gas type LAND ROVER DISCOVERY 1995 Workshop Manual

ENGINE TUNING DATA
1
INFORMATION ENGINE 3.9 V8i
Type3.9 Litre V8i .................................................................................
Firing order1-8-4-3-6-5-7-2 .....................................................................
Cylinder Numbers
Left bank 1-3-5-7..........................................................................
Right bank 2-4-6-8........................................................................
No 1 Cylinder locationPulley end of left bank ...................................................
Timing marksOn crankshaft vibration damper ..................................................................
Spark plugs
Make/type(8.13:1 Compression) Champion RN11YCC......................................
Gap 0.84-0.96mm..................................................................................
Make/type(9.35:1 Compression) Champion RN11YCC......................................
Gap 0.84-0.96mm..................................................................................
Coil
Make/type Bosch 0-221-122-392,........................................................................
Compression ratio8.13:1 or 9.35:1 .........................................................
Fuel injection systemLucas 14 CUX Hot-wire air flow sensor system .....................................................
electronically controlled
Valve Timing Inlet Exhaust
Opens 32°BTDC .............................................................................. 70°BBDC
Closes 73°ABDC .............................................................................. 35°ATDC
Duration 285° ........................................................................... 285°
Valve peak 104°ATDC ....................................................................... 114°BTDC
Idle speed - controlled by MFI system
- all loads off in neutral 665 to 735 rev/min.....................................................
- auto gearbox in gear, air con operating 650±28 rev/min .........................
- auto gearbox in gear, air con off 600±28 rev/min ....................................
- manual gearbox 700±28 rev/min .............................................................
- manual gearbox, air con operating 750±28 rev/min ................................
Base idle speed525±25 rev/min
See FUEL SYSTEM, Fault..............................................................
diagnosis, Base idle speed setting.
Ignition Timing - dynamic at 800 rev/min max,
vacuum disconnected
8.13:1 compression, non catalyst 2°BTDC±1° .....................................
9.35:1 compression, non catalyst 4°BTDC±1° .....................................
9.35:1 compression, catalyst 5°BTDC±1° ............................................
Exhaust gas
CO content at idle 0.5 to 1.0% max.............................................................

05ENGINE TUNING DATA
2
INFORMATION Distributor
Make/type Lucas 35DLM8 electronic........................................................................
Rotation Clockwise............................................................................
Air gap 0.20-0.35mm..............................................................................
Part number Lucas Rover
8.13:1, non catalyst 42584A.......................................................... ERR 4753
9.35:1, non catalyst 42582A.......................................................... ERR 4754
9.35:1, catalyst 42583A................................................................. ERR 4755
Centrifugal Advance
Decelerating check-vacuum hose disconnected
Distributor rpm decelerating speeds
8.13:1 non catalyst
2000 Distributor advance................................................................................. 5°30' to 8°30'
1400 ................................................................................. 6°18' to 8°30'
800 ................................................................................... 2°to 4°
9.35:1 non catalyst
2200 Distributor advance................................................................................. 7°to 10°
1400 ................................................................................. 7°48' to 10°
650 ................................................................................... 1°to 3°
9.35:1 catalyst
2200 Distributor advance................................................................................. 5°30' to 8°30'
1400 ................................................................................. 6°18' to 8°30'
800 ................................................................................... 2°to 4°
Fuel
8.13:1, non catalyst 91 RON minimum unleaded..........................................................
9.35:1, non catalyst 95 RON minimum unleaded..........................................................
9.35:1, catalyst 95 RON minimum unleaded.................................................................
USA-Premium unleaded (PUG) CLC or AKI 90 octane minimum.......................................
95 RON minimum
Australian market variations
Fuel 91 RON minimum unleaded..................................................................................
Compression ratio 8.13:1............................................................
Spark plug Champion RN12YC........................................................................
Spark plug gap 0.84-0.96mm (0.033-0.038 in).................................................................
Ignition Timing at 800 rev/min max
(vacuum pipe disconnected) 2°BTDC±1° ............................................
Exhaust gas idle CO 1% max (hot)........................................................

