings. Tighten to
45 Nm.
47.Reverse removal procedure. 1 to 37.

12ENGINE
8
REPAIR CAMSHAFT DRIVE BELT AND GEARS
Service repair no - 12.65.18
TIMING BELT
Remove
1.Remove front cover plate.
See Front Cover
Plate
2.Position engine at TDC on No. 1 cylinder.
3.If manual gearbox: Remove blanking plug from
flywheel housing and insert timing tool
LRT-12-044. If EDC - timing tool LRT-12-085
must be used.
If automatic gearbox:Sited to the rear of the
engine sump on engine backplate is a blanking
plate. Remove 2 blanking plate bolts and insert
timing tool LRT-12-044 into the larger bolt hole.
4.Engage timing tool pin with slot in flywheel.
5.Check correct alignment of timing mark on
camshaft gear and that crankshaft key aligns
with cast arrow on housing.
6.Insert pin from special tool LRT-12-045 in
injection pump gear and through into pump
flange.
NOTE: If the camshaft gear is to be
removed during these operations its
retaining bolt should be slackened before
the timing belt is removed.
7.Slacken belt tensioner bolt.
8.Remove idler pulley.
9.Remove timing belt.
NOTE: During use, a belt develops a wear
pattern relative to its running direction, if
the original belt is to be re-used it must be
refitted so that it rotates in the original direction.
CAUTION: Belts must be stored on edge
on a clean surface and in such a manner
that bends are not less than 50 mm radius.
Do not bend belts at an acute angle or radius of
less than 50 mm, otherwise premature failure
could result.
10.Mark belt direction of rotation, using soft chalk,
to ensure correct refitment.

12ENGINE
14
REPAIR FLYWHEEL
Service repair no - 12.53.07
Remove
1.Disconnect battery negative lead.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
Assembly
4.Fit two long 8mm bolts into the clutch bolt holes,
diametrically opposite, to use as handles when
lifting the flywheel off the crankshaft.
5.Remove fan cowl
6.Fit crankshaft pulley retainer LRT-12-080 and
secure with four bolts, to restrain crankshaft
while removing flywheel retaining bolts.
7.Remove the bolts and lift off flywheel.
NOTE: To prevent excessive flywheel
run-out, ensure that the mating faces of
the flywheel and crankshaft are clean.Refit
8.Locate the flywheel on the crankshaft and
secure with new patched retaining bolts,
progressively tighten to
147 Nm.
9.Check the flywheel for possible run-out by
mounting a dial test indicator with the stylus in a
loaded condition resting on the flywheel face at a
radius of 114mm from the centre.
10.Turn the flywheel and check that run-out does
not exceed 0,05 to 0,07mm. Should run-out be
excessive, remove the flywheel and check again
for irregularities on the crankshaft and flywheel
mating faces and the dowel.
11.Reverse removal procedure. 1 to 6.

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15
REPAIR CRANKSHAFT REAR OIL SEAL
Service repair no - 12.21.20
Remove
NOTE: The crankshaft rear oil seal is
retained in its own housing, if the seal
requires replacing the housing and seal
assembly (1) must be renewed complete with the
housing seal (3). Housing and seal assemblies are
supplied with their own former/seal guide (2)
already fitted. This former must not be removed
before fitting the assembly to the engine. If a seal
and housing assembly is received without a
former/guide fitted it must be returned to the
supplier. Used formers/guides must be discarded
immediately after use, under no circumstances
should they be reused on other assemblies.
1.Disconnect battery negative lead.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
Assembly
4.Remove flywheel.See Flywheel
5.Remove five bolts and withdraw seal housing
and seal assembly complete with gasket.
Refit
6.Insert slave studs to seal housing mounting face.
7.Position new seal housing gasket over slave
studs and crankshaft flange onto cylinder block.

