air condition LAND ROVER DISCOVERY 1995 Repair Manual

26COOLING SYSTEM
4
REPAIR RADIATOR
Service repair no - 26.40.01
Remove
1.Drain cooling system.
See Adjustment,
Coolant
2.Remove viscous coupling and fan assembly.
See Viscous Coupling, Fan Blades, Pulley
and Fan Cowl
3.Release 2 clips and remove fan cowl.
4.Disconnect radiator top hoses.
5.Disconnect four transmission and engine oil
cooler connections to radiator end tanks. Note oil
spillage will occur when connections are
loosened. Blank off exposed oil connections.
6.Disconnect transmission oil temperature sensor.
7.Remove radiator securing brackets from each
side.
8.Remove radiator unit by lifting from its location.
Check condition of rubber mounting pads.Refit
9.Reverse removal procedure.
10.Clean unions and apply sealant.
11.Lubricate new 'O' rings before fitting.
12.Check radiator sealing strips are securely
located.
13.Transfer oil cooler adaptors if fitting new radiator.
14.Ensure that oil cooler connections are tightened
to
30 Nm.before fitting fan blades and cowl.
15.Clean coolant/oil spillage from vehicle.
16.Check all connections for coolant/oil leaks.

Mpi
3
REPAIR
12.With assistance lift out radiator assembly.
Do not carry out further dismantling if component
is removed for access only.
13.Remove 2 bolts securing radiator rail to radiator.
14.Remove radiator rail.
15.Remove 8 nuts securing fan assemblies to
radiator.
NOTE: Vehicles without air conditioning
have one cooling fan fitted.
Refit
16.Position fan assemblies to radiator and tighten
nuts to
6Nm
17.Position radiator rail to radiator and secure with
bolts.
18.Position radiator to vehicle.
19.Secure radiator to body with the side support
brackets and retaining bolts.
20.Connect multiplugs to cooling fans.
21.Fit and secure 6 hoses to radiator.
22.Secure air cleaner to throttle housing to
brackets.
23.Refill cooling system.
24.Reconnect battery negative lead.

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

41TRANSFER GEARBOX
2
FAULT DIAGNOSIS PROCEDURE
Prior to road test
1.Check oil level in transfer box is correct.
2.Check tightness of level and drain plugs.
3.Check breather system for blockage. To validate
the system the pipe must be removed,
inspected, rectified as necessary and refitted.
4.Remove all traces of oil from exterior of transfer
box.
Take vehicle for short road test.
5.Identify source of leaks and rectify as follows.
Front or rear output seal leaking:-
1.Drain the oil and remove the leaking output
flange.
2.Inspect the seal track on the flange for surface
damage. If damaged renew component.
3.Remove and discard the oil seal.
4.Inspect the seal locating bore and remove any
sharp edges which may damage the new oil
seal.
5.Fit new seal.
6.Fit the output flange and all the other parts.
7.Add oil to correct level into the gearbox.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids
Cover plate gasket leaking.
1.Drain the oil and remove the leaking cover plate.
2.Remove all traces of joint sealant from both joint
faces.
3.Degrease all components and apply a thin film of
Hylomar sealant, to both joint faces.
4.Apply thread sealant to the bolts which come
into contact with gearbox oil.
5.Refit cover plate.
CAUTION: Care must be taken not to
overtighten the fixings.Leak between the main and transfer gearboxes.
1.Site vehicle onto a ramp [hoist].
2.Select neutral in transfer box and select 4th gear
in the main gearbox.
3.Run engine at 2000 rpm with the clutch/drive
engaged.
4.Observe joint between the main and transfer
boxes.
5.If oil leak is found establish if it is gear oil.
6.If so, the leak is originating from the transfer box.
7.Check the two inner (main/transfer) bolts are oil
tight, as these holes are tapped through into the
main transfer case.
8.Remove the transfer box to inspect the
mainshaft collar seal track condition, and the
front face of the transfer case for porosity.
See
Repair, LT230T Transfer Gearbox
9.If these areas require servicing, the transfer
gearbox input seal must also be renewed.
CAUTION: Avoid damaging the new seal
lip and ensure the seal is fitted flush with
the machined face. Also ensure the new
seal is not damaged when refitting the transfer
gearbox.
10.If red A.T.F type oil is seen leaking during the
workshop test, investigate the main gearbox for
cause of leak.
Detent plug or electrical switch leaks.
1.Detent plugs and electrical switches do not
usually leak. It must be noted that they fit into
open tapped holes in the transfer case and
therefore should be considered when looking for
the source of the leak.

