wiring LAND ROVER DISCOVERY 1995 Workshop Manual

GENERAL SPECIFICATION DATA
15
INFORMATION BULBS
REPLACEMENT BULBS TYPE
Exterior lights
Headlamps 12V 60/55W (Halogen)
Headlamps - France amber 12V 60/55W (Halogen)
Auxiliary driving lamps 12V 55W H3 (Halogen)
Sidelamps 12V 5W bayonet
Tail lamps 12V 5/21W bayonet
Reverse lamps 12V 21W bayonet
Stop lamps 12V 21W bayonet
Direction indicator lamps 12V 21W bayonet
Rear side marker lamps 12V 5W capless
Number plate lamps 12V 5W capless
Interior lights
Instrument panel lamps and warning lamps 12V 1.2W bulb/holder unit
Ignition warning lamp (Instrument panel) 12V 2W capless
Interior roof lamps 12V 10W 'Festoon'
Clock illumination 12V 1.2 capless
Cigar lighter illumination 12V 1.2W capless
Door shut face/puddle lamps 12V 5W capless
Auxiliary switch panel illumination (green) 12V 1.2W capless
Heated rear screen warning lamp (amber) 12V 1.2W capless
Hazard warning lamp 12V 1.2W capless
Automatic graphics illumination 12V 5W capless
Heater/air conditioning graphics illumination 12V 1.2W bulb/holder unit
Differential lock warning lamp 12V 1.2W bulb/holder unit
Column switch illumination 12V 1.2W capless
CAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damage
to vehicle wiring and switches.

10MAINTENANCE
4
MAINTENANCE UNDER BONNET [HOOD] MAINTENANCE
CHECK COOLING/HEATER SYSTEMS
Check cooling/heater systems for leaks and hoses for
security and condition.
Cooling system hoses should be changed at first
signs of deterioration.
CHECK CONDITION OF ENGINE MOUNTING
RUBBERS
CHECK BRAKE SERVO HOSE FOR SECURITY
AND CONDITION
CHECK FUEL EVAPORATIVE LOSS CONTROL
SYSTEM FOR LEAKS - V8i CATALYST, Mpi
CHECK FUEL FILLER CAP SEAL FOR LEAKS - V8i
- CATALYST, Mpi
CHECK CONDITION OF HEATER PLUG WIRING
FOR FRAYING, CHAFING AND DETERIORATION -
Tdi
CHECK IGNITION WIRING
Check ignition wiring and high tension leads for
fraying, chafing and deterioration.
CLEAN DISTRIBUTOR CAP - V8i
The electronic ignition employs a Lucas 35DLM8
distributor.
Internal operating parts of distributor are pre-set at
factory and do not normally require resetting.
Adjustments should only be made if unit is known to
be faulty or damaged. Distributor maintenance
consists of following items.
1.Clean outer surfaces of distributor cap to remove
dirt, grease etc.
2.Unclip cap, check cap for cracks.
3.Wipe inside cap with lint free cloth.
4.Check rotor arm, cap and flash shield tracking.
DO NOT DISTURB clear plastic insulating
cover (flash shield) which protects magnetic
pick-up module.
LUBRICATE DISTRIBUTOR ROTOR SPINDLE - V8i
Apply a spot of clean engine oil into rotor spindle after
rotor arm has been removed.
CLEAN/ADJUST SPARK PLUGS - V8i CATALYST
RENEW SPARK PLUGS V8i - V8i CATALYST
Clean, adjust and renew
1.Take great care when fitting spark plugs not to
cross-thread plug, otherwise costly damage to
cylinder head will result.

