1995 LAND ROVER DISCOVERY brakes

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Workshop manual
DISCOVERY
This manual covers vehicles from
1995 model year
01 INTRODUCTION
04 GENERAL SPECIFICATION DATA
05 ENGINE TUNING DATA
07 GENERAL FITTING REMINDERS
09 LUBRICANTS, FLUIDS AND CAPACITIES
10 MAINTENANCE
12 ENGINE Tdi
12 ENGINE 3.9 V8
12 ENGINE 4.0 V8
12 ENGINE Mpi
17 EMISSION CONTROL
19 FUEL SYSTEM Tdi
19 FUEL SYSTEM MFI
19 FUEL SYSTEM SFI
19 FUEL SYSTEM Mpi
19 CRUISE CONTROL
26 COOLING SYSTEM Tdi
26 COOLING SYSTEM V8
26 COOLING SYSTEM Mpi
30 MANIFOLD AND EXHAUST SYSTEM
33 CLUTCH
37 MANUAL GEARBOX
41 TRANSFER GEARBOX
44 AUTOMATIC GEARBOX
47 PROPELLER SHAFTS
51 REAR AXLE AND FINAL DRIVE
54 FRONT AXLE AND FINAL DRIVE
57 STEERING
60 FRONT SUSPENSION
64 REAR SUSPENSION
70 BRAKES
74 WHEELS AND TYRES
75 SUPPLEMENTARY RESTRAINT SYSTEM
76 CHASSIS AND BODY
80 HEATING AND VENTILATION
82 AIR CONDITIONING
84 WIPERS AND WASHERS
86 ELECTRICAL
Published by Rover Technical Communication
Ó1996 Rover Group Limited
Publication Part No. LRL 0079 ENG (2nd Edition)

INTRODUCTION
1
INFORMATION INTRODUCTION
This workshop manual covers vehicles from 1995
model year onwards. Amendments and additional
pages will be issued to ensure that the manual
covers latest models. Amendments and additions
will be identified by the addition of a dated footer
at the bottom of the page.
This Workshop Manual is designed to assist skilled
technicians in the efficient repair and maintenance of
Land Rover vehicles.
Individuals who undertake their own repairs
should have some skill and training, and limit
repairs to components which could not affect the
safety of the vehicle or its passengers. Any
repairs required to safety critical items such as
steering, brakes, suspension or supplementary
restraint system should be carried out by a Land
Rover Dealer. Repairs to such items should
NEVER be attempted by untrained individuals.
WARNINGS, CAUTIONSandNOTESare given
throughout this Manual in the following form:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of personal injury.
CAUTION: This calls attention to
procedures which must be followed to
avoid damage to components.
NOTE: This calls attention to methods
which make a job easier or gives helpful
information.
DIMENSIONS
The dimensions quoted are to design engineering
specification. Alternative unit equivalents, shown in
brackets following the dimensions, have been
converted from the original specification.REFERENCES
References to the left or right hand side in the manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
water pump end of the engine is referred to as the
front.
To reduce repetition, some operations covered in this
Manual do not include reference to testing the vehicle
after repair.
It is essential that work is inspected and tested after
completion and if necessary a road test of the vehicle
is carried out particularly where safety related items
are concerned.
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that Land Rover parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement parts
and accessories: Safety features embodied in the
vehicle may be impaired if other than Land Rover
parts are fitted. In certain territories, legislation
prohibits the fitting of parts not to the vehicle
manufacturer's specification. Torque spanner values
given in the Workshop Manual must be strictly
adhered to. Locking devices, where specified, must be
fitted. If the efficiency of a locking device is impaired
during removal it must be replaced with a new one.
Certain fasteners must not be re-used. These
fasteners are specified in the Workshop Manual.
POISONOUS SUBSTANCES
Many liquids and other substances used are
poisonous and therefore must not be consumed. It is
also advisable to keep all substances away from open
wounds. These substances among others include
anti-freeze, brake fluid, fuel, windscreen washer
additives, air conditioning refrigerant, lubricants and
various adhesives.

