1995 LAND ROVER DISCOVERY Workshop Manual

12ENGINE
16
REPAIR 8.Ensure housing seal is correctly seated in its
groove in new housing and seal assembly.
9.Fit new assembly, with former/guide in-situ, over
crankshaft flange, this action will eject
former/guide.
10.Secure assembly to cylinder block with five bolts
tightened to correct torque, removing slave studs
individually and inserting bolts.
11.Refit flywheel.
See Flywheel
12.Refit clutch.See CLUTCH, Repair, Clutch
Assembly
13.Refit gearbox.See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
14.Reconnect battery negative lead.CRANKSHAFT BEARING BUSH
Service repair no - 12.21.45
1.Disconnect battery negative lead.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
Assembly
4.Remove flywheel.See Flywheel
5.Remove bearing bush.
NOTE: The bearing bush can be removed
by using one of the following methods.
Method 1.
Obtain a short length of steel rod of a diameter having
a good slide fit in the bore of the bush. Pack the bore
with grease and insert the steel rod into the end of the
bore, give a sharp blow with a hammer and the
grease should drive out the bush. It is recommended
that the bush and rod be covered by a suitable cloth
or rag to prevent grease from splashing.

Tdi
17
REPAIR Method 2.
Thread the bore of the existing bush and using a
suitable bolt extract the bush. Thoroughly clean bush
location ensuring all swarf is removed.
Fitting
6.Fit new bush using a suitable shouldered drift,
inserting bush flush with end of crankshaft.
7.Refit flywheel.
See Flywheel
8.Refit clutch.See CLUTCH, Repair, Clutch
Assembly
9.Refit gearbox.See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
10.Reconnect battery negative lead.FLYWHEEL HOUSING
Service repair no - 12.53.01
Remove
1.Disconnect battery negative lead.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
Assembly
4.Remove flywheel.See Flywheel
5.Remove starter motor.
6.Remove two bolts from top of flywheel housing.
7.Remove four bolts from bottom of flywheel
housing.
8.Remove six inner bolts and lift off flywheel
housing.
Refit
9.Clean rear face of housing and mating face on
block, ensuring all old sealant is removed.

12ENGINE
18
REPAIR 10.Apply sealant to flywheel housing mating face on
cylinder block (Fig. J5944).
11.Fit housing to cylinder block and secure with
bolts as removed. Tighten to
45 Nm.
12.Remove surplus sealant from block.
13.Refit starter motor.
14.Refit flywheel.
See Flywheel
15.Refit clutch.See CLUTCH, Repair, Clutch
Assembly
16.Refit gearbox.See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
17.Reconnect battery negative lead.OIL FILTER
Service repair no - 12.60.01
Remove
1.Place drain tray under filter.
2.Unscrew filter anti-clockwise, using a strap or
spanner.
Refit
3.Smear clean engine oil on seal of new filter.
4.Screw on filter until sealing ring touches
machined face, then tighten a further half turn by
hand only. Do not over tighten.

Tdi
19
REPAIR OIL TEMPERATURE CONTROL VALVE
Service repair no - 12.60.69
Remove
1.Disconnect oil cooler pipes.
2.Remove two bolts and carefully withdraw
thermostat extension housing (1) complete with
O ring seal (2), thermostat (3), two washers (4)
and spring (5).
3.Clean adaptor housing.
4.Inspect all parts and renew as necessary.
Refit
5.Fit thermostat to extension housing ensuring pin
locates in hole.
6.Fit two washers and spring to thermostat.
7.Fit a new 'O' ring to extension housing.
8.Insert spring into adaptor and secure extension
housing to adaptor with bolts. Tighten to
9 Nm.
OIL FILTER HEAD GASKET
Service repair no - 12.60.03
Renew
1.Disconnect oil cooler pipes.
2.Disconnect pressure switch lead.
3.Remove securing bolts and withdraw head
complete with gasket.
4.Clean mating faces.
5.Refit head with new gasket.
6.Secure with bolts. Tighten to
45 Nm.
7.Refit pipes and reconnect pressure switch.

12ENGINE
20
REPAIR CYLINDER HEAD GASKET
Service repair no - 12.29.02
Remove
1.Disconnect battery negative lead.
2.Remove bonnet [Hood].
See CHASSIS AND
BODY, Repair, Bonnet [Hood]
3.Drain coolant.
4.Remove air cleaner assembly.
See FUEL
SYSTEM, Repair, Air Cleaner
5.Detach crankcase ventilation valve and side
breather hose from rocker cover and move to
one side.
6.Remove injection pipes.
7.Disconnect spill rail from fuel injectors.
8.Remove fuel injectors and sealing washers.
Identify each injector to the location from which it
is removed.
See FUEL SYSTEM, Repair,
Injectors
9.Remove inter-connecting harness from glow
plugs.
10.Remove glow plugs.
See FUEL SYSTEM,
Repair, Glow Plugs
11.Remove top hose, radiator to thermostat.
12.Disconnect by-pass hose from thermostat.
13.Disconnect hose, thermostat to water pump.
14.Disconnect water temperature sensor lead.
15.Remove hose inter-cooler to induction manifold.
16.Remove induction manifold.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
Manifold - Tdi
17.Remove exhaust manifold and turbocharger
assembly.
See MANIFOLD AND EXHAUST
SYSTEM, Repair, Exhaust Manifold - Tdi
18.Disconnect heater hose from water pump and
move heater rail aside.
19.Disconnect heater hose from rear of cylinder
head.
20.Remove bolt securing air cleaner mounting
bracket to support strut.
21.Remove bolt securing harness bracket to
cylinder head.
22.Remove rear lifting bracket, this will also release
clips securing transmission and engine breather
pipes and multiplug. Note loose spacer under
clip securing engine breather pipe and multiplug.

