1995 LAND ROVER DISCOVERY checking oil

07GENERAL FITTING REMINDERS
2
INFORMATION PREPARATION
1.Before removing a component, clean it and its
surrounding areas as thoroughly as possible.
2.Blank off any openings exposed by component
removal, using greaseproof paper and masking
tape.
3.Immediately seal fuel, oil or hydraulic lines when
separated, using plastic caps or plugs, to
prevent loss of fluid and entry of dirt.
4.Close open ends of oilways, exposed by
component removal, with tapered hardwood
plugs or readily visible plastic plugs.
5.Immediately a component is removed, place it in
a suitable container; use a separate container for
each component and its associated parts.
6.Before dismantling a component, clean it
thoroughly with a recommended cleaning agent;
check that agent is suitable for all materials of
component.
7.Clean bench and provide marking materials,
labels, containers and locking wire before
dismantling a component.
DISMANTLING
1.Observe scrupulous cleanliness when
dismantling components, particularly when
brake, fuel or hydraulic system parts are being
worked on. A particle of dirt or a cloth fragment
could cause a dangerous malfunction if trapped
in these systems.
2.Blow out all tapped holes, crevices, oilways and
fluid passages with an air line. Ensure that any
O-rings used for sealing are correctly replaced or
renewed, if disturbed.
3.Use marking ink to identify mating parts, to
ensure correct reassembly. If a centre punch or
scriber is used they may initiate cracks or
distortion of components.
4.Wire together mating parts where necessary to
prevent accidental interchange (e.g. roller
bearing components).
5.Wire labels on to all parts which are to be
renewed, and to parts requiring further
inspection before being passed for reassembly;
place these parts in separate containers from
those containing parts for rebuild.
6.Do not discard a part due for renewal until after
comparing it with a new part, to ensure that its
correct replacement has been obtained.INSPECTION-GENERAL
1.Never inspect a component for wear or
dimensional check unless it is absolutely clean;
a slight smear of grease can conceal an incipient
failure.
2.When a component is to be checked
dimensionally against figures quoted for it, use
correct equipment (surface plates, micrometers,
dial gauges, etc.) in serviceable condition.
Makeshift checking equipment can be
dangerous.
3.Reject a component if its dimensions are outside
limits quoted, or if damage is apparent. A part
may, however, be refitted if its critical dimension
is exactly limit size, and is otherwise satisfactory.
4.Use 'Plastigauge' 12 Type PG-1 for checking
bearing surface clearances. Directions for its
use, and a scale giving bearing clearances in
0,0025 mm steps are provided with it.

ZF
19
REPAIR 6.Screw in two bolts, diagonally opposite each
other. Tap lightly using a soft headed mallet to
remove pump assembly from intermediate plate.
7.Remove shaft sealing ring and 'O' ring from
pump housing and discard.
8.Using oil seal replacer LST108 fit shaft seal ring
into pump housing.
9.Fit 'O' ring onto circumference of pump housing.
10.Align dowel with hole in intermediate plate and
press pump housing home.11.Fit pump housing to intermediate plate, tighten
eight bolts to
10 Nm.
12.Place bell housing and intermediate plate
assembly on bench, front face up. Using oil
pump rotation sleeve LST111, check that pump
gears rotate freely.
13.Before fitting intermediate plate and bell housing
assembly,check that thrust washer and axial
cage are seated on A clutch housing.
14.Place gasket and disc washer onto bell housing
and intermediate plate assembly using
Petroleum Jelly.
15.Fit bell housing and intermediate plate assembly
to gearcase. Tighten twelve bolts to
46 Nm.
16.Place end float gauge LST111 onto pump
housing and check that axial play is between
0.2-0.4 mm. Replace existing washer, situated at
rear of intermediate plate, with a suitable washer
to give required end float.
17.Refit torque converter into housing using torque
converter handles 18G1501, checking that
dimension from converter fixing bolt boss to
converter housing face is 50 mm. This shows
converter is properly seated in housing.
18.Refit gearbox/transfer box assembly.
See
LT230T Transfer Gearbox