05ENGINE TUNING DATA
6
INFORMATION ENGINE - Mpi - 2.0 LITRE
Type/Capacity 20 T4/1994 cm
3..................................................................
Firing order 1-3-4-2.......................................................................
Compression ration 10 : 1..........................................................
Idle speed:
Controlled by ECM 875±50 rev/min ...........................................................
Exhaust gas Co content:
- Catalyst 0.5% Max. Not adjustable..................................................................
- Non Catalyst 1,0±25% adjustable using Testbook .........................................................
Ignition
Knock sensor ADU 8229...................................................................
Crankshaft sensor ADU 7340............................................................
Ignition Coils
Type NEC 10049.................................................................................
Primary resistance at 20°C 0.4 to 0.61 ohm..............................................
Consumption - engine idling 0.25 to 0.75 amp.............................................
Spark Plugs
Type/Gap GSP 6662 -0,85 mm.........................................................................
Multipoint Fuel Injection
Type Indirect multipoint injection with engine control module.................................................................................
using speed/density method of air flow measurement.
Fuel pressure regulator MKW 10011....................................................
Fuel pump delivery pressure 2.3 - 2.5 bar............................................
Throttle potentiometer voltage
- Throttle closed 0 - 1 Volt......................................................
- Throttle open 4 - 5 Volts.........................................................
MEMS engine control module MKC 10121..........................................
95 RON minimum -UNLEADEDfuel
CAUTION: Do not use LEADED fuel as it will
damage the catalyst. Serious damage to the
engine may occur if a lower octane number fuel
than that recommended is used.

Tdi
11
REPAIR Timing belt fitting and tensioning
NOTE: It is important that belt tensioning
is carried out carefully and accurately. The
following procedure involves tensioning
the belt twice to ensure that it is equally tensioned
between each gear. New and original belts are
tensioned to different figures.
28.Ensure timing marks are correctly aligned, pin
from special tool LRT-12-045 is correctly
inserted in injection pump gear and timing tool
LRT-12-044 (LRT-12-085 if EDC) is fitted to
flywheel housing with pin located in flywheel slot.
Or if automatic: Timing tool LRT-12-044 is fitted
to engine backplate and pin located in ring gear.
29.Fit belt observing rotational marks made during
removal. Feed belt over gears keeping it tight on
drive side.
30.Fit idler pulley.
31.Slacken injection pump gear retaining bolts.
32.Adjust belt to correctly sit in gears.
33.Slacken belt tensioner securing bolt to finger
tight.
34.Insert 13 mm square drive extension bar in
tensioner plate.
NOTE: Belt tensioning should be carried
out using a dial type torque meter having a
range not exceeding
60 Nm.The torque
meter should be used in the almost vertical
position.
35.Apply a tension of
14 to 16 Nmfor a new belt or
11 to 13 Nmfor an original belt. When tension
is correct tighten clamp bolt.
36.Tighten injection pump gear bolts.
37.Remove pin from injection pump gear.
38.Disengage timing pin from timing slot in flywheel
or ring gear.
39.Rotate crankshaft one and three quarter turns in
a clockwise direction; then continue rotation until
timing pin in timing tool can be engaged with slot
in flywheel or ring gear.
40.Disengage timing pin.
41.Insert pin from special tool LRT-12-045 in
injection pump gear and through into pump
flange.
42.Slacken injection pump gear retaining bolts.
43.Slacken tensioner and retension belt.
44.Tighten injection pump gear retaining bolts.
45.Remove pin from injection pump gear.
46.Remove timing tool and refit plug.
47.Fit front cover plate using new gaskets.
See
Front Cover Plate

