1995 LAND ROVER DISCOVERY check oil

Mpi
17
REPAIR 22.Raise vehicle
23.Remove 4 nuts securing downpipe to exhaust
manifold.
24.Release downpipe from exhaust manifold.
25.Collect gasket.
26.Release 4 screws and remove spark plug cover.
27.Release spark plug leads from spark plugs and
release from clips. Place aside.
28.Remove camshaft covers.
29.Remove timing belt.
See Camshaft Front Oil
Seal
30.Progressively loosen and remove 10 cylinder
head bolts in sequence shown.
31.Remove cylinder head complete with manifold,
place on blocks to prevent damage.
32.Remove and discard cylinder head gasket.
33.Remove location dowels from cylinder block.
34.Inspect cylinder head for damage, cracks and
burning.
35.Inspect cylinder block. Ensure that the oil
restrictor is clear and fitted below the block face.
36.Clean all traces of gasket material from head
and block mating faces, using release agent and
plastic scraper.
37.Check cylinder head and block faces for
warpage:
Longitudinal warp = 0.1 mm max.
Transverse warp = 0.1 mm max.
Diagonal warp = 0.1 mm max.
38.Decarbonize cylinder head and pistons if
necessary.
39.Clean cylinder head bolt threads with a wire
brush, check for damage, replace if necessary.
40.Check cylinder block threads by running bolts
into threads using fingers only. Clean any tight
threads using M11 x 1.5 mm tap. Remove all
traces of oil from bolt holes.

Mpi
23
REPAIR CHECK CAMSHAFT DRIVE BELT
Service repair no - 12.65.17
CAUTION: This check must be carried out
at the service intervals specified and
whenever carrying out any repair which
requires the timing belt to be disturbed. Pay
particular attention for signs of belt splitting at
base of teeth.
1.Remove 5 bolts securing timing belt upper cover
2.Remove upper cover.
3.Using a socket and extension bar on the
crankshaft pulley bolt, rotate engine to allow the
timing belt to be inspected.
CAUTION: Do not use camshaft gears or
retaining bolts to rotate engine.
4.Check timing belt condition, renew any belt that
shows signs of oil contamination, cracking,
fraying or splitting at base of teeth.
CAUTION: Cause of oil contamination, if
present, must be rectified.
5.Clean timing belt upper cover.
6.Position upper cover.
7.Fit upper cover securing bolts.

Mpi
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
Timing belt upper cover bolts 5......................................................................
Timing belt centre cover bolts 5.....................................................................
Timing belt lower cover bolts 5......................................................................
Crankshaft pulley centre bolt 85.....................................................................
Crankshaft pulley to timing gear bolts 10........................................................
Tensioner pulley bolt 30..................................................................................
Spark plugs 27................................................................................................
Timing belt upper backplate bolts 10..............................................................
Camshaft gear bolts 65...................................................................................
Exhaust camshaft rear oil seal cover plate bolts 10........................................
Inlet camshaft rear oil seal cover plate bolts 10..............................................
Crankshaft rear oil seal housing bolts 10........................................................
Engine sump bolts
Stage 1 3...............................................................................................
Stage 2 10..............................................................................................
Bell housing nuts 40........................................................................................
L.H. and R.H. engine mounting nuts 85..........................................................
Exhaust manifold to downpipe nuts 10...........................................................
Exhaust downpipe to silencer box nuts 30......................................................
Air conditioning compressor to engine block bolts 45.....................................
Cylinder head bolts
Stage 1 45..............................................................................................
Stage 2 80..............................................................................................
Stage 3 - Further 90°
Camshaft cover bolts 10.................................................................................
Knock sensor 15.............................................................................................
Ignition coil bracket bolts 25............................................................................
Coolant temperature sensor 15......................................................................
Crankshaft sensor bolts 7..............................................................................
Fuel temperature sensor 7.............................................................................
Intake air temperature sensor 7.....................................................................
Fuel rail to inlet manifold bolts 10...................................................................
Fuel feed hose stiffening bracket bolts 7.......................................................
Throttle housing mounting nuts 7...................................................................
Fuel pressure regulator steady bracket bolts 7..............................................
Oxygen sensor 55...........................................................................................