12ENGINE
16
REPAIR 8.Ensure housing seal is correctly seated in its
groove in new housing and seal assembly.
9.Fit new assembly, with former/guide in-situ, over
crankshaft flange, this action will eject
former/guide.
10.Secure assembly to cylinder block with five bolts
tightened to correct torque, removing slave studs
individually and inserting bolts.
11.Refit flywheel.
See Flywheel
12.Refit clutch.See CLUTCH, Repair, Clutch
Assembly
13.Refit gearbox.See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
14.Reconnect battery negative lead.CRANKSHAFT BEARING BUSH
Service repair no - 12.21.45
1.Disconnect battery negative lead.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
Assembly
4.Remove flywheel.See Flywheel
5.Remove bearing bush.
NOTE: The bearing bush can be removed
by using one of the following methods.
Method 1.
Obtain a short length of steel rod of a diameter having
a good slide fit in the bore of the bush. Pack the bore
with grease and insert the steel rod into the end of the
bore, give a sharp blow with a hammer and the
grease should drive out the bush. It is recommended
that the bush and rod be covered by a suitable cloth
or rag to prevent grease from splashing.

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17
REPAIR Method 2.
Thread the bore of the existing bush and using a
suitable bolt extract the bush. Thoroughly clean bush
location ensuring all swarf is removed.
Fitting
6.Fit new bush using a suitable shouldered drift,
inserting bush flush with end of crankshaft.
7.Refit flywheel.
See Flywheel
8.Refit clutch.See CLUTCH, Repair, Clutch
Assembly
9.Refit gearbox.See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
10.Reconnect battery negative lead.FLYWHEEL HOUSING
Service repair no - 12.53.01
Remove
1.Disconnect battery negative lead.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
Assembly
4.Remove flywheel.See Flywheel
5.Remove starter motor.
6.Remove two bolts from top of flywheel housing.
7.Remove four bolts from bottom of flywheel
housing.
8.Remove six inner bolts and lift off flywheel
housing.
Refit
9.Clean rear face of housing and mating face on
block, ensuring all old sealant is removed.

12ENGINE
18
REPAIR 10.Apply sealant to flywheel housing mating face on
cylinder block (Fig. J5944).
11.Fit housing to cylinder block and secure with
bolts as removed. Tighten to
45 Nm.
12.Remove surplus sealant from block.
13.Refit starter motor.
14.Refit flywheel.
See Flywheel
15.Refit clutch.See CLUTCH, Repair, Clutch
Assembly
16.Refit gearbox.See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
17.Reconnect battery negative lead.OIL FILTER
Service repair no - 12.60.01
Remove
1.Place drain tray under filter.
2.Unscrew filter anti-clockwise, using a strap or
spanner.
Refit
3.Smear clean engine oil on seal of new filter.
4.Screw on filter until sealing ring touches
machined face, then tighten a further half turn by
hand only. Do not over tighten.

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.

12ENGINE
10
REPAIR TIMING CHAIN AND CHAINWHEELS
Service repair no - 12.65.12
Remove
1.Remove front cover.
See Front Cover Gasket
2.Remove retaining bolt and washer, remove
distributor drive gear and spacer.
3.Ensure number one piston is at TDC.
4.Remove chainwheels and chain as an assembly.
See V8i Overhaul Manual.
Refit
5.Clean chainwheels and chain.
6.Fit chainwheels to chain, aligning timing marks.
7.Ensure camshaft key is fitted parallel to shaft
axis to ensure adequate lubrication to distributor
drive gear.
8.Engage chainwheel assembly on camshaft and
crankshaft keys, ensure chain wheels are fully
located.
9.Check alignment of timing marks with straight
edge.
10.Fit spacer with flange to front,
11.Fit distributor drive gear with groove towards
spacer.
12.Fit retaining bolt and washer. Tighten to
58 Nm.
13.Fit front cover.See Front Cover Gasket
FLYWHEEL
Service repair no - 12.53.07
Remove
1.Remove gearbox and clutch.
See CLUTCH,
Repair, Clutch Assembly
2.Loosen starter motor bolts.
3.Lock flywheel, remove flywheel bolts and
flywheel.
Refit
4.Clean components for reassembly.
5.Fit flywheel.
6.Clean threads, apply Loctite 270 to threads.
7.Lock flywheel, fit flywheel bolts. Tighten to
80
Nm.