Tdi
1
DESCRIPTION AND OPERATION DESCRIPTION
Air intake
The air cleaner is positioned to the right of the engine
and connected by hoses to a cold air intake duct and
the turbocharger inlet. A crankcase breather hose is
fitted between the air cleaner and the separator.
A single stage turbocharger, fitted between the
exhaust manifold and exhaust pipe, is connected by
hoses to the air cleaner and to an intercooler mounted
on the right of the radiator. The intercooler is
connected by a hose to the inlet manifold.
Fuel system
A 89 litre fuel tank is mounted at the rear of the
vehicle beneath the load space floor. The tank is
vented by a 2 way valve in the filler cap.
A mechanical lift pump, driven by the camshaft, is
mounted on the side of the engine.
A fuel filter, fitted with a replaceable element and
incorporating a water separator, is positioned on the
LH side of the bulkhead.
A Bosch Type injection pump, incorporating a cold
start advance unit and a high idle setting is mounted
on the LH side of the engine and is directly driven by
gears from the crankshaft. The pump meters and
distributes fuel to 4 pintle type injectors located in
pre-combustion chambers in the cylinder heads.
A return line passes excess fuel from the injection
pump and injectors back to the fuel tank.
Glow plugs
Four glow plugs are located in the cylinder head,
directly below each injector.Exhaust gas recirculation (EGR)
Exhaust gas recirculation is controlled by the EGR
control unit mounted in the passenger compartment
on the RH 'A' post behind the fascia and receives the
following inputs:
a. Engine temperature from coolant temperature
transmitter in No. 4 cylinder head.
b. Throttle position from the sensor on the injection
pump.
c. Engine speed from the tachometer.
d. EGR valve lift position.
When all correct signals are received, the EGR
solenoid allows vacuum to open the EGR valve and
recirculate a portion of the exhaust gas.

Tdi
1
FAULT DIAGNOSIS ENGINE OVERHEATING
Before conducting any cooling system diagnosis:
See
Description and operation, Engine Cooling
1.Is coolant level correct?
NO - Allow engine to cool, top up level to
expansion tank seam.
YES - Continue.
2.Is drive belt tension correct?
NO -
See ENGINE, Repair, Compressor
Drive Belt
YES - Continue.
3.Is coolant in radiator frozen?
YES - Slowly thaw and drain system.
See
Adjustment, Coolant
NO - Continue.
4.Is air flow through radiator restricted or blocked?
YES - Apply air pressure from engine side of
radiator to clear obstruction.
NO - Continue.
5.Are there any external leaks, from water pump,
engine gaskets, fast idle thermostat or the heater
unit?
YES - Investigate and rectify.
See Adjustment,
Coolant
NO - Continue.
6.Are fan blades fitted correct way round, concave
side towards engine?
NO - Rectify.
YES - Continue
7.Is viscous unit operating correctly?
See
Description and operation, Viscous Fan
NO - Renew.See Repair, Viscous
Coupling, Fan Blades, Pulley and Fan
Cowl
YES - Carry out a pressure test on radiator cap
and system. Check thermostat type,
operation and correct fitting.
See Repair,
Thermostat
If pressure test leads you to suspect coolant
leakage across gaskets, go to check 10,
otherwise: Continue.8.Are the air conditioning fans operating correctly?
See Electrical Trouble Shooting Manual.
NO - Rectify.
YES - Continue.
9.Is temperature sender and gauge giving
accurate readings?
NO - Sustitute parts and compare readings.
YES - Continue.
10.Carry out cylinder pressure test to determine if
pressure is leaking into cooling system causing
over pressurising and loss of coolant.
If problem is not diagnosed, check the coolant system
for engine oil contamination and engine lubrication
system for coolant contamination.
If only the coolant system is contaminated suspect a
cylinder head gasket.
If both systems are contaminated, suspect the
radiator.
If only the lubrication system is contaminated with
coolant, suspect leakage past cylinder liner seals or
cylinder head gasket.

