engine LAND ROVER DISCOVERY 1995 Service Manual

MAINTENANCE
9
MAINTENANCE
CHECK CONDITION OF DRIVE BELT - V8i - Tdi -
Mpi
RENEW - V8i - Tdi
Renew drive belt V8i.See ENGINE, Repair, Drive
Belt Renew
Renew drive belt Tdi.See ENGINE, Repair, Drive
Belt Renew
RENEW - Mpi
1.Check condition of drive belt, renew a belt that
shows signs of wear, splitting or oil
contamination.
2.Check belt length indicator, belt must be
renewed before indicator reaches R.H. end of
slot.
3.Use 15mm ring wrench on bolt and hold
tensioner pulley fully clockwise.
4.Release drive belt from tensioner pulley and
remove ring wrench.
5.Remove belt from between pulleys.
6.Clean drive belt pulley grooves and ensure
grooves are not damaged.
7.Fit new drive belt around pulley, except
tensioner pulley, ensuring all grooves are
correctly engaged.
8.Hold tensioner pulley fully clockwise and fit drive
centrally around tensioner pulley.
RENEW ANCILLARY DRIVE BELTS
CHECK/TOP UP AUTOMATIC TRANSMISSION
FLUID LEVEL
NOTE: Transmission fluid level is checked
when fluid is cold with engine idling in
neutral.
1.Ensure vehicle is on level ground.
2.Check fluid level registers between MAX and
MIN marking on dipstick.

10MAINTENANCE
10
MAINTENANCE
CHECK/TOP UP COOLING SYSTEM
1.To prevent corrosion of aluminium alloy engine
parts it is imperative that cooling system is filled
with a solution of water and phosphate free
anti-freeze, winter or summer. Never fill or top up
with plain water.
WARNING: Do not remove filler cap when
engine is hot because cooling system is
pressurised and personal scalding could
result.
2.When removing filler cap, turn cap slowly
anti-clockwise, pause and allow all pressure to
escape.
3.Continue to turn until cap is removed.
4.When engine is cold expansion tank coolant
should be level with top of indicator post, visible
inside tank through filler hole.
5.If necessary, top up cooling system with
premixed coolant. Use soft water whenever
possible, if local water supply is hard, rainwater
should be used.
6.When replacing filler cap it is important that it is
tightened down fully. Failure to tighten filler cap
properly may result in water loss, with possible
damage to engine
The cooling system should be drained and flushed at
2 year intervals or at onset of second winter. Refer to
Coolant Requirements.
See COOLING SYSTEM,
Adjustment, Coolant RequirementsCHECK/ TOP UP POWER STEERING FLUID
RESERVOIR
1.Remove fluid reservoir cap. Check that fluid is
up to high mark on dipstick.
CHECK/ TOP UP CLUTCH AND BRAKE FLUID
RESERVOIRS
CAUTION: Brake fluid can damage
paintwork. If spillage occurs, wash
affected area IMMEDIATELY with a large
quantity of water.
CHECK/TOP UP WASHER RESERVOIR
Top up washer reservoir to within 25 mm of filler neck.
Use a screen washer solvent/anti-freeze solution to
assist removing mud, flies and road film and protect
against freezing.
LUBRICATE ACCELERATOR AND CRUISE
CONTROL LINKAGES
CHECK/ADJUST IGNITION TIMING - V8i
CATALYST
Check ignition timing.See ENGINE TUNING
DATA, Information, Engine 3.9 V8i

