key LAND ROVER DISCOVERY 1995 Workshop Manual

INTRODUCTION
7
INFORMATION DYNAMOMETER TESTING - VEHICLES WITH
ANTI-LOCK BRAKES (ABS)
WARNING: Do not attempt to test ABS
function on a dynamometer
Four wheel dynamometers
NOTE: Before testing a vehicle on a four
wheel dynamometer disconnect the valve
relay.
See Electrical Trouble Shooting
Manual.
The ABS function will not work, the ABS warning
light will illuminate. Normal braking will be
available.
Provided that front and rear rollers are rotating at
identical speeds and that normal workshop safety
standards are applied, there is no speed restriction
during testing except any that may apply to the tyres.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
NOTE: ABS will not function on a two
wheel dynamometer. The ABS light will
illuminate during testing. Normal braking
will be available.
If brake testing on a single rig is necessary it must be
carried out with propeller shaft to the rear axle
removed, AND neutral selected in BOTH main and
transfer boxes.
If checking engine performance, the transfer box must
be in high range and drive shaft to stationary axle
removed.
TOWING
CAUTION: The vehicle has permanent
four-wheel drive. The following towing
instructions must be adhered to:
Towing the vehicle on all four wheels with driver
operating steering and brakes.
1.Turn ignition key turn to position '1' to release
steering lock.
2.Select neutral in main gearbox and transfer
gearbox.
3.Secure tow rope, chain or cable to towing eye.
4.Release the parking brake.
CAUTION: The brake servo and power
assisted steering system will not be
functional without the engine running.
Greater pedal pressure will be required to apply
the brakes, the steering system will require
greater effort to turn the front road wheels.
The vehicle tow connection should be used only
in normal road conditions, 'snatch' recovery
should be avoided.
Suspended tow by breakdown vehicle
CAUTION: To prevent vehicle damage,
front or rear propeller shaft MUST BE
removed, dependent upon which axle is
being trailed.
1.Mark propeller shaft drive flanges at transfer
gearbox and axles with identification lines to
enable the propeller shaft to be refitted in its
original position.
2.Remove the propeller shaft fixings, remove the
shaft from the vehicle.
3.If the front axle is to be trailed turn ignition key to
position '1' to release steering lock.
CAUTION: The steering wheel and/or
linkage must be secured in a straight
ahead position. DO NOT use the steering
lock mechanism for this purpose.

INTRODUCTION
13
INFORMATION European vehicle identification number (VIN)
Stamped on the right hand side chassis forward of
rear wheel.
Federal (USA) vehicle identification number
Stamped on a plate rivetted to the upper left hand 'A' -
post, visible through the front screen of the vehicle.Vehicle identification number (VIN)
An adhesive label containing the Vehicle Identification
Number, date of manufacture and gross axle weight
ratings is fixed to the lock face of the front left hand
door. The information includes wheel and tyre sizes
and tyre pressures at gross axle weight ratings.
Key to vehicle identification label
A.Month and year of manufacture
B.Gross vehicle weight rating
C.Gross axle weight rating for front axle
D.Gross axle weight rating for rear axle
E.Vehicle identification number (17 digits)
F.Vehicle identification number - bar code

07GENERAL FITTING REMINDERS
6
INFORMATION FUEL SYSTEM HOSES
CAUTION: All fuel hoses are made up of
two laminations, an armoured rubber outer
sleeve and an inner viton core. If any of
the fuel system hoses have been disconnected, it
is imperative that the internal bore is inspected to
ensure that the viton lining has not become
separated from the amoured outer sleeve. A new
hose must be fitted if separation is evident.
METRIC BOLT IDENTIFICATION
1.An ISO metric bolt or screw, made of steel and
larger than 6 mm in diameter can be identified by
either of the symbols ISO M or M embossed or
indented on top of the head.
2.In addition to marks to identify the manufacture,
the head is also marked with symbols to indicate
the strength grade, e.g. 8.8, 12.9 or 14.9, where
the first figure gives the minimum tensile
strength of the bolt material in tens of kgf/mm
2.
3.Zinc plated ISO metric bolts and nuts are
chromate passivated, a gold-bronze colour.
METRIC NUT IDENTIFICATION
1.A nut with an ISO metric thread is marked on
one face or on one of the flats of the hexagon
with the strength grade symbol 8, 12 or 14.
Some nuts with a strength 4, 5 or 6 are also
marked and some have the metric symbol M on
the flat opposite the strength grade marking.
2.A clock face system is used as an alternative
method of indicating the strength grade. The
external chamfers or a face of the nut is marked
in a position relative to the appropriate hour
mark on a clock face to indicate the strength
grade.
3.A dot is used to locate the 12 o'clock position
and a dash to indicate the strength grade. If the
grade is above 12, two dots identify the 12
o'clock position.
KEYS AND KEYWAYS
1.Remove burrs from edges of keyways with a fine
file and clean thoroughly before attempting to
refit key.
2.Clean and inspect key closely; keys are suitable
for refitting only if indistinguishable from new, as
any indentation may indicate the onset of wear.
TAB WASHERS
1.Fit new washers in all places where they are
used. Always fit a new tab washer.
2.Ensure that the new tab washer is of the same
design as that replaced.

