air condition LAND ROVER DISCOVERY 1995 Owner's Guide

12ENGINE
10
REPAIR
38.Disconnect 2 ignition coil multiplugs.
39.Disconnect 3 vacuum hoses from manifold.
40.Release cover and remove bolt securing earth
lead to cylinder block.
41.Move earth lead aside.
42.Remove 4 bolts securing air conditioning
compressor, move compressor aside.

12ENGINE
12
REPAIR 51.Remove engine L.H. and R.H. mounting lower
nuts.
52.Lower vehicle.
53.Raise engine.
54.Remove engine mountings.
55.Lower engine.
56.Remove bell housing top nut.
57.Raise engine and support gearbox.58.Remove 12 remaining bell housing nuts.
59.Remove engine.
Refit
NOTE: For torque values.See
Specifications, torque, Torque Values
1.Using assistance, lower engine into position.
2.Fit bell housing nuts, tighten to the correct
torque.
3.Remove gearbox support.
4.Lower engine.
5.Fit bell housing top nut, tighten to the correct
torque.
6.Raise engine.
7.Position engine mountings, partially tighten nuts.
8.Lower engine.
9.Remove hoist and chains.
10.Tighten L.H. and R.H. mounting nuts to the
correct torque. Fit engine mounting heatshield.
11.Fit new gasket to exhaust downpipe.
12.Fit exhaust manifold to downpipe nuts and
tighten to the correct torque.
13.Tighten exhaust downpipe to silencer box nuts
to the correct torque.
14.Position air conditioning compressor and secure
with bolts. Tighten to the correct torque.
15.Connect coil multiplugs.
16.Connect harness to starter solenoid and secure
with nuts.
17.Connect earth lead to cylinder block and secure
with nut.
18.Position engine harness to manifold, secure with
bolts.

Mpi
13
REPAIR 19.Connect crankshaft sensor, knock sensor, air
conditioning compressor, fuel injector harness,
inlet manifold air temperature and fuel
temperature sensor multiplugs.
20.Connect fuel hose to pressure regulator and
secure with clip.
21.Fit and tighten fuel pipe to fuel rail union.
22.Connect multiplugs to throttle housing.
23.Connect vacuum hose to manifold.
24.Connect oil pressure switch multiplug.
25.Connect brake servo hose to manifold, secure
with clip.
26.Connect throttle cable to cam.
27.Position engine harness and connect breather
hose to inlet manifold, secure with clip.
28.Connect coolant temperature sensor multiplugs,
secure harness with cable tie.
29.Connect oxygen sensor multiplug, secure
harness with cable tie.
30.Connect alternator harness.
31.Connect heater hose to heater rail and secure
with clip.
32.Connect hose to coolant pump and secure with
clip.
33.Connect inlet hose to power steering pump and
secure with clip.
34.Fit and tighten outlet pipe union to power
steering pump.
35.Connect bypass and top hose, secure with clip.
36.Connect air cleaner to throttle housing hose and
secure with clip.
37.Remove engine lifting bracket.
38.Position spark plug cover and secure with
screws.
39.Fill engine with oil.
40.Fit bonnet [hood].
See CHASSIS AND BODY,
Repair, Bonnet [Hood]
41.Fit radiator.See COOLING SYSTEM, Repair,
Radiator - Mpi
42.Adjust throttle cable.See FUEL SYSTEM,
Adjustment, Throttle Cable Adjustment
ENGINE SUMP GASKET
Service repair no - 12.60.43
Remove
1.Drain engine oil.
2.Refit drain plug, use new sealing washer if
necessary, tighten to the correct torque.
3.Remove 18 bolts securing sump.
NOTE: 25mm long bolt is fitted at rear L.H.
corner of sump.
4.Release sump from cylinder block.
5.Discard gasket.

