lock LAND ROVER DISCOVERY 1995 Service Manual

Tdi
3
SPECIFICATIONS, TORQUE Turbo charger oil drain adaptor to block 42....................................................
Oil drain pipe to turbocharger 25....................................................................
Turbocharger oil drain pipe to adaptor 38.......................................................
Turbocharger oil feed pipe adaptor to block 25...............................................
Turbocharger oil feed pipe to adaptor 25........................................................
Oil feed pipe to turbocharger 19.....................................................................
Turbocharger to cylinder head (stud) 10.........................................................
Turbocharger to cylinder head (nut) 45...........................................................
Turbocharger to blanking plate 25..................................................................
Turbocharger to EGR valve 25.......................................................................
EGR delivery tube to valve 25........................................................................
EGR delivery tube to mixing tube 25..............................................................
Fuel lift pump to filter (union) 15.....................................................................
Fuel filter from lift pump (banjo bolt) 33...........................................................
Fuel filter to fuel injection pump (banjo bolt) 33..............................................
Fuel injection pump from fuel filter (banjo bolt) 25..........................................
Injector pipes to injectors and fuel injection pump 29.....................................
Spill rail to injectors (banjo bolt) 10.................................................................
Spill rail to injection pump (banjo bolt) 25.......................................................
Boost pipe injection pump (banjo bolt) 10.......................................................
Plug, rear of injection pump 29.......................................................................
PAS pump to mounting plate 25.....................................................................
PAS pump mounting plate to auxiliaries mounting bracket 25........................
PAS pump pulley to hub 25............................................................................
Generator to auxiliaries mounting bracket 25.................................................
Starter motor (bolt and nut) 45........................................................................
Tachometer electrical connection 4...............................................................
Air conditioning compressor
Compressor mounting bracket to front cover 45.............................................
Compressor to mounting bracket (stud) 8......................................................
Compressor to mounting bracket (nut) 25......................................................
Belt tensioner pulley to tensioner arm 45........................................................
Belt tensioner assembly to front cover plate 25..............................................
Idler pulley to front cover plate 45...................................................................
Compressor belt guard (nut) 25......................................................................
Sensors to water outlet elbow (air/con) 25......................................................
Blanking plug, water outlet elbow (air/con) 25................................................
Generator mounting bracket to front cover 45................................................
Generator to mounting bracket 85..................................................................
Generator pulley to hub 95.............................................................................
Generator belt guard 25..................................................................................

V8i
1
DESCRIPTION AND OPERATION DESCRIPTION
The V8i engine has cast aluminium cylinder heads
and cylinder block. The two banks of steel cylinder
liners which are pressed down to stops in the block,
are set at 90°to one another. The three ringed
aluminium pistons transmit the power through the
connecting rods to a cast iron five bearing crankshaft,
which drives the centrally located camshaft via a
duplex type chain.
The electronic ignition distributor is driven by a gear
off the front of the camshaft and the lubrication oil
pump is driven by a gear off the front of the
crankshaft. The overhead inlet and exhaust valves are
operated by rocker shafts, pushrods and self adjusting
hydraulic tappets.
Multiport fuel injection ensures that engine
performance, economy and exhaust emissions are
automatically correct for the demands of highway and
off road operation.

12ENGINE
2
DESCRIPTION AND OPERATION
1. Cylinder block
2. Pistons and gudgeon pins (8)
3. Connecting rods (8)
4. Core plugs
5. Camshaft
6. Dipstick
7. Camshaft key
8. Timing chain
9. Camshaft sprocket
10. Distance piece
11. Distributor drive gear
12. Distributor
13. Front cover
14. Front cover oil seal
15. Coolant pump
16. Crankshaft damper / pulley17. Crankshaft sprocket
18. Crankshaft sprocket key
19. Crankshaft
20. Centre main bearing shells (2)
21. Crankshaft rear oil seal
22. Spacer
23. Adaptor plate
24. Rear main bearing cap, shell and side seals
25. Connecting rod caps
26. Main bearing caps and shell bearings
27. Oil filter
28. Oil pump suction pipe/strainer
29. Oil sump
30. Oil sump drain plug
31. Oil pump drive key

12ENGINE
4
FAULT DIAGNOSIS 3.Are 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
YES - Suspect valves held open by hydraulic
tappets due to high oil pressure.
See
Engine Oil Pressure Test
4.Is oil pressure high?
YES - Remove oil filter and cooler adaptor and
check pressure relief valve strainer gauze
for blockage and that the relief valve is
not stuck closed.
See Description and
operation, Description
NO - Carry out cylinder compression tests to
determine condition of head gaskets and
valves.
See Cylinder Compression -
Test
5.Are cylinder compressions satisfactory?
NO -
See Repair, Cylinder Heads - Renew
YES - 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.
6.Are the brakes binding?
YES - Investigate cause of binding.
NO - Continue.
7.Automatic Transmission only. Is the Torque
Converter and Transmission operating correctly?
Carry out Road test, Static tests and Stall tests
to determine condition of Automatic
transmission.
If problem is not diagnosed: repeat tests starting at 1.Engine backfires into exhaust system
1.Are there any leaking joints/connections or holes
in the exhaust system?
YES -
See MANIFOLD AND EXHAUST
SYSTEM, Repair, Exhaust System
Complete
NO - Continue.
2.Is distributor fitted correctly, HT leads in correct
firing order and routed correctly?
NO -
See ELECTRICAL, Repair, Distributor
- V8i
YES - Continue.
3.Is air fuel ratio correct?
NO - Check multiport fuel injection.
See
Electrical Trouble Shooting Manual.
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
Check the crank case and fuel tank ventilation
system.
See EMISSION CONTROL,
Description and operation, Emission Control
YES - Continue.
4.Are cylinder compressions satisfactory?
NO - Carry out compression test to check for
leaking gaskets valves etc.
See
Cylinder Compression - Test
See Repair, Cylinder Heads - Renew
If problem is not diagnosed: repeat tests starting
at 1.

