sway bar LAND ROVER DISCOVERY 1995 Workshop Manual

19FUEL SYSTEM
22
REPAIR FUEL TANK
Service repair no - 19.55.01
WARNING: Ensure that fuel handling
precautions given in Section 01 -
introduction are strictly adhered to when
carrying out following instructions.
CAUTION: Before disconnecting any part
of fuel system, it is imperative that all dust,
dirt and debris is removed from around
components to prevent ingress of foreign matter
into fuel system.
Remove
1.Depressurise fuel system. Disconnect battery
negative lead.
2.Syphon fuel tank into a suitable container that
can be sealed afterwards.
ENSURE TANK IS DRAINED COMPLETELY.
(refer to Warning concerning fuel vapour and
spillage at start of procedure).
3.Remove carpet loadspace floor and tailgate.
4.Fold back sound insulation to reveal access
panel.
5.Remove access panel.
6.Disconnect electrical multi-plug.
7.Disconnect two fuel line unions from fuel pump.
8.Working underneath vehicle mark location of
anti-roll [sway] bar straps.
9.Remove rear anti-roll [sway] bar straps, and
allow bar to swing down clear of tank.
10.Remove tank filler and vent hoses at fuel tank.
11.Remove nut and bolt securing right hand side
fuel tank strap.
12.Disconnect evaporative control pipe at green
end of 'speedfit' connector.
NOTE: To disconnect 'speedfit' connector,
insert forked end of LRT-19-002 into slots
of connector see illustration. Press down
on collet and simultaneously pull pipe from
connector.

19FUEL SYSTEM
22
REPAIRADD: 09/95
12.Mark location of anti-roll [sway] bar straps.
13.Remove nuts and bolts securing anti-roll [sway]
bar straps, and allow bar to swing down clear of
tank.14.Disconnect pressure sensor breather pipe
connection.
15.Disconnect vent line quickfit connector from
liquid/vapour separator.
16.Remove torque screw cap from hose to tank
filler neck clip.
17.Loosen clip screw securing hose to tank filler
neck.
18.Release hose from filler neck and internal filler
neck breather hose from fuel tank.
19.Remove and discard fuel filler neck clip.

19FUEL SYSTEM
24
REPAIRADD: 09/95 Refit
29.Fit NEW pump seal to tank opening.
30.Carefully lower pump into tank opening, pressing
firmly on the pump top flange to allow correct
positioning.
NOTE: Ensure location tag on pump top
flange is engaged correctly to tank
opening lip.
31.Fit locking ring and tighten to
35 Nmusing
service tool LRT-19-009.
32.Fit vent hose to fuel tank clips and connect to
pressure sensor.
33.With assistance, fit fuel tank into position.
34.Fit fuel tank cradle and secure with nuts and
bolts.
35.Align upper fuel tank strap and secure with nut
and bolt.
36.Fit NEW clip to fuel filler neck hose.
37.Connect fuel filler neck internal breather to tank.
38.Connect fuel filler neck hose to tank.
39.Position fuel filler neck hose clip and tighten until
head shears.
40.Connect vent line quickfit connector to
liquid/vapour separator.
41.Connect vent line hose connection.
42.Position anti-roll [sway] bar straps and secure
with nuts and bolts.
43.Remove stand(s) and lower vehicle.
44.Connect both fuel lines to the pump by pushing
the connectors down each line square to the
pump connection until the connectors positively
latches.
45.Connect multiplugs to fuel pump and pressure
sensor.
46.Reconnect battery negative lead.
47.Refill tank with drained fuel.
48.Run the engine to check for any fuel leaks.
49.Fit access panel and secure with screws.
50.Reposition loadspace sound insulation and
carpet.
51.Fit RH luggage compartment side panel.
See
CHASSIS AND BODY, Repair, rear
compartment trim panels
52.Fit tail door tread strip and secure with screws.FUEL TANK - DRAINING - ADVANCED EVAPS
Service repair no - 19.55.02
WARNING: Before removing the fuel tank
it must be drained.
WARNING: Petrol/gasoline vapour is
highly flammable and in confined spaces
is also explosive and toxic. Always have a
fire extinguisher containing FOAM, CO2, GAS or
POWDER close at hand when handling or draining
fuel. See Introduction
CAUTION: Before disconnecting any part
of fuel system, it is imperative that all dust,
dirt and debris is removed from around
components to prevent ingress of foreign matter
into fuel system.
NOTE: Assuming the fuel tank is FULL
drain the following quantities:
Renew Fuel pump = 9 Litres (2.4 US Gallons)
Renew Fuel filler neck = 22 Litres (6 US Gallons)
Renew Fuel tank = COMPLETE DRAIN
1.Depressurise fuel system.
See fuel system -
depressurise - advanced evaps
2.Disconnect battery negative lead.
3.Remove 6 screws securing tail door tread strip
and remove tread strip.
4.Remove RH luggage compartment side panel.
See CHASSIS AND BODY, Repair,