Mpi
23
REPAIR CHECK CAMSHAFT DRIVE BELT
Service repair no - 12.65.17
CAUTION: This check must be carried out
at the service intervals specified and
whenever carrying out any repair which
requires the timing belt to be disturbed. Pay
particular attention for signs of belt splitting at
base of teeth.
1.Remove 5 bolts securing timing belt upper cover
2.Remove upper cover.
3.Using a socket and extension bar on the
crankshaft pulley bolt, rotate engine to allow the
timing belt to be inspected.
CAUTION: Do not use camshaft gears or
retaining bolts to rotate engine.
4.Check timing belt condition, renew any belt that
shows signs of oil contamination, cracking,
fraying or splitting at base of teeth.
CAUTION: Cause of oil contamination, if
present, must be rectified.
5.Clean timing belt upper cover.
6.Position upper cover.
7.Fit upper cover securing bolts.

Mpi
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
ENGINE
Timing belt upper cover bolts 5......................................................................
Timing belt centre cover bolts 5.....................................................................
Timing belt lower cover bolts 5......................................................................
Crankshaft pulley centre bolt 85.....................................................................
Crankshaft pulley to timing gear bolts 10........................................................
Tensioner pulley bolt 30..................................................................................
Spark plugs 27................................................................................................
Timing belt upper backplate bolts 10..............................................................
Camshaft gear bolts 65...................................................................................
Exhaust camshaft rear oil seal cover plate bolts 10........................................
Inlet camshaft rear oil seal cover plate bolts 10..............................................
Crankshaft rear oil seal housing bolts 10........................................................
Engine sump bolts
Stage 1 3...............................................................................................
Stage 2 10..............................................................................................
Bell housing nuts 40........................................................................................
L.H. and R.H. engine mounting nuts 85..........................................................
Exhaust manifold to downpipe nuts 10...........................................................
Exhaust downpipe to silencer box nuts 30......................................................
Air conditioning compressor to engine block bolts 45.....................................
Cylinder head bolts
Stage 1 45..............................................................................................
Stage 2 80..............................................................................................
Stage 3 - Further 90°
Camshaft cover bolts 10.................................................................................
Knock sensor 15.............................................................................................
Ignition coil bracket bolts 25............................................................................
Coolant temperature sensor 15......................................................................
Crankshaft sensor bolts 7..............................................................................
Fuel temperature sensor 7.............................................................................
Intake air temperature sensor 7.....................................................................
Fuel rail to inlet manifold bolts 10...................................................................
Fuel feed hose stiffening bracket bolts 7.......................................................
Throttle housing mounting nuts 7...................................................................
Fuel pressure regulator steady bracket bolts 7..............................................
Oxygen sensor 55...........................................................................................

EMISSION CONTROL
1
DESCRIPTION AND OPERATION REV: 09/95 EMISSION CONTROL
Three systems are used to control the vehicle
atmospheric emissions these are:
Engine crankcase fume emissions.
Fuel tank Evaporative emissions
Engine exhaust gas emissions.
Crankcase ventilation system - 3.9 MFi models
only
The crankcase ventilation system which is an integral
part of the air supply to the engine combustion
chambers, is often overlooked when diagnosing
problems associated with engine performance. A
blocked ventilation pipe or filter or excessive air leak
into the inlet system through a damaged pipe or
leaking gasket can effect the mixture, performance
and economy of the engine.
1. Three way connector
2. Air filter
3. Oil separatorThe purpose of the crankcase ventilation system is to
ensure that any noxious gas generated in the engine
crankcase is rendered harmless by burning in the
combustion chambers as follows:
Oil laden noxious gas in the engine crankcase is
drawn through an oil separator 3 located on the right
cylinder head rocker cover, where the oil is separated
and returned to the sump. The gas flows through a
restrictor in the three way connection 1 and into the
inlet plenum chamber where it is drawn into the
combustion chambers and burned. The volume of
fresh air which is drawn from the atmospheric side of
the throttle butterfly to mix with the gas, depends on
the position of the throttle and the engine speed.
The air filter 2 fitted to the left cylinder head rocker
cover, must be maintained in clean condition to
ensure sufficient air enters the crankcase under
varying throttle openings and manifold depression, to
prevent excessive crankcase pressure or depression
developing.