44AUTOMATIC GEARBOX
20
REPAIR ELIMINATING LEAKS BETWEEN GEARBOX
HOUSING AND INTERMEDIATE PLATE
1.Remove gearbox and transfer box assembly.
See LT230T Transfer Gearbox
2.Place gearbox on bench. Remove torque
converter using torque converter handles
18G1501, taking care not to damage torque
converter/oil pump housing oil seal.
3.Remove twelve hexagonal bolts (inner ring
pattern).
4.Remove bell housing/intermediate plate
assembly from gearbox case and discard
gasket.
5.Place new gasket onto intermediate plate using
Petroleum Jelly.
6.Before fitting bell housing assembly check that
thrust washer and axial cage are seated on A
clutch housing.
7.Fit bell housing assembly with disc washer to
gearcase. Tighten twelve bolts to
46Nm.
8.Place end-float gauge LST111 onto pump
housing and check that axial play is between
0.2-0.4 mm. Replace existing washer, situated at
rear of intermediate plate, with a suitable washer
to give required end-float.
9.Refit torque converter using torque converter
handles 18G1501. Checking that dimension
from converter fixing boss to converter housing
case is 50mm. This dimension shows converter
is properly seated.
10.Refit gearbox/transfer box assembly.
See
LT230T Transfer Gearbox

FRONT AXLE AND FINAL DRIVE
1
FAULT DIAGNOSIS FAULT DIAGNOSIS
Complaint - Oil leaks
An external leak of lubrication can be caused by a
faulty internal seal. For example, if the seals which
separate the differential from the swivel housings are
faulty and the vehicle is operating or parked on an
embankment, oil may leak across the axle leaving one
swivel with a high level and the other swivel and
differential lacking lubrication.
See 'Description and Operation' for illustrations of oil
seal locations.
When investigating leaks or checking oil levels, it is
essential that all the lubrication is drained from any
housing with a high level and that the other levels are
checked.
Swivel oil should be checked for signs of grease
leaking from the hub bearings and the hub grease
should not contain oil.
Check that the axle ventilation system is clear, as a
blockage can cause internal pressure to force oil past
the seals.
If the vehicle is driven in deep water with defective oil
seals, water may contaminate the lubricants and when
checked, give a false impression that the housing has
been overfilled with oil.
Do not assume that a high oil level is due to over
filling or, that a low level is because of an external
leak.

82AIR CONDITIONING
6
ADJUSTMENT SYSTEM TEST
1.Place the vehicle in a ventilated, shaded area
free from excessive draught, with the doors and
windows open.
2.Check that the surface of the condenser is not
restricted with dirt, leaves, flies, etc. Do not
neglect to check the surface between the
condenser and the radiator. Clean as necessary.
3.Switch on the ignition and the air conditioner air
flow control. Check that the blower is operating
efficiently at low, medium and high speeds.
Switch off the blower and the ignition.
4.Check that the evaporator condensate drain
tubes are open and clear.
5.Check the tension of the compressor driving belt,
and adjust if necessary.
6.Inspect all connections for the presence of
refrigerant oil. If oil is evident, check for leaks,
and repair as necessary.
NOTE: The compressor oil is soluble in
Refrigerant R134a and is deposited when
the refrigerant evaporates from a leak.
7.Start the engine.
8.Set the temperature controls to cold and switch
the air conditioner blower control on and off
several times, checking that the magnetic clutch
on the compressor engages and releases each
time.9.With the temperature control at maximum
cooling and the blower control at high speed,
warm up the engine and fast idle at 1000
rev/min. Check the sight glass for bubbles or
foam. The sight glass should be generally clear
after five minutes running, occasional bubbles
being acceptable. Continuous bubbles may
appear in a serviceable system on a cool day, or
if there is insufficient air flow over the condenser
at a high ambient temperature.
10.Repeat at 1800 rev/min.
11.Gradually increase the engine speed to the high
range, and check the sight glass at intervals.
12.Check for frosting on the service valves.
13.Check the high pressure hoses and connections
by hand for varying temperature. Low
temperature indicates a restriction or blockage at
that point.
14.Switch off the air conditioning blower and stop
the engine.
15.If the air conditioning equipment is still not
satisfactory, carry out a pressure test as
previously described in this section.
COMPRESSOR DRIVE BELT
Service repair no - 82.10.01.
Tdi -
See ENGINE, Repair, Compressor drive belt
V8i and MpiSee ENGINE, Repair, Drive belt