01INTRODUCTION
6
INFORMATION 2.Raise front road wheels to enable an axle stand
to be installed under left hand axle tube.
3.Position an axle stand under right hand axle
tube, carefully lower jack until axle sits securely
on both axle stands, remove trolley jack.
4.Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5.Reverse procedure when removing vehicle from
stands.
Raise rear of vehicle
1.Position cup of hydraulic arm under differential
casing.
2.Raise vehicle to enable axle stands to be
installed under left and right hand axle tubes.
3.Lower jack until axle sits securely on axle
stands, remove trolley jack.
4.Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5.Reverse procedure when removing vehicle from
stands.
HYDRAULIC VEHICLE RAMP (FOUR POST)
Use only a 'drive on' type ramp which supports vehicle
by its own road wheels. If a 'wheel-free' condition is
required, use a 'drive on' ramp incorporating a
'wheel-free' system that supports under axle casings.
Alternatively, place vehicle on a firm, flat floor and
support on axle stands.
TWO POST VEHICLE RAMPS
The manufacturer of LAND ROVER VEHICLES
DOES NOT recommend using 'Two Post' ramps
that employ four adjustable support arms. These
are NOT considered safe for Land Rover vehicles.
If vehicle is installed on a Two Post ramp
responsibility for safety of vehicle and personnel
performing service operations is in the hands of
the Service Provider.DYNAMOMETER TESTING - NON ANTI-LOCK
BRAKE VEHICLES
Viscous coupling
The front and rear axles cannot be driven
independently due to the viscous coupling. This
eliminates the need for differential lock by
progressively locking the centre differential
automatically if slip occurs at any wheel.
WARNING: DO NOT attempt to drive
individual wheels with vehicle supported
on floor jacks or stands.
Four wheel dynamometers
Provided that front and rear dynamometer rollers are
rotating at identical speeds and that normal workshop
safety standards are applied, there is no speed
restriction during testing except any that may apply to
the tyres.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
If brake testing on a single axle rig is necessary it
must be carried out with propeller shaft to rear axle
removed, AND neutral selected in BOTH main
gearbox and transfer gearbox. When checking brakes,
run engine at idle speed to maintain servo vacuum.
If checking engine performance, the transfer box must
be in high range and propeller shaft to stationary axle
must be removed.

INTRODUCTION
7
INFORMATION DYNAMOMETER TESTING - VEHICLES WITH
ANTI-LOCK BRAKES (ABS)
WARNING: Do not attempt to test ABS
function on a dynamometer
Four wheel dynamometers
NOTE: Before testing a vehicle on a four
wheel dynamometer disconnect the valve
relay.
See Electrical Trouble Shooting
Manual.
The ABS function will not work, the ABS warning
light will illuminate. Normal braking will be
available.
Provided that front and rear rollers are rotating at
identical speeds and that normal workshop safety
standards are applied, there is no speed restriction
during testing except any that may apply to the tyres.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
NOTE: ABS will not function on a two
wheel dynamometer. The ABS light will
illuminate during testing. Normal braking
will be available.
If brake testing on a single rig is necessary it must be
carried out with propeller shaft to the rear axle
removed, AND neutral selected in BOTH main and
transfer boxes.
If checking engine performance, the transfer box must
be in high range and drive shaft to stationary axle
removed.
TOWING
CAUTION: The vehicle has permanent
four-wheel drive. The following towing
instructions must be adhered to:
Towing the vehicle on all four wheels with driver
operating steering and brakes.
1.Turn ignition key turn to position '1' to release
steering lock.
2.Select neutral in main gearbox and transfer
gearbox.
3.Secure tow rope, chain or cable to towing eye.
4.Release the parking brake.
CAUTION: The brake servo and power
assisted steering system will not be
functional without the engine running.
Greater pedal pressure will be required to apply
the brakes, the steering system will require
greater effort to turn the front road wheels.
The vehicle tow connection should be used only
in normal road conditions, 'snatch' recovery
should be avoided.
Suspended tow by breakdown vehicle
CAUTION: To prevent vehicle damage,
front or rear propeller shaft MUST BE
removed, dependent upon which axle is
being trailed.
1.Mark propeller shaft drive flanges at transfer
gearbox and axles with identification lines to
enable the propeller shaft to be refitted in its
original position.
2.Remove the propeller shaft fixings, remove the
shaft from the vehicle.
3.If the front axle is to be trailed turn ignition key to
position '1' to release steering lock.
CAUTION: The steering wheel and/or
linkage must be secured in a straight
ahead position. DO NOT use the steering
lock mechanism for this purpose.

04GENERAL SPECIFICATION DATA
12
INFORMATION SHOCK ABSORBERS
Type Telescopic, double-acting non-adjustable.................................................................................
Bore diameter 35.47mm...................................................................
BRAKES
Front service brake
Type Outboard discs with four piston calipers.................................................................................
Operation Hydraulic, servo assisted self-adjusting.........................................................................
Pad material non asbestos.....................................................................
Rear service brake
Type Outboard discs with two piston calipers.................................................................................
Operation Hydraulic, servo assisted, self-adjusting.........................................................................
Pad material non asbestos.....................................................................
Parking brake
Type Mechanical-cable operated drum brake on the rear of.................................................................................
the transfer gearbox output shaft
Lining material non asbestos..................................................................
Servo/master cylinder non ABS
Manufacturer Lucas....................................................................
Servo type LSC 115........................................................................
Master cylinder type AS/AS.........................................................
Anti-lock brake system
Manufacturer/type Wabco 4 wheel sensed add on anti-lock brake............................................................
system.
Servo/master cylinder ABS
Manufacturer Lucas....................................................................
Master cylinder type CV/CV.........................................................