MANIFOLD AND EXHAUST SYSTEM
3
REPAIR MANIFOLD AND EXHAUST SYSTEM - Tdi
Remove
1.Raise vehicle on a ramp [hoist].
2.Remove anti-roll[sway] bar bolts to chassis and
allow to swing down clear of axle.
See REAR
SUSPENSION, Repair, Anti-roll [sway] Bar
Assembly Rear
3.Remove exhaust support bracket behind
catalyst.
4.Disconnect exhaust at manifold.
5.Disconnect flange between rear and front
exhaust.
6.Fit axle stands in suitable place on chassis.
7.Allow hoist to lower until front suspension is fully
extended.
8.Manoeuvre front exhaust section fron
underneath vehicle.
9.Remove bolts securing three hanger brackets to
chassis. Lower rear exhaust assembly onto rear
axle. Detach rubbers from hanging brackets.
10.Place extended axle stands underneath chassis
in front of chassis mounted rear towing brackets.11.Lower hoist until vehicle weight is supported
securely on stands.
12.Lower hoist until rear suspension is almost fully
extended.
13.Move rear exhaust to a diagonal position, centre
silencer to right of vehicle.
14.Facing rear of vehicle, twist assembly
anti-clockwise clear of rear axle.
15.Remove rear exhaust assembly from vehicle.
Refit
16.Position rear exhaust assembly over rear axle in
a diagonal position, as for removing.
17.Twist assembly clockwise until it is in mounting
position.
18.Reverse removal procedure instructions 1 to 15
using a new manifold gasket and applying
exhaust sealer to system joints.
19.Examine system for leaks, ensuring that system
does not foul under body components. Rectify if
necessary.

REAR AXLE AND FINAL DRIVE
1
REPAIR REAR AXLE
Service repair no - 51.25.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
the axle when lowering or repositioning
axle.
1.Drain brake system.
2.Support chassis rear.
3.Remove road wheels.
4.Support axle weight with hydraulic jack.
5.Disconnect ABS wiring harness multi-plug at
jump hose bracket, if applicable.
6.Disconnect shock absorbers.
7.Disconnect flexible brake hose at connection
under floor.
8.Disconnect lower links at axle.
9.Mark differential and propeller shaft flanges with
identification marks for assembly. Remove four
nuts and bolts. Lower propeller shaft and tie to
one side.10.Disconnect pivot bracket ball joint at axle
bracket.
11.Release bolts and remove coil spring retaining
plates.
12.Lower axle and remove road springs.
13.Disconnect anti-roll[sway] bar links to axle.
See
REAR SUSPENSION, Repair, Anti-Roll[Sway]
Bar Ball Joint Links
14.Remove axle assembly.
Refit
15.Position axle and fit lower links. Tighten to
176
Nm
16.Reverse removal procedure.
17.Tighten pivot bracket ball joint to axle to
176 Nm.
18.Tighten propeller shaft to differential drive flange
to
47 Nm
19.Bleed brake system.See BRAKES, Repair,
Brake System Bleed