17EMISSION CONTROL
2
DESCRIPTION AND OPERATION REV: 09/95 Exhaust emission control.
The fuel injection system provides accurately metered
quantities of fuel to the combustion chambers to
ensure the most efficient air to fuel ratio under all
conditions of operation. A further improvement to
combustion is made by measuring the oxygen content
of the exhaust gases to enable the quantity of fuel
injected to be varied, according to conditions, to
correct any unsatisfactory composition of the exhaust.
The main components of the exhaust emission
system are two Catalytic converters which are an
integral part of the front exhaust pipe assembly. The
Catalytic converters are included in the system to
reduce the emission, to atmosphere, of carbon
monoxide, oxides of nitrogen, and hydrocarbons. The
active constituents of the converters are platinum and
rhodium. The correct functioning of the converters is
dependent upon close control of the oxygen
concentration in the exhaust gas entering the catalyst.
The oxygen content of the exhaust gas is monitored
by the heated oxygen sensors. Information on the
heated oxygen sensors is contained in the relevant
Fuel System section,
See FUEL SYSTEM MFI,
Description and operation, or See FUEL SYSTEM
SFI, Description and operation,
The ECM can then
make an appropriate adjustment to the fuel supply to
correct the composition of the exhaust.
CAUTION: Unleaded fuel only must be
used on vehicles fitted with catalytic
converters. As a reminder,a label to
indicate this is adhered to the inside of the fuel
filler flap. Furthermore the filler neck is designed
to accommodate only unleaded fuel pump
nozzles.

17EMISSION CONTROL
8
DESCRIPTION AND OPERATION ADD: 09/95 System operation
The system is designed to prevent fuel vapour
escaping to atmosphere, and consists of four roll-over
valves fitted internally in the fuel tank, connected to
the liquid/vapour separator by a nylon line. The
separator is mounted to the side of the filler neck. An
EVAP canister is positioned in the engine
compartment mounted on the right front side valance.
The liquid/vapour separator and EVAP canister are
connected by a nylon line which runs the length of the
chassis.
Pressure/vacuum relief valves are incorporated into
the fuel filler cap and are designed to protect the fuel
tank from permanent deformation in the event of
system pressure or vacuum exceeding the system
operating parameters. There are no other relief or
one-way valves in the system.
A vent line flow restrictor known as an anti-trickle fill
valve is fitted to the filler pipe in the line between the
tank and EVAP canister. The function of this valve is
to prevent overfilling the tank by trickling fuel in,
thereby preserving the vapour space in the tank to
allow for fuel expansion during hot weather.
The valve achieves this by blocking the vent line
during the fuel filling process. The valve is operated
by the action of inserting the filler gun so that when
the fuel in the tank reaches the level of the filling
breather, flow cut off occurs due to fuel filling the filler
pipe.During normal vehicle operation and when the engine
is switched off, the venting system between the fuel
tank and EVAP canister is open to allow the free
passage of vapour.
The EVAP canister, which is connected by a nylon
hose to the plenum chamber, absorbs and stores the
fuel vapour from the fuel tank when the engine is not
running. With the engine running, vapour is purged
from the EVAP canister by allowing outside air to be
drawn through the EVAP canister vent solenoid and
link pipe by the influence of manifold vacuum to the
EVAP canister purge connection on the canister.
Filter pads are fitted above and below the charcoal
and in the EVAP canister vent solenoid to prevent the
ingress of foreign matter into the purge line.
The EVAP canister purge valve, which is fitted in the
line from the EVAP canister to the plenum, is
controlled by the ECM which determines the most
emission acceptable time at which purging should
take place. This will normally be at engine speeds
above idle and when the vehicle is in motion.
The EVAP canister vent solenoid is mounted on the
side of the EVAP canister bracket and is connected to
the EVAP canister by a length of large bore hose. The
ECVS is controlled by the ECM and is normally open.
The function of the ECVS is to block the air intake
side of the EVAP canister. When the system receives
an ECM signal the valve closes; this allows the
system leak check to take place. The leak check only
occurs when pre-determined vehicle operating
conditions are met.

