hood release LAND ROVER DISCOVERY 1995 Workshop Manual

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
20
REPAIR CYLINDER HEAD GASKET
Service repair no - 12.29.02
Remove
1.Disconnect battery negative lead.
2.Remove bonnet [Hood].
See CHASSIS AND
BODY, Repair, Bonnet [Hood]
3.Drain coolant.
4.Remove air cleaner assembly.
See FUEL
SYSTEM, Repair, Air Cleaner
5.Detach crankcase ventilation valve and side
breather hose from rocker cover and move to
one side.
6.Remove injection pipes.
7.Disconnect spill rail from fuel injectors.
8.Remove fuel injectors and sealing washers.
Identify each injector to the location from which it
is removed.
See FUEL SYSTEM, Repair,
Injectors
9.Remove inter-connecting harness from glow
plugs.
10.Remove glow plugs.
See FUEL SYSTEM,
Repair, Glow Plugs
11.Remove top hose, radiator to thermostat.
12.Disconnect by-pass hose from thermostat.
13.Disconnect hose, thermostat to water pump.
14.Disconnect water temperature sensor lead.
15.Remove hose inter-cooler to induction manifold.
16.Remove induction manifold.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
Manifold - Tdi
17.Remove exhaust manifold and turbocharger
assembly.
See MANIFOLD AND EXHAUST
SYSTEM, Repair, Exhaust Manifold - Tdi
18.Disconnect heater hose from water pump and
move heater rail aside.
19.Disconnect heater hose from rear of cylinder
head.
20.Remove bolt securing air cleaner mounting
bracket to support strut.
21.Remove bolt securing harness bracket to
cylinder head.
22.Remove rear lifting bracket, this will also release
clips securing transmission and engine breather
pipes and multiplug. Note loose spacer under
clip securing engine breather pipe and multiplug.

12ENGINE
12
REPAIR
12.Ensure service tools LRT-12-010 and
LRT-12-091 are scrupulously clean. Coat seal
guide and oil seal journal with clean engine oil.
CAUTION: Do not handle oilseal lip, check
it is not damaged. Ensure outside diameter
remains clean and dry.
13.Position oil seal guide LRT-12-010 on crankshaft
flange.
NOTE: Lubricant coating must cover seal
guide outer surface completely to ensure
that oil seal lip is not turned back during
assembly. Position oil seal, lipped side towards
engine, on seal guide. Seal outside diameter
MUST be clean and dry.
14.Fit oil seal using tool LRT-12-091. Remove seal
guide.
15.Tighten rear main bearing cap to
90 Nm.
16.Fit sump.
17.Fit flywheel or flexible drive plate and ring gear.ENGINE
Service repair no - 12.41.01
Remove
1.Park vehicle on level ground and apply park
brake.
2.De-pressurise fuel system.
See FUEL
SYSTEM, Repair, Depressurising Fuel
System
3.Remove bonnet [hood].See CHASSIS AND
BODY, Repair, Bonnet [Hood]
4.Remove battery.See ELECTRICAL, Repair,
Battery
5.Remove radiator/oil coolers.See COOLING
SYSTEM, Repair, Radiator/Oil Coolers
6.Place an absorbent cloth around fuel feed hose
at fuel rail and release compression nut.
Remove feed hose from rail, seal end of pipes
with masking tape to prevent ingress of dirt.
7.Release fuel return hose clamp and remove
hose from pressure regulator, seal both
openings with masking tape to prevent ingress of
dirt.
8.Remove vacuum hose from rear of regulator.
9.Manual vehicles: Disconnect throttle cable from
bracket. Automatic vehicles: Detach throttle
bracket from plenum chamber and lay assembly
to one side.
See FUEL SYSTEM, Repair,
Plenum Chamber DO NOT DISTURB KICK
DOWN CABLE SETTING.
10.Remove ram housing.See FUEL SYSTEM,
Repair, Ram Housing
11.Remove air flow sensor.See FUEL SYSTEM,
Repair, Air Flow Sensor
12.Remove air cleaner assembly.See FUEL
SYSTEM, Repair, Air Cleaner Assembly
13.Remove Generator.See ELECTRICAL,
Description and operation, Generator
14.Release air conditioning compressor from its
mounting and lay to one side. DO NOT
discharge air conditioning system.
See AIR
CONDITIONING, Repair, Compressor

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
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
6
REPAIR ENGINE
Service repair no - 12.41.01
Remove
1.Site vehicle onto ramp [hoist].
2.Remove the drive belt.
See SECTION 10,
Maintenance, Under Bonnet [Hood]
Maintenance
3.Remove radiator.See COOLING SYSTEM,
Repair, Radiator - Mpi
4.Remove bonnet [hood].See CHASSIS AND
BODY, Repair, Bonnet [Hood]
5.Drain engine oil.
6.Position absorbent cloth around fuel pipe to fuel
rail union.
Unscrew union to relieve pressure.
CAUTION: Plug the connections
7.Release clip and disconnect hose from coolant
pump.
8.Release clip and disconnect hose from heater
rail.

