gearbox LAND ROVER DISCOVERY 1995 Service Manual

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.

Tdi
11
REPAIR FUEL INJECTION PUMP AND TIMING
Service repair no - 19.30.07
NOTE: The following text refers to a Tdi
vehicle with a manual gearbox without
electronic diesel control. Where reference
is made to the timing tool substitute the following
information for automatic and EDC variants.
If manual gearbox:Timing tool LRT-12-044 fits into
the base of the flywheel housing
If manual gearbox with EDC:Timing tool
LRT-12-085 must be used and also fits into the base
of the flywheel housing.
If automatic gearbox:Timing tool LRT-12-044 fits
into the larger bolt hole of coverplate on engine
backplate, sited near to the rear of sump. Pin locates
in ring gear.
Remove
1.Disconnect battery negative lead.
2.Remove injection pipes, pump to injector.
3.Remove oil filler cap from rocker cover.
4.Viewing valve mechanism through filler aperture,
turn crankshaft clockwise until No. 1 cylinder is
just before TDC.
5.Refit oil filler cap.
6.Remove blanking plug from flywheel housing.
7.Fit timing tool LRT-12-044 to flywheel housing,
do not engage centre pin.
8.Continue rotating crankshaft clockwise until
centre pin engages with timing slot in flywheel.
9.Remove injection pump access plate, complete
with gasket, from front cover plate.
10.Fit pin from LRT-12-045 to injection pump gear.
11.Remove drive gear to pump hub fixing bolts and
plate.

SFI
1
DESCRIPTION AND OPERATION ENGINE MANAGEMENT SYSTEM
Description
The engine management system (EMS) maintains
optimum engine performance over the entire
operating range. The correct amount of fuel is
metered into each cylinder inlet tract and the ignition
timing is adjusted at each spark plug.
The system is controlled by the ENGINE CONTROL
MODULE (ECM) which receives data from sensors
located on and around the engine. From this
information it provides the correct fuel requirements
and ignition timing at all engine loads and speeds.
The fuel injection system uses a hot wire Mass Air
Flow Sensor to calculate the amount of air flowing into
the engine.
The ignition system does not use a distributor. It is a
direct ignition system (DIS), using four double ended
coils. The circuit to each coil is completed by
switching inside the ECM.
The on board diagnostic system detects any faults
which may occur within the EMS. Fault diagnosis
includes failure of all EMS sensors and actuators,
emissions related items, fuel supply and exhaust
systems.
The system incorporates certain default strategies to
enable the vehicle to be driven in case of sensor
failure. This may mean that a fault is not detected by
the driver. The fault is indicated by illumination of the
malfunction indicator light (MIL) on North American
specification vehicles.
A further feature of the system is 'robust
immobilisation'.Crankshaft position sensor (CKP Sensor)
The crankshaft position sensor is the most important
sensor on the engine. It is located in the left hand side
of the flywheel housing and uses a different thickness
of spacer for manual and automatic gearboxes. The
signal it produces informs the ECM:
- the engine is turning
- how fast the engine is turning
- which stage the engine is at in the cycle.
As there is no default strategy, failure of the
crankshaft sensor will result in the engine failing to
start. The fault is indicated by illumination of the
malfunction indicator light (MIL) on North American
specification vehicles.
Camshaft position sensor (CMP Sensor)
The camshaft position sensor is located in the engine
front cover. It produces one pulse every two
revolutions. The signal is used in two areas, injector
timing corrections for fully sequential fuelling and
active knock control.
If the camshaft sensor fails, default operation is to
continue normal ignition timing. The fuel injectors will
be actuated sequentially, timing the injection with
respect to top dead centre. Injection will either be
correct or one revolution out of synchronisation. The
fault is not easily detected by the driver. The fault is
indicated by illumination of the malfunction indicator
light (MIL) on North American specification vehicles.
Mass air flow sensor (MAF Sensor)
The 'hot wire' type mass air flow sensor is mounted
rigidly to the air filter and connected by flexible hose to
the plenum chamber inlet. The sensing element of the
MAF Sensor is a hot wire anenometer consisting of
two wires, a sensing wire which is heated and a
compensating wire which is not heated. Air flows
across the wires cooling the heated one, changing its
resistance. The ECM measures this change in
resistance and calculates the amount of air flowing
into the engine.
As there is no default strategy, failure will result in the
engine starting, and dying when it reaches 550
rev/min, when the ECM detects no MAF Sensor
signal. The fault is indicated by illumination of the
malfunction indicator light (MIL) on North American
specification vehicles.