V8i
1
REPAIR DRIVE BELT
A single 'serpentine drive belt' is introduced for 1995
model year. This belt drives the water pump and all
the ancilliaries. It is essential that the belt is fitted
exactly as shown in illustrations RR3956 and RR3957.
It should also be noted that the water pump/viscous
fan is driven in a counter clockwise direction.
A drive belt tensioner automatically tensions the drive
belt, eliminating the need for tensioning individual
drive belts. Turning the tensioner pulley in a clockwise
direction will release drive belt tension.
Under normal highway use the belt must be changed
at 120,000 kilometres, 75,000 miles or five years
whichever occurs first.
The drive belt must be examined at every service and
replaced if necessary.
Off road driving
Regular examination of the drive belt is essential if the
vehicle is used off road. The vehicle driver should be
requested to identify the type of mileage the vehicle
has covered.
After every off road session the owner should inspect
the belt for cuts and possible damage caused by
stones. If belt has jumped, reposition belt correctly. A
new belt must be fitted at the next service or before,
dependant on the type of damage sustained.
Fan cowl
To ensure easy access to the drive belt the top portion
of the fan cowl is detachable.
Check condition
Check condition of drive belt. Renew a belt that shows
signs of wear, splitting or oil contamination.DRIVE BELT RENEW
Service repair no - 86.10.03
Air conditioning
Non air conditioning

12ENGINE
2
REPAIR Remove
1.Remove fan cowl upper.
2.Release drive belt tension by turning tensioner
clockwise.
3.With tension released, remove belt from
generator pulley.
4.Release tensioner pulley.
5.Remove drive belt. Mark direction of rotation on
belt if refitting
Refit
6.Clean drive belt pulley grooves and ensure
grooves are not damaged.
7.Position belt correctly around all pulleys except
generator. Illustrations RR3956 and RR3957
show correct drive belt run.
8.Turn drive belt tensioner clockwise.
9.Locate drive belt on generator pulley.
10.Ensure drive belt is squarely located on pulleys
with all grooves engaged.
11.Release tensioner to tension drive belt.
12.Fit upper fan cowl section.DRIVE BELT - CHECK TENSION
As the drive belt is automatically tensioned, no tension
check or adjustment should be necessary. If the drive
belt is believed to be slack carry out the following
checks:
1.Visually check drive belt tension.
2.Watch movement of tensioner with engine
running, 5 mm 'bounce' is normal. If tensioner
movement is 12 mm or more, fit a new tensioner.
See Drive Belt Tensioner
3.Inspect tensioner. Is the tensioner arm and
spring case in contact? If so fit a new tensioner.
4.Using a recognised drive belt tensioning gauge,
check belt tension several times, running engine
between checks. The checks should be made at
the same point on the belt, away from the
tensioner.
Drive belt tension, with used tensioner and used drive
belt should be more than:-
270N. Non air conditioning or
295N with air conditioning.

12ENGINE
4
REPAIR CYLINDER HEAD GASKETS - RENEW
Service repair no - 12.29.01
1.Drain cooling system.
See COOLING SYSTEM,
Adjustment, Coolant
2.Remove inlet manifold.See FUEL SYSTEM,
Repair, Intake Manifold
3.Remove generator.
4.If fitted, remove compressor.
See AIR
CONDITIONING, Repair, Compressor
5.Remove rocker shafts.See Rocker Shaft
Renew
6.Remove push rods.
7.Remove both exhaust manifolds.
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust Manifold - V8i
8.Remove air cleaner assembly.See FUEL
SYSTEM, Repair, Air Cleaner Assembly
9.Remove air flow sensor.See FUEL SYSTEM,
Repair, Air Flow Sensor
10.Remove ground leads from rear of left hand
cylinder head
11.Right hand cylinder head - remove breather pipe
from lifting bracket.
12.Loosen cylinder head bolts, reversing tightening
sequence.
13.Remove cylinder heads.
14.Remove cylinder head gaskets.
15.Clean exhaust mating faces.
16.Clean head and block faces.
17.Fit new cylinder head gaskets, word TOP
uppermost. DO NOT use sealant.
18.Oil cylinder bores.
19.Clean threads of head bolts and lightly oil.
20.Locate cylinder heads on block.
21.Locate cylinder head bolts in position illustrated.
96 mm long bolts - 2, 4, 6, 7, 8, 9, 10
66 mm long bolts - 1, 3, 5
NOTE: There are no bolts fitted in the four
lower holes in each cylinder head.
NOTE: Left hand cylinder head illustrated,
arrow points to front of vehicle.
22.Tighten bolts progressively in sequence, shown
to
20 Nmthen a further 180°±5°
23.Reverse removal procedure. 1 to 11.

