oil LAND ROVER DISCOVERY 1995 Repair Manual

V8i
13
REPAIR
NOTE: Release bolts securing compressor
mounting bracket to engine and remove
bracket to enable temporary lifting eye
ETC 5964 to be fitted. Secure lifting eye to
mounting bracket fixing points with suitable bolts
of equivalent size, pitch and thread. Leave lifting
eye attached until engine is reinstalled in vehicle.
15.Place drain tray underneath vehicle.
16.Disconnect hose from reservoir to power
steering pump. Secure hose end above level of
fluid reservoir to avoid unnecessary loss of fluid.
17.Disconnect power steering pump to power
steering box hose. Seal hose and pump
openings with masking tape to prevent ingress of
dirt. Wipe away any fluid spillage from chassis or
steering box.
18.Disconnect fuel temperature and coolant
temperature sensor multi-plugs.
19.Disconnect leads from coil.
20.Identify each injector multi-plug for re-assembly
and disconnect plugs from injectors.
21.Manoeuvre harness from behind fuel rails and
place to one side clear of engine assembly.
22.Remove two clamps securing gearbox oil cooler
pipes to engine block.
23.Remove engine mounting fixings on both sides
of cylinder block.
24.Fit lifting chains to engine lifting eyes as shown
in illustration RR1780E.
1. L/H Front chain 356mm total overall length.
2. R/H Front chain 330mm total overall length.
3. R/H Rear chain 457mm total overall length.
NOTE: All chain dimensions are measured
from end of lifting hook to end of last link
in chain.
25.Fit chain lifting eye to a suitable engine hoist.
Raise hoist high enough to enable engine
mountings to be removed, and withdraw rubber
mountings.
26.Lower hoist until engine rests securely on engine
mounting brackets. Remove lifting chains and
hoist.
27.Disconnect two heater hoses located on top of
right hand rocker cover.
28.Remove ground strap from rear of left hand
cylinder head. DO NOT remove from retaining
clip.
29.Remove all electrical harnesses from retaining
clips at rear of engine.
30.Remove transmission breather pipes from
retaining clip on rear lifting eye.
31.Remove top two bolts securing bell housing to
cylinder block.
32.Raise front of vehicle, lower vehicle on to axle
stands.
33.Remove bell housing bottom cover. Remove
gasket from bell housing face.
34.Remove nuts securing exhaust downpipes to
manifolds, remove heat shield from right hand
side downpipe.
35.Remove electrical leads from starter motor
solenoid. Disconnect multi-plug from oil level
sensor on side of sump, if fitted.
NOTE: Instructions 37, 38 and 39 refer to
automatic vehicles only.
36.With assistance rotate engine at crankshaft
pulley until two access holes in drive plate/ring
gear assembly are visible.
37.Remove two bolts visible through access holes.
Mark one access hole and one bolt hole to
ensure unit is reassembled in its original position
38.Rotate crankshaft 180Ê until two remaining
access holes are visible, remove two bolts.

V8i
15
REPAIR OIL SUMP
Service repair no - 12.60.44
Remove
1.Drain engine oil
See SECTION 10,
Maintenance, Under Vehicle Maintenance
2.Fit drain plug. Tighten to40 Nm.
3.If fitted, disconnect low oil level sensor multiplug.
4.Remove bolt securing dipstick tube to rocker
cover.
5.Working form the centre outwards, progressively
loosen and remove 17 bolts securing sump.
Remove sump.
6.Remove all traces of sealant from mating
surfaces of sump, cylinder block and front cover,
using a suitable solvent or plastic scraper.
7.Degrease mating surfaces of sump, cylinder
block and front cover.Refit
8.Apply RTV Hylosil White sealant to mating
surface of sump.
9.Position sump, tighten bolts finger tight.
10.Tighten bolts progressively in sequence shown.
Tighten to
18 Nm.
11.Fit bolt securing dipstick tube to rocker cover.
12.If fitted, connect low oil level sensor multiplug.