V8i
1
FAULT DIAGNOSIS ENGINE OVERHEATING
Before conducting any cooling system diagnosis:
See
Description and operation, Engine Cooling
1.Is coolant level correct?
NO - Allow engine to cool, top up level to
expansion tank seam.
YES - Continue.
2.Is drive belt tension correct?
NO -
See ENGINE, Repair, Drive Belt -
Check Tension
YES - Continue.
3.Is ignition timing correct?
NO -
See ELECTRICAL, Adjustment,
Ignition Timing
YES - Continue.
4.Is coolant in radiator frozen?
YES - Slowly thaw and drain system.
See
Adjustment, Coolant Requirements
NO - Continue.
5.Is air flow through radiator restricted or blocked?
YES - Apply air pressure from engine side of
radiator to clear obstruction.
NO - Continue.
6.Are there any external leaks, from water pump,
engine gaskets or the heater unit?
YES - Investigate and rectify.
See Adjustment,
Coolant Requirements
NO - Continue.
7.Are fan blades fitted correct way round, concave
side towards engine?
NO - Rectify.
YES - Continue.8.Is viscous unit operating correctly?
See
Description and operation, Viscous Fan
NO - Renew.See Repair, Viscous
Coupling, Fan Blades, Pulley and Fan
Cowl
YES - Carry out a pressure test on radiator cap
and system. Check thermostat type,
operation and correct fitting
See Repair,
Thermostat
If pressure test leads you to suspect coolant
leakage across gaskets, go to check 11,
otherwise: Continue.
9.Are the air conditioning fans operating correctly?
See Electrical Trouble Shooting Manual.K5
NO - Rectify.
YES - Continue.
10.Is temperature sender and gauge giving
accurate readings?
NO - Substitute parts and compare readings.
YES - Continue.
11.Carry out cylinder pressure test to determine if
pressure is leaking into cooling system causing
over pressurising and loss of coolant.
If problem is not diagnosed, check the coolant system
for engine oil contamination and engine lubrication
system for coolant contamination.
If the coolant only, or both systems are contaminated,
suspect cylinder head gaskets or radiator.
If only the lubrication stystem is contaminated with
coolant, suspect inlet manifold or front cover gaskets.

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.

82AIR CONDITIONING
2
ADJUSTMENT SERVICING PRECAUTIONS
Care must be taken when handling refrigeration
system components. Units must not be lifted by their
hoses, pipes or capillary lines. Hoses and lines must
not be subjected to any twist or stress. Ensure that
hoses are positioned in their correct run before fully
tightening the couplings, and ensure that all clips and
supports are used. Torque wrenches of the correct
type must be used when tightening refrigerant
connections to the stated value. An additional wrench
must be used to hold the union to prevent twisting of
the pipe.
Before connecting any hose or pipe ensure that
refrigerant oil is applied to the seat of the new '0' ring
but not to the threads.
Check the oil trap for the amount of oil lost.
All protective plugs on components must be left in
place until immediately prior to connection.
The receiver/drier contains desiccant which absorbs
moisture. It must be positively sealed at all times.
CAUTION: Whenever the refrigerant
system is opened, the receiver/drier must
be renewed immediately before evacuating
and recharging the system.
Use alcohol and a clean cloth to clean dirty
connections.
Ensure that all new parts fitted are marked for use
withR134a.
Refrigerant oil
Use the approved refrigerant lubricating oil:
Nippon Denso ND-OIL 8
Unipart R134a ND-OIL8
CAUTION: Do not use any other type of
refrigerant oil.
Refrigerant oil easily absorbs water and must not be
stored for long periods. Do not pour unused oil back
into the container.
When renewing system components, add the
following quantities of refrigerant oil:
Condenser 40ml..........................................................
Evaporator 80ml..........................................................
Pipe or hose 20ml........................................................
Receiver/drier 20ml......................................................
Total of refrigerant oil in system = 180ml = 6.3 Fl
ozA new compressor is sealed and pressurised with
Nitrogen gas, slowly release the sealing cap, gas
pressure should be heard to release as the seal is
broken.
NOTE: A new compressor should always
have its sealing caps in place and must
not be removed until immediately prior to
fitting
Fitting a new compressor
A new compressor is supplied with an oil fill (X) of:
180ml
A calculated quantity of oil must be drained from a
new compressor before fitting.
To calculate the quantity of oil to be drained:
1.Remove sealing plugs from the OLD compressor
2.Invert compressor and gravity drain oil into
measuring cylinder. Rotating the compressor
clutch plate will assist complete draining.
3.Note the quantity of oil drained (Y).
4.Calculate the quantity (Q) of oil to be drained
from the NEW compressor using the following
formula:
X - (Y + 20ml) = Q
Rapid refrigerant discharge
When the air conditioning system is involved in
accident damage and the circuit is punctured, the
refrigerant is discharged rapidly. The rapid discharged
of refrigerant will also result in the loss of most of the
oil from the system. The compressor must be
removed and all the remaining oil in the compressor
drained and refilled as follows:
1.Gravity drain all the oil, assist by rotating the
clutch plate (not the pulley).
2.Refill the compressor with the following amount
of new refrigerant oil:
130ml
3.Plug the inlet and outlet ports.