ENGINE
60
OVERHAUL Main bearing clearance - checking
CAUTION: If crankshaft has been
reground, oversize main bearing shells
must be fitted.
1.Degrease new main bearing shells and ensure
all traces of oil are removed from crankshaft
journals.
2.Fit new main bearing shells to saddles and
main bearing caps ensuring that tags are
located in recesses in saddles and bearing
caps.
NOTE: Number 5 main bearing shells are
wider than numbers 1 to 4.
3.Using assistance, fit crankshaft.
4.Place a piece of Plastigage across width of
each main journal.
5.Fit main bearing caps to their correct location
ensuring that direction marks are facing the
correct way; fit each pair of main bearing cap
bolts and tighten to 133 Nm.
CAUTION: Do not rotate crankshaft.
6.Remove main bearing caps and bearing shells.
CAUTION: Retain main bearing shells and
cap bolts with their respective main
bearing caps.
7.Measure widest portion of Plastigage on each
main bearing journal using the scale supplied;
the graduation that corresponds to the widest
portion of Plastigage indicates main bearing
clearance.
Main bearing clearance = 0.031 to 0.079 mm8.If main bearing clearances are incorrect, use a
combination of standard and oversize main
bearing shells and re-check clearances.
CAUTION: Keep main bearing shells
selected in their fitted order.
9.Remove all traces of Plastigage using an oily
rag.
10.Using assistance, remove crankshaft.
11.Remove upper main bearing shells and keep in
their fitted order.

ENGINE
OVERHAUL61
Crankshaft end-float - checking
1.Lubricate upper main bearing shells and
crankshaft main bearing journals with engine
oil.
2.Lubricate new standard size thrust washers
with engine oil and position washers in recess
in centre main bearing saddle.
NOTE: Grooved side of washers must face
outwards.
3.Using assistance, fit crankshaft.
4.Attach a DTI to rear face of cylinder block with
stylus contacting end of crankshaft; push
crankshaft fully rearwards and zero gauge.
5.Push crankshaft fully forwards and measure
end-float.
6.If end-float exceeds 0.05 to 0.15 mm, remove
crankshaft, fit combinations of standard and
oversize thrust washers to achieve correct
end-float.
CAUTION: Variations of thrust washer
thicknesses on each side of crankshaft
must not exceed 0.08 mm.
7.When end-float is correct, remove DTI.
8.Using assistance, remove crankshaft and
thrust washers. Ensure that thrust washers are
identified to their location.

ENGINE
62
OVERHAUL Big-end bearing clearance - checking
1.Fit pistons and connecting rods.
2.Degrease new big-end bearing shells.
3.Fit big-end bearing shells to connecting rods
ensuring that tag is located in recess in
connecting rod.
4.Fit big-end bearing shells to bearing caps
ensuring that tag is located in recess in cap.
5.Temporarily fit crankshaft pulley bolt and rotate
crankshaft to bring numbers 1 and 4 journals to
BDC.
6.Remove all traces of oil from crankshaft
journals.
7.Pull numbers 1 and 4 connecting rods on to
crankshaft journals, remove plastic tubing from
connecting rod bolts.
8.Place a strip of Plastigage across width of
numbers 1 and 4 big-end journals.
9.Fit bearing caps and shells to connecting rods
ensuring that reference marks on caps and
rods are aligned.
10.Fit big-end bearing cap nuts and tighten to 59
Nm.
CAUTION: Do not rotate crankshaft.
11.Remove big-end bearing caps and shells.
12.Measure widest portion of Plastigage on
crankshaft journals using the scale supplied;
the graduation that corresponds to the widest
portion of Plastigage indicates big-end bearing
clearance.
Big-end bearing clearance = 0.025 to 0.075
mm13.If big-end bearing clearances are incorrect, use
a combination of standard and oversize
bearing shells and re-check clearance.
CAUTION: Retain selected shells with their
respective connecting rods and caps.
14.Remove all traces of Plastigage using an oily
rag.
15.Repeat above procedures for numbers 2 and 3
big-end bearings.