V8i
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
Adaptor plate to crankshaft 84........................................................................
Generator and power steering mounting bracket to cylinder head 30............
Cylinder head:
Stage 1: 20.............................................................................................
Stage 2: - Further 180°±5°
Drive plate to converter 39..............................................................................
Engine mountings to engine and chassis 55..................................................
Engine mounting rubbers to brackets 30........................................................
Flexible drive plate to crankshaft adaptor plate 41.......................................... **
Flywheel to crankshaft bolts 78....................................................................... **
Lifting eye to cylinder heads 39......................................................................
Main bearing cap rear bolts 92....................................................................... *
Oil sump drain plug 40....................................................................................
Oil sump to cylinder block 18..........................................................................
Rocker cover to cylinder head 9....................................................................
Rocker shaft bracket to cylinder head 38........................................................
Spark plug 21..................................................................................................
Starter motor attachment 44...........................................................................
* These bolts must have threads coated in lubricant EXP16A before assembly.
** These bolts must have threads coated in sealant Loctite 270
METRIC Nm
M5 6......................................................................................................
M6 9......................................................................................................
M8 25.....................................................................................................
M10 45...................................................................................................
M12 90...................................................................................................
M14 105..................................................................................................
M16 180..................................................................................................
UNC / UNF
1/4 9......................................................................................................
5/16 24...................................................................................................
3/8 39.....................................................................................................
7/16 78...................................................................................................
1/2 90.....................................................................................................
5/8 136....................................................................................................
NOTE: Torque values above are for all screws and bolts used except for those specified.

V8i
1
SERVICE TOOLS ENGINE
LRT-12-034 Spring compressor
MS1519A
LRT-12-010 Crankshaft rear seal guide
RO1014
LRT-12-052 Oil pressure test kit

12ENGINE
2
REPAIR CRANKSHAFT FRONT OIL SEAL
Service repair no - 12.21.14 - Crankshaft Front Oil
Seal
Remove
1.Remove crankshaft pulley.
See ENGINE 3.9 V8,
Repair, Crankshaft Pulley Assembly
2.Screw tool LRT-12-088 into oil seal.
3.Turn centre bolt of tool to extract oil seal.
4.Remove oil seal from tool.
Refit
5.Clean seal seating and pulley seal register.
6.Lubricate seal with oil.
7.Locate oil seal in housing and drive into place
using LRT-12-089.
8.Lubricate oil seal lip.
9.Locate seat in front cover.
10.Drift seat into position using tool LRT-12-089.
11.Refit crankshaft pulley.
See ENGINE 3.9 V8,
Repair, Crankshaft Pulley Assembly; Refit

4.0 V8
3
REPAIR ENGINE ASSEMBLY
Service repair no - 12.41.01/99
Remove
1.Position vehicle on ramp.
2.Remove bonnet.
See CHASSIS AND BODY,Repair, Bonnet [Hood]
3.Remove radiator.See COOLING SYSTEM,
Repair, Radiator
4.Remove plenum chamber.See FUEL SYSTEM
SFI, Repair, Plenum Chamber
5.Remove mass air flow sensor.See FUEL
SYSTEM SFI, Repair, Mass Air Flow Sensor
(MAF Sensor)
6.Slacken hose clip securing bottom hose to
expansion tank.
7.Disconnect hose.
8.Remove 2 nuts securing expansion tank.
9.Remove nut and bolt securing expansion tank.
10.Remove expansion tank.
11.Disconnect servo vacuum hose from ram
housing.
12.Disconnect battery sensing lead Lucar from
generator.
13.Remove generator terminal cover.
14.Remove 2 terminal nuts and release leads from
terminals.
15.Release purge hose from ram pipe housing.
16.Position cloth to absorb fuel spillage.
17.Slacken clip securing fuel return hose to fuel rail.
18.Disconnect hose.
19.Plug connections.
20.Disconnect fuel feed hose union.
21.Plug connections. Position hoses aside.
22.Slacken clip securing heater return hose to pipe.
23.Disconnect hose.24.Slacken clip securing heater feed adaptor hose
to inlet manifold.
25.Remove bolt securing pipe bracket.
26.Disconnect feed hose from inlet manifold.
27.Disconnect hose/pipe assembly.
28.Disconnect leads from spark plugs and remove
ignition coils.
See FUEL SYSTEM SFI, Repair,
Ignition Coils
29.Disconnect fuel temperature sensor multiplug.
30.Disconnect coolant sensor multiplug.
31.Disconnect temperature gauge sensor lead.
32.Release camshaft sensor multiplug from bracket
and disconnect multiplug.
33.Disconnect oil pressure switch Lucar.
34.Disconnect air intake temperature sensor
multiplug.
35.Disconnect 8 injector multiplugs.
36.Remove 4 nuts securing harness brackets to
inlet manifold.
37.Release harness brackets.
38.Remove bolts securing gearbox breather pipes
to engine lifting bracket.

