tow bar LAND ROVER DISCOVERY 1995 Workshop Manual

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.

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

64REAR SUSPENSION
4
REPAIR ANTI-ROLL[SWAY] BAR ASSEMBLY REAR
Service repair no - 64.35.08.
KEY
1. Anti-roll[sway] bar
2. Rubber bush
3. Strap
4. Nut, bolt, washer5. Nut and washer
6. Ball joint link arm
7. Bolt and washer
8. Castellated nut and cotter pin
Remove
1.Note for reassembly, position of rubber bushes
on anti-roll bar.
2.Remove four nuts, bolts and washers securing
two bush straps.
3.Remove nuts, bolts, washers and rubber bushes
from the ball joint links and remove anti-roll bar.Refit
4.Position rubber bushes on anti-roll bar. Fit joint
towards axle.
5.Fit anti-roll bar with two straps. Ensure ball joint
link arms point down as shown. Loosely fit, bolts,
washers and new nyloc nuts.
6.Fit bolt, washers and rubber bushes. Fit anti-roll
bar to ball joint links. Tighten to
68Nm.
7.Tighten nuts securing straps to30Nm.

76CHASSIS AND BODY
12
REPAIR REAR DOOR TRIM PANEL
Service repair no - 76.34.09
Remove
1.Remove the two screws securing the door pull
and remove it from the door.
2.Remove the finisher from the inner door handle.
3.Using a trim panel removing tool release the
seventeen trim panel fasteners and withdraw the
panel from the door.
4.If necessary remove the sixteen screws securing
the stowage bins to the trim panel and detach
the bins.
Refit
5.Reverse removal procedure.REAR DOOR LOCK AND INNER AND OUTER
RELEASE HANDLES
Service repair no - 76.37.16/74/77/78
Remove
1.Disconnect battery negative lead.
2.Remove the door pull, the trim panel and the
vapour protective sheet, to allow access to the
door handles and lock mechanisms.
3.Disconnect the inner release handle connecting
rod at the lock.
4.Remove the two screws securing the inner
handle and withdraw the handle complete with
connecting rod.
NOTE: Two identical 'Y' shaped levers
(bellcranks) are fitted to the rear door lock
mechanism and are referred to as inner
and outer 'Y' levers; the inner one being the
nearest to the inner door panel.
5.If fitted, remove the central locking actuator
control rod link from the actuator and from the
inner 'Y' lever.
6.Detach the remote button connecting rod at the
inner 'Y' lever and withdraw from inside the door.
7.Detach the lock and barrel connecting rods from
the upper leg of the inner 'Y' lever.

ELECTRICAL
47
REPAIR
10.From above, remove top bolt securing starter
motor and position earth lead aside.
NOTE: To assist removal, use 230 mm
extension bar positioned between engine
mounting bracket and exhaust manifold.
11.Remove bottom bolt securing starter motor.
12.Remove starter motor.Refit
13.Ensure mating faces are clean.
14.Locate starter motor in fitted position and fit
bottom bolt finger tight.
15.Fit top bolt. Tighten to
42 Nm.
16.Bottom bolt. Tighten to42 Nm.
17.Connect feed wires to solenoid terminal. Secure
with nut.
18.Connect Lucar to starter solenoid.
19.Manoeuvre heat shield down and forward to
position bracket against engine mounting.
Engage clip on solenoid.
20.Align bracket to hole using suitable tool and fit
retaining bolt.
21.Clean flange mating surfaces, locate propeller
shaft and align reference marks.
22.Fit bolts and NEW nyloc nuts. Tighten to
48 Nm.
NOTE: Fit bolts with head towards transfer
box and away from differential.
23.Lower vehicle.
24.Reconnect battery negative lead.