82AIR CONDITIONING
4
ADJUSTMENT Evacuation and recharging
1.Add refrigerant oil to compressor if necessary.
2.Renew the receiver/drier.
CAUTION: When a major repair has been
carried out, a leak test should be carried
out using inert gas.
3.Connect a Refrigerant Station to the high and
low pressure servicing connections.
CAUTION: Whenever the refrigerant
system is opened, the receiver/drier must
be renewed immediately before evacuating
and recharging the system.
4.Operate the refrigerant evacuation system
according to the manufacturer's instructions.
NOTE: If the vacuum reading is below
700mmHg after 15 minutes, suspect a leak
in the system. Partially recharge the
system and check for leaks using an electronic
leak tester. Check suction lines first, then run the
compressor for 5 minutes and then check the high
pressure lines.
CAUTION: The system must be evacuated
immediately before recharging
commences. Delay between evacuation
and recharging is not permitted.
5.Operate the refrigerant recharging system
according to the manufacturer's instructions:-
Refrigerant required to charge system:
Without rear air conditioning = 0.90kg (32 fl/oz)
With rear air conditioning = 1.15kg (40 fl/oz)
6.If the full charge has not been accepted by the
system, start the engine and run it at 1500
rev/min for a minimum of 2 minutes.
Switch on the air conditioning system, open the
car windows, set the temperature control to cold
and switch the blower to maximum speed.
7.Consult Refrigerant Station Manual for correct
procedure to complete the charge.
8.Carry out the air conditioning system
performance test.LEAK TEST SYSTEM
The following instructions refer to an electronic type
Refrigerant Leak Detector for use with R134a, which
are the safest and most sensitive.
CAUTION: When a major repair has been
carried out, a leak test should be carried
out using an inert gas (see below).
1.Place the vehicle in a well ventilated area but
free from draughts, as leakage from the system
could be dissipated without detection.
2.Follow the instructions issued by the
manufacturer of the particular leak detector
being used.
3.Commence searching for leaks by passing the
detector probe around all joints and components,
refrigerant gas is heavier than air.
4.Insert the probe into an air outlet of the
evaporator or into the evaporator drain tube.
Switch the air conditioning blower on and off at
intervals of ten seconds. Any leaking refrigerant
will be gathered in by the blower and detected.
5.Insert the probe between the magnetic clutch
and compressor to check the shaft seal for
leaks.
6.Check all service valve connections, valve plate,
head and base plate joints and back seal plate.
7.Check the condenser for leaks at the pipe
unions.
8.If any leaks are found, the system must be
discharged before rectification.
9.Rectify any leaks and recheck for leaks during
evacuation prior to charging.
Leak test using inert gas
Use Nitrogen or Helium gas.
1.Connect gas line to recharging station.
2.Pressurise system to 3 bar.
3.Carry out leak test as above.