4.0 V8
5
REPAIR 77.Release sensor/shield and remove.
78.Disconnect sensor multiplug.
79.Remove sensor.
80.Remove starter motor heatshield.
See
ELECTRICAL, Repair, Starter Motor
Heatshield - 4.0 V8
81.Disconnect solenoid Lucar.
82.Disconnect RH and LH knock sensor multiplugs.
See FUEL SYSTEM SFI, Repair, Knock
Sensor
83.Release harness from engine.
84.Remove nut securing handbrake cable
heatshield.
85.Release speed sensor lead from clip on
heatshield.
86.Remove heatshield.
87.Disconnect top oil cooler pipe union from
transmission.
88.Release union.
89.Remove 'O' ring and discard.
90.Plug pipe and transmission.
91.Remove bolt securing oil cooler pipe bracket tosump. Collect spacer.
92.Remove 3 bolts from top of bell housing.
93.Collect 2 harness brackets.
94.Remove 2 bolts, LH and RH side of bell housing.
95.Remove centre LH bell housing bolt using long
extension.
96.Remove 2 lower bolts from bell housing.
97.Fit suitable wooden block in access plate hole to
retain torque converter.
98.Secure block with cover plate and tighten one
cover plate bolt.
99.Support gearbox on a jack.
100.Lower ramp.
101.Position lifting chains and attach hooks to engine
lifting eyes.
102.Raise engine.
103.Raise jack.
104.Break engine to gearbox joint.
105.Raise engine.

12ENGINE
6
REPAIR
106.Remove top starter bolt securing engine earth
cable.
107.Remove nut securing kick-down cable clip to LH
cylinder head.
108.With assistance, raise engine, move aside all
pipes and wires. Move engine clear of vehicle.
109.Lower engine onto bench.
Refit
110.Clean engine and gearbox mating faces.
111.Clean dowel and dowel holes.
112.With assistance raise engine off bench. Lower
and guide engine into engine compartment
ensuring no wires or pipes become trapped.
113.Position clip securing kick-down cable to LH
cylinder head.
114.Fit and tighten nut.
115.Position engine earth cable and secure to starter
with top bolt. Tighten to
45 Nm.
116.Lower engine.
117.With assistance, engage engine with gearbox.
118.Fit 3 bottom bell housing bolts. Tighten to
46
Nm.
119.Lower jack supporting gearbox.
120.Lower engine onto mounting brackets.
121.Fit centre RH bell housing bolt.
122.Fit centre LH bell housing bolt.
123.Fit harness brackets to 2 top bell housing bolts.
124.Fit bolts. Tighten to
46 Nm.
125.Remove plugs from tranmission and oil cooler
pipe.
126.Clean pipe, lubricate NEW 'O' ring and fit to
pipe.
127.Connect pipe to transmission and secure with
union. Tighten to
30 Nm.
128.Align pipe bracket to sump, position spacer and
fit bolt. Tighten to
18 Nm.
129.Fit heatshield and secure with nut.
130.Secure transducer lead to clip on heatshield.131.Slacken bell housing access plate bolt.
132.Move plate aside.
133.Remove block.
134.Align drive plate and torque converter.
135.Fit 2 torque converter bolts.
136.Rotate engine and fit second 2 bolts. Tighten to
45 Nm.
137.Rotate engine and tighten first 2 bolts to Tighten
to
45 Nm.
138.Clean cover plate and mating face.
139.Position cover plate and fit bolts. Tighten to
45
Nm.
140.Position access plate.
141.Fit 2 remaining bolts and tighten all bolts to
Tighten to
9 Nm.
142.Position engine harness around engine.
143.Connect knock sensor multiplug.
144.Connect starter solenoid Lucar.
145.Position starter motor heatshield and secure clip
to solenoid.
146.Align shield bracket to engine mounting bracket
and fit bolt. Tighten to
9 Nm.
147.Clean crankshaft sensor mating faces.
148.Position sensor and connect multiplug.
149.Position/align sensor and shield to backplate. Fit
bolts. Tighten to
6 Nm.
150.Fit tie bar, align to transmission and fit bolts.
Tighten to
25 Nm.
151.Fit tie bar securing nut. Tighten to45 Nm.
152.Fit catalytic converter/front pipe assembly.See
EMISSION CONTROL, Repair, Catalytic
Converter/Front Pipe - 4.0 V8
153.Raise engine.
154.Fit RH mounting rubber.
155.Move engine over.
156.Fit LH mounting rubber.
157.Lower engine.
158.Disconnect hoist.
159.Fit engine mounting nuts. Tighten to
55 Nm.
160.Remove plugs from steering pump and steering
box.
161.Clean PAS hose unions.
162.Lubricate 'O' rings and fit to hose unions.
163.Position hose.
164.Align unions to pump and steering box. Tighten
14mm thread to
15 Nm, 16mm thread to
Tighten to
20 Nm.
165.Remove plugs from feed hose and PAS pump.
166.Connect hose to pump and tighten clip.
167.Untie compressor and position to engine
bracket.
168.Position heatshield and fit bolts. Tighten to
25
Nm.
169.Connect compressor multiplug.
170.Position drive belt.