Tdi
3
REPAIR TURBOCHARGER OIL FEED PIPE
Service repair no - 19.42.14
Remove
1.Disconnect battery negative lead.
2.Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Manifold
and Exhaust System - Tdi
3.Remove banjo bolt securing oil feed pipe to
turbocharger, discard 2 sealing washers.
4.Unscrew union, disconnect oil feed pipe from
cylinder block.
CAUTION: Plug the connections.
5.Move oil feed pipe from behind turbocharger and
remove.
Refit
6.Reverse removal procedure. use new sealing
washers.
7.Tighten banjo bolt to
20 Nm.
8.Check/top-up engine oil level.TURBOCHARGER OIL DRAIN PIPE
Service repair no - 19.42.12
Remove
1.Disconnect battery negative lead.
2.Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Manifold
and Exhaust System - Tdi
3.Unscrew union and disconnect oil drain pipe
from cylinder lock.
4.Remove 2 bolts securing oil drain pipe to
turbocharger.
5.Remove oil drain pipe, remove and discard
gasket.
CAUTION: Plug the connection.
Refit
6.Ensure mating surfaces of oil pipe, turbocharger
and engine block are clean.
7.Reverse removal procedure. Use a new gasket.
8.Tighten oil drain pipe to turbocharger bolts to
25
Nm.
9.Check/top-up engine oil level.

19FUEL SYSTEM
4
REPAIR TURBOCHARGER ACTUATOR
Service repair no - 19.42.31
Remove
1.Remove exhaust manifold and turbocharger.
See MANIFOLD AND EXHAUST SYSTEM,
Repair, Exhaust Manifold - Tdi
2.Remove 2 nuts securing the actuator to the
turbocharger bracket.
3.Release clip and disconnect hose from actuator.
4.Remove and discard clip securing control lever
to wastegate spindle.
5.Remove turbocharger actuator.
Refit
6.Fit the replacement actuator and secure with
nuts.
7.Push the control lever as far as possible towards
the actuator and apply pressure to keep the
lever in this position.
8.Pressurise the actuator to 57 - 62 cm Hg and
hold this pressure.
CAUTION: Use only the threaded end of
the lever to make adjustments. Forcing the
complete lever in or out will change the
calibration with the possibility of damaging engine
boost.
9.Screw the lever in either direction until the eye
on the end will locate easily over the wastegate
spindle and secure with a new clip.
10.Release the pressure and tighten the locknut.
11.Refit exhaust manifold and turbocharger.
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust Manifold - Tdi
TURBOCHARGER AND GASKET
Service repair no - Turbocharger - 19.42.01
Service repair no - Gasket - 19.42.25
Remove
1.Disconnect battery negative lead.
2.Remove air cleaner assembly.
See Air Cleaner
3.Remove exhaust manifold assembly.See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust Manifold - Tdi
4.Remove and discard clip securing control lever
to wastegate spindle.
5.Remove 4 bolts and 2 clamp plates securing
turbocharger to exhaust manifold.
6.Remove turbocharger and discard gaskets.
Refit
7.Clean mating faces of turbocharger and exhaust
manifold.
8.Reverse removal procedure. Use new clip to
secure control lever to wastegate spindle.
Tighten to
45 Nm.
9.Check/top-up engine oil level.

19FUEL SYSTEM
6
REPAIR 15.Disconnect hose, plug return hose and rail.
Remove cloth.
16.Remove 6 nuts securing fuel rail and ignition coil
bracket to inlet manifold.
17.Release ignition coil bracket from inlet manifold
studs. Place aside.
18.Release fuel rail and injectors from inlet
manifold.
Do not carry out further dismantling if component
is removed for access only.
19.Remove fuel rail and injectors.
20.Remove 2 bolts securing fuel pressure regulator
to fuel rail.
21.Remove pressure regulator assembly.
22.Remove 'O' ring from fuel pressure regulator and
discard.
23.Remove 8 clips securing injectors to fuel rail.
24.Remove injectors from fuel rail.
25.Remove 2 'O' rings from each injector and
discard.Refit
26.Ensure mating surfaces between inlet manifold
and ram pipe housing are clean.
27.Ensure all locations in fuel rail and inlet manifold
are clean.
28.Lubricate and fit new 'O' rings to injectors and
fuel pressure regulator.
29.Fit fuel pressure regulator to fuel rail. Secure
with bolts. Tighten to
10 Nm.
30.Fit injectors to fuel rail. Secure with clips.
31.Position fuel rail to inlet manifold. Engage
injectors, one bank at a time.
32.Position ignition coil bracket on inlet manifold
studs.
33.Secure ignition coil bracket and fuel rail to inlet
manifold with nuts. Tighten to
8 Nm.
34.Remove plugs from fuel feed and return pipes
and rail.
35.Connect hose and tighten clip.
36.Clean feed pipe union and connect fuel feed
pipe to fuel rail. Tighten union to
16 Nm.
37.Connect multiplugs to fuel injectors and fuel
temperature sensor.
38.Remove cloth from inlet manifold.
39.Apply a thin, uniform coating of Loctite 577
sealant to mating face of inlet manifold.
40.Fit ram housing to inlet manifold. Secure with
bolts. Tighten to
24 Nm.
41.Connect purge hose, crankcase breather hose,
servo and pressure regulator vacuum hoses to
ram housing.
42.Fit plenum chamber.
See Plenum Chamber
43.Reconnect battery negative lead.
44.Start engine. Check for leaks around fuel rail and
injectors.