MAINTENANCE
11
MAINTENANCE
CHECK/ADJUST ENGINE IDLE SPEED - Tdi
For idle speed.See ENGINE TUNING DATA,
Information, 300 Tdi Engine
CHECK ENGINE IDLE SPEED - Mpi
For idle speed.See ENGINE TUNING DATA,
Information, Engine - Mpi - 2.0 Litre
CHECK/ADJUST STEERING BOX V8i - Tdi - Mpi
Check steering box for fluid leaks.
Check that there is no backlash in steering box in
straight ahead position. Adjust steering box if
necessary.
See STEERING, Adjustment, Power
Steering Box
CLEAN BATTERY CONNECTIONS
NOTE: Some 96 models are fitted with
battery backed-up sounder
See
ELECTRICAL, Repair, Battery
Remove battery terminals, clean and coat with
petroleum jelly.
A low maintenance battery is installed in vehicle.
Dependent upon climate conditions electrolyte levels
should be checked as follows:
Temperate climates every three years.
Hot climates every year.
RENEW CAMSHAFT DRIVE BELT - Tdi
Renew camshaft drive belt.See ENGINE, Repair,
Camshaft Drive Belt and Gears
The engine timing gears are driven by a flexible
rubber belt which must be renewed at intervals
determined by the severity of operating conditions.
In reasonable, temperate climate operation, renew the
belt every 120,000 km (72,000 miles) or every 6 years
whichever occurs earlier.
In adverse operating conditions such as work in dusty
atmospheres, high ambient temperatures and desert
and tropical zones, renew the belt every 60,000 km
(36,000 miles) or every 3 years whichever occurs
earlier.
CAUTION: If the drive belt is not renewed
at the correct interval, it could fail,
resulting in serious damage.
RENEW CAMSHAFT DRIVE BELT - Mpi
Renew every 160,000 km (96,000 miles) or every 6
years. In adverse conditions every 80,000 km (48,000
miles).
For details of renewing camshaft drive belt.
See
ENGINE, Repair, Camshaft Drive Belt - Mpi
CHECK CAMSHAFT DRIVE BELT - Mpi
For details of checking camshaft drive belt.See
ENGINE, Repair, Check Camshaft Drive Belt - Mpi

10MAINTENANCE
12
MAINTENANCE
EXTERNALLY CHECK INTERCOOLER FOR
OBSTRUCTION - Tdi
Clear any trapped dirt or flies from vanes of
intercooler
CLEAN INTERCOOLER ELEMENT - Tdi
Remove
1.Remove intercooler element.
2.Flush intercooler with ICI 'GENKLENE'or
à oD-SOLVE' propriety cleaner, following the
manufacturer's instructions.
3.Dry the intercooler completely ensuring that no
liquid remains in the element.
Refit
4.Refit intercooler element.UNDER VEHICLE MAINTENANCE
Vehicles operating under severe conditions of dust,
sand, mud and water should have oils changed and
lubrication carried out at more frequent intervals than
is recommended in maintenance schedules.
RENEW ENGINE OIL AND FILTER - Tdi
CAUTION: Serious damage to the
turbocharger will result if engine is run
above idling speed before oil pressure is
restored.
RENEW ENGINE OIL - V8i
RENEW ENGINE OIL AND FILTER - V8i
CAUTION: To prevent an airlock occuring
after removing filter, fill new filter with oil
and fit immediately after removing old
filter. If airlock does occur fill oil pump with
petroleum jelly.
RENEW ENGINE OIL AND FILTER - Mpi
CHECK/TOP UP MANUAL GEARBOX OIL - V8i
1.Site vehicle on lift or level ground.
2.Remove oil filler level plug. If necessary, inject
new oil into the gearbox until it runs out of filler
hole. Fit plug. Tighten to
30 Nm.
RENEW MANUAL GEARBOX OIL - Tdi - Mpi
RENEW MANUAL GEARBOX OIL - V8i

MAINTENANCE
13
MAINTENANCE
RENEW AUTOMATIC GEARBOX FLUID AND OIL
SCREEN
1.Site vehicle on lift or level ground. Place
container to drain gearbox fluid into. Disconnect
battery negative lead.
2.Remove gearbox dipstick, located at rear of right
hand rocker cover, to aid oil drainage. Release
plug from bottom of sump and allow fluid to drain
completely.
3.Refit plug using a new sealing washer. Tighten
to
10 Nm
Refill ZF Automatic Gearbox and Check Fluid
Level.
NOTE: The fluid level must checked when
fluid is cold and engine idling in park.
4.Ensure vehicle is on level ground.
5.Refill or top-up with correct quantity and grade of
fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
6.Start and run engine. Apply footbrake, select
position 1 then back to park. Check fluid level,
this must be between the two marks on the
dipstick.
Oil screen replacement ZF automatic gearbox.
See AUTOMATIC GEARBOX, Repair, Oil Screen

