1995 LAND ROVER DISCOVERY engine

INTRODUCTION
11
INFORMATION CROSS REFERENCE OF EMISSION SYSTEM
TERMINOLOGY
NEW TERM (ACRONYM)
Accelerator pedal (AP).................................................
Air cleaner (ACL)..........................................................
Air conditioning (AC)....................................................
Battery positive voltage (B+)........................................
Closed loop (CL)..........................................................
Closed throttle position (CTP)......................................
Canister purge valve (CANPV)....................................
Data link connector (DLC)...........................................
Diagnostic trouble code (DTC).....................................
Distributor ignition (DI).................................................
Engine control module (ECM)......................................
Engine coolant level (ECL)...........................................
Engine coolant temperature (ECT)..............................
Engine coolant temperature sensor (ECTS)................
Engine speed (RPM)....................................................
Evaporative emission system (EVAP)..........................
Engine fuel temperature sensor (EFTS)......................
4th gear, 3rd gear etc. (4GR, 3GR)..............................
Fuel pump (FP)............................................................
Fan control module (FCM)...........................................
Generator (GEN)..........................................................
Ground (GND)..............................................................
Heated oxygen sensor (H02S)....................................
Idle air control (IAC)......................................................
Idle air control valve (IACV).........................................
Ignition control module (ICM).......................................
Inertia fuel shutoff (IFS)................................................
Inertia fuel shutoff switch (IFSS)..................................
Intake air temperature (IAT).........................................
Malfunction indicator lamp (MIL)..................................
Manifold vacuum zone (MVZ)......................................
Mass air flow sensor (MAFS).......................................
Multiport fuel injection (MFI)........................................
On board diagnostic (OBD)..........................................
Open loop (OL)............................................................
Park/neutral position (PNP).........................................
Park/neutral position switch (PNPS)............................
Programmable read only memory (PROM)..................
Relay module (RM)......................................................
Service reminder indicator (SRI)..................................
Solid state relay module (SSRM).................................
Three way catalytic converter (TWC)..........................
Throttle body (TB)........................................................
Throttle position sensor (TPS)......................................
Torque converter clutch (TCC)....................................
Transmission range (TR)..............................................
Transmission range selector (TRS).............................
Vehicle speed sensor (VSS)........................................
Wide open throttle (WOT)............................................OLD TERM (ACRONYM)
Throttle pedal (-)..........................................................
Air cleaner (-)...............................................................
Air conditioning (AC)....................................................
Battery plus, bat +, bat feed (B+).................................
Closed loop (-).............................................................
Closed throttle, idle position (-)....................................
Charcoal canister purge valve (-).................................
Serial link (-)................................................................
Fault code (-)...............................................................
Electronic ignition (-)....................................................
Electronic control unit (ECU)........................................
Coolant level (-)...........................................................
Coolant temperature (temp).........................................
Coolant temperature thermistor (-)..............................
Engine speed (rev/min)................................................
Evaporative loss system (ELC)...................................
Fuel temperature thermistor (-)....................................
Fourth gear, 3rd gear (-)..............................................
Fuel pump (-)...............................................................
Condenser fan timer (-)................................................
Alternator (-)................................................................
Ground, earth (B-)........................................................
Lambda (02) sensor (-)................................................
Idle speed control (ISC)................................................
Stepper motor (-).........................................................
Ignition module (-)........................................................
Inertia switch (-)...........................................................
Inertia switch (-)...........................................................
Intake temperature/ambient temperature (-)................
EFI warning lamp (-)....................................................
Manifold depression, vacuum (-).................................
Air flow meter (-)..........................................................
Electronic fuel injection (EFI).......................................
Fault code display unit (-)............................................
Open loop (-)...............................................................
Park or neutral (-).........................................................
Start inhibit switch (-)...................................................
Chip, PROM (PROM)...................................................
Relay (-).......................................................................
Check engine light (-)...................................................
Control unit (-)..............................................................
Catalyst, catalytic converter (CAT)..............................
Throttle housing (-)......................................................
Throttle potentiometer (-).............................................
Direct drive clutch (DDC)..............................................
Transmission gear (-)...................................................
Shift lever, shifter (-)....................................................
Road speed transducer (-)...........................................
Full throttle, wide open throttle (WOT).........................

