1995 LAND ROVER DISCOVERY Workshop Manual

MAINTENANCE
11
MAINTENANCE
CHECK/ADJUST ENGINE IDLE SPEED - Tdi
For idle speed.See ENGINE TUNING DATA,
Information, 300 Tdi Engine
CHECK ENGINE IDLE SPEED - Mpi
For idle speed.See ENGINE TUNING DATA,
Information, Engine - Mpi - 2.0 Litre
CHECK/ADJUST STEERING BOX V8i - Tdi - Mpi
Check steering box for fluid leaks.
Check that there is no backlash in steering box in
straight ahead position. Adjust steering box if
necessary.
See STEERING, Adjustment, Power
Steering Box
CLEAN BATTERY CONNECTIONS
NOTE: Some 96 models are fitted with
battery backed-up sounder
See
ELECTRICAL, Repair, Battery
Remove battery terminals, clean and coat with
petroleum jelly.
A low maintenance battery is installed in vehicle.
Dependent upon climate conditions electrolyte levels
should be checked as follows:
Temperate climates every three years.
Hot climates every year.
RENEW CAMSHAFT DRIVE BELT - Tdi
Renew camshaft drive belt.See ENGINE, Repair,
Camshaft Drive Belt and Gears
The engine timing gears are driven by a flexible
rubber belt which must be renewed at intervals
determined by the severity of operating conditions.
In reasonable, temperate climate operation, renew the
belt every 120,000 km (72,000 miles) or every 6 years
whichever occurs earlier.
In adverse operating conditions such as work in dusty
atmospheres, high ambient temperatures and desert
and tropical zones, renew the belt every 60,000 km
(36,000 miles) or every 3 years whichever occurs
earlier.
CAUTION: If the drive belt is not renewed
at the correct interval, it could fail,
resulting in serious damage.
RENEW CAMSHAFT DRIVE BELT - Mpi
Renew every 160,000 km (96,000 miles) or every 6
years. In adverse conditions every 80,000 km (48,000
miles).
For details of renewing camshaft drive belt.
See
ENGINE, Repair, Camshaft Drive Belt - Mpi
CHECK CAMSHAFT DRIVE BELT - Mpi
For details of checking camshaft drive belt.See
ENGINE, Repair, Check Camshaft Drive Belt - Mpi

10MAINTENANCE
12
MAINTENANCE
EXTERNALLY CHECK INTERCOOLER FOR
OBSTRUCTION - Tdi
Clear any trapped dirt or flies from vanes of
intercooler
CLEAN INTERCOOLER ELEMENT - Tdi
Remove
1.Remove intercooler element.
2.Flush intercooler with ICI 'GENKLENE'or
à oD-SOLVE' propriety cleaner, following the
manufacturer's instructions.
3.Dry the intercooler completely ensuring that no
liquid remains in the element.
Refit
4.Refit intercooler element.UNDER VEHICLE MAINTENANCE
Vehicles operating under severe conditions of dust,
sand, mud and water should have oils changed and
lubrication carried out at more frequent intervals than
is recommended in maintenance schedules.
RENEW ENGINE OIL AND FILTER - Tdi
CAUTION: Serious damage to the
turbocharger will result if engine is run
above idling speed before oil pressure is
restored.
RENEW ENGINE OIL - V8i
RENEW ENGINE OIL AND FILTER - V8i
CAUTION: To prevent an airlock occuring
after removing filter, fill new filter with oil
and fit immediately after removing old
filter. If airlock does occur fill oil pump with
petroleum jelly.
RENEW ENGINE OIL AND FILTER - Mpi
CHECK/TOP UP MANUAL GEARBOX OIL - V8i
1.Site vehicle on lift or level ground.
2.Remove oil filler level plug. If necessary, inject
new oil into the gearbox until it runs out of filler
hole. Fit plug. Tighten to
30 Nm.
RENEW MANUAL GEARBOX OIL - Tdi - Mpi
RENEW MANUAL GEARBOX OIL - V8i

MAINTENANCE
13
MAINTENANCE
RENEW AUTOMATIC GEARBOX FLUID AND OIL
SCREEN
1.Site vehicle on lift or level ground. Place
container to drain gearbox fluid into. Disconnect
battery negative lead.
2.Remove gearbox dipstick, located at rear of right
hand rocker cover, to aid oil drainage. Release
plug from bottom of sump and allow fluid to drain
completely.
3.Refit plug using a new sealing washer. Tighten
to
10 Nm
Refill ZF Automatic Gearbox and Check Fluid
Level.
NOTE: The fluid level must checked when
fluid is cold and engine idling in park.
4.Ensure vehicle is on level ground.
5.Refill or top-up with correct quantity and grade of
fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
6.Start and run engine. Apply footbrake, select
position 1 then back to park. Check fluid level,
this must be between the two marks on the
dipstick.
Oil screen replacement ZF automatic gearbox.
See AUTOMATIC GEARBOX, Repair, Oil Screen