V8i
9
REPAIR FRONT COVER GASKET
Service repair no - 12.65.04
1.Remove crankshaft pulley.
See Crankshaft
Pulley Assembly. Do not remove pulleys
2.Remove water pump pulley.
3.Release distributor cap clips.
4.Release plug leads from plugs and clips.
5.Place cap and leads to one side.
6.Turn engine until No. 1 piston is at T.D.C.
7.Check position of rotor arm.
8.Remove fixings securing power steering pump
bracket to water pump bracket.
9.Remove power steering pump bracket from
water pump.
10.Remove clips securing wiring to generator
tensioner.
11.Disconnect distributor feed wire.
12.Pivot power steering pump away from front
cover, tighten pivot to retain in position.
13.Disconnect vacuum pipe from distributor.
14.Remove water pump bottom hose.
15.Disconnect oil pressure switch.
16.Disconnect heater hose at water pump.
17.Remove generator tensioner from water pump,
move tensioner aside.
18.Mark distributor position to front cover.
19.Remove distributor clamp, remove distributor.
See ELECTRICAL, Repair, Distributor - V8i
20.Remove fixings sump to front cover.
21.Loosen four adjacent sump fixings.
22.Remove generator support strut from front cover,
move strut aside.
23.Loosen remaining front cover fixings and remove
front cover.
24.Remove front cover gasket.Refit
25.Clean timing cover, clean block face.
26.Lightly grease gasket faces.
27.Fit new gasket to block face.
28.Apply hylosil to sump gasket.
29.Clean threads of cover fixing bolts, apply Loctite
372 to threads.
30.Fit timing cover, fit fixing bolts. Tighten to
28
Nm.
31.Fit generator support strut to front cover.
32.Tighten sump to timing cover fixings to
10 Nm.
33.Tighten sump fixings to10 Nm.
34.Lubricate distributor O ring.
35.Fit distributor in position marked.
36.Align oil pump drive, if distributor does not seat
correctly.
37.Fit distributor clamp. Tighten to
20 Nm.
38.Locate generator tensioner on water pump
bracket.
39.Connect heater hose, tighten clip.
40.Connect oil pressure switch.
41.Connect bottom hose, tighten clip.
42.Connect vacuum pipe to distributor.
43.Loosen power steering pump pivot, lower pump.
44.Connect distributor feed wire.
45.Connect wire ties to generator tensioner.
46.Fit power steering pump bracket to water pump.
Tighten to
28 Nm.
47.Fit power steering pump to bracket.
48.Position distributor cap. Fit plug leads to plugs
and clips.
49.Clip distributor cap in position.
50.Fit water pump pulley. Tighten to
10 Nm.
51.Fit crankshaft pulley.See Crankshaft Pulley
Assembly
52.Tension drive belts correctly.
53.Check ignition timing.
54.Refill cooling system.

Tdi
17
REPAIR VEHICLE SPEED SENSOR
Service repair no - 18.30.22
Remove
NOTE: The following procedure is carried
out with the ramp still raised.
1.Disconnect battery negative lead.
2.Disconnect sensor multi-plug.
3.Remove sensor retaining screw.
4.Remove sensor retaining plate.
5.Remove sensor from transfer box.
Refit
6.Reverse removal procedure.CLUTCH PEDAL SWITCH
Service repair no - 18.30.67
Remove
1.Disconnect battery negative lead.
2.Disconnect switch wiring lucars.
3.Turn rear body of switch to release locknut
4.Remove locknut.
5.Remove switch from mounting bracket.
Refit
6.Reverse removal procedure.

19FUEL SYSTEM
18
REPAIR BRAKE PEDAL SWITCH
Service repair no - 18.30.66
Remove
1.Disconnect battery negative lead.
2.Disconnect switch wiring Lucars.
3.Loosen rear locknut.
4.Remove front locknut.
5.Remove switch from mounting bracket.
Refit
6.Reverse removal procedure.COOLANT TEMPERATURE SENSOR
Service repair no - 18.30.68
Remove
1.Disconnect battery negative lead.2.Disconnect sensor multi-plug.
3.Remove sensor.
4.Clean off water spillage from sensor area.
Refit
5.Fit a new copper washer.
6.Fit sensor and tighten securely.
7.Refill cooling system.
8.Run engine, check for water leaks around
sensor.

