automatic transmission LAND ROVER DISCOVERY 1995 Workshop Manual

GENERAL SPECIFICATION DATA
9
INFORMATION TRANSMISSION 3.9 V8i
Manual gearbox
Type R380 Single helical constant mesh.......................................................................
Speeds 5 forward 1 reverse all synchromesh.............................................................................
Clutch
Make and type Borg and beck diaphram type..................................................................
Clutch plate diameter 266.5mm........................................................
Automatic gearbox
Type ZF4HP Four speed and reverse with fluid torque converter.....................................................................
Transfer box
Type LT230T Two speed reduction on main gearbox output, front....................................................................
and rear drive permanently engaged via a lockable
differential.
Propeller shafts
Type
Front Tubular 51mm diameter.................................................................................
Front - Catalyst vehicles Solid bar 28.6mm diameter...................................................
Rear Tubular 51mm diameter.................................................................................
Universal joints Open type Hookes O3EHD.................................................................
Rear axle
Type Spiral bevel, fully floating shafts.................................................................................
Ratio 3.54:1.................................................................................
Front axle
Type Spiral bevel, enclosed constant velocity joints, fully.................................................................................
floating shafts
Angularity of universal joint on full lock 32° ............................
Ratio 3.54:1.................................................................................

GENERAL SPECIFICATION DATA
21
INFORMATION TRANSMISSION - 300 Tdi
Manual gearbox
Type R380 Single helical constant mesh.......................................................................
Speeds 5 forward 1 reverse all synchromesh.............................................................................
Automatic gearbox
Type ZF4HP Four speed and reverse with fluid torque converter.....................................................................
Transfer box
Type LT230T Two speed reduction on main gearbox output. Front....................................................................
and rear drive permanently engaged via a lockable
differential

MAINTENANCE
9
MAINTENANCE
CHECK CONDITION OF DRIVE BELT - V8i - Tdi -
Mpi
RENEW - V8i - Tdi
Renew drive belt V8i.See ENGINE, Repair, Drive
Belt Renew
Renew drive belt Tdi.See ENGINE, Repair, Drive
Belt Renew
RENEW - Mpi
1.Check condition of drive belt, renew a belt that
shows signs of wear, splitting or oil
contamination.
2.Check belt length indicator, belt must be
renewed before indicator reaches R.H. end of
slot.
3.Use 15mm ring wrench on bolt and hold
tensioner pulley fully clockwise.
4.Release drive belt from tensioner pulley and
remove ring wrench.
5.Remove belt from between pulleys.
6.Clean drive belt pulley grooves and ensure
grooves are not damaged.
7.Fit new drive belt around pulley, except
tensioner pulley, ensuring all grooves are
correctly engaged.
8.Hold tensioner pulley fully clockwise and fit drive
centrally around tensioner pulley.
RENEW ANCILLARY DRIVE BELTS
CHECK/TOP UP AUTOMATIC TRANSMISSION
FLUID LEVEL
NOTE: Transmission fluid level is checked
when fluid is cold with engine idling in
neutral.
1.Ensure vehicle is on level ground.
2.Check fluid level registers between MAX and
MIN marking on dipstick.

10MAINTENANCE
18
MAINTENANCE
ABS VEHICLES - CHECK ROAD WHEEL SPEED
SENSOR ELECTRICAL HARNESS FOR DAMAGE
RENEW OXYGEN SENSORS
See EMISSION CONTROL, Repair, Heated
Oxygen Sensor (HO2S)
RENEW CATALYTIC CONVERTERS
See MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust System Complete
REPORT ANY UNUSUAL FEATURES OF VEHICLE
CONDITION AND ADDITIONAL WORK REQUIREDCARRY OUT ROAD TEST
For details of dynamometer testing.See
INTRODUCTION, Information, Dynamometer
Testing - Non Anti-lock brake vehicles See
INTRODUCTION, Information, Dynamometer
Testing - Vehicles with Anti-lock brakes (ABS)
Check following items:
1.Inhibitor switch only operates in P and N.
2.Engine for excessive noise.
3.Clutch for slip, judder or spin.
4.Automatic gear selection/shift speeds.
5.Gear selection/noise - high/low range.
6.Steering for abnormal noise/effort.
7.Steering for free play.
8.All instruments, gauges and warning indicators.
9.Heater and air conditioning systems.
10.Heated rear screen.
11.Shock absorbers - ride irregularities.
12.Foot brake, on emergency stop, pulling to one
side, binding, pedal effort.
13.Parkbrake efficiency.
14.Seat reclining and latching.
15.Fully extend seat belt, check operation of
retraction and latching. Inertia belts lock when
snatched or vehicle on slope.
16.Road wheel balance.
17.Transmission for vibrations.
18.Body noises, squeaks and rattles.
19.Excessive exhaust smoke.
20.Engine idle speed.
21.Endorse service record.
22.Report any unusual features of vehicle condition
and additional work required.
ENDORSE SERVICE RECORD

Tdi
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.

