1995 LAND ROVER DISCOVERY service

Tdi
7
REPAIR
9.Move intercooler upwards and clear of fan cowl.
Refit
10.Ensure locatiing lug grommets are fitted and in
good condition.
11.Ensure foam pad is in good condition and
attached to intercooler.
12.Move intercooler into position.
13.Reverse removal procedure.GLOW PLUGS
Service repair no - 19.60.31
Remove
1.Disconnect battery negative lead.
No.1 glow plug - air conditioning models
2.Release drive belt from compressor pulley.See
ENGINE, Repair, Drive Belt Renew
3.Remove 4 bolts securing compressor to front
cover, move compressor aside.
No.3 glow plug
4.Remove bolt securing Hummel valve, withdraw
valve, remove and discard 'O' ring.

19FUEL SYSTEM
8
REPAIR
All glow plugs
5.Remove terminal nut from glow plug, disconnect
wire from glow plug terminal.
6.Remove glow plug.
Refit
7.Clean glow plug and seating.
8.Coat threads of glow plug with suitable anti-seize
compound operational to a temperature of
1000°C.
9.Fit glow plug. Tighten to
23 Nm.
10.Connect wire to glow plug terminal and secure
with nut.
NOTE: Feed wire must be connected to
No. 4 glow plug terminal.
11.
No. 3 glow plug:Lubricate new 'O' ring with
engine oil and fit to Hummel valve. Fit valve and
secure with bolt. Tighten to
15 Nm.
No. 1 glow plug - air conditioning models
12.Position compressor to front cover, fit bolts.
Tighten to
25 Nm.
13.Fit drive belt to compressor pulley and adjust
tension.
See ENGINE, Repair, Drive Belt
Renew
All models
14.Reconnect battery negative lead.EGR VALVE
Service repair no - 19.45.01
Remove
1.Disconnect multiplug from EGR valve.
2.Disconnect vacuum pipe from EGR valve.
3.Remove 2 Allen screws securing EGR valve to
exhaust manifold.
4.Remove 2 bolts securing hose to EGR valve.
5.Remove EGR valve and discard gaskets.
Refit
6.Clean mating faces of EGR valve and exhaust
manifold.
7.Reverse removal procedure. Tighten bolts to
25
Nm.

Tdi
9
REPAIR GLOW PLUG CONTROL UNIT
Service repair no - 19.60.33
Remove
1.Disconnect battery negative lead.
2.Remove nut and bolt securing control unit to
mounting bracket.
3.Disconnect multiplug and remove control unit.
Refit
4.Reverse removal procedure.EGR CONTROL UNIT
Service repair no - 19.45.06
Remove
1.Release 2 glovebox stays from fascia and pivot
glovebox fully downwards.
2.Remove 2 plastic nuts securing control unit to
body.
3.Release control unit from fixings.
4.Disconnect multiplug and remove control unit.
Refit
5.Reverse removal procedure.

19FUEL SYSTEM
10
REPAIR EGR THROTTLE POSITION SENSOR
Service repair no - 19.30.14
Remove
1.Remove 2 screws securing sensor mounting
plate to injection pump.
2.Disconnect sensor multiplug from harness.
3.Remove sensor assembly.
Refit
4.Position sensor assembly on injection pump and
fit and tighten screws.
5.Connect multiplug.
6.Adjust sensor.
See Adjustment, EGR Throttle
Position Sensor
INJECTORS
Service repair no - 19.60.10
Remove
1.Remove oil filler cap and remove sound
deadening pad from top of engine.
2.Remove high pressure pipe from relevant
injector and injection pump.
3.Disconnect spill return hose(s) from injector.
4.Plug pipes and injector connections to prevent
the ingress of dirt and foreign matter.
5.Remove nut securing injector clamp plate to
cylinder head.
6.Remove injector.
Refit
7.Reverse removal procedure. Renew copper
washer on injector. Tighten injector clamp plate
nut to
25 Nm.