Mpi
13
REPAIR 19.Connect crankshaft sensor, knock sensor, air
conditioning compressor, fuel injector harness,
inlet manifold air temperature and fuel
temperature sensor multiplugs.
20.Connect fuel hose to pressure regulator and
secure with clip.
21.Fit and tighten fuel pipe to fuel rail union.
22.Connect multiplugs to throttle housing.
23.Connect vacuum hose to manifold.
24.Connect oil pressure switch multiplug.
25.Connect brake servo hose to manifold, secure
with clip.
26.Connect throttle cable to cam.
27.Position engine harness and connect breather
hose to inlet manifold, secure with clip.
28.Connect coolant temperature sensor multiplugs,
secure harness with cable tie.
29.Connect oxygen sensor multiplug, secure
harness with cable tie.
30.Connect alternator harness.
31.Connect heater hose to heater rail and secure
with clip.
32.Connect hose to coolant pump and secure with
clip.
33.Connect inlet hose to power steering pump and
secure with clip.
34.Fit and tighten outlet pipe union to power
steering pump.
35.Connect bypass and top hose, secure with clip.
36.Connect air cleaner to throttle housing hose and
secure with clip.
37.Remove engine lifting bracket.
38.Position spark plug cover and secure with
screws.
39.Fill engine with oil.
40.Fit bonnet [hood].
See CHASSIS AND BODY,
Repair, Bonnet [Hood]
41.Fit radiator.See COOLING SYSTEM, Repair,
Radiator - Mpi
42.Adjust throttle cable.See FUEL SYSTEM,
Adjustment, Throttle Cable Adjustment
ENGINE SUMP GASKET
Service repair no - 12.60.43
Remove
1.Drain engine oil.
2.Refit drain plug, use new sealing washer if
necessary, tighten to the correct torque.
3.Remove 18 bolts securing sump.
NOTE: 25mm long bolt is fitted at rear L.H.
corner of sump.
4.Release sump from cylinder block.
5.Discard gasket.

19FUEL SYSTEM
6
REPAIR FUEL FILTER ELEMENT
Service repair no - 19.25.07
Remove
1.Disconnect battery negative lead.
2.Clean area around filter head.
3.Place a suitable container beneath filter bowl to
collect any spillage.
4.Loosen bleed screw.
5.Loosen drain tap, allow fuel to drain into
container.
6.Unscrew filter element, discard element.
Refit
7.Clean seal and seating in filter head.
8.Lubricate filter element seal with fuel.
9.Position filter element to filter head and hand
tighten.
10.Reconnect battery negative lead.
11.Crank engine until fuel is drawn through the
system and starts.INTERCOOLER
Service repair no - 19.42.15
Remove
1.Disconnect battery negative lead.
2.Release 2 clips securing fan cowl to radiator top
cover.
3.Remove 4 bolts securing radiator top cover,
remove top cover.
4.Remove nut, bolt and washers securing
intercooler side cover bracket to bonnet [hood]
platform.
5.Release bracket from side cover lug, position
bracket and power steering reservoir aside.
6.Position side cover away from intercooler.
7.Loosen 2 clips and disconnect top hose from
intercooler.
8.Loosen 2 clips and disconnect bottom hose from
intercooler.

MFI
5
REPAIR INERTIA FUEL SHUTOFF SWITCH
Service repair no - 18.30.35
The inertia fuel shutoff switch is located on the
bulkhead next to the washer reservoir under bonnet
[hood].
Remove
1.Disconnect battery negative lead.
2.Disconnect multiplug from inertia switch.
3.Remove 2 screws securing inertia switch to
mounting bracket.
4.Remove inertia switch.
Refit
5.Position inertia switch to mounting bracket and
secure with screws.
6.Connect multiplug to inertia switch.
7.Reconnect battery negative lead.ENGINE FUEL TEMPERATURE SENSOR
Service repair no - 19.22.08
Remove
NOTE: Fuel leakage will not occur when
sensor is removed from fuel rail, therefore
it is not necessary to depressurise the fuel
system.
1.Disconnect battery negative lead.
2.Disconnect multi-plug from sensor.
3.Release sensor from fuel feed rail.
Refit
4.Reverse removal procedure. Ensure sensor is
tightened securely in fuel rail.

CHASSIS AND BODY
35
REPAIR AIR INTAKE PLENUM COWL
Service repair no - 76.11.08
Remove
1.Remove the windscreen wiper arms.
2.Remove the securing nuts and the steel and
rubber washers from the wiper spindles.
3.Open the vehicle bonnet [hood].
4.Remove the rubber seal from the cowl flange.
5.Release the screen washer tubes from the
washer jets on the cowl.
6.Remove the centre bolt securing the cowl centre
section.
7.Remove the retainers securing the centre
section to the outer section.
8.Detach the centre section from the bulkhead.
9.Remove the nuts and bolts and detach the outer
sections of the cowl.Refit
10.Reverse removal procedure.