12ENGINE
8
REPAIR CRANKSHAFT PULLEY ASSEMBLY
Service repair no - 12.21.01
1.Remove viscous coupling.
See COOLING
SYSTEM, Repair, Viscous Coupling, Fan
Blades, Pulley and Fan Cowl
2.Remove drive belt.See Drive Belt
3.Raise vehicle on ramp [hoist].
4.Remove bell housing bottom cover.
5.Remove engine undertray.
6.With assistance to stop flywheel rotation, remove
crankshaft pulley assembly retaining bolt.
7.Remove crankshaft pulley assembly.
8.If required: Place assembly in vice and remove
pulley.
9.Fit pulley to torsional vibration damper.
10.Lubricate seal face of assembly.
11.Fit pulley assembly.
12.With assistance to stop flywheel rotation, fit
retaining bolt. Tighten to
280 Nm.
13.Reverse removal procedure. 1 to 5.FRONT COVER OIL SEAL - RENEW
Service repair no - 12.21.14
1.Remove crankshaft pulley.
See Crankshaft
Pulley Assembly. Do not remove pulleys.
2.Remove eight screws and remove mud
excluder.
3.Fit button of 18G1328 to crankshaft, fit extractor
to seal.
4.Turn centre bolt of extractor to remove seal.
5.Remove seal from extractor.
6.Clean seal seating.
7.Lubricate outside diameter of seal.
8.Locate seal in front cover.
9.Fit adaptor 18G1291/5 to 18G1291/4.
10.Fit tool to seal.
11.Fit and tighten centre bolt to crankshaft, tighten
centre locknut to seat seal.
12.Slacken locknut and remove tool.
13.Lubricate seal lip.
14.Fit mud excluder and tighten screws.
15.Fit crankshaft pulley assembly.

V8i
9
REPAIR FRONT COVER GASKET
Service repair no - 12.65.04
1.Remove crankshaft pulley.
See Crankshaft
Pulley Assembly. Do not remove pulleys
2.Remove water pump pulley.
3.Release distributor cap clips.
4.Release plug leads from plugs and clips.
5.Place cap and leads to one side.
6.Turn engine until No. 1 piston is at T.D.C.
7.Check position of rotor arm.
8.Remove fixings securing power steering pump
bracket to water pump bracket.
9.Remove power steering pump bracket from
water pump.
10.Remove clips securing wiring to generator
tensioner.
11.Disconnect distributor feed wire.
12.Pivot power steering pump away from front
cover, tighten pivot to retain in position.
13.Disconnect vacuum pipe from distributor.
14.Remove water pump bottom hose.
15.Disconnect oil pressure switch.
16.Disconnect heater hose at water pump.
17.Remove generator tensioner from water pump,
move tensioner aside.
18.Mark distributor position to front cover.
19.Remove distributor clamp, remove distributor.
See ELECTRICAL, Repair, Distributor - V8i
20.Remove fixings sump to front cover.
21.Loosen four adjacent sump fixings.
22.Remove generator support strut from front cover,
move strut aside.
23.Loosen remaining front cover fixings and remove
front cover.
24.Remove front cover gasket.Refit
25.Clean timing cover, clean block face.
26.Lightly grease gasket faces.
27.Fit new gasket to block face.
28.Apply hylosil to sump gasket.
29.Clean threads of cover fixing bolts, apply Loctite
372 to threads.
30.Fit timing cover, fit fixing bolts. Tighten to
28
Nm.
31.Fit generator support strut to front cover.
32.Tighten sump to timing cover fixings to
10 Nm.
33.Tighten sump fixings to10 Nm.
34.Lubricate distributor O ring.
35.Fit distributor in position marked.
36.Align oil pump drive, if distributor does not seat
correctly.
37.Fit distributor clamp. Tighten to
20 Nm.
38.Locate generator tensioner on water pump
bracket.
39.Connect heater hose, tighten clip.
40.Connect oil pressure switch.
41.Connect bottom hose, tighten clip.
42.Connect vacuum pipe to distributor.
43.Loosen power steering pump pivot, lower pump.
44.Connect distributor feed wire.
45.Connect wire ties to generator tensioner.
46.Fit power steering pump bracket to water pump.
Tighten to
28 Nm.
47.Fit power steering pump to bracket.
48.Position distributor cap. Fit plug leads to plugs
and clips.
49.Clip distributor cap in position.
50.Fit water pump pulley. Tighten to
10 Nm.
51.Fit crankshaft pulley.See Crankshaft Pulley
Assembly
52.Tension drive belts correctly.
53.Check ignition timing.
54.Refill cooling system.

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.