19FUEL SYSTEM
6
DESCRIPTION AND OPERATION REV: 09/95 Idle air control (IAC)
Idle speed is controlled by a stepper motor which
consists of two coils. When energised in the correct
sequence the coils move a plunger which opens and
closes the throttle bypass controlling the quantity of
idle air. The stepper motor controls idle speed by
moving the plunger a set distance called a step. Fully
open is zero steps and fully closed 180 steps. Failure
of the stepper motor will result in low or high idle
speed, poor idle, engine stall or non start. The fault is
indicated by illumination of the malfunction indicator
light (MIL) on North American specification vehicles.Heated oxygen sensor (HO2S)
The oxygen sensors consist of a titanium metal
sensor surrounded by a gas permeable ceramic
coating. Oxygen in the exhaust gas diffuses through
the ceramic coating on the sensor, and reacts with the
titanium wire altering the resistance of the wire. From
this resistance change the ECM calculates the
amount of oxygen in the exhaust gas. The injected
fuel quantity is then adjusted to achieve the correct
air/fuel ratio, thus reducing the emissions of carbon
monoxide (CO), hydrocarbons (HC),and oxides of
nitrogen (NO
2). Two HO2 sensors are fitted, one in
each exhaust downpipe just ahead of the catalyst.
Note that if the wiring to these sensors is crossed, the
vehicle will start and idle correctly until the sensors
reach operating temperature. Then the ECM will read
the signals from them and send one bank of cylinders
very rich and the other very weak. The engine will
misfire, have a rough idle and emit black smoke, with
possible catalyst damage.
In the event of sensor failure, the system will default to
'open loop'. Operation and fuelling will be calculated
using signals from the remaining ECM inputs.
The fault is indicated by illumination of the malfunction
indicator light (MIL). ECM diagnostics also uses HO2
sensors to detect catalyst damage, misfire and fuel
system faults.
North American vehicles have two extra HO2 sensors
mounted one after each catalyst. These are used to
determine whether the catalysts are operating
efficently.
CAUTION: Although robust within the
vehicle environment, HO2 sensors are
easily damaged by dropping, excessive
heat and contamination. Care must be exercised
when working on the exhaust system not to
damage the sensor housing or tip.

Mpi
5
REPAIR 6.Remove nut securing throttle cable bracket to
brake servo and release cable.
7.Release grommet from bulkhead and withdraw
cable.
8.Locate cable in bulkhead.
9.Connect cable to throttle pedal.
10.Connect cable to cam.
11.Adjust throttle cable.THROTTLE POTENTIOMETER
Service repair no - 19.22.49
Remove
1.Disconnect throttle potentiometer multiplug.
2.Remove 2 screws securing throttle
potentiometer, remove potentiometer.
Refit
3.Clean mating faces of throttle potentiometer and
throttle housing.
4.Fit throttle potentiometer, fit and tighten screws.
CAUTION: Ensure throttle potentiometer is
correctly engaged with throttle cam and
that wiring outlet faces downwards.
5.Connect multiplug.
6.Check with diagnostic equipment.

CRUISE CONTROL
3
REPAIR
5.Disconnect 2 Lucars from horn contacts.
6.Remove 2 screws securing cruise control switch
to steering wheel.
7.Remove 3 bolts securing mounting bracket to
steering wheel and remove mounting bracket.
8.Remove cruise control switch from steering
wheel.
Refit
9.Reverse removal procedure. Ensuring wiring
harness is routed correctly.
10. Models fitted with airbags:Refit driver's airbag
module and follow all safety precautions.
See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair, Driver's Airbag Module
ROTARY COUPLER
Service repair no - 19.75.54
The rotary coupler is located behind the steering
wheel. Access is gained by removing the steering
wheel and steering column shroud.
NOTE: On vehicles fitted with airbags.See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair, Rotary Coupler
Remove
1.Disconnect battery negative lead.
2.Remove steering wheel.
See STEERING,
Repair, Steering Wheel
3.Release 2 turnbuckles securing lower dash
closing panel and lower.
4.Remove 3 screws securing lower half of shroud
to steering column.
5.Disconnect rotary coupler multiplug from
steering column harness.

