water pump LAND ROVER DISCOVERY 1995 Workshop Manual

INTRODUCTION
1
INFORMATION INTRODUCTION
This workshop manual covers vehicles from 1995
model year onwards. Amendments and additional
pages will be issued to ensure that the manual
covers latest models. Amendments and additions
will be identified by the addition of a dated footer
at the bottom of the page.
This Workshop Manual is designed to assist skilled
technicians in the efficient repair and maintenance of
Land Rover vehicles.
Individuals who undertake their own repairs
should have some skill and training, and limit
repairs to components which could not affect the
safety of the vehicle or its passengers. Any
repairs required to safety critical items such as
steering, brakes, suspension or supplementary
restraint system should be carried out by a Land
Rover Dealer. Repairs to such items should
NEVER be attempted by untrained individuals.
WARNINGS, CAUTIONSandNOTESare given
throughout this Manual in the following form:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of personal injury.
CAUTION: This calls attention to
procedures which must be followed to
avoid damage to components.
NOTE: This calls attention to methods
which make a job easier or gives helpful
information.
DIMENSIONS
The dimensions quoted are to design engineering
specification. Alternative unit equivalents, shown in
brackets following the dimensions, have been
converted from the original specification.REFERENCES
References to the left or right hand side in the manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
water pump end of the engine is referred to as the
front.
To reduce repetition, some operations covered in this
Manual do not include reference to testing the vehicle
after repair.
It is essential that work is inspected and tested after
completion and if necessary a road test of the vehicle
is carried out particularly where safety related items
are concerned.
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that Land Rover parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement parts
and accessories: Safety features embodied in the
vehicle may be impaired if other than Land Rover
parts are fitted. In certain territories, legislation
prohibits the fitting of parts not to the vehicle
manufacturer's specification. Torque spanner values
given in the Workshop Manual must be strictly
adhered to. Locking devices, where specified, must be
fitted. If the efficiency of a locking device is impaired
during removal it must be replaced with a new one.
Certain fasteners must not be re-used. These
fasteners are specified in the Workshop Manual.
POISONOUS SUBSTANCES
Many liquids and other substances used are
poisonous and therefore must not be consumed. It is
also advisable to keep all substances away from open
wounds. These substances among others include
anti-freeze, brake fluid, fuel, windscreen washer
additives, air conditioning refrigerant, lubricants and
various adhesives.

04GENERAL SPECIFICATION DATA
10
INFORMATION COOLING SYSTEM 3.9 V8i
System type Pressurised, spill return, thermostatically controlled.....................................................................
water and anti-freeze mixture. Pump assisted thermo
syphon. Coolant radiator combined with oil cooler.
Fan and viscous coupling assembly 11 blade axial flow 433mm diameter.................................
Pump type Centifugal, impellor, belt driven.........................................................................
Thermostat opening 88 degrees..........................................................
Expansion tank cap pressure 15 p.s.i. (system pressure)............................................
STEERING
Power steering box
Make/type Adwest Varamatic - worm and roller box........................................................................
Ratio Variable: straight ahead 19.3:1 on lock 14.3:1.................................................................................
Steering wheel turns, lock-to-lock 3.375....................................
Steering pump
Make/type -V8i ZF - Unicorn.................................................................
Make/type - Mpi & Tdi Hobourn-Eaton series 500......................................................
Steering geometry
Steering wheel diameter 405mm..................................................
Steering wheel diameter airbag model 400mm.............................
Toe-out measurement 0 to 2mm toe out......................................................
Toe-out included angle 0Ê to 0Ê 16'.....................................................
Camber angle 0Ê.................................................................. Check with vehicle in static..............
unladen condition, that is, vehicle
with water,
Castor angle 3Ê..................................................................... oil and five gallons of fuel. Rock..............
the vehicle up and down at the
front to allow
Swivel pin inclination static 7Ê............................................... it to take up a position..............