GENERAL SPECIFICATION DATA
25
INFORMATION VEHICLE DIMENSIONS
Dimensions
Overall length (including spare wheel) 4538 mm.............................
Overall length (including tow hitch) 4581 mm..................................
Overall width 2189 mm....................................................................
Overall height 1914 mm...................................................................
Wheelbase 2540 mm.......................................................................
Track front/rear 1486 mm.................................................................
Width between wheel boxes 1080 mm............................................
Seating capacity 5 to 7...............................................................
Performance
Tyre size fitted 205 R16 radial..................................................................
Tyre size fitted 235/70 R16 radial..................................................................
Max. gradient (EEC kerb weight) 45° .....................................
Approach angle (EEC kerb weight) 35° ..................................
Departure angle with tow hitch (EEC kerb weight) 20° ...........
Departure angle without tow hitch
(EEC kerb weight) 29° ............................................................
Ramp break over angle 33° ....................................................
Min. ground clearance (unladen) 204 mm.....................................
Wading depth 500 mm...................................................................
Towing weights
On road Off road
Unbraked trailers 750 kg.............................................................. 500 kg
Trailers with overrun brakes - Mpi 2750 kg.................................... 1000 kg
Trailers with overrun brakes - V8i & Tdi 3500 kg........................... 1000 kg
4 wheel trailers with coupled brakes
(FULLY BRAKED)* 4000 kg.......................................................... 1000 kg
NOTE: * Only applies to vehicles modified to accept coupled brakes.
NOTE: All weight figures are subject to local restrictions.

GENERAL FITTING REMINDERS
5
INFORMATION JOINTS AND JOINT FACES
1.Always use correct gaskets where they are
specified.
2.Use jointing compound only when
recommended. Otherwise fit joints dry.
3.When jointing compound is used, apply in a thin
uniform film to metal surfaces; take great care to
prevent it from entering oilways, pipes or blind
tapped holes.
4.Remove all traces of old jointing materials prior
to reassembly. Do not use a tool which could
damage joint faces.
5.Inspect joint faces for scratches or burrs and
remove with a fine file or oil stone; do not allow
removed material or dirt to enter tapped holes or
enclosed parts.
6.Blow out any pipes, channels or crevices with
compressed air, fit new 'O' rings or seals
displaced by air blast.FLEXIBLE HYDRAULIC PIPES, HOSES
1.Before removing any brake or power steering
hose, clean end fittings and area surrounding
them as thoroughly as possible.
2.Obtain appropriate plugs or caps before
detaching hose end fittings, so that ports can be
immediately covered to exclude dirt.
3.Clean hose externally and blow through with
airline. Examine carefully for cracks, separation
of plies, security of end fittings and external
damage. Reject any hose found faulty.
4.When refitting hose, ensure that no unnecessary
bends are introduced, and that hose is not
twisted before or during tightening of union nuts.
5.Containers for hydraulic fluid must be kept
absolutely clean.
6.Do not store brake fluid in an unsealed
container. It will absorb water, and fluid in this
condition would be dangerous to use due to a
lowering of its boiling point.
7.Do not allow brake fluid to be contaminated with
mineral oil, or use a container which has
previously contained mineral oil.
8.Do not re-use brake fluid bled from system.
9.Always use clean brake fluid to clean hydraulic
components.
10.Fit a cap to seal a hydraulic union and a plug to
its socket after removal to prevent ingress of dirt.
11.Absolute cleanliness must be observed with
hydraulic components at all times.
12.After any work on hydraulic systems, inspect
carefully for leaks underneath the vehicle while a
second operator applies maximum pressure to
the brakes (engine running) and operates the
steering.

MAINTENANCE
1
MAINTENANCE SERVICE SCHEDULE
This section gives information on the range of service
procedures.
Where required, instructions are given for carrying out
each service procedure, or a cross reference is given,
where the procedure can be found in this manual.
Service Schedule sheets are published separately to
reflect the maintenance needs and intervals for each
vehicle variant and model year. The procedures given
must be used in conjunction with the Service
Schedule sheets.
The Service Schedule sheets are available from:-
Land Rover Merchandising
PO Box 534
Erdington
Birmingham B24 0QS.
England.VEHICLE INTERIOR
CHECK SEATS & BELTS
Check condition and security of seats, seat belt
mountings, seat belts, buckles and opertion of inertia
seat belts. Lubricate seat tilt pivots.
CHECK OPERATION OF FOOT BRAKE AND
CLUTCH
If pedal feels 'spongy' bleed system.See BRAKES,
Repair, Brake System Bleed
or.See CLUTCH,
Repair, Bleed hydraulic system
Check all hoses and pipes for security, fractures and
leaks. Fit new hoses and pipes as necessary.
CHECK OPERATION OF LAMPS
Check operation of all lamps, horns and warning
indicators.
CHECK OPERATION OF WIPERS
Check operation of front/rear screen wipers and
washers and condition of wiper blades.
AIR BAG MODULE(S)
Check air bag module covers.
Check visually for signs of damage.
Renew every ten years.