MAINTENANCE
17
MAINTENANCE
CHECK/TIGHTEN FRONT AND REAR AXLE
SUSPENSION LINK FIXINGS, CHECK CONDITION
OF MOUNTING RUBBERS
DRAIN FUEL SEDIMENTER - Tdi
Fuel sedimenter
The sedimenter is attached to left-hand side of
chassis frame near fuel tank. It increases the working
life of the fuel filter by removing larger droplets of
water and larger particles of foreign matter from fuel.
Drain off water
1.Loosen drain plug, allow water to run out.
Tighten plug immediately pure diesel fuel starts
to flow.
RENEW FUEL FILTER
WARNING: Ensure that fuel handling
precautions given in Section 01 -
Introduction regarding fuel handling are
strictly adhered to when carrying out following
instructions.
See INTRODUCTION, Information,
Fuel Handling Precautions
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
1.Depressurise fuel system.
See FUEL SYSTEM,
Repair, Depressurising Fuel System
2.The fuel line filter is located on right hand
chassis side member forward of fuel tank filler
neck. Access to filter is gained through right
hand rear wheel arch.
3.Thoroughly clean area around hose connections
to prevent ingress of foreign matter into fuel
system.
4.Loosen two fuel unions and remove hoses from
filter canister.
5.Release securing bolt and bracket, remove filter
from chassis side member.
6.Fit a new filter observing direction of flow arrow
on canister.
7.Fit inlet and outlet hoses. Tighten to
30 Nm.
8.Refit fuel pump relay.
9.Reconnect battery negative lead.
10.Recode radio.
11.Start engine and inspect hose connections for
fuel leaks.

10MAINTENANCE
18
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
19
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.

12ENGINE
2
REPAIR DRIVE BELT RENEW
Service repair no - 86.10.03
NOTE: If cast lines on tensioner arm and
tensioner spring case are aligned, a new
drive belt must be fitted.
Remove
1.Remove fan cowl upper.
2.Apply ring spanner to tensioner pulley retaining
bolt.
3.Turn spanner to release pulley tension from belt.
4.Detach belt from pulley.
5.Release tensioner.
6.Complete removal of belt. Mark direction on belt
if refitting.
Refit
7.Reverse removal procedure.COMPRESSOR DRIVE BELT
Service repair no - 86.10.02
Remove
1.Remove auxiliary drive belt.
See Drive Belt
Renew
2.Remove compressor shield.
3.Loosen tensioner retaining bolts.
4.Remove compressor drive belt. Mark direction
on belt if refitting.
Refit
5.Fit compressor drive belt.
6.Fit torque meter to centre of tensioner and apply
and hold a torque of
35 Nm.Tighten 3 tensioner
retaining bolts.
7.Rotate crankshaft 2 full turns.
8.Reapply and hold a torque of
35 Nmto
tensioner, then fully loosen and retighten 3
tensioner retaining screws to
25 Nm.

Tdi
3
REPAIR ENGINE
Service repair no - 12.41.01
Remove
CAUTION: Seal all exposed pipe ends
against ingress of dirt after disconnection.
1.Park vehicle on level ground and apply park
brake.
2.Disconnect battery negative lead.
3.Remove bonnet [hood].
See CHASSIS AND
BODY, Repair, Bonnet [Hood]
4.If air conditioning is fitted, remove RH footwell
side trim panel and disconnect harness multiplug
from relay.
5.Disconnect the two engine harness multiplugs
on LH side of footwell.
6.Remove engine harness grommet from
bulkhead and move harness into engine bay.
7.Release battery positive lead from retaining clip
at base of suspension turret.
8.Remove Radiator Assembly.
See COOLING
SYSTEM, Repair, Radiator
9.Discharge air conditioning system.See AIR
CONDITIONING, Adjustment, Refrigerant
Recovery Recycling Recharging
Remove retaining bolts and disconnect both pipe
adaptors from rear of compressor.
10.Remove rocker cover insulation.
11.Disconnect cyclone hose from air cleaner hose.
12.Remove air cleaner hose from turbocharger.
13.Remove feed pipe/hose from turbocharger and
intercooler.
14.Disconnect heater hoses from cylinder head and
heater rails.
15.Remove bolt securing transmission breather
pipe clip to cylinder head; move breather pipes
aside.
16.Disconnect inlet and outlet hoses from power
steering pump.
17.Disconnect bypass hose from thermostat
housing.
18.Release bypass hose from retaining clips on
front timing cover.
19.Remove split pin securing inner throttle cable to
injector pump.
20.Depress tags on outer cable adjusting nut,
remove cable from mounting bracket, and move
aside.
21.If automatic transmission is fitted, release
kickdown cable from injector pump and mounting
bracket.