01INTRODUCTION
12
INFORMATION VEHICLE IDENTIFICATION NUMBER (VIN)
The Vehicle Identification Number and the
recommended maximum vehicle weights are stamped
on a plate located under the bonnet [hood] riveted to
the front of the engine compartment.
Vehicle Identification Number Plate (UK, Australia,
R.O.W., Europe)
A.Build date (Australia). Type approval
B.VIN (17 digits)
C.Maximum permitted laden weight for vehicle
D.Maximum vehicle and trailer weight
E.Maximum road weight-front axle
F.Maximum road weight-rear axle
The number is also stamped on the right side of the
chassis forward of the spring mounting turret.
Vehicle Identification Number Plate (Saudi Arabia)
A.Year of manufacture
B.Month of manufacture
C.Maximum vehicle weight
D.Maximum road weight-front axle
E.Maximum road weight-rear axle
F.VIN (17 digits)
The vehicle identification number identifies the
manufacturer, model range, wheel base, body type,
engine, steering, transmission, model year and place
of manufacture. The following example shows the
coding process.
SALWorld manufacturer identifier
LHRange Rover or
LJDiscovery
GClass 100 inch
B2 door
F300 Tdi or
VV8i Petrol
85 speed LHD or
75 speed RHD
M1995 MY
ASolihull site

01INTRODUCTION
14
INFORMATION LOCATION OF IDENTIFICATION NUMBERS
Engine serial number - 300Tdi Engine
The 300Tdi engine number is stamped on the cylinder
block on the right hand side of the engine above the
camshaft front cover plate.
Engine serial number - Mpi engine
Stamped on the R.H. face of the cylinder block
adjacent to the gearbox.
Engine serial number - V8i engine
Stamped on a cast pad on the cylinder block, between
numbers 3 and 5 cylinders.
NOTE: The appropriate engine
compression ratio is stamped above the
serial number.
Main gearbox R380
Stamped on a cast pad on the bottom right hand side
of the gearbox.
Transfer gearbox LT230
The serial number is stamped on the left hand side of
the gearbox casing below the mainshaft rear bearing
housing adjacent to the bottom cover.
Front and rear axles
Serial number is stamped on top of the left hand axle
tube.

01INTRODUCTION
16
INFORMATION FAULT DIAGNOSTIC EQUIPMENT
TESTBOOK
Todays Land Rover Vehicles are equipped with a
large amount of electronics to provide the best
performance of the vehicles systems.
Diagnostic equipment named TESTBOOK is available
to expand the diagnostic abilities of the dealer
workshop. This repair manual is produced with
Testbook in mind.
Features of Testbook include :- Fully upgradable
support for the technician. Structured diagnostics to
accommodate all skill levels. Touch screen operation.
Direct print out of screen information and test results.
ELECTRICAL TROUBLESHOOTING MANUAL
The Electrical Troubleshooting Manual is a separate
publication that is intended for use by trained Land
Rover technicians as an aid to diagnosing electrical
concerns.
It provides circuit diagrams, system diagnosis flow
charts, electrical component location tables, electrical
component location views and circuit operation
details.READING THIS MANUAL
This manual is divided into sections shown on the
contents page, alongside a range of icons, familiar to
service technicians.
Relevant information is contained within each of these
sections. These are further divided into the following
sub-sections which appear at the foot of each page :-
Description and operation.
Fault diagnosis.
Adjustment.
Repair.
Overhaul.
Specifications, Torque.
Service tools.
To avoid repeating information through the sections,
where part of the repair operation impacts on another
section, a cross reference is given to direct the reader
to where the information is sited.
For example:
The maintenance section states the need to renew
V8i drive belt. A cross reference sites this information
in: Section: V8i Engine
- Sub-section: Repairs
- Heading: Drive belt renew.
Sections that contain derivatives such as engines are
further separated within that section.
American terminology.
A few words used in this manual differ to words used
in America. Where this occurs the American word is
placed inside brackets. For example: bonnet [hood],
wing [fender], ramp [hoist].

