LAND ROVER DISCOVERY 1995 Manual Online

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.

Tdi
1
REPAIR DRIVE BELT INFORMATION
A single 'serpentine drive belt' drives all the
ancilliaries bar the air conditioning compressor, which
has a separate drive belt. It is essential that the belts
are fitted exactly as shown. It should also be noted
that the water pump/viscous fan is driven in a
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 160,000 kilometres, 96,000 miles or eight 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.

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.

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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.

12ENGINE
4
REPAIR 22.Disconnect feed pipe and spill return pipe from
injector pump.
23.Disconnect both pipes from fuel lift pump.
24.Disconnect servo hose from vacuum pump.
25.Remove three retaining nuts and disconnect
exhaust down pipe.
26.Remove oil cooler pipes from oil filter adaptor.
27.If automatic transmission is fitted, disconnect
feed and return pipes at gearbox oil cooler.
Remove retaining bracket from LH side of
cylinder block and release both oil cooler pipes.
28.Support gearbox.
29.Disconnect ground strap from starter motor.
30.On vehicles with automatic transmission, remove
fixings and detach drive plate housing access
panel and gasket.31.Working through drive plate housing aperture
mark the torque convertor and drive plate to
facilitate reassembly.
32.Remove the four convertor to flexible drive
securing bolts, rotating crankshaft to gain access
to each individual bolt.
33.Fit engine lifting bracket to the two RH rear
cylinder head fixing bolts.
34.Using suitable hoist, fit lifting chains to engine.
35.Remove four bolts, from both sides, securing
front engine mounting brackets to cylinder block.
36.Remove two bolts, from both sides, securing
front engine mounting bracket to bell housing.

Tdi
5
REPAIR
37.Remove nuts and plain washers securing front
engine mountings to chassis,and lift both engine
mounting bracket assemblies from vehicle.
38.Remove engine to bell housing fixings. Leave
starter motor attached.
39.Raise engine to separate from transmission.
40.Check all connections to engine have been
disconnected.
41.Remove engine.Refit
42.Apply Hylomar to mating faces of bell housing.
Lubricate splines of gearbox primary pinion with
Rocol MV 3.
If automatic transmission, coat the four drive
plate to torque convertor bolts with Loctite 290.
Tighten to
39 Nm.
43.Lower engine and locate with transmission.
If manual transmission locate primary pinion into
clutch and engage bell housing dowels. Fit
engine to bell housing fixings. Tighten to
40 Nm.
If automatic transmission fixings. Tighten to46
Nm.
44.Raise engine, refit front engine mounting
brackets to cylinder block and bell housing.
45.Remove gearbox support and lower engine.
46.Tighten front engine mountings to chassis
fixings. Tighten to
45 Nm.
47.Reverse removal procedure. 1 to 37.

12ENGINE
6
REPAIR CRANKSHAFT PULLEY
Service repair no - 12.21.01
Remove
1.Disconnect battery negative lead.
2.Drain coolant.
3.Remove top hose from radiator.
4.Remove intercooler to induction manifold hose.
5.Remove viscous fan and coupling.
See
COOLING SYSTEM, Repair, Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
6.Remove fan cowl.
7.Remove drive belt.
See Drive Belt Renew
8.Fit crankshaft pulley retainer LRT-12-080 and
secure with four bolts.
9.Remove crankshaft pulley retaining bolt using
socket and suitable long bar.
10.Remove pulley retainer.
11.Remove pulley, if necessary using extractor
LRT-12-049 with thrust pad from LRT-12-031.Refit
12.Refit in reverse order, lightly greasing pulley
spigot. Tighten to
80 Nm + 90°.

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REPAIR FRONT COVER PLATE
Service repair no - 12.65.01
Remove
1.Disconnect battery negative lead.
2.Drain coolant.
3.Remove top hose from radiator.
4.Remove inter-cooler to induction manifold hose.
5.Remove viscous coupling and fan.
See
COOLING SYSTEM, Repair, Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
6.Remove fan cowl.
7.Remove drive belt.
See Drive Belt Renew
8.Remove crankshaft pulley.See Crankshaft
Pulley
9.Remove 14 bolts securing front cover plate,
noting top two bolts also retain thermostat hose
clips.
10.Remove cover plate complete with gasket.
11.Remove small gasket from centre bolt boss.
Seal replacement
12.Remove worn seal from cover and clean recess.
13.Support cover and fit new seal, open side fitted
into recess, using special tool LRT-12-077.
Refit
14.Refit in reverse order to removal using new
gaskets, fitting the securing bolts as shown in
illustration ST3475. Tighten to
25 Nm.

12ENGINE
8
REPAIR CAMSHAFT DRIVE BELT AND GEARS
Service repair no - 12.65.18
TIMING BELT
Remove
1.Remove front cover plate.
See Front Cover
Plate
2.Position engine at TDC on No. 1 cylinder.
3.If manual gearbox: Remove blanking plug from
flywheel housing and insert timing tool
LRT-12-044. If EDC - timing tool LRT-12-085
must be used.
If automatic gearbox:Sited to the rear of the
engine sump on engine backplate is a blanking
plate. Remove 2 blanking plate bolts and insert
timing tool LRT-12-044 into the larger bolt hole.
4.Engage timing tool pin with slot in flywheel.
5.Check correct alignment of timing mark on
camshaft gear and that crankshaft key aligns
with cast arrow on housing.
6.Insert pin from special tool LRT-12-045 in
injection pump gear and through into pump
flange.
NOTE: If the camshaft gear is to be
removed during these operations its
retaining bolt should be slackened before
the timing belt is removed.
7.Slacken belt tensioner bolt.
8.Remove idler pulley.
9.Remove timing belt.
NOTE: During use, a belt develops a wear
pattern relative to its running direction, if
the original belt is to be re-used it must be
refitted so that it rotates in the original direction.
CAUTION: Belts must be stored on edge
on a clean surface and in such a manner
that bends are not less than 50 mm radius.
Do not bend belts at an acute angle or radius of
less than 50 mm, otherwise premature failure
could result.
10.Mark belt direction of rotation, using soft chalk,
to ensure correct refitment.

Tdi
9
REPAIR Belt tensioner
NOTE: The belt tensioner need only be
removed if it is being replaced or for
access purposes to remove front cover.
11.Remove securing bolt and withdraw tensioner
complete with spacer.
Crankshaft gear/front cover oil seal
12.If the crankshaft gear cannot be removed by
hand, use special tool LRT-12-078 with main
body and thrust button from special tool
LRT-12-031 as illustrated ST3478M. Withdraw
gear complete with 'O' ring seal.
13.If necessary prise out oil seal from front cover.
14.Lubricate a new crankshaft oil seal with clean
engine oil.
15.With lip side leading, drive-in seal squarely using
special tool LRT-12-079.
16.Lubricate new 'O' ring seal with petroleum jelly
and slide onto shaft, taking care not to damage
seal on the woodruff keys.
17.Fit crankshaft gear, tap fully home ensuring 'O'
ring seal is properly seated.
CAMSHAFT GEAR/FRONT COVER OIL SEAL
Service repair no - 12.13.05
18.Remove centre bolt from camshaft gear and
withdraw gear.
19.Remove existing oil seal from front cover using
special tool LRT-12-038.
20.Lubricate a new camshaft oil seal with clean
engine oil.