1995 LAND ROVER DISCOVERY battery

26COOLING SYSTEM
6
REPAIR WATER PUMP
Service repair no - 26.50.01
Remove
WARNING: Disconnect battery negative
terminal to prevent engine being started
before removing or adjusting drive belts.
1.Drain engine cooling system.
See Adjustment,
Coolant
2.Remove fan blades and pulley.See Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
3.Disconnect inlet hose from water pump.
4.Remove water pump bolts.
5.Remove water pump and joint washer.
Refit
6.Lightly grease new joint washer, position on
timing cover.
7.Clean threads of all long bolts and coat with
Loctite 572 thread lubricant-sealant.
8.Locate water pump in position. Tighten
remaining water pump housing bolts evenly to
28 Nm.
9.Reverse removal procedure. 1 to 3.
10.Check for coolant leaks around all hose
connections and joint faces.

26COOLING SYSTEM
2
REPAIR RADIATOR
Service repair no - 26.40.01
Remove
1.Disconnect battery negative lead.
WARNING: Do not carry out the next
instruction until the coolant is cool to
avoid personal injury from scalding.
2.Slacken clip and release bottom hose from
radiator, allow coolant to drain into a suitable
container
3.Slacken clip and release bottom hose from
radiator rail.
4.Slacken clip and release top hose from radiator.
5.Release air cleaner to throttle housing hose from
securing brackets.
6.Slacken clip and release bypass hose from
radiator.
7.Slacken clip and release top expansion hose
from radiator.
8.Remove 2 bolts securing radiator side support
brackets.
9.Collect L.H. support bracket and position R.H.
support bracket aside.
10.Slacken clip and release heater hose from
radiator rail.
11.Disconnect 2 multiplugs from cooling fan
assemblies.

Mpi
3
REPAIR
12.With assistance lift out radiator assembly.
Do not carry out further dismantling if component
is removed for access only.
13.Remove 2 bolts securing radiator rail to radiator.
14.Remove radiator rail.
15.Remove 8 nuts securing fan assemblies to
radiator.
NOTE: Vehicles without air conditioning
have one cooling fan fitted.
Refit
16.Position fan assemblies to radiator and tighten
nuts to
6Nm
17.Position radiator rail to radiator and secure with
bolts.
18.Position radiator to vehicle.
19.Secure radiator to body with the side support
brackets and retaining bolts.
20.Connect multiplugs to cooling fans.
21.Fit and secure 6 hoses to radiator.
22.Secure air cleaner to throttle housing to
brackets.
23.Refill cooling system.
24.Reconnect battery negative lead.

30MANIFOLD AND EXHAUST SYSTEM
4
REPAIR EXHAUST MANIFOLD - Tdi
Service repair no - 30.15.10
Remove
1.Disconnect battery negative lead.
2.Remove heat shield from rear of air intake
manifold.
3.Release dip stick tube from cylinder block.
4.Disconnect the intake hose from the manifold.
5.Remove the two bolts and two nuts securing the
intake manifold to the cylinder head and
withdraw the inlet manifold.
6.Remove air filter inlet pipe to turbo unit.
7.Remove intercooler pipe from turbo to
intercooler.
8.Disconnect the EGR pipe from the inlet manifold
hose.
9.Remove the three fixings at the exhaust pipe
flange.
10.Release the turbo charger oil pipes from the
cylinder block.
11.Remove the turbo boost pipes.
12.Remove seven bolts securing the exhaust
manifold, release the heater rail and remove the
manifold gasket, complete with turbo unit.
13.Remove four bolts and disconnect diaphragm
rod from manifold, and remove turbo charger if
necessary.
Refit
14.Reverse removal procedure. 1 to 12. Use a new
manifold and exhaust flange gaskets.
15.Reconnect battery negative lead. Start engine
and check for leaks.