30MANIFOLD AND EXHAUST SYSTEM
2
REPAIR Remove
Catalysts - remove and refit 1 to 5
1.Raise vehicle on a ramp [hoist].
2. Catalyst vehicles only:Disconnect two heated
oxygen sensor wiring connectors.
NOTE: NAS models have four heated
oxygen sensors fitted.
3.Remove two nuts securing rear exhaust
assembly to front exhaust assembly.
4.Remove nuts and release front downpipes from
manifolds. Discard gaskets.
5.Lower front exhaust assembly with catalysts (if
fitted), retain olive.
NOTE: Assistance is required for removing
and refitting rear exhaust assembly.
6.Remove bolts securing three hanger brackets to
chassis. Lower exhaust assembly onto rear axle.
Detach rubbers from hanging brackets.
7.Place extended axle stands underneath chassis,
in front of chassis mounted rear towing brackets.
8.Lower ramp[hoist] until vehicle weight is
supported securely on stands.
9.Lower ramp [hoist] until rear shock absorbers
are ALMOST fully extended.
10.Move rear exhaust to a diagonal position, centre
silencer to right of vehicle.
11.Facing rear of vehicle, twist assembly
anti-clockwise clear of rear axle.
12.Remove rear exhaust assembly from vehicle.
Refit
13.Position rear exhaust assembly over rear axle in
a diagonal position, as for removing.
14.Twist assembly clockwise until it is in mounting
position.
15.Reverse removal procedure. 1. to 9. using new
manifold gaskets and applying exhaust sealer to
system joint.
16.Examine system for leaks, ensuring that system
does not foul underbody components. Rectify if
necessary.EXHAUST MANIFOLD - V8i
Service repair no - Left hand - 30.15.10
Service repair no - Right hand - 30.15.11
Remove
1.Disconnect front exhaust pipe(s) from
manifold(s).
2.Tap back bolt locking tabs and remove eight
bolts, lock tabs and washers.
3.Remove manifold(s) and old gaskets.
Refit
4.Ensure that mating surfaces of cylinder head
and exhaust manifold are clean and smooth.
5.Coat threads of each bolt with anti-seize
compound.
6.Place manifold and new gaskets in position on
cylinder head and fit securing bolts, new
lockplates and plain washers. Plain washers are
fitted between manifold and lockplates.
7.Evenly tighten manifold bolts to
20Nmbend
over lockplate tabs.
8.Reconnect front exhaust pipe, using new
exhaust flange gaskets.

ZF
7
REPAIR Accessories removal/fitting
If fitting a replacement transmission assembly to the
vehicle, remove the following items from the existing
assembly and fit to the replacement.
CAUTION: It is important to remove the
spacer from the extension shaft and fit
onto the replacement unit.
50.Breather pipe union and washers from main
gearbox.
51.Breather pipe, union and washers from transfer
gearbox.
52.Main gearbox selector lever.
53.RH mounting bracket assembly.
54.Oil cooler pipe unions.
55.Fit blanks to all apertures where unions have
been removed and blank off pipe ends.
Refit
1.Fit transmission to cradle and hoist.
2.Locate hoist under vehicle and remove torque
convertor retaining strap.
3.Ensure low range gear is engaged.
4.Apply approved sealant to bell housing face.
5.Carefully raise assembly, align bell housing with
flywheel housing and bring mating faces
together.
6.Fit nuts and bolts to secure transmission to
engine.
7.Locate electrical wiring and breather pipes to
position.
8.Secure kick down cable clip to bell housing.
9.Raise hoist sufficiently to take weight.
10.Remove block and jack from engine sump.
11.Fit filler/dipstick tube to gearbox sump and
secure bracket to bell housing.
12.Apply Loctite to torque convertor bolts
13.Working through starter aperture refit the four
torque convertor to flexible drive securing bolts,
rotating crankshaft to gain access to bolt
locations.
14.Refit starter and heatshield.
15.Secure breather pipes and harness with ties.
16.Fit left hand mounting bracket assembly to
gearbox.
17.Raise transmission and support with a suitable
ramp [hoist] jack.
18.Remove two bolts securing transmission to
cradle, lower hoist and remove from under
vehicle.
19.Apply Loctite to above bolts and fit to transfer
gearbox input bearing support plate.
20.Fit chassis cross member.21.Secure gearbox mounting brackets to chassis
cross member.
22.Remove ramp [hoist] jack.
23.Connect electrical leads to differential lock
switch.
24.Connect inhibitor switch multi-plug.
25.Connect selector cable to lever on side of
gearbox.
26.Connect oil cooler pipes to gearbox and secure
retaining bracket to gearbox sump.
27.Secure silencer to chassis and refit exhaust front
pipe.
28.Refit front propeller shaft to transfer gearbox.
29.Refit rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
30.Connect speedometer cable to transfer gearbox.
31.Refill transfer gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
32.Lower ramp [hoist] to ground level.
33.Reconnect turbo-charger hose to inter-cooler.
34.Reconnect top hose to radiator.
35.Refill cooling system with correct mixture of
coolant.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
36.Reconnect kick down cable to fuel injection
pump.
37.Secure breather pipe clip to rear of cylinder
head.
38.Engage harness with clips along top of
bulkhead.
39.On left hand drive vehicles only, connect
multi-plug to top of brake fluid reservoir.
40.Refit insulation pad to rocker cover and inlet
manifold, secure with oil filler cap.
41.Refit gaiter and knob to transfer gear lever.
42.Select high range gear.
43.Reconnect battery terminals.
44.Refill main gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids