1995 LAND ROVER DISCOVERY transmission

12ENGINE
6
REPAIR
106.Remove top starter bolt securing engine earth
cable.
107.Remove nut securing kick-down cable clip to LH
cylinder head.
108.With assistance, raise engine, move aside all
pipes and wires. Move engine clear of vehicle.
109.Lower engine onto bench.
Refit
110.Clean engine and gearbox mating faces.
111.Clean dowel and dowel holes.
112.With assistance raise engine off bench. Lower
and guide engine into engine compartment
ensuring no wires or pipes become trapped.
113.Position clip securing kick-down cable to LH
cylinder head.
114.Fit and tighten nut.
115.Position engine earth cable and secure to starter
with top bolt. Tighten to
45 Nm.
116.Lower engine.
117.With assistance, engage engine with gearbox.
118.Fit 3 bottom bell housing bolts. Tighten to
46
Nm.
119.Lower jack supporting gearbox.
120.Lower engine onto mounting brackets.
121.Fit centre RH bell housing bolt.
122.Fit centre LH bell housing bolt.
123.Fit harness brackets to 2 top bell housing bolts.
124.Fit bolts. Tighten to
46 Nm.
125.Remove plugs from tranmission and oil cooler
pipe.
126.Clean pipe, lubricate NEW 'O' ring and fit to
pipe.
127.Connect pipe to transmission and secure with
union. Tighten to
30 Nm.
128.Align pipe bracket to sump, position spacer and
fit bolt. Tighten to
18 Nm.
129.Fit heatshield and secure with nut.
130.Secure transducer lead to clip on heatshield.131.Slacken bell housing access plate bolt.
132.Move plate aside.
133.Remove block.
134.Align drive plate and torque converter.
135.Fit 2 torque converter bolts.
136.Rotate engine and fit second 2 bolts. Tighten to
45 Nm.
137.Rotate engine and tighten first 2 bolts to Tighten
to
45 Nm.
138.Clean cover plate and mating face.
139.Position cover plate and fit bolts. Tighten to
45
Nm.
140.Position access plate.
141.Fit 2 remaining bolts and tighten all bolts to
Tighten to
9 Nm.
142.Position engine harness around engine.
143.Connect knock sensor multiplug.
144.Connect starter solenoid Lucar.
145.Position starter motor heatshield and secure clip
to solenoid.
146.Align shield bracket to engine mounting bracket
and fit bolt. Tighten to
9 Nm.
147.Clean crankshaft sensor mating faces.
148.Position sensor and connect multiplug.
149.Position/align sensor and shield to backplate. Fit
bolts. Tighten to
6 Nm.
150.Fit tie bar, align to transmission and fit bolts.
Tighten to
25 Nm.
151.Fit tie bar securing nut. Tighten to45 Nm.
152.Fit catalytic converter/front pipe assembly.See
EMISSION CONTROL, Repair, Catalytic
Converter/Front Pipe - 4.0 V8
153.Raise engine.
154.Fit RH mounting rubber.
155.Move engine over.
156.Fit LH mounting rubber.
157.Lower engine.
158.Disconnect hoist.
159.Fit engine mounting nuts. Tighten to
55 Nm.
160.Remove plugs from steering pump and steering
box.
161.Clean PAS hose unions.
162.Lubricate 'O' rings and fit to hose unions.
163.Position hose.
164.Align unions to pump and steering box. Tighten
14mm thread to
15 Nm, 16mm thread to
Tighten to
20 Nm.
165.Remove plugs from feed hose and PAS pump.
166.Connect hose to pump and tighten clip.
167.Untie compressor and position to engine
bracket.
168.Position heatshield and fit bolts. Tighten to
25
Nm.
169.Connect compressor multiplug.
170.Position drive belt.

