oil level LAND ROVER DISCOVERY 1995 Workshop Manual

LUBRICANTS, FLUIDS AND CAPACITIES
1
INFORMATION RECOMMENDED LUBRICANTS AND FLUIDS -
USA VEHICLES
AMBIENT TEMPERATURE°C
COMPONENT SPECIFICATION VISCOSITY -30 -20 -10 0 10 20 30 40 50
Engine Use oils to API 5W/20 )
service level
SGSH 5W/30 )
or 5W/40 )
RES.22.OL.G4
or
CCMC G4 10W/30
10W/40 )
10W/50 )
15W/40 )
15W/50 )
20W/40 )
20W/50 )
Automatic gearbox ATF Dexron IID
Final drive units API or GL5 90 EP
Swivel pin housings MIL - L - 2105 or
MIL - L - 2105B, C
or D 80W EP
Power steering ATF Dexron IID
LT 230T API GL4 or GL5
transfer gearbox MIL - L - 2105 or
MIL - L - 2105B
Brake reservoir Brake fluid must have a minimum
boiling point of 260°C (500ÊF) and
comply with FMVSS/116/DOT 4
Lubrication nipples
(hubs, ball joints,
etc.)NLGI-2 multipurpose lithium based
grease
See table on page 3 for remaining vehicle components

09LUBRICANTS, FLUIDS AND CAPACITIES
4
INFORMATION CAPACITIES
The following capacity figures are approximate and are provided as a guide only.
Capacities (approx.)* Litres Imp.Unit US unit
Engine sump oil
- 300Tdi models 5,8...................................................... 10.20 pt 12.30 pt
- V8i petrol models 3.9 6,1............................................ 10.70 pt 12.90 pt
- Mpi petrol models 4,90.................................................. 8.70 pt 10.40 pt
Extra when refilling after fitting new filter
- 300Tdi models 0,85...................................................... 1.50 pt 1.80 pt
- V8i petrol models 0,56.................................................. 1.00 pt 1.20 pt
- Mpi 0,4........................................................................ 0.70 pt 0.85 pt
Manual gearbox 2,67............................................................... 4.70 pt 5.70 pt
Automatic gearbox 9,1........................................................... 16.00 pt 19.20 pt
Transfer gearbox oil 2,30......................................................... 4.00 pt 4.90 pt
Front differential 1,70............................................................... 3.00 pt 3.60 pt
Rear differential 1,70................................................................ 3.00 pt 3.60 pt
Power steering box and reservoir LHD 2,90............................ 5.00 pt 6.00 pt
Power steering box and reservoir RHD 3,40............................ 6.00 pt 7.20 pt
Swivel pin housing oil (each) 0,35............................................ 0.60 pt 0.75 pt
Fuel tank usable fuel 89,0........................................................ 19.5 gall 23 gall
Cooling system
- 300Tdi models 11,50...................................................... 20.20 pt 24.30 pt
- V8i petrol models 11,30.................................................. 20.00 pt 23.90 pt
- Mpi 10,00........................................................................ 17.60 pt 21.00 pt
Washer bottle 7,0................................................................... 12.30 pt 14.80 pt
NOTE: * All levels must be checked by dipstick or level plugs as applicable. When draining oil
from the ZF automatic gearbox, oil will remain in the torque converter, refill to high level on
dipstick only.

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
12
MAINTENANCE
EXTERNALLY CHECK INTERCOOLER FOR
OBSTRUCTION - Tdi
Clear any trapped dirt or flies from vanes of
intercooler
CLEAN INTERCOOLER ELEMENT - Tdi
Remove
1.Remove intercooler element.
2.Flush intercooler with ICI 'GENKLENE'or
à oD-SOLVE' propriety cleaner, following the
manufacturer's instructions.
3.Dry the intercooler completely ensuring that no
liquid remains in the element.
Refit
4.Refit intercooler element.UNDER VEHICLE MAINTENANCE
Vehicles operating under severe conditions of dust,
sand, mud and water should have oils changed and
lubrication carried out at more frequent intervals than
is recommended in maintenance schedules.
RENEW ENGINE OIL AND FILTER - Tdi
CAUTION: Serious damage to the
turbocharger will result if engine is run
above idling speed before oil pressure is
restored.
RENEW ENGINE OIL - V8i
RENEW ENGINE OIL AND FILTER - V8i
CAUTION: To prevent an airlock occuring
after removing filter, fill new filter with oil
and fit immediately after removing old
filter. If airlock does occur fill oil pump with
petroleum jelly.
RENEW ENGINE OIL AND FILTER - Mpi
CHECK/TOP UP MANUAL GEARBOX OIL - V8i
1.Site vehicle on lift or level ground.
2.Remove oil filler level plug. If necessary, inject
new oil into the gearbox until it runs out of filler
hole. Fit plug. Tighten to
30 Nm.
RENEW MANUAL GEARBOX OIL - Tdi - Mpi
RENEW MANUAL GEARBOX OIL - V8i