54FRONT AXLE AND FINAL DRIVE
4
REPAIR Refit
11.Clean stub axle and drive shaft and fit hub
assembly to axle.
12.Fit spacing washer.
13.Fit hub adjusting nut. Tighten to
61 Nm.
14.Back off adjusting nut 90°. Tighten to4 Nm.
This will give the required hub end float of
0,010mm
15.Fit a new lock washer.
16.Fit locknut. Tighten to61 Nm.
17.Tab over lock washer to secure adjusting nut
and locknut.
18.Fit a new joint washer to driving member and fit
member to hub and secure with five bolts.
Tighten to
65 Nm.
19.Fit original drive shaft shim and secure with a
circlip.
20.To check drive shaft end play mount a dial
gauge using bracket LRT-99-503 and rest pin in
a loaded condition on end of drive shaft.
21.Fit a suitable bolt to threaded end of drive shaft.
Move drive shaft in and out noting dial gauge
reading. End play should be between0,08 to
0,25 mm.
22.If end play requires adjustment, remove circlip,
measure shim thickness and fit an appropriate
shim to give required end-play.
23.Remove bolt from drive shaft, fit circlip and dust
cap.
24.Fit brake caliper. Tighten to
82 Nm.
25.Bleed brake system.See BRAKES, Repair,
Brake System Bleed
26.Fit road wheel, remove axle stands and tighten
road wheel nuts to
126 Nm.
27.Operate footbrake to locate brake pads before
taking vehicle on road.

57STEERING
2
FAULT DIAGNOSIS POWER STEERING SYSTEM - TEST
NOTE: If steering lacks power assistance.
Check pressure of hydraulic pump before
fitting new components. Use fault
diagnosis chart to assist in tracing faults.
A. Steering box.
B. Steering pump.
C. Existing hose, steering box to pump.
D. Hose LRT-57-030.
E. Test adaptor LRT-57-001.
F. Pressure gauge LRT-57-005.
G. Thread adaptor LRT-57-004.
H. Thread adaptor LRT-57-022.Procedure
1.A hydraulic pressure gauge and test adaptor is
used to test power steering system. This gauge
is able to measure 140 kgf/cm
2. The maximum
power steering system pressure is 77 kgf/cm2.
2.Some fault conditions of hydraulic pump may
obtain pressures up to 105 kgf/cm
2. Pressure on
gauge is same pressure being exerted upon
steering wheel. When testing, turn steering
wheel gradually while reading pressure gauge.
3.Check and maintain maximum fluid level of
reservoir.
4.Examine power steering units and connections
for leaks. All leaks must be rectified before
attempting to test the system.
5.Check steering pump drive belt tension.
See
ENGINE, Repair, Drive Belt
6.Assemble test equipment and fit to vehicle, as
shown in RR3959M.
7.Open tap of adaptor.
8.Bleed system, take care not to overload
pressure gauge.
9.With system in good condition, pressures should
be:
(A) Steering wheel held on full lock and engine
running at 1,000 rev/min, 70 to 77 kgf/cm
2.
(B) Steering wheel held on full lock and engine
idling, 28 kgf/cm
2.
Checks should be carried out on both full lock
positions.
CAUTION: Do not maintain this pressure
for more than 30 seconds in any one
minute to avoid overheating fluid and
possibly damaging seals.
10.Release steering wheel and with engine idling.
Pressure should read below 7 kgf/cm
2.
11.If pressures differ to those given a fault exists.
12.To determine if fault is steering box or pump.
Close adaptor tap for a maximum five seconds.
13.If gauge does not register specified pressure,
pump is faulty.
14.Fit a new pump, bleed system and repeat test. If
low pressure or a substantial imbalance exists,
fault is in steering box valve and worm
assembly.

STEERING
3
FAULT DIAGNOSIS STEERING DAMPER
The power steering system, as well as reducing the
effort required to manoeuvre the vehicle when
parking, also helps to dampen any deflections of the
road wheels, being transmitted back to the steering
wheel.
When operating the vehicle off road, the road wheels
are often deflected by ruts and boulders causing the
steering wheel to turn left and right. This phenomenon
is known as 'steering kickback'. To subdue the effects
of 'steering kickback', a hydraulic damper is fitted in
the steering linkage between the track rod and the
differential casing. The damper, which offers the same
resistance in extension and compression, is sealed for
life.
Steering damper check
Check the condition operation of the hydraulic
steering damper as follows:
Check procedure
1.Inspect damper for casing damage or leaks.
2.Clamp one end of the damper horizontally in a
vice using soft jaws. Compress and extend the
unit by hand. Resistance should be equal in both
directions.
3.If it is felt that the unit is outside acceptable
limits, fit a new steering damperSTEERING FAULTS
Symptom:-
Excessive kickback through steering wheel - when
driven on rough terrain.
1.Is the steering damper in good working order?
See Steering Damper
NO - Renew unit.See Repair, Steering
Damper
YES - Continue.
2.Is there any looseness or free play in the
steering ball joints and linkage?
YES -
See Steering Linkage Inspect
NO - Continue.
3.Is there any looseness or worn bushes in front
suspension?
YES -
See FRONT SUSPENSION, Repair,
Radius Arm
NOTE: When replacing suspension bushes
ALL bushes and fixings must be replaced.
NO - Continue.
4.Is the steering exceptionally light/sensitive when
driven on good road surface?
YES - See fault symptom -Steering
excessively light/sensitive and
freeplay at steering wheel.
NO - Suspect axle swivel resistance.
5.Check the resistance of the axle swivels.
See
FRONT AXLE AND FINAL DRIVE, Overhaul,
Front Stub Axle, Constant Velocity Joint and
Swivel Pin Housing Non ABS See FRONT
AXLE AND FINAL DRIVE, Overhaul, Front
Stub Axle, Constant Velocity Joint and
Swivel Pin Housing ABS

STEERING
5
FAULT DIAGNOSIS Symptom :-
Steering excessively light/sensitive. Excessive
freeplay at steering wheel.
1.Are steering box adjustments correct?
NO -
See Adjustment, Power Steering Box
WARNING: Adjustments of steering box
should not be required while in warranty
period. If box is within warranty, it must be
returned to manufacturer. No attempt must be
made to introduce backlash.
YES - Suspect worn panhard rod or radius arm
bushes Check condition of ball joints and
the lower steering column shaft universal
joints for wear.
See Repair, Lower
Steering Shaft and Universal Joints
Symptom :-
Steering vibration, road wheel shimmy - wobble.
Vibration through the steering linkage powerful
enough to induce high frequency oscillation of the
steering wheel, is generally caused by out of balance
road wheels. However there are a number of other
possible causes of this symptom which if severe, may
be described as shimmy or wobble. Regardless of the
terminology used by the owner/driver to describe the
symptoms, the following diagnostic checks should be
carried out in the order presented.
1.Check the tyres and balance of the road wheels.
See GENERAL SPECIFICATION DATA,
Information, Wheels and Tyres See
WHEELS AND TYRES, Fault diagnosis, Fault
- Symptoms See WHEELS AND TYRES,
Repair, Wheel Balancing
2.Check the steering hydraulic damper function.
See Steering Damper
3.Check steering column universal joints for wear
and correct alignment.
See Repair, Lower
Steering Shaft and Universal Joints
4.Check steering linkage ball joints for wear,
correct alignment and security, including steering
box and tie rod.
See Steering Linkage Inspect
5.Check all front suspension rubbers for wear.
Check all fixing torques, including radius arm
bushes, panhard rod and anti-roll [sway] bar.
See FRONT SUSPENSION, Repair, Panhard
Rod See FRONT SUSPENSION, Repair,
Radius Arm See FRONT SUSPENSION,
Repair, Anti-Roll[Sway] Bar Assembly See
FRONT SUSPENSION, Repair, Front Shock
Absorber
6.Fit new radius arm bushes using NTC 6860. Fit
harmonic damper if vehicle has air suspension.
Fit new nuts, bolts and washers.
7. Coil spring vehicles only- If problem persists
fit damper kit STC 241 (2 off front) and STC
1474 (2 off rear). Road test vehicle.
8.Check the power steering box adjustments and
operation.
See Overhaul, Power Steering Box
9.Check the hub bearing end floats and determine
the condition of the hub bearings. As applicable.
See FRONT AXLE AND FINAL DRIVE, Repair,
Front Hub Assembly
10.Check the resistance and condition of the
swivels.
See FRONT AXLE AND FINAL
DRIVE, Description and operation,
Description
If problem is not diagnosed: Repeat
checks starting at 1.
11.Carry out a full steering geometry check.
See
INTRODUCTION, Information, Steering