10MAINTENANCE
14
MAINTENANCE
RENEW TRANSFER GEARBOX OIL
1.Site vehicle on lift or level ground.
2.Disconnect battery negative lead.
3.Clean immediate area around filler/level and
drain plugs.
WARNING: When draining gearbox care
should be taken to ensure that oil is not
hot as personal scalding could result.
4.Place a container under gearbox to drain oil into.
5.Remove filler/level plug to vent gearbox and
assist draining.
6.Remove drain plug and allow oil to drain.
7.Thoroughly clean drain plug threads prior to
applying fresh 'Hylomar' sealant. Fit plug
Tighten to
30 Nm.
8.Fill gearbox with correct quantity and grade of oil
until oil seeps from filler level hole. Wipe away
any surplus oil.
9.Thoroughly clean filler/level plug threads prior to
applying fresh 'Hylomar' sealant. Fit plug
Tighten to
30 Nm.
10.Reconnect battery negative lead.
CHECK/TOP UP TRANSFER GEARBOX OIL
1.Site vehicle on lift or level ground.
2.Disconnect battery negative lead.
3.Clean immediate area around filler/level plug.
4.Remove plug and fill gearbox with recommended
grade of oil, until oil starts to seep from filler/level
hole.
5.Clean any previously applied sealant from
filler/level plug.
6.Apply Hylomar sealant to threads of plug and
refit plug. Tighten to
30 Nm.
7.Wipe away any surplus oil.
8.Reconnect battery negative lead.

MAINTENANCE
15
MAINTENANCE
RENEW FRONT AND REAR AXLE OIL
1.Site vehicle on lift or level ground. Place
container under axle to be drained.
2.Using a 13mm square drive wrench, remove
drain and filler/level plugs from axle. Allow oil to
drain completely. Clean and refit drain plug.
3.Inject new oil of recommended make and grade
until it reaches level hole. Clean and refit
filler/level plug and wipe away surplus oil.
CHECK/TOP UP FRONT AND REAR AXLE OIL
1.Site vehicle on lift or level ground.
2.Using a 13mm square drive wrench, remove
filler/level plug from axle.
3.If necessary inject new oil of recommended
make and grade until it reaches level hole. Clean
and refit filler/level plug and wipe away surplus
oil.
CHECK/TOP UP SWIVEL PIN HOUSING OIL
RENEW SWIVEL PIN HOUSING OIL
1.Site vehicle on lift or level ground. Place
container under swivel to be drained.
2.Remove drain and level plugs, allow oil to drain
completely, clean and refit drain plug.
3.Remove filler plug and inject recommended
make and grade of oil it reaches level hole.
4.Clean and refit level and filler plugs, wipe away
any surplus oil.

10MAINTENANCE
16
MAINTENANCE
LUBRICATE PROPELLER SHAFT SLIDING , AND
UNIVERSAL JOINTS
1.Clean all grease nipples on front and rear
propeller shafts.
2.Using a low pressure hand grease gun, apply
recommended grease, to grease nipples at front
and rear propeller shaft universal and sliding
joints.
NOTE: The rear propeller shaft flexible
coupling is not fitted with a grease nipple.
CHECK VISUALLY BRAKE, FUEL, CLUTCH
PIPES/UNIONS FOR CHAFING LEAKS AND
CORROSION
CHECK EXHAUST SYSTEM FOR LEAKS,
SECURITY AND DAMAGE
CHECK FOR FLUID LEAKS FROM POWER
STEERING AND SUSPENSION SYSTEMS,
HYDRAULIC PIPES AND UNIONS FOR CHAFING
AND CORROSION
CHECK/TIGHTEN STEERING UNIT AND STEERING
ROD BALL JOINT FIXINGS, CHECK CONDITION
OF OF BALL JOINTS AND DUST COVERS
Ball joints are lubricated for their normal life during
manufacture and require no further lubrication. This
applies ONLY if rubber boot has not been dislodged
or damaged. Joints should be checked at specified
mileage intervals but more frequently if vehicle is used
under arduous conditions.
1.Check for wear in joints by moving ball joint up
and down vigorously. If free movement is
apparent fit a new joint assembly.

MAINTENANCE
17
MAINTENANCE
CHECK/TIGHTEN FRONT AND REAR AXLE
SUSPENSION LINK FIXINGS, CHECK CONDITION
OF MOUNTING RUBBERS
DRAIN FUEL SEDIMENTER - Tdi
Fuel sedimenter
The sedimenter is attached to left-hand side of
chassis frame near fuel tank. It increases the working
life of the fuel filter by removing larger droplets of
water and larger particles of foreign matter from fuel.
Drain off water
1.Loosen drain plug, allow water to run out.
Tighten plug immediately pure diesel fuel starts
to flow.
RENEW FUEL FILTER
WARNING: Ensure that fuel handling
precautions given in Section 01 -
Introduction regarding fuel handling are
strictly adhered to when carrying out following
instructions.
See INTRODUCTION, Information,
Fuel Handling Precautions
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
1.Depressurise fuel system.
See FUEL SYSTEM,
Repair, Depressurising Fuel System
2.The fuel line filter is located on right hand
chassis side member forward of fuel tank filler
neck. Access to filter is gained through right
hand rear wheel arch.
3.Thoroughly clean area around hose connections
to prevent ingress of foreign matter into fuel
system.
4.Loosen two fuel unions and remove hoses from
filter canister.
5.Release securing bolt and bracket, remove filter
from chassis side member.
6.Fit a new filter observing direction of flow arrow
on canister.
7.Fit inlet and outlet hoses. Tighten to
30 Nm.
8.Refit fuel pump relay.
9.Reconnect battery negative lead.
10.Recode radio.
11.Start engine and inspect hose connections for
fuel leaks.

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