run flat LAND ROVER DISCOVERY 1995 Workshop Manual

01INTRODUCTION
6
INFORMATION 2.Raise front road wheels to enable an axle stand
to be installed under left hand axle tube.
3.Position an axle stand under right hand axle
tube, carefully lower jack until axle sits securely
on both axle stands, remove trolley jack.
4.Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5.Reverse procedure when removing vehicle from
stands.
Raise rear of vehicle
1.Position cup of hydraulic arm under differential
casing.
2.Raise vehicle to enable axle stands to be
installed under left and right hand axle tubes.
3.Lower jack until axle sits securely on axle
stands, remove trolley jack.
4.Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5.Reverse procedure when removing vehicle from
stands.
HYDRAULIC VEHICLE RAMP (FOUR POST)
Use only a 'drive on' type ramp which supports vehicle
by its own road wheels. If a 'wheel-free' condition is
required, use a 'drive on' ramp incorporating a
'wheel-free' system that supports under axle casings.
Alternatively, place vehicle on a firm, flat floor and
support on axle stands.
TWO POST VEHICLE RAMPS
The manufacturer of LAND ROVER VEHICLES
DOES NOT recommend using 'Two Post' ramps
that employ four adjustable support arms. These
are NOT considered safe for Land Rover vehicles.
If vehicle is installed on a Two Post ramp
responsibility for safety of vehicle and personnel
performing service operations is in the hands of
the Service Provider.DYNAMOMETER TESTING - NON ANTI-LOCK
BRAKE VEHICLES
Viscous coupling
The front and rear axles cannot be driven
independently due to the viscous coupling. This
eliminates the need for differential lock by
progressively locking the centre differential
automatically if slip occurs at any wheel.
WARNING: DO NOT attempt to drive
individual wheels with vehicle supported
on floor jacks or stands.
Four wheel dynamometers
Provided that front and rear dynamometer 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.
If brake testing on a single axle rig is necessary it
must be carried out with propeller shaft to rear axle
removed, AND neutral selected in BOTH main
gearbox and transfer gearbox. When checking brakes,
run engine at idle speed to maintain servo vacuum.
If checking engine performance, the transfer box must
be in high range and propeller shaft to stationary axle
must be removed.

GENERAL FITTING REMINDERS
7
INFORMATION COTTER PINS
1.Fit new cotter pins throughout when replacing
any unit.
2.Always fit cotter pins where cotter pins were
originally used. Do not substitute spring
washers: there is always a good reason for the
use of a cotter pin.
3.All cotter pins should be fitted as shown unless
otherwise stated.
NUTS
1.When tightening a slotted or castellated nut
never loosen it back to insert cotter pin or locking
wire except in those recommended cases where
this forms part of an adjustment. If difficulty is
experienced, alternative washers or nuts should
be selected, or washer thickness reduced.
2.Where self-locking nuts have been removed it is
advisable to replace them with new ones of the
same type.
NOTE: Where bearing pre-load is involved
nuts should be tightened in accordance
with special instructions.
LOCKING WIRE
1.Fit new locking wire of the correct type for all
assemblies incorporating it.
2.Arrange wire so that its tension tends to tighten
the bolt heads, or nuts, to which it is fitted.SCREW THREADS
1.Both UNF and Metric threads to ISO standards
are used. See below for thread identification.
2.Damaged threads must always be discarded.
Cleaning up threads with a die or tap impairs the
strength and closeness of fit of the threads and
is not recommended.
3.Always ensure that replacement bolts are at
least equal in strength to those replaced.
4.Do not allow oil, grease or jointing compound to
enter blind threaded holes. The hydraulic action
on screwing in the bolt or stud could split the
housing.
5.Always tighten a nut or bolt to the recommended
torque value. Damaged or corroded threads can
affect the torque reading.
6.To check or re-tighten a bolt or screw to a
specified torque value first loosen a quarter of a
turn, then re-tighten to the correct value.
7.Oil thread lightly before tightening to ensure a
free running thread, except in the case of
threads treated with sealant/lubricant, and
self-locking nuts.
UNIFIED THREAD IDENTIFICATION
1. Bolts
A circular recess is stamped in the upper surface
of the bolt head.
2. Nuts
A continuous line of circles is indented on one of
the flats of the hexagon, parallel to the axis of
the nut.
3. Studs, Brake Rods, etc.
The component is reduced to the core diameter
for a short length at its extremity.

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.

