1995 LAND ROVER DISCOVERY fuel pump

Tdi
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
Engine block
Bearing cap 133...............................................................................................
Blanking plug, oil gallery, rear 37....................................................................
Oil squirt jet assembly 17................................................................................
Drain plug, cylinder block 25...........................................................................
Oil squirt jet, vacuum pump cam 7.................................................................
Connecting rod to cap 59................................................................................
Oil pick up assembly to bearing cap 9...........................................................
Oil pick up assembly to front cover 25............................................................
Camshaft thrust plate 9..................................................................................
Oil drain pipe to block (internal) 25.................................................................
Oil drain pipe to block (external) 25................................................................
Sump to cylinder block and front cover 25......................................................
Drain plug, oil sump 35...................................................................................
Tappet guide 14..............................................................................................
Breather side cover assembly 25....................................................................
Baffle plate to breather side cover 4..............................................................
Vacuum pump 25............................................................................................
Fuel lift pump 25.............................................................................................
Flywheel housing 45.......................................................................................
Flywheel housing clutch cover stud 10...........................................................
Plug, flywheel housing 12...............................................................................
Rear oil seal assembly 25...............................................................................
Oil filter adaptor 45..........................................................................................
Waxstat adaptor to oil filter adaptor 9............................................................
Oil pressure switch 17.....................................................................................
Oil filter, spin on 13.........................................................................................
Oil cooler unions to filter adaptor 45...............................................................
Oil level tube 25..............................................................................................
Engine mounting foot to cylinder block 85......................................................
Engine mounting foot to flywheel housing 45.................................................
Engine mounting foot rubber to mounting foot (bolt and nut) 85.....................
Flywheel to crankshaft 146..............................................................................
Clutch cover plate to flywheel 34....................................................................
Flex drive plate to crankshaft (auto) 146..........................................................
Flex drive plate to ring gear (auto) 25.............................................................
Flex drive plate to torque converter (auto) 45.................................................

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..........................................................................

Tdi
3
SPECIFICATIONS, TORQUE Turbo charger oil drain adaptor to block 42....................................................
Oil drain pipe to turbocharger 25....................................................................
Turbocharger oil drain pipe to adaptor 38.......................................................
Turbocharger oil feed pipe adaptor to block 25...............................................
Turbocharger oil feed pipe to adaptor 25........................................................
Oil feed pipe to turbocharger 19.....................................................................
Turbocharger to cylinder head (stud) 10.........................................................
Turbocharger to cylinder head (nut) 45...........................................................
Turbocharger to blanking plate 25..................................................................
Turbocharger to EGR valve 25.......................................................................
EGR delivery tube to valve 25........................................................................
EGR delivery tube to mixing tube 25..............................................................
Fuel lift pump to filter (union) 15.....................................................................
Fuel filter from lift pump (banjo bolt) 33...........................................................
Fuel filter to fuel injection pump (banjo bolt) 33..............................................
Fuel injection pump from fuel filter (banjo bolt) 25..........................................
Injector pipes to injectors and fuel injection pump 29.....................................
Spill rail to injectors (banjo bolt) 10.................................................................
Spill rail to injection pump (banjo bolt) 25.......................................................
Boost pipe injection pump (banjo bolt) 10.......................................................
Plug, rear of injection pump 29.......................................................................
PAS pump to mounting plate 25.....................................................................
PAS pump mounting plate to auxiliaries mounting bracket 25........................
PAS pump pulley to hub 25............................................................................
Generator to auxiliaries mounting bracket 25.................................................
Starter motor (bolt and nut) 45........................................................................
Tachometer electrical connection 4...............................................................
Air conditioning compressor
Compressor mounting bracket to front cover 45.............................................
Compressor to mounting bracket (stud) 8......................................................
Compressor to mounting bracket (nut) 25......................................................
Belt tensioner pulley to tensioner arm 45........................................................
Belt tensioner assembly to front cover plate 25..............................................
Idler pulley to front cover plate 45...................................................................
Compressor belt guard (nut) 25......................................................................
Sensors to water outlet elbow (air/con) 25......................................................
Blanking plug, water outlet elbow (air/con) 25................................................
Generator mounting bracket to front cover 45................................................
Generator to mounting bracket 85..................................................................
Generator pulley to hub 95.............................................................................
Generator belt guard 25..................................................................................