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.

12ENGINE
2
DESCRIPTION AND OPERATION
1. Cylinder block
2. Pistons and gudgeon pins (8)
3. Connecting rods (8)
4. Core plugs
5. Camshaft
6. Dipstick
7. Camshaft key
8. Timing chain
9. Camshaft sprocket
10. Distance piece
11. Distributor drive gear
12. Distributor
13. Front cover
14. Front cover oil seal
15. Coolant pump
16. Crankshaft damper / pulley17. Crankshaft sprocket
18. Crankshaft sprocket key
19. Crankshaft
20. Centre main bearing shells (2)
21. Crankshaft rear oil seal
22. Spacer
23. Adaptor plate
24. Rear main bearing cap, shell and side seals
25. Connecting rod caps
26. Main bearing caps and shell bearings
27. Oil filter
28. Oil pump suction pipe/strainer
29. Oil sump
30. Oil sump drain plug
31. Oil pump drive key

V8i
5
DESCRIPTION AND OPERATION Distributor and timing chain lubrication
The distributor and timing chain are lubricated from
the camshaft front bearing. The feed to the timing
chain is channelled along the camshaft sprocket, key
and spacer where it sprays onto the chain.
1. Bearing
2. Camshaft
3. Key
4. Camshaft timing chain sprocket
5. Spacer
6. Distributor drive gearHydraulic tappets
1. Clip
2. Pushrod seat
3. Inner sleeve
4. Upper chamber
5. Non-return ball valve
6. Spring
7. Outer sleeve
8. Lower chamber - high pressure
The purpose of the hydraulic tappet is to provide
maintenance free and quiet operation of the inlet and
exhaust valves. It achieves its designed purpose by
utilizing engine oil pressure to eliminate the
mechanical clearance between the rockers and the
valve stems.
During normal operation, engine oil pressure present
in the upper chamber 4, passes through the
non-return ball valve 5 and into the lower (high
pressure) chamber 8.
When the cam begins to lift the outer sleeve 7, the
resistance of the cylinder valve spring felt through the
pushrod seat 2, causes the inner sleeve 3, to move
downwards inside the outer. This slight downward
movement of the inner sleeve closes the ball valve 5
and increases the hydraulic pressure in the high
pressure chamber, sufficient to ensure that the push
rod opens the valve fully.
As the tappet assembly moves off the peak of the cam
the ball valve 5 opens to equalize the pressure in both
chambers which ensures that the valve fully closes
when the tappet is on the back of the cam.

12ENGINE
10
REPAIR TIMING CHAIN AND CHAINWHEELS
Service repair no - 12.65.12
Remove
1.Remove front cover.
See Front Cover Gasket
2.Remove retaining bolt and washer, remove
distributor drive gear and spacer.
3.Ensure number one piston is at TDC.
4.Remove chainwheels and chain as an assembly.
See V8i Overhaul Manual.
Refit
5.Clean chainwheels and chain.
6.Fit chainwheels to chain, aligning timing marks.
7.Ensure camshaft key is fitted parallel to shaft
axis to ensure adequate lubrication to distributor
drive gear.
8.Engage chainwheel assembly on camshaft and
crankshaft keys, ensure chain wheels are fully
located.
9.Check alignment of timing marks with straight
edge.
10.Fit spacer with flange to front,
11.Fit distributor drive gear with groove towards
spacer.
12.Fit retaining bolt and washer. Tighten to
58 Nm.
13.Fit front cover.See Front Cover Gasket
FLYWHEEL
Service repair no - 12.53.07
Remove
1.Remove gearbox and clutch.
See CLUTCH,
Repair, Clutch Assembly
2.Loosen starter motor bolts.
3.Lock flywheel, remove flywheel bolts and
flywheel.
Refit
4.Clean components for reassembly.
5.Fit flywheel.
6.Clean threads, apply Loctite 270 to threads.
7.Lock flywheel, fit flywheel bolts. Tighten to
80
Nm.