04GENERAL SPECIFICATION DATA
20
INFORMATION Lubrication
System Wet sump, pressure fed.............................................................................
Pressure, engine warm at normal operating speeds 25 - 55lbf/in
2= 1,76 - 3,87Kgf cm2........
Oil pump:
- Type G-rotor integral with front cover.......................................................................
- Drive off crankshaft nose.....................................................................
Oil pressure relief valve Non-adjustable....................................................
Relief valve spring:
- Full length 51,6mm......................................................................
- Compressed length at 7.71Kg load 31mm................................
Oil filter Screw-on disposable canister.............................................................................
Engine oil cooler Combined with coolant radiator and intercooler...............................................................
FUEL SYSTEM - 300 Tdi
Fuel lift pump type Mechanical with hand primer............................................................
Fuel lift pump pressure 42 - 55 kpa at 1800 rpm.....................................................
Fuel filter Paper element in disposable canister..........................................................................
Air cleaner Paper element type........................................................................
COOLING SYSTEM - 300 Tdi
System type Pressurised, spill return, thermostatically controlled.....................................................................
water and anti freeze mixture. Pump assisted thermo
syphon. Coolant radiator combined with oil cooler and
turbo intercooler.
Cooling fan 11 blade axial flow 433 mm diameter. 1.29:1 drive.......................................................................
ratio. Viscous coupling.
Pump type Centrifugal, impellor, belt driven.........................................................................
Thermostat opening 88° .........................................................
Expansion tank cap pressure 15lbf/in
2= 1,06Kgf cm2(system pressure) ...........................................
CLUTCH - 300 Tdi
Type Valeo diaphragm spring.................................................................................
Centre plate diameter 235 mm.......................................................
Facing material Verto F202 grooved.................................................................
Release bearing Ball journal...............................................................

LUBRICANTS, FLUIDS AND CAPACITIES
5
INFORMATION ANTI-FREEZE
ENGINE TYPE MIXTURE STRENGTH PERCENTAGE PROTECTION
CONCENTRATION LOWER
TEMPERATURE
LIMIT
V8i Engine One part anti-freeze
Diesel Engine One part water 50%
Complete protection-33°F
Vehicle may be driven away immediately from cold - 36°C
Safe limit protection-41°C
Coolant in mushy state. Engine may be started and driven away after warm-up
period-42°F
Lower protection-47°C
Prevents frost damage to cylinder head, block and radiator. Thaw out before
starting engine-53°F
CAUTION: Anti-freeze content must never be allowed to fall below 25% otherwise damage to the
engine is liable to occur. Also, anti-freeze content should not exceed 60% as this will greatly
reduce the cooling effect of the coolant.
FUEL REQUIREMENTS
Catalyst vehicles
Vehicles equipped with catalytic converter are designed to use ONLY unleaded fuel. Unleaded fuel must be used
for the emission control system to operate properly. Its use will also reduce spark plug fouling, exhaust system
corrosion and engine oil deterioration.
Using fuel that contains lead will result in damage to the emission control system and could result in loss of
warranty coverage. The effectiveness of the catalysts in the catalytic converters will be seriously impaired if leaded
fuel is used. The vehicle is equipped with an electronic fuel injection system, which includes two oxygen sensors.
Leaded fuel will damage the sensors, and will deteriorate the emission control system.
Regulations require that pumps delivering unleaded fuel be labelledUNLEADED.Only these pumps have nozzles
which fit the filler neck of the vehicle fuel tank.