19FUEL SYSTEM
2
DESCRIPTION AND OPERATION CRUISE CONTROL SYSTEM - V8i/Tdi AUTO EDC
Description
The cruise control system consists of
electro-mechanical devices, and comprises of the
following components.
ELECTRONIC CONTROL UNIT (ECU)
The microprocessor based ECU evaluates the signals
provided by the driver controls, brake pedal switch,
clutch pedal switch on manual models, and the
vehicle speed sensor. The ECU activates the vacuum
pump as required. The ECU also has a memory
function for set speed storage.
Driver operated switches
The main cruise control switch is located in the
auxiliary switch panel and activates the cruise control
system. The steering wheel switches provide
'set/accelerate' and 'resume/decelerate' features.
These switches provide the interface between driver
and cruise control system.
Brake pedal switch
The brake pedal switch is located under the lower
dash attached to the brake pedal mounting bracket.
The switch provides for fast disengagement of the
cruise control system and rapid return of the throttle
levers to the idle position when the brake pedal is
applied.
Clutch pedal switch
The clutch pedal switch is located under the lower
dash attached to the clutch pedal mounting bracket.
The switch provides for fast disengagement of the
cruise control system and rapid return of the throttle
levers to the idle position when the clutch pedal is
applied.Vehicle speed sensor
The vehicle speed sensor is located on the side of the
transfer box adjacent to park brake. The sensor
provides road speed data to the ECU. The cruise
control system cannot be engaged until the road
speed exceeds 45 km/h, (28 mph) the system will
automatically disengage at a road speed of 42 km/h
(26 mph).
Vacuum pump
The vacuum pump is energised when the main cruise
control switch is operated, and is actuated by the
steering wheel and brake pedal switches. The pump
provides a vacuum source to the cruise control
actuator. A control valve in the pump provides for
steady increase of road speed or purge of the system
when the brake pedal is applied.
Actuator
The actuator provides the servo mechanism link
between the cruise control system and throttle linkage
and is operated by vacuum from the vacuum pump.
Neutral lockout relay - automatic vehicles
The relay module is located in the right hand side
footwell, accessible by removing the trim casing.
The function of the relay module is to disengage the
cruise control system if neutral, or park, is selected in
the main gearbox, when the system is engaged.
Engine speed trip ECU - Manual vehicles
This unit is located in the right hand side footwell,
accessible by removing the trim casing.
The function of the unit is to disengage cruise control
if engine speed exceeds 5000 rev/min.