V8i
1
DESCRIPTION AND OPERATION DESCRIPTION
The V8i engine has cast aluminium cylinder heads
and cylinder block. The two banks of steel cylinder
liners which are pressed down to stops in the block,
are set at 90°to one another. The three ringed
aluminium pistons transmit the power through the
connecting rods to a cast iron five bearing crankshaft,
which drives the centrally located camshaft via a
duplex type chain.
The electronic ignition distributor is driven by a gear
off the front of the camshaft and the lubrication oil
pump is driven by a gear off the front of the
crankshaft. The overhead inlet and exhaust valves are
operated by rocker shafts, pushrods and self adjusting
hydraulic tappets.
Multiport fuel injection ensures that engine
performance, economy and exhaust emissions are
automatically correct for the demands of highway and
off road operation.

V8i
3
FAULT DIAGNOSIS ENGINE STARTING PROBLEMS
Engine fails to crank in park or neutral (Automatic
Transmission)
1.Is battery in good state of charge?
NO -
See INTRODUCTION, Information,
Jump Starting
YES - Continue.
2.Is automatic transmission inhibitor switch faulty
or gear selection linkage incorrectly adjusted?
YES -
See AUTOMATIC GEARBOX, Repair,
Inhibitor Switch
,
NO -
See Electrical Trouble Shooting
Manual.
If problem is not diagnosed repeat tests, starting
at 1.
Engine fails to crank (Manual Transmission)
1.Is battery in good state of charge?
NO -
See INTRODUCTION, Information,
Jump Starting
YES -See Electrical Trouble Shooting
Manual.
If problem is not diagnosed repeat tests, starting
at 1.
Engine cranks but fails to start
1.Is the cranking speed fast enough (120 rpm)?
NO -
See INTRODUCTION, Information,
Jump Starting
If necessary also.See Electrical Trouble
Shooting Manual.
YES - Continue.
2.Is there combustion in any cylinder?
NO -
See ELECTRICAL, Fault diagnosis,
Lucas Constant Energy Ignition
System - V8i See Electrical Trouble
Shooting Manual.
YES - Continue.
3.Are the fuel supply, tank, pump, ventilation and
emission control systems in correct working
order or the fuel contaminated?
NO -
See FUEL SYSTEM, Repair, Fuel
Filter See FUEL SYSTEM, Repair,
Fuel Tank See FUEL SYSTEM, Repair,
Fuel pump and Sender Unit See
EMISSION CONTROL, Description and
operation, Emission control
If problem is not diagnosed repeat tests, starting
at 2.ENGINE RUNNING PROBLEMS
Engine runs at high speed but will not idle (stops)
Engine idle speed erratic Engine starts but stops
immediately
Engine stalls Engine misfires/hesitation
1.Multiport fuel injection.
See Electrical Trouble
Shooting Manual. See ELECTRICAL, Fault
diagnosis, Lucas Constant Energy Ignition
System - V8i
Check brake vacuum connections.See
BRAKES, Description and operation, Brake
Servo Unit
Check heater/ventilation unit vacuum
connections.
See HEATING AND
VENTILATION, Description and operation,
Heating and Ventilation Unit
If problem is not diagnosed continue.
2.Are HT leads correctly routed and clipped?
NO -
See ELECTRICAL, Repair, Distributor
- V8i
YES - Continue.
3.Is fuel supply, tank, pump, ventilation and
emission control systems in correct working
order or the fuel contaminated?
NO -
See FUEL SYSTEM, Repair, Fuel
Filter See FUEL SYSTEM, Repair,
Fuel Tank See FUEL SYSTEM, Repair,
Fuel Pump and Sender Unit See
EMISSION CONTROL, Description and
operation, Emission Control
If problem is not diagnosed repeat tests, starting
at 1.
Engine lacks power/poor performance
1.Is throttle travel restricted or cable incorrectly
adjusted?
YES - Check thickness of carpets.
See FUEL
SYSTEM, Repair, Throttle Cable See
FUEL SYSTEM, Repair, Accelerator
Pedal
NO - Continue.
2.Are the Ignition and Multiport Fuel Injection
systems in order?
NO -
See Electrical Trouble Shooting
Manual.A1 See ELECTRICAL, Fault
diagnosis, Lucas Constant Energy
Ignition System - V8i See
ELECTRICAL, Repair, Distributor - V8i
YES - Continue.