57STEERING
8
FAULT DIAGNOSIS 4. DIRECTIONAL STABILITY
From 1. GENERAL STEERING:
1.Is directional stability concern when vehicle is
towing?
YES - Check towing/vehicle loading parameters
in Owner's Handbook.
NO - go to 3.
2.Is problem resolved?
YES - end
NO - continue.
3.Check condition of rear trailing link/chassis
bushes.
4.Is problem resolved?
YES - end
NO - continue.
5.Check condition of front and rear shock
absorbers. If in doubt change units in pairs, side
to side.
6.Is problem resolved?
YES - end
NO - continue.
7.Check steering damper.
See Steering Damper
8.Is problem resolved?
YES - end
NO - continue.
9.Check wheel balance
10.Is problem resolved?
YES - end
NO - contact local technical office.POWER STEERING FLUID LEAKS
1.Is fluid level correct?
YES - go to 3.
NO - Refill or drain to correct level. Bleed
system, check for leaks.
See Repair,
Power Steering System - Bleed
2.Is problem resolved?
YES - end
NO - continue.
3.Are hoses or joints leaking? Check on full lock
with engine at 2000 rev/min.
YES - loosen and retorque joints.
NO - go to 6.
4.Does leak remain?
YES - change PAS pipe.
NO - end.
5.Does leak remain?
YES - suspect seal in component. Check and
replace as necessary.
NO - end.
6.Is oil escaping from filler cap?
YES - bleed system.
See Repair, Power
Steering System - Bleed
NO - go to 8.
7.Is oil still escaping from filler cap?
YES - go back to 1.
NO - end.
8.Is oil leaking from PAS pump?
YES - go to 10.
NO - continue.
9.Is oil leaking from PAS box?
YES - go to 10.
NO - end.
10.Clean unit, add tracer dye to system. Retest
11.Is oil still leaking?
YES - establish leak point. Repair or replace
unit as necessary.
NO - end.

STEERING
9
FAULT DIAGNOSIS POWER STEERING SYSTEM - EXCESSIVE NOISE
1.Is fluid level correct?
YES - go to 3.
NO - Refill or drain to correct level. Bleed
system, check for leaks.
See Repair,
Power Steering System - Bleed
2.Is problem resolved?
YES - end
NO - continue.
3.Is pressure hose from pump to box touching
body in a hard foul condition?
YES - reroute hose away from body.
NO - go to 5.
4.Does noise remain?
YES - continue.
NO - end.
5.Is noise a whistle or hiss on full lock?
YES - noise is not a fault unless excessive.
Compare with other vehicles
NO - go to 8.
6.Is noise excessive?
YES - continue.
NO - end.
7.Change steering box and/or pump.
8.Is noise a squeal on full lock?
YES - check/reset drive belt tension.
See
ENGINE, Repair, Drive Belt
NO - go to 10.
9.Does squeal remain?
YES - drive belt contaminated, change belt.
NO - end.
10.Is noise a continuous moan?
YES - bleed PAS system.
See Repair, Power
Steering System - Bleed
NO - go to 13.
11.Does moan remain?
YES - do figure 8 manoeuvres.
NO - end.
12.Does moan remain?
YES - continue
NO - end.13.Is noise an intermittent "grunt"?
YES -
See Power Steering System - Grunt
NO - continue.
14.Is it a clunking noise?
YES - reset drive belt tension.
See ENGINE,
Repair, Drive Belt
NO - contact local technical office.
15.Does noise remain?
YES - Suspect suspension or drive train.
NO - end.
POWER STEERING SYSTEM - GRUNT
Steering box grunts intermittently when turning
from lock to lock:
1.Is fluid level correct?
YES - go to 3.
NO - refill or drain to correct level. Bleed
system, check for leaks.
See Repair,
Power Steering System - Bleed
2.Does grunt remain?
YES - continue
NO - end.
3.Is correct low pressure hose ANR 3152, steering
box to reservoir fitted?
YES - go to 5.
NO - Fit correct hose.
4.Does grunt remain?
YES - continue
NO - end.
5.Purge box by doing figure 8 manoeuvres e.g. on
car park, followed by 10 minutes normal road
use.
6.Does grunt remain?
YES - Contact local technical office
NO - end.