CRUISE CONTROL
1
FAULT DIAGNOSIS ROAD TEST
CAUTION: Do not engage cruise control
when vehicle is being used in low transfer
gear or reverse.
WARNING: The use of cruise control is not
recommended on winding, snow covered
or slippery roads or in heavy traffic
conditions where a constant speed cannot be
maintained.
1.Start engine, depress main control switch to
actuate cruise control system. Accelerate to
approximately 50 km/h, (30 mph), operate
'set/acc'switch, immediately release switch,
remove foot from accelerator pedal. Vehicle
should maintain speed at which'set/acc'switch
was operated.
2.Operate'set/acc'switch and hold at that
position, vehicle should accelerate smoothly until
switch is released. Vehicle should now maintain
new speed at which'set/acc'switch was
released.
3.Momentarily touch and release'set/acc'switch,
vehicle speed should increase 1.6 km/h (1 mph)
for each touch. Note that five touches will
increase speed 8 km/h (5 mph).
4.Apply'res/decel'switch while vehicle is in cruise
control mode, cruise control should disengage.
Slow to approximately 55 km/h, (35 mph)
operate'res/decel'switch, immediately release
switch and remove foot from accelerator, vehicle
should smoothly accelerate to previously set
speed. Increase speed using accelerator pedal,
release pedal, vehicle should return to previously
set speed.
NOTE: The cruise control system fitted to
the diesel engine is not as responsive as
that fitted to the petrol engine, due to the
characteristics of diesel engines. Therefore, at
speeds below approx. 65 km/h (40 mph), the
vehicle speed may drop when cruise is selected
and then slowly regain the 'set' speed.5.Operate brake pedal, cruise control system
should immediately disengage returning vehicle
to driver control at accelerator pedal. Operate
'res/decel'switch, vehicle should accelerate to
previously set speed without driver operation of
accelerator pedal.
6.Operate'res/decel'switch and allow vehicle to
decelerate to below 42 km/h, (26 mph). Operate
'res/decel'switch, cruise control system should
remain disengaged.
7.Operate'set/acc'switch below 40 km/h, (28
mph), cruise control system should remain
disengaged. Accelerate, using accelerator pedal
to above 45 km/h, (28 mph), operate'res/decel'
switch, and remove foot from accelerator pedal,
vehicle should smoothly adjust to previously
memorised speed.
8. Automatic vehicles- select neutral, system
should disengage.Manual vehicles- depress
clutch, system should disengage.
9.Cruise at 80 km/h (50 mph), declutch, select
neutral, remove foot from clutch. Operate
'res/decel'switch. Engine should rev to 5000
rev/min, cruise control disengages, engine
returns to idle.
10.Engage forward gear. Operate'res/decel'
switch. Remove foot from accelerator. Speed
should accelerate to previous set speed.
11.Depress main control switch in control system
should immediately disengage and erase
previously set speed from ECU memory.
See
Electrical Trouble Shooting Manual.
ELECTRICAL TESTS
Electrical functionality can be checked using
TestBook.
CABLE SETTING - TDi AUTOMATIC MODELS
1.An incorrectly adjusted kickdown cable can
prevent correct operation of the cruise control
system.
See AUTOMATIC GEARBOX,
Adjustment, kickdown cable adjustment.

CLUTCH
1
DESCRIPTION AND OPERATION DESCRIPTION
The clutch unit fitted with the manual transmission,
comprises a single dry plate friction disc and
diaphragm spring clutch unit, secured to the engine
flywheel.OPERATION
The unit is operated hydraulically by the clutch master
cylinder 12 and a slave cylinder 13 attached to the
transmission bell housing.
1. Crankshaft and flywheel
2. Friction plate
3. Clutch cover
4. Diaphragm spring
5. Pressure plate
6. Fulcrum posts (9) for diaphragm spring
7. Bearing rings (2) for diaphragm spring
8. Retraction links and bolts (3) for pressure plate
9. Release bearing
10. Release lever11. Release lever pivot post
12. Master cylinder
13. Slave cylinder
14. Master cylinder pedal pushrod
15. Primary shaft and taper bearing (in gearbox)
16. Gearbox front cover
17. Primary shaft flywheel bush
18. Pedal pivot and return spring
19. Hydraulic damper (Diesel only)

33CLUTCH
2
DESCRIPTION AND OPERATION When the clutch pedal is depressed, hydraulic fluid
transmits the movement via the slave cylinder, release
lever 10, bearing 9, to the inner fingers of the
diaphragm spring 4.
The diaphragm spring 4 pivots on the bearing rings 7
and fulcrum posts 6 causing the pressure plate 5 to
release the clamping force on the friction plate and
linings 2.As the the clamping force is removed from the friction
plate 2, the plate slides on the splines of the primary
shaft 15 and takes up a neutral position between the
flywheel 1 and the pressure plate 5 , thus breaking the
drive between the engine and the gearbox.
NOTE: Diesel engined vehicles have an
hydraulic damper 19 fitted into the system.
The damper contains a steel diaphragm
which absorbs slight hydraulic pulses caused by
cyclic variations of the diesel engine crankshaft at
low rpm.