4.0 V8
1
REPAIR CRANKSHAFT PULLEY
Service repair no - 12.21.01 - Crankshaft Pulley
Remove
1.Disconnect battery negative lead.
2.Remove cooling fan.
See COOLING SYSTEM,
Repair, Viscous Coupling, Fan Blades,
Pulley and Fan Cowl
3.Slacken 3 water pump pulley securing bolts.
4.Remove drive belt.
See ENGINE 3.9 V8,
Repair, Drive Belt Renew
5.Remove water pump pulley bolts. Remove water
pump pulley.
6.Raise and support front of vehicle.
7.Remove 9 bolts securing bell housing access
cover (2 dowel bolts).
8.Remove access plate.
NOTE: It will be necessary to have an
assistant position a large flat ended
screwdriver between ring gear and adaptor
plate to prevent ring gear rotating.
9.Remove crankshaft pulley bolt. Collect pulley
and tool.
Refit
10.Clean seal running surface on pulley.
11.Clean key and keyway.
12.Fit crankshaft pulley.
NOTE: It will be necessary to have an
assistant position a large flat ended
screwdriver between ring gear and adaptor
plate to prevent ring gear rotating.
13.Refit crankshaft pulley bolt. Tighten to
270 Nm.
14.Ensure mating faces between bell housing
access cover and mating face are clean.
15.Fit access cover.
16.Fit cover bolts. Tighten to
10 Nm.
17.Remove supports and lower vehicle.
18.Ensure mating faces between water pump pulley
and pump are clean.
19.Refit water pump pulley. Fit bolts finger tight.
20.Fit drive belt.
See ENGINE 3.9 V8, Repair,
Drive Belt Renew
21.Tighten water pump pulley bolts to Tighten to24
Nm.
22.Refit cooling fan.See COOLING SYSTEM,
Repair, Viscous Coupling, Fan Blades,
Pulley and Fan Cowl
23.Reconnect battery negative lead.

12ENGINE
4
REPAIR 39.Release battery positive lead terminal cover.
40.Remove terminal nut
41.Release terminal from battery.
42.Release fusebox main feed lead.
43.Position battery cable over engine.
44.Pivot jockey pulley downwards to release drive
belt tension.
45.Release belt from pulleys.
46.Remove drive belt.
47.Disconnect compressor multiplug
48.Remove 4 bolts securing compressor.
49.Remove heatshield.
50.Release compressor from bracket and tie aside.
51.Slacken clip securing PAS hose to pump.
52.Disconnect hose.
53.Plug hose and pump.
54.Disconnect PAS hose connection at pump and
steering box.
55.Release unions and remove hose.
56.Remove and discard 'O' rings.
57.Plug pump and steering box.
58.Remove LH and RH engine mounting nuts.
59.Position lifting chains and attach hooks to engine
lifting eyes.
60.Raise engine sufficiently to release engine
mountings.
61.Release engine mountings and remove.
62.Lower engine until it just rests on engine
mounting brackets.
63.Disconnect chains.
64.Raise ramp.
65.Remove catalytic converter/front pipe assembly.
See EMISSION CONTROL, Repair, Catalytic
Converter/Front Pipe - 4.0 V8
66.Remove 9 bolts securing bell housing bottom
cover. Note position of 2 dowel bolts.
67.Remove cover.
68.Remove locknut securing transfer box tie bar.
69.Remove 2 bolts securing tie bar to tranmission.
70.Remove tie bar.
71.Remove 2 and slacken 1 bolt, securing bell
housing access plate and position aside.
72.Mark drive plate to torque converter relationship.
73.With assistance, rotate crankshaft for access to
first bolt (torque converter to drive plate).
74.Remove first bolt.
75.Repeat steps for the remaining 3 bolts.
76.Remove 2 bolts securing crankshaft sensor
shield to engine backplate.
See FUEL SYSTEM
SFI, Repair, Crankshaft Position Sensor
(CKP Sensor)