V8i
3
FAULT DIAGNOSIS ENGINE STARTING PROBLEMS
Engine fails to crank in park or neutral (Automatic
Transmission)
1.Is battery in good state of charge?
NO -
See INTRODUCTION, Information,
Jump Starting
YES - Continue.
2.Is automatic transmission inhibitor switch faulty
or gear selection linkage incorrectly adjusted?
YES -
See AUTOMATIC GEARBOX, Repair,
Inhibitor Switch
,
NO -
See Electrical Trouble Shooting
Manual.
If problem is not diagnosed repeat tests, starting
at 1.
Engine fails to crank (Manual Transmission)
1.Is battery in good state of charge?
NO -
See INTRODUCTION, Information,
Jump Starting
YES -See Electrical Trouble Shooting
Manual.
If problem is not diagnosed repeat tests, starting
at 1.
Engine cranks but fails to start
1.Is the cranking speed fast enough (120 rpm)?
NO -
See INTRODUCTION, Information,
Jump Starting
If necessary also.See Electrical Trouble
Shooting Manual.
YES - Continue.
2.Is there combustion in any cylinder?
NO -
See ELECTRICAL, Fault diagnosis,
Lucas Constant Energy Ignition
System - V8i See Electrical Trouble
Shooting Manual.
YES - Continue.
3.Are the 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 See
EMISSION CONTROL, Description and
operation, Emission control
If problem is not diagnosed repeat tests, starting
at 2.ENGINE RUNNING PROBLEMS
Engine runs at high speed but will not idle (stops)
Engine idle speed erratic Engine starts but stops
immediately
Engine stalls Engine misfires/hesitation
1.Multiport fuel injection.
See Electrical Trouble
Shooting Manual. See ELECTRICAL, Fault
diagnosis, Lucas Constant Energy Ignition
System - V8i
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.
2.Are HT leads correctly routed and clipped?
NO -
See ELECTRICAL, Repair, Distributor
- V8i
YES - Continue.
3.Is 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 See
EMISSION CONTROL, Description and
operation, Emission Control
If problem is not diagnosed repeat tests, starting
at 1.
Engine lacks power/poor performance
1.Is throttle travel restricted or cable incorrectly
adjusted?
YES - Check thickness of carpets.
See FUEL
SYSTEM, Repair, Throttle Cable See
FUEL SYSTEM, Repair, Accelerator
Pedal
NO - Continue.
2.Are the Ignition and Multiport Fuel Injection
systems in order?
NO -
See Electrical Trouble Shooting
Manual.A1 See ELECTRICAL, Fault
diagnosis, Lucas Constant Energy
Ignition System - V8i See
ELECTRICAL, Repair, Distributor - V8i
YES - Continue.

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
11
REPAIR FLEXIBLE DRIVE PLATE AND RING GEAR
Service repair no - 12.53.13
Remove
1.Remove transmission.
See AUTOMATIC
GEARBOX, Repair, LT230T Transfer Gearbox
with Automatic Gearbox Assembly - V8i
2.Remove flexible drive plate and ring gear
assembly.
See V8i Overhaul Manual.
Refit
3.Clean all components for reassembly.
4.Fit ring gear and flexible drive plate assembly.
See V8i Overhaul Manual.
5.Fit transmission.CRANKSHAFT REAR OIL SEAL
Service repair no - 12.21.20
1.Automatic transmission, remove drive plate.
See Flexible Drive Plate and Ring Gear
OR manual transmission, remove flywheel.See
Flywheel
2.Remove sump.See Oil Sump
3.Remove rear main bearing cap.
4.Remove cross seals from cap.
5.Remove crankshaft rear oil seal.
6.Clean main bearing cap and oil seal area of
block.
7.Fit new cross seals to bearing cap.
8.Apply Hylomar SQ32M to block as illustrated.
9.Lubricate bearing shell and cross seals using
clean engine oil.
10.Fit bearing cap, do not tighten bolts.
11.Ensure cap is fully home and seated squarely on
the block.