1995 LAND ROVER DISCOVERY clutch

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.

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

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REPAIR
37.Remove nuts and plain washers securing front
engine mountings to chassis,and lift both engine
mounting bracket assemblies from vehicle.
38.Remove engine to bell housing fixings. Leave
starter motor attached.
39.Raise engine to separate from transmission.
40.Check all connections to engine have been
disconnected.
41.Remove engine.Refit
42.Apply Hylomar to mating faces of bell housing.
Lubricate splines of gearbox primary pinion with
Rocol MV 3.
If automatic transmission, coat the four drive
plate to torque convertor bolts with Loctite 290.
Tighten to
39 Nm.
43.Lower engine and locate with transmission.
If manual transmission locate primary pinion into
clutch and engage bell housing dowels. Fit
engine to bell housing fixings. Tighten to
40 Nm.
If automatic transmission fixings. Tighten to46
Nm.
44.Raise engine, refit front engine mounting
brackets to cylinder block and bell housing.
45.Remove gearbox support and lower engine.
46.Tighten front engine mountings to chassis
fixings. Tighten to
45 Nm.
47.Reverse removal procedure. 1 to 37.

12ENGINE
14
REPAIR FLYWHEEL
Service repair no - 12.53.07
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.Fit two long 8mm bolts into the clutch bolt holes,
diametrically opposite, to use as handles when
lifting the flywheel off the crankshaft.
5.Remove fan cowl
6.Fit crankshaft pulley retainer LRT-12-080 and
secure with four bolts, to restrain crankshaft
while removing flywheel retaining bolts.
7.Remove the bolts and lift off flywheel.
NOTE: To prevent excessive flywheel
run-out, ensure that the mating faces of
the flywheel and crankshaft are clean.Refit
8.Locate the flywheel on the crankshaft and
secure with new patched retaining bolts,
progressively tighten to
147 Nm.
9.Check the flywheel for possible run-out by
mounting a dial test indicator with the stylus in a
loaded condition resting on the flywheel face at a
radius of 114mm from the centre.
10.Turn the flywheel and check that run-out does
not exceed 0,05 to 0,07mm. Should run-out be
excessive, remove the flywheel and check again
for irregularities on the crankshaft and flywheel
mating faces and the dowel.
11.Reverse removal procedure. 1 to 6.

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REPAIR CRANKSHAFT REAR OIL SEAL
Service repair no - 12.21.20
Remove
NOTE: The crankshaft rear oil seal is
retained in its own housing, if the seal
requires replacing the housing and seal
assembly (1) must be renewed complete with the
housing seal (3). Housing and seal assemblies are
supplied with their own former/seal guide (2)
already fitted. This former must not be removed
before fitting the assembly to the engine. If a seal
and housing assembly is received without a
former/guide fitted it must be returned to the
supplier. Used formers/guides must be discarded
immediately after use, under no circumstances
should they be reused on other assemblies.
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 five bolts and withdraw seal housing
and seal assembly complete with gasket.
Refit
6.Insert slave studs to seal housing mounting face.
7.Position new seal housing gasket over slave
studs and crankshaft flange onto cylinder block.

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.

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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.