19FUEL SYSTEM
10
DESCRIPTION AND OPERATION Vehicle speed sensor
The vehicle speed sensor is located on the transfer
box behind the transmission brake. The unit has a
multirole as the vehicle electronic speedometer
sensor and as a sensor for 'surge damping', (a
function which smooths out engine response to sharp
accelerator movement and reduces vehicle 'bucking').
The sensor is an additional input for engine overheat
protection.
Brake and clutch switches
The brake and clutch switches are located on the
pedal box and serve as safety features to the system.
They return information to the ECM which limits
maximum fuel quantity under braking.
Throttle position sensor
The accelerator pedal is connected directly to a
sensor mounted in the pedal box. Driver demand is
relayed back to the ECM to increase or decrease
injected fuel quantity.
Incorporated in the sensor is a backup idle switch
which the system will default to in the event of sensor
failure.
Boost pressure sensor
The boost pressure sensor is mounted on the
bulkhead. It relays boost pressure information to the
ECM which compensates fuel quantity to reduce
smoke during acceleration.
Electro-pneumatic modulator
The electro-pneumatic modulator is located on the
inner wing just forward of the air cleaner. It regulates
vacuum signals from the source to the EGR valve.
The ECM controls the modulator to open the EGR
valve according to required airflow.Exhaust gas recirculation valve
The EGR valve is located on the engine exhaust
manifold and is controlled by vacuum from the
electro-pneumatic modulator.
Once open the EGR valve directs a quantity of
exhaust gas back into the inlet manifold to be burnt
inside the engine. This reduces NOx (Oxides of
nitrogen) emissions of the engine.
Temperature sensors
Water, Fuel and Air temperature sensors monitor
engine conditions and relay their information back to
the ECM which makes adjustments to injected fuel
quantity, injection timing, EGR and corrections to
measured boost pressure and airflow.

19FUEL SYSTEM
2
FAULT DIAGNOSIS BASE IDLE SPEED SETTING
NOTE: Base idle speed is set at factory. It
should not require further adjustment
unless plenum chamber is changed. The
adjustment screw is sealed with a plug to prevent
unauthorised alteration. Check ignition timing
before attempting following procedure, since this
will affect idle speed.
Equipment required
Two blanking hoses.these are manufactured using
a new air by-pass valve hose - Part No.ETC7874. Cut
two equal pieces 90mm long from hose and seal one
end of each, using 13mm diameter bar. Use a suitable
clamp to ensure an air tight seal.
Checking procedure
1.Drive vehicle at least two miles until engine and
transmission are hot. Switch off engine.
2.Check all electrical loads are OFF, including air
conditioning.
3.Remove air by-pass valve hose.
4.Fit blanking hoses to both plenum chamber and
air by-pass valve. Ensure hoses are securely
fitted to prevent air leaks. Note throttle cable and
cruise control actuator have been omitted from
illustration.5.Start engine and check idle speed is within
limits.
See ENGINE TUNING DATA,
Information, Engine 3.9 v8i
Adjusting base idle speed
6.Drill tamper proof plug and insert a self tapping
screw to enable plug to be extracted.
7.Start engine, adjust idle screw clockwise to
decrease or counter-clockwise to increase idle
speed.
8.Stop engine, remove blanking hoses. Reconnect
hose to plenum.
9.Fit new tamper proof plug.

CRUISE CONTROL
1
DESCRIPTION AND OPERATION CRUISE CONTROL COMPONENT LOCATIONS -
Tdi AUTO EDC
COMPONENT LOCATION
1. Cruise control unit Under LH dash...................................................
2. Engagement (on/off) switch Dash panel....................................
3. Cruise control switch Steering wheel...............................................
4. Rotary coupler Steering wheel.........................................................
5. Vacuum pump Box section under jack.........................................................
6. Brake/vent switch Brake pedal....................................................
7. Vehicle speed sensor Transfer box behind transmission brake..............................................
8. Neutral lock-out relay Behind RH lower 'A' post trim casing..............................................
9. Actuator RH engine compartment...................................................................

V8i
1
DESCRIPTION AND OPERATION ENGINE COOLING
Description
The V8i engine uses a pressurised cooling system
and cross flow radiator which is supplied from a
separate header tank. The coolant radiator also
incorporates a section at the left hand end for cooling
the transmission oil and a section at the other end for
cooling the engine oil.The belt driven viscous fan and centrifugal water
pump is located in the engine front cover with ports for
circulation of coolant to both banks of cylinders and
cylinder heads. Coolant returns to the top of the
radiator via ports in the inlet manifold where the
thermostat is mounted horizontally.
Coolant also circulates through the vehicle heating
system and is used to heat air entering the inlet
manifold plenum chamber.
Coolant circulation (engine hot)
1. Cross flow radiator
2. Header tank
3. Viscous fan and water pump
4. Heater pipes
5. Plenum chamber connection
6. Thermostat