FRONT AXLE AND FINAL DRIVE
1
REPAIR FRONT AXLE ASSEMBLY
Service repair no - 54.15.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
axle when lowering or repositioning axle.
1.Support chassis front.
2.Remove road wheels.
3.Support axle weight with hydraulic jack.
4.Remove radius arms to chassis frame nuts.
5.Disconnect steering damper from track rod.
Using a extractor remove track rod links from
swivel pin arms.
6.Remove four nuts and bolts securing radius
arms to axle bracket.
7.Remove radius arms.
8.Remove bolts securing brake hose brackets.
Refit bolts to prevent oil leakage.
9.Remove ABS sensor, if applicable.
10.Remove bolts from brake calipers and tie to one
side.
11.Remove nuts and washers securing shock
absorbers to axle.
12.Disconnect drag link from swivel pin housing
arm.
13.Remove two nuts and bolts securing panhard
rod to axle bracket. Lift rod clear of axle.
14.Mark for reassembly drive shaft flanges.
Remove four nuts and bolts, tie propeller shaft to
one side.
15.Lower axle assembly and remove road springs.
16.Disconnect anti-roll[sway] bar link.
See FRONT
SUSPENSION, Repair, Anti-Roll[Sway] Bar
Ball Joint Links
17.Remove axle assembly.
Refit
18.Position axle under vehicle, supporting left side
of axle.
19.Reverse removal procedure.
20.Tighten propeller shaft bolts to
47 Nm.
21.Tighten panhard rod to axle bracket to88 Nm.
22.Tighten drag link to hub arm to40 Nm.
23.Tighten upper swivel pin bolts.See
Specifications, torque, Torque Values
24.Tighten radius arms to axle bolts to197 Nm.
25.Tighten radius arms to chassis side member
nuts to
197 Nm.
26.Tighten track rod end to40 Nm.
Fit new split [cotter] pin.

STEERING
5
FAULT DIAGNOSIS Symptom :-
Steering excessively light/sensitive. Excessive
freeplay at steering wheel.
1.Are steering box adjustments correct?
NO -
See Adjustment, Power Steering Box
WARNING: Adjustments of steering box
should not be required while in warranty
period. If box is within warranty, it must be
returned to manufacturer. No attempt must be
made to introduce backlash.
YES - Suspect worn panhard rod or radius arm
bushes Check condition of ball joints and
the lower steering column shaft universal
joints for wear.
See Repair, Lower
Steering Shaft and Universal Joints
Symptom :-
Steering vibration, road wheel shimmy - wobble.
Vibration through the steering linkage powerful
enough to induce high frequency oscillation of the
steering wheel, is generally caused by out of balance
road wheels. However there are a number of other
possible causes of this symptom which if severe, may
be described as shimmy or wobble. Regardless of the
terminology used by the owner/driver to describe the
symptoms, the following diagnostic checks should be
carried out in the order presented.
1.Check the tyres and balance of the road wheels.
See GENERAL SPECIFICATION DATA,
Information, Wheels and Tyres See
WHEELS AND TYRES, Fault diagnosis, Fault
- Symptoms See WHEELS AND TYRES,
Repair, Wheel Balancing
2.Check the steering hydraulic damper function.
See Steering Damper
3.Check steering column universal joints for wear
and correct alignment.
See Repair, Lower
Steering Shaft and Universal Joints
4.Check steering linkage ball joints for wear,
correct alignment and security, including steering
box and tie rod.
See Steering Linkage Inspect
5.Check all front suspension rubbers for wear.
Check all fixing torques, including radius arm
bushes, panhard rod and anti-roll [sway] bar.
See FRONT SUSPENSION, Repair, Panhard
Rod See FRONT SUSPENSION, Repair,
Radius Arm See FRONT SUSPENSION,
Repair, Anti-Roll[Sway] Bar Assembly See
FRONT SUSPENSION, Repair, Front Shock
Absorber
6.Fit new radius arm bushes using NTC 6860. Fit
harmonic damper if vehicle has air suspension.
Fit new nuts, bolts and washers.
7. Coil spring vehicles only- If problem persists
fit damper kit STC 241 (2 off front) and STC
1474 (2 off rear). Road test vehicle.
8.Check the power steering box adjustments and
operation.
See Overhaul, Power Steering Box
9.Check the hub bearing end floats and determine
the condition of the hub bearings. As applicable.
See FRONT AXLE AND FINAL DRIVE, Repair,
Front Hub Assembly
10.Check the resistance and condition of the
swivels.
See FRONT AXLE AND FINAL
DRIVE, Description and operation,
Description
If problem is not diagnosed: Repeat
checks starting at 1.
11.Carry out a full steering geometry check.
See
INTRODUCTION, Information, Steering