57STEERING
10
FAULT DIAGNOSIS VISUAL AND SAFETY CHECKS
WARNING: Before taking vehicle out on
the public highway for road test, it is
important that the following basic visual
checks are carried out to ensure that the vehicle
complies with legal requirements.
Tyres and wheel rims
1.Check and adjust tyre pressures.
See
GENERAL SPECIFICATION DATA,
Information, Tyre Pressures
Note that this information refers to standard tyres
fitted as original equipment.
2.Check condition of tyres. Inspect for signs of
uneven wear, damage and feathering. Check
tread depth.
3.Ensure that the tyre make, type and general
condition are common across each axle.
4.Check wheel rims for signs of damage and
excessive run out.
5.Carry out road test.
See Road Test Procedure
ROAD TEST PROCEDURE
General steering/handling problems can usually be
classified into one of the categories listed and ARE
GENERALLY RELATED TO THE AGE, CONDITION
AND USE OF THE VEHICLE.
WARNING: Ensure that all road tests are
conducted by suitably qualified drivers in
a safe and legal manner, and where local
traffic conditions allow.
1.Carry out visual and safety checks.
See Visual
and Safety Checks
Confirm general nature of complaint with customer,
simulating where possible the conditions under which
the problem occurs. Carry out following road test
procedure to establish the problem.2.Steering load assessment - drive at 16 km/h (10
mph). Put 90°turn input into steering wheel,
check self centering. The self centering should
be equal on each lock BUT not necessarily
return to exactly straight ahead without
assistance from the driver.
3.Steering assessment - drive at 64 km/h (40 mph)
on a staight FLAT road (no camber), check for
steering veer. The vehicle should follow a
straight path with NO tendency to follow a
curved path. If vehicle veers towards the kerb,
vehicle may be 'camber sensitive'. A small
amount of veer in direction of camber is
acceptable.
4.Directional stability assessment - drive at 112
km/h (70 mph) or maximum legal speed on a
straight flat road. Carry out a normal lane
change. Vehicle should quickly settle into a new
straight path.
5.Braking assessment (medium effort) - drive at 96
km/h (60 mph) on a straight flat road. Apply
steady medium braking effort, noting any
tendency to veer. Carry out brake test three
times, if a veer is consistently noted carry out a
braking efficiency test on a rolling road.
6.Braking assessment (full effort) - drive at 96
km/h (60 mph) on a straight flat road. Apply full
braking effort, noting any tendency to veer. Carry
out brake test three times, if a veer is
consistently noted carry out a braking efficiency
test on a rolling road.
If the symptom described by the customer is stiff
steering or steering niggle, carry out stiff steering
procedure.
See Stiff Steering Checklist
If not proceed with basic checks and adjustments.
See Visual Check and Basic Adjustments

WHEELS AND TYRES
1
FAULT DIAGNOSIS TYRE WEAR CHART
FAULT CAUSE REMEDY
Rapid wear at Tyres under-inflated Inflate to correct pressure
shoulders Worn suspension components Replace worn components
i.e. ball joints, panhard
rod bushes,steering damper
Excessive cornering speeds
Rapid wear at
centreTyres over-inflated Inflate to correct pressure
of tread
Wear at one
shoulderTrack out of adjustment Adjust track to correct figure
Bent panhard rod Check and replace worn or damaged
components
Bald spots or tyre Wheel out of balance Balance wheel and tyre
cupping assembly
Excessive radial runout Check runout and replace tyre
if necessary
Shock absorber worn Replace shock
Excessive braking
Tyre scalloped Track out of adjustment Adjust toe to correct figure
Worn suspension components Replace as necessary
Excessive cornering speeds
CAUTION: This diagnosis chart is for general guidance only and does not necessarily include
every cause of abnormal tyre wear.

74WHEELS AND TYRES
2
REPAIR When the indicators appear in two or more adjacent
grooves, at three locations around the tyre, a new tyre
must be fitted.
NOTE: Do not attempt to interchange
tyres, e.g. from front to rear, as tyre wear
produces characteristic patterns
depending on their position. If tyre position is
changed after wear has occured, the performance
of the tyre will be adversely affected.
NOTE: Territorial vehicle regulations
governing tyre wear MUST be adhered to.
WHEELS INSPECTION
Regularly check the condition of the wheels. Replace
any wheel that is bent, cracked, dented or has
excessive runout.
VALVES INSPECTION
Check condition of inflation valve. Replace any valve
that is worn, cracked, loose, or leaking air.TYRE PRESSURES
Maximum tyre life and performance will be
obtained only if tyres are maintained at the correct
pressures.
Tyre pressures must be checked at least once a
month and at least once a week, preferably daily, if
the vehicle is used off road.
The tyre inflation pressure is calculated to give the
vehicle satisfactory ride and steering characteristics
without compromising tyre tread life. For
recommended tyre pressures in all conditions.
See
GENERAL SPECIFICATION DATA, Information,
Wheels and Tyres
American vehicles - A label attached to the inside
edge of the driver's door also provides tyre pressure
information.
Always check tyre inflation pressures using an
accurate gauge and inflate tyres to the
recommended pressures only.
Check and adjust tyre pressuresONLYwhen the
tyres are cold, vehicle parked for three hours or more,
or driven for less than 3.2 km (2 miles) at speeds
below 64 km/h (40 mph). Do not reduce inflation
pressures if the tyres are hot or the vehicle has been
driven for more than 3.2 km (2 miles) at speeds over
64 km/h (40 mph), as pressures can increase by 0.41
bars (6 p.s.i) over cold inflation pressures.
CheckALLtyre pressures including the spare. Refit
the valve caps as they form a positive seal and keep
dust out of the valve.