Tdi
21
REPAIR 23.Remove rocker cover.
24.Remove nuts and bolts and withdraw rocker
shaft assembly.
25.Remove push rods, store as an identified set to
allow refitment to same location.
26.Remove valve stem caps.
27.Evenly slacken, then remove, bolts retaining
cylinder head to block. Two of the bolts also
secure the air cleaner mounting bracket.
28.Lift off cylinder head and remove gasket.
Refit
29.Ensure face of cylinder block is thoroughly clean.
30.Select new gasket of correct thickness.
CAUTION: Three thicknesses of gasket are
available, different thicknesses are
identified by the number of small holes
punched in the right hand side of the gasket. One
hole identifies the thinnest gasket and three holes
the thickest. When renewing gaskets the gasket
being fitted must be of the same thickness as the
one removed. Therefore if the removed gasket had
two holes punched in the side the replacement
gasket must also have two holes punched in the
side.
31.Place gasket on cylinder block with identification
holes positioned towards rear on right hand side
and side marked TOP uppermost.
32.Clean mating face of cylinder head.
33.Lower cylinder head onto block ensuring correct
location with dowels.

12ENGINE
22
REPAIR
NOTE: Cylinder head retaining bolts can
be used up to a maximum of five times.
34.Lubricate threads of bolts with light oil and fit to
positions illustrated.
Bolt sizes:
M10 x 117mm locations 3, 5, 12, and 13.
M12 x 140mm locations 1, 2, 7, 8, 9, 10, 15, 16, 17,
and 18.
M12 x 100mm locations 4, 6, 11, 14.
35.Tighten bolts so that underside of heads just
make contact with cylinder head.
36.Following the sequence illustrated tighten all
bolts to
40 Nm.
37.Attach degree disc special tool LRT-12-007 to a
power bar.
38.Make a suitable pointer from welding rod and
attach to a bolt screwed into a rocker shaft
securing bolt hole.
39.Tighten all bolts through 60°strictly in sequence
illustrated.
40.Repeat 60°tightening procedure, again strictly in
sequence illustrated.
41.Tighten the ten longer bolts (M12 x 140mm) a
further 20°, again following the sequence
illustrated.
NOTE: Repositioning of the pointer will be
necessary to reach all bolts, the pointer
can be fitted to the rocker shaft securing
studs using two nuts.
CAUTION: The double tightening
procedure must be carried out, on no
account should tightening be performed in
one operation, otherwise damage to the cylinder
head may occur.
42.Fit valve stem caps.
43.Fit push rods to locations from which they were
removed.
44.Fit rocker shaft assembly evenly tightening
securing nuts and bolts to correct torque.
45.Fit rocker cover ensuring oil seal is satisfactory
for continued use.
NOTE: Rocker cover seals can be re-used
up to a maximum of five times.
46.Secure rocker cover with special seal washers
and nuts tightened to correct torque.
47.Refit remainder of items by reversing operations
1 to 22 tightening securing bolts to correct torque
where applicable.

Tdi
23
REPAIR VACUUM PUMP
Service repair no - 70.50.19
Remove
NOTE: To ease pump removal set engine
to T.D.C. on No.1 cylinder.
1.Disconnect battery negative lead.
2.Detach servo hose from vacuum pump.
3.Remove six bolts securing vacuum pump.
4.Detach pump complete with harness bracket.
Note location of bracket for refitting.
Refit
5.Clean mating faces of pump and block.
6.Loosely assemble pump to block with a new
gasket and with harness bracket located under
head of bolt noted during removal.
7.Evenly tighten bolts, to depress pump plunger,
finally tightening to
25 Nm.
8.Connect vacuum hose and secure with clip.
9.Reconnect battery negative lead.GENERATOR
Service repair no - 86.10.02
Remove
1.Disconnect battery negative lead.
2.Remove drive belt.
See Drive Belt Renew
3.Disconnect electrical leads from rear of
generator.
4.Remove securing bolt from bottom of generator.
5.Remove long through bolt from top fixing and
withdraw generator.
Refit
6.Reverse removal procedure.