MAINTENANCE
13
MAINTENANCE
RENEW AUTOMATIC GEARBOX FLUID AND OIL
SCREEN
1.Site vehicle on lift or level ground. Place
container to drain gearbox fluid into. Disconnect
battery negative lead.
2.Remove gearbox dipstick, located at rear of right
hand rocker cover, to aid oil drainage. Release
plug from bottom of sump and allow fluid to drain
completely.
3.Refit plug using a new sealing washer. Tighten
to
10 Nm
Refill ZF Automatic Gearbox and Check Fluid
Level.
NOTE: The fluid level must checked when
fluid is cold and engine idling in park.
4.Ensure vehicle is on level ground.
5.Refill or top-up with correct quantity and grade of
fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
6.Start and run engine. Apply footbrake, select
position 1 then back to park. Check fluid level,
this must be between the two marks on the
dipstick.
Oil screen replacement ZF automatic gearbox.
See AUTOMATIC GEARBOX, Repair, Oil Screen

10MAINTENANCE
14
MAINTENANCE
RENEW TRANSFER GEARBOX OIL
1.Site vehicle on lift or level ground.
2.Disconnect battery negative lead.
3.Clean immediate area around filler/level and
drain plugs.
WARNING: When draining gearbox care
should be taken to ensure that oil is not
hot as personal scalding could result.
4.Place a container under gearbox to drain oil into.
5.Remove filler/level plug to vent gearbox and
assist draining.
6.Remove drain plug and allow oil to drain.
7.Thoroughly clean drain plug threads prior to
applying fresh 'Hylomar' sealant. Fit plug
Tighten to
30 Nm.
8.Fill gearbox with correct quantity and grade of oil
until oil seeps from filler level hole. Wipe away
any surplus oil.
9.Thoroughly clean filler/level plug threads prior to
applying fresh 'Hylomar' sealant. Fit plug
Tighten to
30 Nm.
10.Reconnect battery negative lead.
CHECK/TOP UP TRANSFER GEARBOX OIL
1.Site vehicle on lift or level ground.
2.Disconnect battery negative lead.
3.Clean immediate area around filler/level plug.
4.Remove plug and fill gearbox with recommended
grade of oil, until oil starts to seep from filler/level
hole.
5.Clean any previously applied sealant from
filler/level plug.
6.Apply Hylomar sealant to threads of plug and
refit plug. Tighten to
30 Nm.
7.Wipe away any surplus oil.
8.Reconnect battery negative lead.

MAINTENANCE
15
MAINTENANCE
RENEW FRONT AND REAR AXLE OIL
1.Site vehicle on lift or level ground. Place
container under axle to be drained.
2.Using a 13mm square drive wrench, remove
drain and filler/level plugs from axle. Allow oil to
drain completely. Clean and refit drain plug.
3.Inject new oil of recommended make and grade
until it reaches level hole. Clean and refit
filler/level plug and wipe away surplus oil.
CHECK/TOP UP FRONT AND REAR AXLE OIL
1.Site vehicle on lift or level ground.
2.Using a 13mm square drive wrench, remove
filler/level plug from axle.
3.If necessary inject new oil of recommended
make and grade until it reaches level hole. Clean
and refit filler/level plug and wipe away surplus
oil.
CHECK/TOP UP SWIVEL PIN HOUSING OIL
RENEW SWIVEL PIN HOUSING OIL
1.Site vehicle on lift or level ground. Place
container under swivel to be drained.
2.Remove drain and level plugs, allow oil to drain
completely, clean and refit drain plug.
3.Remove filler plug and inject recommended
make and grade of oil it reaches level hole.
4.Clean and refit level and filler plugs, wipe away
any surplus oil.

Tdi
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Engine block
Bearing cap 133...............................................................................................
Blanking plug, oil gallery, rear 37....................................................................
Oil squirt jet assembly 17................................................................................
Drain plug, cylinder block 25...........................................................................
Oil squirt jet, vacuum pump cam 7.................................................................
Connecting rod to cap 59................................................................................
Oil pick up assembly to bearing cap 9...........................................................
Oil pick up assembly to front cover 25............................................................
Camshaft thrust plate 9..................................................................................
Oil drain pipe to block (internal) 25.................................................................
Oil drain pipe to block (external) 25................................................................
Sump to cylinder block and front cover 25......................................................
Drain plug, oil sump 35...................................................................................
Tappet guide 14..............................................................................................
Breather side cover assembly 25....................................................................
Baffle plate to breather side cover 4..............................................................
Vacuum pump 25............................................................................................
Fuel lift pump 25.............................................................................................
Flywheel housing 45.......................................................................................
Flywheel housing clutch cover stud 10...........................................................
Plug, flywheel housing 12...............................................................................
Rear oil seal assembly 25...............................................................................
Oil filter adaptor 45..........................................................................................
Waxstat adaptor to oil filter adaptor 9............................................................
Oil pressure switch 17.....................................................................................
Oil filter, spin on 13.........................................................................................
Oil cooler unions to filter adaptor 45...............................................................
Oil level tube 25..............................................................................................
Engine mounting foot to cylinder block 85......................................................
Engine mounting foot to flywheel housing 45.................................................
Engine mounting foot rubber to mounting foot (bolt and nut) 85.....................
Flywheel to crankshaft 146..............................................................................
Clutch cover plate to flywheel 34....................................................................
Flex drive plate to crankshaft (auto) 146..........................................................
Flex drive plate to ring gear (auto) 25.............................................................
Flex drive plate to torque converter (auto) 45.................................................