19FUEL SYSTEM
12
REPAIR Refit
15.Ensure locations on fuel pressure regulator and
fuel rail are clean.
16.Fit new spacer ring and 'O' ring to fuel pressure
regulator. Lubricate 'O' ring with silicone grease.
17.Fit pressure regulator assembly to fuel rail.
18.Secure regulator connecting pipe in clip.
19.Secure with bolts. Tighten to
10 Nm.
20.Align ignition coil bracket to inlet manifold studs.
21.Secure ignition coil bracket and fuel rail to inlet
manifold with nuts. Tighten to
8 Nm.
22.Remove plugs.
23.Connect return pipe to regulator connecting pipe.
Secure with clip.
24.Connect vacuum hose to fuel pressure regulator.
25.Remove cloth.
26.Reconnect battery negative lead.
27.Start engine. Check for leaks around fuel
pressure regulator, fuel feed and fuel return
unions.IDLE AIR CONTROL (IAC)
Service repair no - 19.22.54
Remove
1.Disconnect battery negative lead.
2.Disconnect IAC multiplug.
3.Remove 2 bolts securing IAC to plenum.
4.Remove IAC.
5.Remove gasket and discard.
Refit
6.Ensure all mating faces are clean.
7.Using a new gasket, fit IAC to plenum. Secure
with bolts. Tighten to
2.3 Nm.
8.Connect multiplug.
9.Reconnect battery negative lead.

19FUEL SYSTEM
4
DESCRIPTION AND OPERATION
Injectors
The four fuel injectors are fitted between the
pressurised fuel rail and inlet manifold. Each injector
comprises of a solenoid operated needle valve and a
specially designed nozzle to ensure good fuel
atomisation.
Engine coolant temperature sensor
The coolant temperature sensor is mounted in the
thermostat housing and is immersed in the engine
coolant. The sensor is a resistive device in which the
resistance varies with temperature
Throttle housing
The throttle housing is attached to the inlet manifold
via a rubber sandwich plate and incorporates a throttle
disc which is connected to the throttle pedal via the
throttle lever and a cable.
There are two breather pipes; one either side of the
throttle disc. When the engine is running with the
throttle disc open, both pipes are subject to manifold
depression and draw crankcase fumes into the
manifold. When the throttle disc is closed, only the
pipe on the inlet manifold side of the disc is subject to
manifold depression. This pipe incorporates a
restrictor to prevent engine oil being drawn into the
engine by the substantially greater manifold
depression.
Also incorporated in the throttle housing are the
throttle potentiometer and stepper motor.
Throttle potentiometer
The throttle potentiometer is mounted in front of the
throttle housing and is directly coupled to the throttle
disc shaft.
Three wires connect the throttle potentiometer to the
ECM; a 5 volt supply to the potentiometer, an earth
return to the ECM and an output voltage to the ECM
which indicates the rate of throttle disc movement.
Stepper motor
The stepper motor is contained within the throttle
housing and operates a cam and push rod via a
reduction gear. The push rod is in direct contact with
the throttle lever and moves the throttle disc to control
idle and fast idle speed. The stepper motor maximum
movement is 3.75 revolutions accomplished in steps
of 7.5°. The reduction gear converts this into 180°of
cam movement.
The throttle lever has a throttle position setting screw
which rests on the stepper motor operating pin when
the throttle pedal is released and is used to set the
relationship between engine speed and stepper motor
position.
In the side of the throttle housing is a throttle air
bypass bleed screw to provide easier and more
sensitive setting of the stepper motor position at idle.
The stepper motor position is checked using Testbook
and should be within the range of 20 to 40 steps when
the engine is run in. If it is identified as being outside
this range it can be adjusted to within range by turning
the throttle air bypass bleed screw. It is important to
follow Testbook setting procedure when adjusting this
screw to prevent mismatching of throttle body
settings. This ensures that the stepper motor is at the
optimum position within its range for providing further
movement to compensate for changes in engine load
or temperature in accordance with signals from the
ECM
NOTE: The stepper motor and throttle
position setting screws must only be
adjusted when Testbook identifies the
requirement.