4.0 V8
7
REPAIR 171.Route drive belt around pulleys.
172.Pivot tensioner downwards.
173.Align belt to tensioner and release tensioner.
174.Connect battery positive lead and tighten.
175.Secure terminal cover.
176.Align gearbox breather pipe, clip to engine lifting
eye and fit bolt. Tighten to
9 Nm.
177.Align and secure engine harness brackets to
inlet manifold and fit nuts. Tighten to
9 Nm.
178.Connect injector multiplugs.
179.Connect air intake temperature sensor multiplug.
180.Connect fuel temperature sensor multiplug.
181.Connect coolant temperature multiplug.
182.Connect temperature gauge connector.
183.Connect oil pressure switch Lucar.
184.Connect camshaft sensor multiplug and secure
to bracket.
185.Fit ignition coil bracket.
See FUEL SYSTEM
SFI, Repair, Ignition Coils
186.Position heater hose/pipe assembly.
187.Connect hose to inlet manifold.
188.Align pipe to bracket and fit bolt. Tighten to
9
Nm.
189.Tighten hose clip.
190.Connect heater return hose and tighten clip.
191.Remove plugs from fuel feed and return hose
connections.
192.Clean feed unions.
193.Connect return hose and tighten clip.
194.Connect feed hose union and tighten.
195.Remove cloth.
196.Connect purge hose.
197.Connect leads to generator, tighten terminal nuts
and fit cover.
198.Connect sensing Lucar.
199.Connect servo vacuum hose.
200.Position expansion tank and secure with fixings.
201.Connect hose and tighten clip.
202.Lower ramp.
203.Fit mass air flow sensor.
See FUEL SYSTEM
SFI, Repair, Mass Air Flow Sensor (MAF
Sensor)
204.Fit plenum chamber.See FUEL SYSTEM SFI,
Repair, Plenum Chamber
205.Fit radiator.See COOLING SYSTEM, Repair,
Radiator
206.Fit bonnet.See CHASSIS AND BODY, Repair,
Bonnet [Hood]
207.Reconnect battery negative lead.
208.Bleed power steering system.
See STEERING,
Repair, Power Steering System - Bleed
209.Drain engine oil and refill.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids - USA
Vehicles
210.Start engine. Check for fuel, coolant and oil
leaks.FRONT COVER GASKET
Service repair no - 12.65.04 - Front Cover Gasket
Remove
1.Disconnect battery negative lead.
2.Drain cooling system.
See COOLING SYSTEM
V8, Adjustment, Coolant
3.Remove radiatorSee COOLING SYSTEM,
Repair, Radiator
4.Remove water pump pulley.See COOLING
SYSTEM, Repair, Viscous Coupling, Fan
Blades, Pulley and Fan Cowl
5.Slacken bottom hose clip. Remove hose from
water pump.
6.Raise vehicle on ramp.
7.Disconnect oil cooler hoses from front cover and
position aside. Plug hoses and connections.
8.Disconnect Lucar from oil pressure switch.

12ENGINE
8
REPAIR
9.Disconnect multiplug from camshaft sensor.
See FUEL SYSTEM SFI, Repair, Camshaft
Position Sensor (CMP Sensor)
10.Remove 9 bolts securing front cover.
11.Remove 2 bolts securing sump to front cover.
12.Loosen 4 bolts securing sump adjacent to front
cover (2 each side).
13.Release front cover assembly.
14.Remove oil seal.
15.Remove and discard gasket.Refit
16.Clean sealant from threads of cover bolts.
17.Clean old sealant from front cover and block joint
face.
CAUTION: Use a plastic scraper.
18.Apply Hylosil jointing compound to gasket
position on cover and block.
19.Fit new gasket to block face.
20.Ensure oil seal register in cover is clean.
21.Lubricate outer face of NEW oil seal.
22.Using LRT-12-089, fit seal to cover.
23.Lubricate oil pump drive gear and position in
pump with groove away from engine.
24.Locate alignment tool LRT-12-090 on front cover
and oil pump drive gear.
25.Position front cover over crankshaft.
26.Press and rotate tool to engage drive gear until
drive gear keyway aligns with Woodruff key.
27.Fit cover to cylinder block.