12ENGINE
4
FAULT DIAGNOSIS 3.Are fuel supply, tank, pump, ventilation and
emission control systems in correct working
order or the fuel contaminated?
NO -
See FUEL SYSTEM, Repair, Fuel
Filter See FUEL SYSTEM, Repair,
Fuel Tank See FUEL SYSTEM, Repair,
Fuel Pump and Sender Unit
YES - Suspect valves held open by hydraulic
tappets due to high oil pressure.
See
Engine Oil Pressure Test
4.Is oil pressure high?
YES - Remove oil filter and cooler adaptor and
check pressure relief valve strainer gauze
for blockage and that the relief valve is
not stuck closed.
See Description and
operation, Description
NO - Carry out cylinder compression tests to
determine condition of head gaskets and
valves.
See Cylinder Compression -
Test
5.Are cylinder compressions satisfactory?
NO -
See Repair, Cylinder Heads - Renew
YES - Check brake vacuum connections.See
BRAKES, Description and operation,
Brake Servo Unit
Check heater/ventilation unit vacuum connections.
See HEATING AND VENTILATION, Description and
operation, Heating and Ventilation Unit
If problem is not diagnosed: Continue.
6.Are the brakes binding?
YES - Investigate cause of binding.
NO - Continue.
7.Automatic Transmission only. Is the Torque
Converter and Transmission operating correctly?
Carry out Road test, Static tests and Stall tests
to determine condition of Automatic
transmission.
If problem is not diagnosed: repeat tests starting at 1.Engine backfires into exhaust system
1.Are there any leaking joints/connections or holes
in the exhaust system?
YES -
See MANIFOLD AND EXHAUST
SYSTEM, Repair, Exhaust System
Complete
NO - Continue.
2.Is distributor fitted correctly, HT leads in correct
firing order and routed correctly?
NO -
See ELECTRICAL, Repair, Distributor
- V8i
YES - Continue.
3.Is air fuel ratio correct?
NO - Check multiport fuel injection.
See
Electrical Trouble Shooting Manual.
Check brake vacuum connections.See
BRAKES, Description and operation, Brake
Servo Unit
Check heater/ventilation unit vacuum
connections.
See HEATING AND
VENTILATION, Description and operation,
Heating and Ventilation Unit
Check the crank case and fuel tank ventilation
system.
See EMISSION CONTROL,
Description and operation, Emission Control
YES - Continue.
4.Are cylinder compressions satisfactory?
NO - Carry out compression test to check for
leaking gaskets valves etc.
See
Cylinder Compression - Test
See Repair, Cylinder Heads - Renew
If problem is not diagnosed: repeat tests starting
at 1.