EMISSION CONTROL
1
FAULT DIAGNOSIS REV: 09/95 TESTING EVAPORATIVE EMISSION CONTROL -
PRE ADVANCED EVAPS
The following pressure test procedure is intended to
provide a method for ensuring that the system does
not leak excessively and will effectively control
evaporative emissions.
Equipment required.
Nitrogen cylinder (compressed air may be used to
pressure the system when there has NEVER been
fuel present in the fuel or evaporative control
systems).
Water manometer (0 - 30" H2O or more).
Pipework and a "T" piece.
Method.
1.Ensure that there is at least two gallons of fuel in
the petrol tank unless there has never been any
fuel in the system.
2.Disconnect, at the adsorption canister, the pipe
to the vapour separator.
3.Connect this pipe to the nitrogen cylinder and
the water manometer using the "T" piece.
4.Pressurize the system to between 26.5 and 27.5
inches of water, allow the reading to stabilize,
then turn off the nitrogen supply.
5.Measure the pressure drop within a period of 2
minutes 30 seconds. If the drop is greater than
2.5 inches of water the system has failed the
test. Note that a fully sealed system will show a
slight increase in pressure.
6.Should the system fail the test, maintain the
pressure in the system and apply a soap
solution round all the joints and connections until
bubbles appear to reveal the source of the leak.
7.Repeat the test and if successful, dismantle the
test equipment and reconnect the pipe to the
adsorption canister.LEAK DETECTION PROCEDURE - ADVANCED
EVAPS
1.Connect TestBook to the vehicle and confirm
that the fault code(s) displayed relate to an
EVAP system fault.
2.Examine components in fuel and EVAP system
for damage or poorly connected joints.
3.Repair or replace components to rectify any
faults found, then reset the Check Engine light
using TestBook.
4.Carry out Drive Cycle,
See Drive Cycle -
Advanced EVAPS
5.Using TestBook confirm that the Evaporative
Loss Control (ELC) Inspection and Maintenance
(IM) flag has cleared. This procedure should
confirm that the ELC test was carried out during
the drive cycle and that the fault was cured.
6.If the IM flag is still shown, use TestBook to
interrogate the engine management system to
ascertain which of the following situations exists:
·If a fault code is shown then further investigation
is required, proceed to the next step.
·If the IM flag is still shown, but no faults are
indicated the conditions for the ELC check have
not been met and the drive cycle must be
repeated.
7.Connect the Leak Detection/EVAP Diagnostic
Station to the vehicle and carry out the
procedures given in the operating instructions
supplied with the equipment.
8.Rectify faults indicated by the Leak
Detection/EVAP Diagnostic Station and return to
step 4.

EMISSION CONTROL
1
REPAIR POSITIVE CRANKCASE VENTILATION AIR
INTAKE FILTER
Service repair no - 17.10.02
The PCV air intake filter is located at the rear of the
left hand rocker cover, beneath the throttle linkage
bracket.
Remove
1.Pry the filter outer cover upwards to release it
from its mounting.
2.Remove the sponge filter from the cover and
discard the sponge.
Refit
3.Insert a new filter into the filter cover.
4.Press the filter onto its mounting until it clips
firmly into position.POSITIVE CRANKCASE VENTILATION BREATHER
FILTER
Service repair no - 17.10.03
Remove
1.Release the hose clamp and pull the hose off the
canister.
2.Unscrew the canister and remove it from the
rocker cover.
3.Remove the large rubber 'O' ring and inspect for
deterioration.
4.Visually inspect the condition of the wire screen
within the canister, if in poor condition, replace
the whole assembly, if the filter unit is in an
acceptable condition, clean as follows.
5.Immerse the canister in a small amount of
solvent (mineral spirits) and allow time for the
solvent to dissolve or loosen any debris.
6.Remove the canister from the solvent bath and
allow to dry in still air.
WARNING: Do not use a compressed air
line to dry, clean or remove any remaining
particles of debris within the canister as
this could cause fire or personal injury.
Refit
7.If the original canister is being refitted, fit a new
'O' ring.
8.Screw the canister into the rocker cover securely
- hand tight only.
9.Refit the hose and tighten the hose clamp
securely.