MAINTENANCE
7
MAINTENANCE
CHECK/ADJUST VALVE CLEARANCES. - Tdi
Valve adjustment.See GENERAL SPECIFICATION
DATA, Information, 300 Tdi Engine
RENEW FUEL FILTER ELEMENT - Tdi
Drain off water and sediment
CAUTION: It is essential that any water
and sediment in fuel filter is drained off, as
water in fuel can result in damage to
injection pump.
1.Hold a small receptacle beneath drain cock.
Unscrew the drain cock half a turn.
2.Drain off water and sediment.
3.Tighten the drain cock immediately fuel starts to
flow from drain cock.
NOTE: Any delay in tightening drain cock
when fuel starts to flow could possibly
mean bleeding fuel system.
Renew fuel filter element
1.Clean area around filter, place a container
beneath.
2.Unscrew filter, a quantity of fuel will be released,
and discard filter.
3.Wet seal of new filter with fuel.
4.Screw new filter into position.
5.Ensure that drain cock is secure.
RENEW AIR CLEANER ELEMENT V8i CATALYST
Mpi - Tdi - V8i NON CATALYST
To renew air cleaner element - V8i, Mpi,Tdi
See FUEL SYSTEM, Repair, Air Cleaner

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
17
MAINTENANCE
CHECK/TIGHTEN FRONT AND REAR AXLE
SUSPENSION LINK FIXINGS, CHECK CONDITION
OF MOUNTING RUBBERS
DRAIN FUEL SEDIMENTER - Tdi
Fuel sedimenter
The sedimenter is attached to left-hand side of
chassis frame near fuel tank. It increases the working
life of the fuel filter by removing larger droplets of
water and larger particles of foreign matter from fuel.
Drain off water
1.Loosen drain plug, allow water to run out.
Tighten plug immediately pure diesel fuel starts
to flow.
RENEW FUEL FILTER
WARNING: Ensure that fuel handling
precautions given in Section 01 -
Introduction regarding fuel handling are
strictly adhered to when carrying out following
instructions.
See INTRODUCTION, Information,
Fuel Handling Precautions
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
1.Depressurise fuel system.
See FUEL SYSTEM,
Repair, Depressurising Fuel System
2.The fuel line filter is located on right hand
chassis side member forward of fuel tank filler
neck. Access to filter is gained through right
hand rear wheel arch.
3.Thoroughly clean area around hose connections
to prevent ingress of foreign matter into fuel
system.
4.Loosen two fuel unions and remove hoses from
filter canister.
5.Release securing bolt and bracket, remove filter
from chassis side member.
6.Fit a new filter observing direction of flow arrow
on canister.
7.Fit inlet and outlet hoses. Tighten to
30 Nm.
8.Refit fuel pump relay.
9.Reconnect battery negative lead.
10.Recode radio.
11.Start engine and inspect hose connections for
fuel leaks.

Tdi
1
REPAIR DRIVE BELT INFORMATION
A single 'serpentine drive belt' drives all the
ancilliaries bar the air conditioning compressor, which
has a separate drive belt. It is essential that the belts
are fitted exactly as shown. It should also be noted
that the water pump/viscous fan is driven in a
clockwise direction.
A drive belt tensioner automatically tensions the drive
belt, eliminating the need for tensioning individual
drive belts. Turning the tensioner pulley in a clockwise
direction will release drive belt tension.
Under normal highway use the belt must be changed
at 160,000 kilometres, 96,000 miles or eight years
whichever occurs first.
The drive belt must be examined at every service and
replaced if necessary.Off road driving
Regular examination of the drive belt is essential if the
vehicle is used off road. The vehicle driver should be
requested to identify the type of mileage the vehicle
has covered.
After every off road session the owner should inspect
the belt for cuts and possible damage caused by
stones. If belt has jumped, reposition belt correctly. A
new belt must be fitted at the next service or before,
dependant on the type of damage sustained.
Fan cowl
To ensure easy access to the drive belt the top portion
of the fan cowl is detachable.
Check condition
Check condition of drive belt. Renew a belt that shows
signs of wear, splitting or oil contamination.