V8i
1
FAULT DIAGNOSIS ENGINE OIL PRESSURE TEST
Service tools:
LRT-12-052: Pressure test equipment
WARNING: Use suitable exhaust
extraction equipment, if test is being
carried out in workshop.
WARNING: If vehicle has been running,
engine oil will be hot, care must be taken
when fitting equipment to prevent
personal injury due to scalding.
Test
1.Check lubricant is to correct level.
2.Place vehicle on a ramp [hoist].
3.Disconnect battery negative lead. Remove oil
pressure switch.
4.Fit the test gauge.
5.Reconnect battery negative lead.
6.Start and run engine to normal operating
temperature.
7.At a steady engine speed of 2500 rev/min -
engine oil pressure reading should be - 2.75 bar
(40 lbf/in
2).
8.If the pressure is low - Remove and overhaul oil
pump
CYLINDER COMPRESSION - TEST
Equipment:
Compression pressure gauge
Test
1.Start and run engine until normal engine
operating temperature is achieved (thermostat
open).
2.Remove all spark plugs.
3.Disconnect both coil negative (WB) leads
4.Insert compression gauge, crank engine until
reading stabilises.
5.Expected readings, throttle fully open, battery
fully charged:
8.31:1 = 10.2-10.9 bar, 150-160lbf/in
2
9.35:1 = 11.5-12.2 bar, 170-180lbf/in2

12ENGINE
2
FAULT DIAGNOSIS ENGINE NOISES
Excessive or obtrusive noise from the engine
compartment originates from three main sources:
A. The exhaust system, which makes an
unmistakable and easy to diagnose noise.
B. External components emit the greatest variety of
noises, but are also easy to diagnose by simply
removing the drive belt.
C. Engine internal mechanical noises which can
vary in volume and pitch and may be a
combination of, tapping - knocking or rumbling,
are the most difficult to diagnose. The following
is therefore a guide to diagnosis of engine
internal mechanical noises only.
Engine internal mechanical noises.
Single or multiple, light tapping noise, particularly
when engine is cold.
See Description and
operation, Description
1.Is engine oil level correct?
NO - Top up to correct level.
See
LUBRICANTS, FLUIDS AND
CAPACITIES, Information,
Recommended Lubricants and Fluids
YES - Continue.
2.Is the lubricating pressure correct?
NO -
See Engine Oil Pressure Test
YES - Suspect valve operating mechanism.
3.To confirm diagnosis, remove the rocker covers
and with the engine idling, insert a feeler gauge
of 0,015mm between each rocker and valve
stem. A faulty valve operating mechanism will
emit a different noise when the feeler gauge is
inserted.
See Repair, Rocker Shaft Renew
Heavy knocking noise (particularly on load and
when engine is hot).
See Description and
operation, Description
1.Is engine oil level correct?
NO - Top up to correct level.
See
LUBRICANTS, FLUIDS AND
CAPACITIES, Information,
Recommended Lubricants and Fluids
YES - Continue.
2.Is the lubricating pressure correct?
NO -
See Engine Oil Pressure Test
YES - Drain engine oil and filter, and examine
for metallic contamination.
3.Is the oil contaminated with metal particles?
YES - Suspect faulty big end bearings. To
confirm diagnosis, short out the ignition to
each spark plug in turn. The noise will
disappear or be reduced when the
cylinder with the faulty big end is shorted
out.
4.If noise is not conclusively diagnosed, check the
security of the flywheel and crankshaft front
pulley. Temporarily release the drive belt to
reduce general noise level and use a
stethoscope to locate source of noise.
Heavy rumbling noise (particularly during hard
acceleration).
See Description and operation,
Description
1.Is engine oil level correct?
NO - Top up to correct level.
See
LUBRICANTS, FLUIDS AND
CAPACITIES, Information,
Recommended Lubricants and Fluids
YES - Continue.
2.Is the lubricating pressure correct?
NO -
See Engine Oil Pressure Test
YES - Drain engine oil and filter, and examine
for metallic contamination.
3.Is the oil contaminated with metal particles?
YES - Suspect faulty main bearings. If noise is
not conclusively diagnosed, check the
security of the flywheel and crankshaft
front pulley. Temporarily release the drive
belt to reduce general noise level and use
a stethoscope to locate source of noise.