Tdi
11
REPAIR FUEL INJECTION PUMP AND TIMING
Service repair no - 19.30.07
NOTE: The following text refers to a Tdi
vehicle with a manual gearbox without
electronic diesel control. Where reference
is made to the timing tool substitute the following
information for automatic and EDC variants.
If manual gearbox:Timing tool LRT-12-044 fits into
the base of the flywheel housing
If manual gearbox with EDC:Timing tool
LRT-12-085 must be used and also fits into the base
of the flywheel housing.
If automatic gearbox:Timing tool LRT-12-044 fits
into the larger bolt hole of coverplate on engine
backplate, sited near to the rear of sump. Pin locates
in ring gear.
Remove
1.Disconnect battery negative lead.
2.Remove injection pipes, pump to injector.
3.Remove oil filler cap from rocker cover.
4.Viewing valve mechanism through filler aperture,
turn crankshaft clockwise until No. 1 cylinder is
just before TDC.
5.Refit oil filler cap.
6.Remove blanking plug from flywheel housing.
7.Fit timing tool LRT-12-044 to flywheel housing,
do not engage centre pin.
8.Continue rotating crankshaft clockwise until
centre pin engages with timing slot in flywheel.
9.Remove injection pump access plate, complete
with gasket, from front cover plate.
10.Fit pin from LRT-12-045 to injection pump gear.
11.Remove drive gear to pump hub fixing bolts and
plate.

19FUEL SYSTEM
14
REPAIR ENGINE CONTROL MODULE (ECM)
Service repair no - 18.30.03
NOTE: The ECM is not a serviceable item,
in the event of failure it must be renewed.
Remove
1.Disconnect battery negative lead.
2.Remove 'A' post trim pad.
3.Loosen multi-plug screw to ECM.
4.Disconnect multi-plug from ECM.
5.Secure multi-plug and harness aside.
6.Remove retaining nuts from ECM.
7.Manoeuvre ECM from its mounted position.
Refit
8.Refitting is the reverse of removal procedure.
9.Reconnect harness plug. Ensure plug is pushed
firmly into location and retaining clip secures
plug in position.
10.Tighten screw securing multi-plug.AIRFLOW METER
Service repair no - 18.30.15
NOTE: The air flow meter is not a
serviceable item, in the event of failure it
must be renewed.
Remove
1.Disconnect battery negative lead.
2.Release vacuum tube from EGR vacuum
capsule.
3.Disconnect airflow meter multi-plug.
4.Loosen air cleaner hose to air flow meter
retaining clip.
5.Disconnect hose from airflow meter.
6.Loosen turbo charger hose to airflow meter
retaining clip.
7.Disconnect hose from airflow meter.
8.Remove meter to mounting bracket bolts.
9.Remove airflow meter.
Refit
10.Reverse removal procedure. Ensure multi-plug is
firmly reconnected and hose clamps are
securely tightened to prevent unmetered air
entering the engine.

Tdi
15
REPAIR BOOST PRESSURE SENSOR
Service repair no - 18.30.63
Remove
1.Disconnect battery negative lead.
2.Disconnect sensor multi-plug.
3.Disconnect pressure tube union.
4.Retrieve and discard union copper washers.
5.Place pressure tube aside.
6.Remove sensor to mounting bracket bolts.
7.Remove sensor.
Refit
8.Renew all copper washers.
9.Reverse removal procedure.
INJECTION TIMING SENSOR
Service repair no - 18.30.64
Remove
1.Disconnect battery negative lead.
2.Disconnect sensor multi-plug.
3.Disconnect spill return pipe to injector.
4.Disconnect injector union.
5.Remove copper washers.
6.Remove injector clamp fixing.
7.Remove clamp.
8.Remove injector.
9.Remove injector copper washers.
Refit
10.Renew all copper washers.
11.Reverse removal procedure.
12.Check for leaks when running.

19FUEL SYSTEM
16
REPAIR ENGINE SPEED SENSOR
Service repair no - 18.30.65
Remove
1.Disconnect battery negative lead.
2.Disconnect sensor multi-plug.
3.Place vehicle on ramp and apply handbrake.
4.Raise ramp.
5.Remove sensor retaining nut.
6.Remove sensor from housing.
7.Clean housing mating faces.
Refit
8.Reverse removal procedure.