26COOLING SYSTEM
4
REPAIR RADIATOR
Service repair no - 26.40.01
Remove
1.Drain cooling system.
See Adjustment,
Coolant
2.Remove viscous coupling and fan assembly.
See Viscous Coupling, Fan Blades, Pulley
and Fan Cowl
3.Release 2 clips and remove fan cowl.
4.Disconnect radiator top hoses.
5.Disconnect four transmission and engine oil
cooler connections to radiator end tanks. Note oil
spillage will occur when connections are
loosened. Blank off exposed oil connections.
6.Disconnect transmission oil temperature sensor.
7.Remove radiator securing brackets from each
side.
8.Remove radiator unit by lifting from its location.
Check condition of rubber mounting pads.Refit
9.Reverse removal procedure.
10.Clean unions and apply sealant.
11.Lubricate new 'O' rings before fitting.
12.Check radiator sealing strips are securely
located.
13.Transfer oil cooler adaptors if fitting new radiator.
14.Ensure that oil cooler connections are tightened
to
30 Nm.before fitting fan blades and cowl.
15.Clean coolant/oil spillage from vehicle.
16.Check all connections for coolant/oil leaks.

CLUTCH
1
DESCRIPTION AND OPERATION DESCRIPTION
The clutch unit fitted with the manual transmission,
comprises a single dry plate friction disc and
diaphragm spring clutch unit, secured to the engine
flywheel.OPERATION
The unit is operated hydraulically by the clutch master
cylinder 12 and a slave cylinder 13 attached to the
transmission bell housing.
1. Crankshaft and flywheel
2. Friction plate
3. Clutch cover
4. Diaphragm spring
5. Pressure plate
6. Fulcrum posts (9) for diaphragm spring
7. Bearing rings (2) for diaphragm spring
8. Retraction links and bolts (3) for pressure plate
9. Release bearing
10. Release lever11. Release lever pivot post
12. Master cylinder
13. Slave cylinder
14. Master cylinder pedal pushrod
15. Primary shaft and taper bearing (in gearbox)
16. Gearbox front cover
17. Primary shaft flywheel bush
18. Pedal pivot and return spring
19. Hydraulic damper (Diesel only)

CLUTCH
1
FAULT DIAGNOSIS CLUTCH ASSEMBLY CONDITIONS
For the clutch to operate correctly as described and
illustrated in the "Description and Operation", it is
important the following conditions are satisfied:-
A. The primary shaft 15 must be free in the
crankshaft spigot bush 17.
B. The friction plate 2 must be able to slide easily
on the splines on the primary shaft 15, to a
position where it does not contact either the
flywheel or the pressure plate.
C. The friction plate must not be distorted or the
linings contaminated with oil, which may cause it
to stick or continue to run in contact with the
flywheel or pressure plate.
A number of faults can develop in the operation of the
clutch for a variety of reasons and although most
faults are due to normal wear at high mileage,
problems can also occur if the unit has been renewed
by an unskilled operator.
Recognising and diagnosing a particular clutch fault is
therefore of paramount importance in ensuring, that
the problem is rectified at the first attempt.
Problems which develop in the clutch are as follows:-
A. Clutch spin/drag
B. Clutch slip
C. Clutch judder/fierceCLUTCH SPIN - DRAG
Symptoms
Clutch spin is that, with engine running and clutch
pedal depressed, the gears cannot be immediately
engaged without making a grinding noise. This
indicates the clutch is not making a clean break.
However, if the clutch pedal is held depressed for
several seconds the friction plate will eventually break
free from the engine and the gear will engage silently.
Clutch spin as it becomes more severe develops into
clutch drag, making the silent engagement of a gear
impossible, regardless of how long the pedal is held
depressed.
CLUTCH SLIP
Symptoms
Clutch slip is most evident climbing a hill or when the
vehicle is moving off from stationary with a heavy
load. As the clutch is released slip occurs between the
engine and the transmission, allowing the engine
speed to increase without a corresponding increase in
vehicle speed.
Clutch slip can develop to the stage where no power
is transmitted through the clutch as the pedal is
released.
CLUTCH JUDDER - FIERCE
Symptoms
Clutch judder or fierce engagement, like slip, is most
likely to occur when the vehicle is moving off from
stationary. As the clutch pedal is released the vehicle
will move rapidly or in a series of jerks, which can not
be controlled even by careful operation of the clutch
by the driver.
It should be noted that a vehicle may display all the
symptoms or any combination of the symptoms
described, depending on the driving conditions vehicle
load and operating temperatures.