V8i
5
REPAIR CYLINDER HEADS - RENEW
Service repair no - 12.29.15
1.Remove cylinder heads and gaskets.
See
Cylinder Head Gaskets - Renew
2.Remove spark plugs.
3.Using spring compressor LRT-12-034, remove
seals, valves, collets, springs and caps.
CAUTION: Keep components in fitted
order
4.From left hand cylinder head, remove earth lead
studs.
5.Remove three bolts securing power steering
pump mounting bracket to cylinder head.
6.Remove four bolts securing generator mounting
bracket to cylinder head.
7.Right hand cylinder head, remove rear lifting
bracket.
8.Fit lifting bracket to new right hand cylinder
head.
9.Fit mounting brackets and earth lead studs to
new cylinder head. Tighten bolts to
30 Nm.
10.Regrind valves- refer to engine overhaul
publication
11.Lubricate valve stems, fit valves, springs, and
caps. Fit new inlet and exhaust valve stem seals.
12.Using spring compressor LRT-12-034, compress
springs, fit collets. Tap valve to check correct
collet seating.
13.Fit spark plugs.
14.Fit cylinder heads with new gaskets.
See
Cylinder Head Gaskets - Renew
ROCKER COVER - RIGHT HAND - RENEW
Service repair no - 12.29.41
1.Disconnect battery negative lead.
2.Disconnect purge pipe from charcoal canister at
plenum.
3.Remove breather pipe from rocker cover.
4.Remove coolant pipes from inlet manifold.
5.Remove spark plug leads from plugs and
retaining clips.
6.Remove four rocker cover bolts. Moving fuel
pipes aside, remove rocker cover.
7.Discard rocker cover gasket.
8.Remove plug lead retaining clips from rocker
cover, fit to new rocker cover.
9.Clean and dry rocker cover and cylinder head
mating faces, using Bostik cleaner 6001.
NOTE: Gasket fits one way round only. It
must be fitted accurately, first time.
Subsequent movement will destroy
bonding.
10.Apply Bostik 1775 impact adhesive to rocker
cover seal face and gasket, using a brush to
ensure an even film. Allow adhesive to become
touch dry.

V8i
13
REPAIR
NOTE: Release bolts securing compressor
mounting bracket to engine and remove
bracket to enable temporary lifting eye
ETC 5964 to be fitted. Secure lifting eye to
mounting bracket fixing points with suitable bolts
of equivalent size, pitch and thread. Leave lifting
eye attached until engine is reinstalled in vehicle.
15.Place drain tray underneath vehicle.
16.Disconnect hose from reservoir to power
steering pump. Secure hose end above level of
fluid reservoir to avoid unnecessary loss of fluid.
17.Disconnect power steering pump to power
steering box hose. Seal hose and pump
openings with masking tape to prevent ingress of
dirt. Wipe away any fluid spillage from chassis or
steering box.
18.Disconnect fuel temperature and coolant
temperature sensor multi-plugs.
19.Disconnect leads from coil.
20.Identify each injector multi-plug for re-assembly
and disconnect plugs from injectors.
21.Manoeuvre harness from behind fuel rails and
place to one side clear of engine assembly.
22.Remove two clamps securing gearbox oil cooler
pipes to engine block.
23.Remove engine mounting fixings on both sides
of cylinder block.
24.Fit lifting chains to engine lifting eyes as shown
in illustration RR1780E.
1. L/H Front chain 356mm total overall length.
2. R/H Front chain 330mm total overall length.
3. R/H Rear chain 457mm total overall length.
NOTE: All chain dimensions are measured
from end of lifting hook to end of last link
in chain.
25.Fit chain lifting eye to a suitable engine hoist.
Raise hoist high enough to enable engine
mountings to be removed, and withdraw rubber
mountings.
26.Lower hoist until engine rests securely on engine
mounting brackets. Remove lifting chains and
hoist.
27.Disconnect two heater hoses located on top of
right hand rocker cover.
28.Remove ground strap from rear of left hand
cylinder head. DO NOT remove from retaining
clip.
29.Remove all electrical harnesses from retaining
clips at rear of engine.
30.Remove transmission breather pipes from
retaining clip on rear lifting eye.
31.Remove top two bolts securing bell housing to
cylinder block.
32.Raise front of vehicle, lower vehicle on to axle
stands.
33.Remove bell housing bottom cover. Remove
gasket from bell housing face.
34.Remove nuts securing exhaust downpipes to
manifolds, remove heat shield from right hand
side downpipe.
35.Remove electrical leads from starter motor
solenoid. Disconnect multi-plug from oil level
sensor on side of sump, if fitted.
NOTE: Instructions 37, 38 and 39 refer to
automatic vehicles only.
36.With assistance rotate engine at crankshaft
pulley until two access holes in drive plate/ring
gear assembly are visible.
37.Remove two bolts visible through access holes.
Mark one access hole and one bolt hole to
ensure unit is reassembled in its original position
38.Rotate crankshaft 180Ê until two remaining
access holes are visible, remove two bolts.