1995 LAND ROVER DISCOVERY catalytic converter

INTRODUCTION
11
INFORMATION CROSS REFERENCE OF EMISSION SYSTEM
TERMINOLOGY
NEW TERM (ACRONYM)
Accelerator pedal (AP).................................................
Air cleaner (ACL)..........................................................
Air conditioning (AC)....................................................
Battery positive voltage (B+)........................................
Closed loop (CL)..........................................................
Closed throttle position (CTP)......................................
Canister purge valve (CANPV)....................................
Data link connector (DLC)...........................................
Diagnostic trouble code (DTC).....................................
Distributor ignition (DI).................................................
Engine control module (ECM)......................................
Engine coolant level (ECL)...........................................
Engine coolant temperature (ECT)..............................
Engine coolant temperature sensor (ECTS)................
Engine speed (RPM)....................................................
Evaporative emission system (EVAP)..........................
Engine fuel temperature sensor (EFTS)......................
4th gear, 3rd gear etc. (4GR, 3GR)..............................
Fuel pump (FP)............................................................
Fan control module (FCM)...........................................
Generator (GEN)..........................................................
Ground (GND)..............................................................
Heated oxygen sensor (H02S)....................................
Idle air control (IAC)......................................................
Idle air control valve (IACV).........................................
Ignition control module (ICM).......................................
Inertia fuel shutoff (IFS)................................................
Inertia fuel shutoff switch (IFSS)..................................
Intake air temperature (IAT).........................................
Malfunction indicator lamp (MIL)..................................
Manifold vacuum zone (MVZ)......................................
Mass air flow sensor (MAFS).......................................
Multiport fuel injection (MFI)........................................
On board diagnostic (OBD)..........................................
Open loop (OL)............................................................
Park/neutral position (PNP).........................................
Park/neutral position switch (PNPS)............................
Programmable read only memory (PROM)..................
Relay module (RM)......................................................
Service reminder indicator (SRI)..................................
Solid state relay module (SSRM).................................
Three way catalytic converter (TWC)..........................
Throttle body (TB)........................................................
Throttle position sensor (TPS)......................................
Torque converter clutch (TCC)....................................
Transmission range (TR)..............................................
Transmission range selector (TRS).............................
Vehicle speed sensor (VSS)........................................
Wide open throttle (WOT)............................................OLD TERM (ACRONYM)
Throttle pedal (-)..........................................................
Air cleaner (-)...............................................................
Air conditioning (AC)....................................................
Battery plus, bat +, bat feed (B+).................................
Closed loop (-).............................................................
Closed throttle, idle position (-)....................................
Charcoal canister purge valve (-).................................
Serial link (-)................................................................
Fault code (-)...............................................................
Electronic ignition (-)....................................................
Electronic control unit (ECU)........................................
Coolant level (-)...........................................................
Coolant temperature (temp).........................................
Coolant temperature thermistor (-)..............................
Engine speed (rev/min)................................................
Evaporative loss system (ELC)...................................
Fuel temperature thermistor (-)....................................
Fourth gear, 3rd gear (-)..............................................
Fuel pump (-)...............................................................
Condenser fan timer (-)................................................
Alternator (-)................................................................
Ground, earth (B-)........................................................
Lambda (02) sensor (-)................................................
Idle speed control (ISC)................................................
Stepper motor (-).........................................................
Ignition module (-)........................................................
Inertia switch (-)...........................................................
Inertia switch (-)...........................................................
Intake temperature/ambient temperature (-)................
EFI warning lamp (-)....................................................
Manifold depression, vacuum (-).................................
Air flow meter (-)..........................................................
Electronic fuel injection (EFI).......................................
Fault code display unit (-)............................................
Open loop (-)...............................................................
Park or neutral (-).........................................................
Start inhibit switch (-)...................................................
Chip, PROM (PROM)...................................................
Relay (-).......................................................................
Check engine light (-)...................................................
Control unit (-)..............................................................
Catalyst, catalytic converter (CAT)..............................
Throttle housing (-)......................................................
Throttle potentiometer (-).............................................
Direct drive clutch (DDC)..............................................
Transmission gear (-)...................................................
Shift lever, shifter (-)....................................................
Road speed transducer (-)...........................................
Full throttle, wide open throttle (WOT).........................

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.

09LUBRICANTS, FLUIDS AND CAPACITIES
6
INFORMATION RECOMMENDED FUEL
Petrol engines
- with catalytic converter unleaded only, 95 RON (USA 90 CLC or AKI)................................................
- non catalytic, 9.35:1 compression ratio leaded 97 RON/unleaded 95 RON.......................
- non catalytic, 8.13:1 compression ratio leaded 90 RON/unleaded 95 RON.......................
- Australia minimum 91 RON unleaded......................................................................
Diesel engines
300Tdi Diesel fuel oil,distillate,diesel fuel, automotive gas or...........................................................................
Derv to British standard 2869, Class A1 or A2
Using fuel with an octane rating lower than stated above could seriously impair vehicle performance.
CAUTION: Do not use oxygenated fuels such as blends of methanol/ gasoline or ethanol/gasoline
(e.g. 'Gasohol'). Take care not to spill fuel during refuelling.