33CLUTCH
2
FAULT DIAGNOSIS FAULT/SYMPTOM CHART
Symptoms
Slip Spin/Drag Judder/Fierce Fault Item
* * * Worn or oil on clutch linings 2
* * * Mechanical damage45678
* * Distorted clutch plate 2
* Failed or air in hydraulic system 12 13
* * Primary shaft tight fit in crankshaft bush 15 17
* Clutch splines sticking 2 15
* Weak clutch plate springs or insecure/worn
engine/gearbox mountings6
* Insecure/worn propeller shafts
* Insecure/worn suspension components/rubber
bushes
For items refered to in this chart.See Description and operation, Description
CLUTCH NOISE - MECHANICAL FAULTS
Noise from clutch or gearbox in neutral, which
disappears when clutch is depressed.
Suspect gearbox input/primary shaft bearings.
See MANUAL GEARBOX, Fault diagnosis,
Manual Gearbox
- Noise from gearbox in neutral, which
disappears when clutch is depressed
Noise from clutch or gearbox in neutral, which
changes tone or becomes worse when the clutch
is depressed.
Suspect worn release bearing.
Knocking/rattling from clutch or gearbox in
neutral, which is reduced or disappears when the
clutch is depressed.
Suspect worn/weak release lever retainer or
clutch unit.
Noise from clutch or gearbox in neutral, which
disappears when clutch is depressed.
Suspect gearbox fault.
See MANUAL GEARBOX, Fault diagnosis,
Manual Gearbox
- Noise from gearbox in neutral, which
disappears when clutch is depressed.HYDRAULIC FAULTS
Unable to dis-engage clutch, little or no pedal
resistance.
1.Check condition, specification and level of fluid.
2.Check pipes and cylinders for leaks.
3.Check that air vent in reservoir lid is clear.
Suspect faulty master cylinder if no fluid leaks
present.
See Repair, Master Cylinder
Spongy pedal operation
1.Check condition, specification and level of fluid.
2.Check that air vent in reservoir lid is clear.
Suspect air in fluid.
See Repair, Bleed Hydraulic System
Clutch is difficult to dis-engage and/or does not
immediately re-engage when pedal is released.
1.Check condition, specification and level of fluid.
2.Check that air vent in reservoir lid is clear.
Suspect pedal pivot, master cylinder or slave
cylinder seizure.
See Repair, Master Cylinder

CLUTCH
1
REPAIR CLUTCH ASSEMBLY
Service repair no - 33.10.01
Clutch pressure plate
Renew pressure plate if diaphragm spring fingers are
worn or if pressure plate shows signs of wear, cracks
or burning.
Clutch driven plate
Renew driven plate if centre hub splines are worn or if
lining is contaminated, burned or unevenly worn.
Service tools:
Clutch centralising tool
LRT-12-001 - V8
LRT-12-040 - Tdi
LRT-12-057 - Mpi
Remove
1.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
2.Mark position of clutch cover to flywheel for
reassembly.
3.Remove clutch cover securing bolts, working
evenly and diagonally.
4.Do not disturb three bolts in clutch cover.
5.Remove clutch assembly.
6.Withdraw clutch driven plate.
Refit
NOTE: To prevent clutch plate sticking,
lubricate splines using Rocol MV 3 or
Rocol MTS 1000 grease.
7.Renew/refit clutch driver plate and clutch
assembly using centralising tool, where
applicable, align assembly marks.
8.Secure clutch assembly cover fixings evenly,
working in a diagonal sequence. Tighten to
28
Nm.
9.Fit gearbox to engine.

CLUTCH
3
REPAIR Refit
7.Fit the master cylinder and fixings.
8.Fit push-rod to pedal and retain with clevis pin
and washer.
9.Raise fasica fuse box panel.
10.Fit fluid pipe to master cylinder.
11.Bleed system.
See Bleed Hydraulic System
RELEASE BEARING ASSEMBLY
Service repair no - 33.10.07
Remove
1.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
2.Remove clutch slave cylinder.See Slave
Cylinder
3.Withdraw retainer staple.
4.Withdraw bearing and sleeve. If required, press
bearing off sleeve. Fit replacement bearing with
domed face outwards from sleeve.
5.Remove spring clip and fixings.
6.Withdraw release lever assembly.
Refit
7.Smear pivot with grease and fit release lever and
retain with spring clip and bolt.
8.Smear release bearing sleeve inner diameter
with molybdenum disulphide base grease.
9.Reverse removal procedure. 1 to 4.