FRONT SUSPENSION
5
REPAIR ANTI-ROLL[SWAY] BAR ASSEMBLY FRONT
Service repair no - 60.10.01
KEY
1. Anti-roll[sway] bar
2. Rubber bush
3. Strap
4. Nut, bolt, washer5. Nut and washer
6. Castellated nut and cotter pin
7. Ball joint link arm
Remove
1.Mark for reassembly position of rubber bushes
on anti- roll[sway] bar.
2.Remove four nuts, bolts and washers securing
two bush straps.
3.Remove nuts, bolts, washers and rubber bushes
from ball joint links and remove anti-roll[sway]
bar.Refit
4.Position bushes on anti-roll[sway] bar. Ensure
split points towards axle on RH bush and away
from axle on LH bush.
5.Fit anti-roll[sway] bar with two straps. To ensure
correct fit angled sides of bar should point down
as shown. Loosely fit the bolts, washers and
nyloc nuts.
6.Fit bolt, washers and rubber bushes. Using new
nuts fit anti-roll[sway] bar to ball joint links.
Tighten to
68Nm.
7.Tighten nuts securing straps to30Nm

60FRONT SUSPENSION
6
REPAIR ANTI-ROLL[SWAY] BAR BALL JOINT LINKS
Service repair no - 60.10.04.
Remove
1.Remove two nuts, bolts, washers and rubber
bushes from ball joint links.
2.Remove cotter pin and loosen castellated nut a
few turns.
3.Release ball joint using special tool 18G 1063A
as shown.
4.Remove castellated nut and ball joint link.
Refit
5.Fit ball joint link and castellated nut. Ensure ball
joint link arm points up. Tighten to
40Nmand fit
new cotter pin.
6.Align anti-roll bar to ball joint links.
7.Fit bolts, washers and rubber bushes using new
self locking nuts secure anti-roll[sway] bar to ball
joint links. Tighten to
68Nm.

FRONT SUSPENSION
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
Anti-roll[sway] bar front
- Strap nyloc nuts 30..............................................................................
- Ball link self lock nut 68........................................................................
- Castellated nut 40................................................................................
Drag link to axle 40.........................................................................................
Securing ring for mounting turret 14...............................................................
Radius arm to chassis 176...............................................................................
Panhard rod mounting arm to chassis 88.......................................................
Panhard rod to axle 88....................................................................................
Panhard rod to mounting bracket 88...............................................................
Tie bar to Panhard rod 110..............................................................................
Radius arm to axle (front only) 197..................................................................
Torque values below are for all screws and bolts used except for those that are specified otherwise.
METRIC Nm
M5 6...........................................................................
M6 9...........................................................................
M8 25...........................................................................
M10 45.........................................................................
M12 90.........................................................................
M14 105.........................................................................
M16 180.........................................................................
UNC / UNF
1/4 9...........................................................................
5/16 24.........................................................................
3/8 39...........................................................................
7/16 78.........................................................................
1/2 90...........................................................................
5/8 136...........................................................................