12ENGINE
20
REPAIR CYLINDER HEAD GASKET
Service repair no - 12.29.02
Remove
1.Disconnect battery negative lead.
2.Remove bonnet [Hood].
See CHASSIS AND
BODY, Repair, Bonnet [Hood]
3.Drain coolant.
4.Remove air cleaner assembly.
See FUEL
SYSTEM, Repair, Air Cleaner
5.Detach crankcase ventilation valve and side
breather hose from rocker cover and move to
one side.
6.Remove injection pipes.
7.Disconnect spill rail from fuel injectors.
8.Remove fuel injectors and sealing washers.
Identify each injector to the location from which it
is removed.
See FUEL SYSTEM, Repair,
Injectors
9.Remove inter-connecting harness from glow
plugs.
10.Remove glow plugs.
See FUEL SYSTEM,
Repair, Glow Plugs
11.Remove top hose, radiator to thermostat.
12.Disconnect by-pass hose from thermostat.
13.Disconnect hose, thermostat to water pump.
14.Disconnect water temperature sensor lead.
15.Remove hose inter-cooler to induction manifold.
16.Remove induction manifold.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
Manifold - Tdi
17.Remove exhaust manifold and turbocharger
assembly.
See MANIFOLD AND EXHAUST
SYSTEM, Repair, Exhaust Manifold - Tdi
18.Disconnect heater hose from water pump and
move heater rail aside.
19.Disconnect heater hose from rear of cylinder
head.
20.Remove bolt securing air cleaner mounting
bracket to support strut.
21.Remove bolt securing harness bracket to
cylinder head.
22.Remove rear lifting bracket, this will also release
clips securing transmission and engine breather
pipes and multiplug. Note loose spacer under
clip securing engine breather pipe and multiplug.

12ENGINE
2
SPECIFICATIONS, TORQUECylinder head
Cylinder head to cylinder block See repair section......................................................
Stub pipe heater feed 22.................................................................................
Water temperature sensor 14.........................................................................
Blanking plug cylinder head 14.......................................................................
Engine lifting brackets 25................................................................................
Electrical harness clip bracket 25...................................................................
Exhaust manifold stud 10................................................................................
Exhaust manifold nut 45.................................................................................
Inlet manifold stud 8.......................................................................................
Inlet manifold nut and bolt 25..........................................................................
Air temperature sensor, inlet manifold 14.......................................................
Blanking plug, inlet manifold 14......................................................................
Heatshield to inlet manifold 6.........................................................................
Glow plug 20...................................................................................................
Glow plug terminal nut 2................................................................................
Injector clamp (stud) 8...................................................................................
Injector clamp (nut) 25....................................................................................
Thermostat housing 25...................................................................................
Water outlet elbow to thermostat housing 25..................................................
Water temperature switch, thermostat housing 11..........................................
Plug thermostat housing 6.............................................................................
Rocker shaft pedestal bolt 5 + 50° .....................................................................
Rocker cover (stud) 8.....................................................................................
Rocker cover (fixing nut) 10............................................................................
Breather cyclone to rocker cover 9................................................................
Tappet adjusting nut 16..................................................................................
Front cover to cylinder block 25......................................................................
Front cover plate to front cover 25..................................................................
Static idler - timing belt (stud) 10.....................................................................
Static idler - timing belt (nut) 45......................................................................
Tensioner (timing belt) 45...............................................................................
Camshaft hub bolt 80......................................................................................
Timing pulley to camshaft hub 25...................................................................
Fuel injection pump (stud) 8...........................................................................
Fuel injection pump (nut) 25...........................................................................
Abutment bracket to injection pump 25...........................................................
Support bracket injection pump to cylinder block 25.......................................
Fuel injection pump access plte to front cover plate 25..................................
Timing pulley to injection pump hub 25...........................................................
TV Damper pulley bolt to crankshaft 80 + 90° .....................................................
Fan pulley to hub 25.......................................................................................
Fan and viscous coupling to hub 45...............................................................
Auto tensioner, auxiliary drive (stud) 14..........................................................
Auto tensioner, auxiliary drive (nut) 45...........................................................
Auxiliary mounting bracket to cylinder block (stud) 8.....................................
Auxiliary mounting bracket to cylinder block (bolt and nut) 25........................
Water pump to block and mounting plate 25..................................................
Water pump pulley to hub 25..........................................................................