10MAINTENANCE
18
MAINTENANCE
ABS VEHICLES - CHECK ROAD WHEEL SPEED
SENSOR ELECTRICAL HARNESS FOR DAMAGE
RENEW OXYGEN SENSORS
See EMISSION CONTROL, Repair, Heated
Oxygen Sensor (HO2S)
RENEW CATALYTIC CONVERTERS
See MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust System Complete
REPORT ANY UNUSUAL FEATURES OF VEHICLE
CONDITION AND ADDITIONAL WORK REQUIREDCARRY OUT ROAD TEST
For details of dynamometer testing.See
INTRODUCTION, Information, Dynamometer
Testing - Non Anti-lock brake vehicles See
INTRODUCTION, Information, Dynamometer
Testing - Vehicles with Anti-lock brakes (ABS)
Check following items:
1.Inhibitor switch only operates in P and N.
2.Engine for excessive noise.
3.Clutch for slip, judder or spin.
4.Automatic gear selection/shift speeds.
5.Gear selection/noise - high/low range.
6.Steering for abnormal noise/effort.
7.Steering for free play.
8.All instruments, gauges and warning indicators.
9.Heater and air conditioning systems.
10.Heated rear screen.
11.Shock absorbers - ride irregularities.
12.Foot brake, on emergency stop, pulling to one
side, binding, pedal effort.
13.Parkbrake efficiency.
14.Seat reclining and latching.
15.Fully extend seat belt, check operation of
retraction and latching. Inertia belts lock when
snatched or vehicle on slope.
16.Road wheel balance.
17.Transmission for vibrations.
18.Body noises, squeaks and rattles.
19.Excessive exhaust smoke.
20.Engine idle speed.
21.Endorse service record.
22.Report any unusual features of vehicle condition
and additional work required.
ENDORSE SERVICE RECORD

12ENGINE
4
REPAIR 39.Release battery positive lead terminal cover.
40.Remove terminal nut
41.Release terminal from battery.
42.Release fusebox main feed lead.
43.Position battery cable over engine.
44.Pivot jockey pulley downwards to release drive
belt tension.
45.Release belt from pulleys.
46.Remove drive belt.
47.Disconnect compressor multiplug
48.Remove 4 bolts securing compressor.
49.Remove heatshield.
50.Release compressor from bracket and tie aside.
51.Slacken clip securing PAS hose to pump.
52.Disconnect hose.
53.Plug hose and pump.
54.Disconnect PAS hose connection at pump and
steering box.
55.Release unions and remove hose.
56.Remove and discard 'O' rings.
57.Plug pump and steering box.
58.Remove LH and RH engine mounting nuts.
59.Position lifting chains and attach hooks to engine
lifting eyes.
60.Raise engine sufficiently to release engine
mountings.
61.Release engine mountings and remove.
62.Lower engine until it just rests on engine
mounting brackets.
63.Disconnect chains.
64.Raise ramp.
65.Remove catalytic converter/front pipe assembly.
See EMISSION CONTROL, Repair, Catalytic
Converter/Front Pipe - 4.0 V8
66.Remove 9 bolts securing bell housing bottom
cover. Note position of 2 dowel bolts.
67.Remove cover.
68.Remove locknut securing transfer box tie bar.
69.Remove 2 bolts securing tie bar to tranmission.
70.Remove tie bar.
71.Remove 2 and slacken 1 bolt, securing bell
housing access plate and position aside.
72.Mark drive plate to torque converter relationship.
73.With assistance, rotate crankshaft for access to
first bolt (torque converter to drive plate).
74.Remove first bolt.
75.Repeat steps for the remaining 3 bolts.
76.Remove 2 bolts securing crankshaft sensor
shield to engine backplate.
See FUEL SYSTEM
SFI, Repair, Crankshaft Position Sensor
(CKP Sensor)

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.

17EMISSION CONTROL
2
DESCRIPTION AND OPERATION REV: 09/95 Exhaust emission control.
The fuel injection system provides accurately metered
quantities of fuel to the combustion chambers to
ensure the most efficient air to fuel ratio under all
conditions of operation. A further improvement to
combustion is made by measuring the oxygen content
of the exhaust gases to enable the quantity of fuel
injected to be varied, according to conditions, to
correct any unsatisfactory composition of the exhaust.
The main components of the exhaust emission
system are two Catalytic converters which are an
integral part of the front exhaust pipe assembly. The
Catalytic converters are included in the system to
reduce the emission, to atmosphere, of carbon
monoxide, oxides of nitrogen, and hydrocarbons. The
active constituents of the converters are platinum and
rhodium. The correct functioning of the converters is
dependent upon close control of the oxygen
concentration in the exhaust gas entering the catalyst.
The oxygen content of the exhaust gas is monitored
by the heated oxygen sensors. Information on the
heated oxygen sensors is contained in the relevant
Fuel System section,
See FUEL SYSTEM MFI,
Description and operation, or See FUEL SYSTEM
SFI, Description and operation,
The ECM can then
make an appropriate adjustment to the fuel supply to
correct the composition of the exhaust.
CAUTION: Unleaded fuel only must be
used on vehicles fitted with catalytic
converters. As a reminder,a label to
indicate this is adhered to the inside of the fuel
filler flap. Furthermore the filler neck is designed
to accommodate only unleaded fuel pump
nozzles.

EMISSION CONTROL
3
DESCRIPTION AND OPERATION REV: 09/95
EXHAUST SYSTEM
1. Manifold to front pipe connection.
2. Heated oxygen sensor - pre-catalytic converter.
3. Front silencer support bracket.
4. Heated oxygen sensor - post-catalytic converter.
5. Front pipe to silencer joint.
6. Silencer rear support bracket.
7. Rear silencer support bracket.