MANIFOLD AND EXHAUST SYSTEM
5
REPAIR INLET MANIFOLD GASKET - Mpi
Service repair no - 30.15.08
Remove
1.Disconnect battery negative lead.
2.Position absorbent cloth around fuel pipe to fuel
rail union. Unscrew union to relieve fuel
pressure. Re-tighten union.
CAUTION: Plug connections.
3.Release clip and remove air cleaner to throttle
housing hose.
4.Disconnect stepper motor multiplug.
5.Disconnect throttle potentiometer multiplug.
6.Release throttle cable from abutment bracket.
7.Release throttle cable from cam. Remove
coolant bypass hose.
8.Disconnect fuel temperature sensor multiplug.
9.Release clip and disconnect brake servo hose
from manifold.

MANIFOLD AND EXHAUST SYSTEM
7
REPAIR Refit
19.Ensure mating faces of inlet manifold and
cylinder head are clean.
20.Fit a new gasket, position inlet manifold to
cylinder head.
21.Fit nuts and bolts, tighten in the order shown to
the correct torque
25Nm
22.Position engine breather hose to manifold and
secure with bolts.
23.Connect fuel injector harness and intake air
temperature sensor multiplug.
24.Connect fuel hose to pressure regulator and
secure with clip.
25.Fit fuel pipe to fuel rail, tighten union to
10Nm
26.Connect vacuum hoses to manifold.
27.Position engine harness and cam cover brackets
to manifold, secure with bolts.
28.Connect breather hose and brake servo hose to
manifold, secure with clips.
29.Connect multiplug to fuel temperature sensor.
30.Connect breather hose to throttle housing and
secure with clip.
31.Connect throttle cable to cam and secure to
abutment bracket.
32.Connect coolant bypass hose to throttle housing.
33.Connect stepper motor and throttle
potentiometer multiplugs.
34.Connect air cleaner hose to throttle housing and
secure with clip.
35.Connect battery negative lead.
36.Adjust throttle cable.EXHAUST MANIFOLD GASKET - Mpi
Service repair no - 30.15.12
Remove
1.Raise vehicle.
2.Loosen 2 nuts securing downpipe to silencer
box.
3.Remove 4 nuts securing downpipe to exhaust
manifold.
4.Release downpipe from exhaust manifold.
5.Discard gasket.

MANIFOLD AND EXHAUST SYSTEM
9
REPAIR MANIFOLD CHAMBER GASKET - Mpi
Service repair no - 30.15.37
Remove
1.Disconnect battery negative lead.
2.Position absorbent cloth around fuel pipe to fuel
rail union. Loosen union to relieve pressure.
Re-tighten union.
3.Release clip and remove air cleaner to throttle
housing hose.
4.Disconnect stepper motor and throttle
potentiometer multiplugs.
5.Release clip and disconnect breather hose from
throttle housing.
6.Release throttle cable from abutment bracket.
7.Release throttle cable from cam. Remove
coolant bypass hose from throttle housing.
8.Disconnect fuel temperature sensor multiplug.
9.Release clip and disconnect brake servo hose
from manifold.

30MANIFOLD AND EXHAUST SYSTEM
10
REPAIR 10.Release clip and disconnect breather hose from
manifold.
11.Release 2 bolts securing camshaft cover
brackets to manifold.
12.Disconnect 4 vacuum hoses from manifold.
13.Remove 6 bolts securing manifold chamber to
lower manifold.
14.Remove manifold chamber and collect gaskets.
Refit
NOTE: For torque values.See
Specifications, torque, Torque Values
15.Ensure mating faces of manifold chamber and
lower manifold are clean.
16.Fit a new gasket, position manifold chamber to
lower manifold.
17.Fit bolts, tighten to the correct torque.
18.Connect vacuum hoses to manifold.
19.Position camshaft cover brackets to manifold,
secure with bolts.
20.Connect breather hose and brake servo hose to
manifold, secure with clips.
21.Connect multiplug to fuel temperature sensor.
22.Connect breather hose to throttle housing and
secure with clip.
23.Connect throttle cable to cam and secure to
abutment bracket.
24.Connect coolant bypass hose to throttle housing.
25.Connect stepper motor and throttle
potentiometer multiplugs.
26.Connect air cleaner hose to throttle housing and
secure with clip.
27.Reconnect battery negative lead.
28.Adjust throttle cable.