GENERAL SPECIFICATION DATA
1
INFORMATION ENGINE 3.9 V8i
Type V8i.................................................................................
Number of cylinders Eight, two banks of four.........................................................
Bore 94,00 mm.................................................................................
Stroke 71,12 mm...............................................................................
Capacity 3950 cc...........................................................................
Compression ratio 8.13:1 or 9.35:1............................................................
Valve operation Overhead by push-rod................................................................
Maximum power - 8.13:1 127kW at 4550 rev/min............................
- 9.35:1 134kW at 4750 rev/min............................
Crankshaft
Main journal diameter 58,409-58,422 mm.......................................................
Minimum regrind diameter 57,393-57,406 mm...............................................
Crankpin journal diameter 50,800-50,812 mm................................................
Minimum regrind diameter 49,784-49,797 mm...............................................
Crankshaft end thrust/(end float) Taken on thrust washers of centre main bearing......................................
0,10-0,20 mm
Main bearings
Number and material 5, Lead-indium........................................................
Diametrical clearance 0,010-0,048 mm.......................................................
Undersize bearing shells 0,254 mm, 0,508 mm..................................................
Connecting rods
Type Horizontally split big-end, plain small-end.................................................................................
Length between centres 143,81-143,71 mm...................................................
Big-end bearings
Type and material Lead-indium............................................................
Diametrical clearance 0,015-0,055 mm.......................................................
End-float crankpin 0,15-0,36mm............................................................
Undersize bearing shells 0,254 mm, 0,508 mm..................................................
Piston pins
Length 72,67-72,79 mm..............................................................................
Diameter 22,215-22,220 mm..........................................................................
Fit-in connecting rod Press fit.........................................................
Clearance in piston 0,002-0,007 mm..........................................................

04GENERAL SPECIFICATION DATA
2
INFORMATION Pistons
Clearance in bore, measured at bottom
of skirt at right angles to piston pin 0,018-0,041 mm...................................
Piston rings
Number of compression rings 2..........................................
Number of control rings 1....................................................
No 1 compression ring Molybdenum barrel faced.....................................................
No 2 compression ring Tapered and marked 'T' or 'TOP'.....................................................
Width of compression rings 1,478-1,49 mm..............................................
Compression ring gap 0,40-0,65 mm......................................................
Oil control ring width 3,0 mm.........................................................
Oil control ring rail gap 0,38-1,40 mm.....................................................
Camshaft
Location Central...........................................................................
Bearings Tin - aluminium...........................................................................
Number of bearings 5..........................................................
Drive Chain 9,52 mm pitch x 54 pitches..................................................................................
TappetsHydraulic-self-adjusting ...........................................................................
Valves
Length: Inlet 116,59-117,35 mm..................................
Exhaust 116,59-117,35 mm...........................
Seat angle: Inlet 45°to 45 1/2° ..................................
Exhaust 45°to 45 1/2° ...........................
Head diameter: Inlet 39,75-40,00 mm..................................
Exhaust 34,226-34,480 mm...........................
Stem diameter: Inlet 8,664-8,679 mm..................................
Exhaust 8,651-8,666 mm...........................
Stem to guide clearance: Inlet 0,025-0,066 mm..................................
Exhaust 0,038-0,078 mm...........................
Valve lift (Inlet and Exhaust) 9,49 mm............................................
Valve spring length fitted 40,4 mm at pressure of 29,5 kg..................................................
Lubrication
System type Wet sump, pressure fed.....................................................................
Oil pump type Eccentric rotor...................................................................
Oil pressure 2.75 bar (40 lb/in
2) at 2500 rev/min with engine at ......................................................................
running temperature
Oil filter-internal Wire screen, pump intake filter.................................................................
Oil filter-external Full flow, self-contained cartridge...............................................................

GENERAL SPECIFICATION DATA
3
INFORMATION ENGINE 4.0 V8
Type 4.0 litre V8.................................................................................
Number of cylinders Eight, two banks of four.........................................................
Bore 94.00 mm................................................................................. 3.70 in
Stroke 71.12 mm............................................................................... 2.80 in
Capacity 3950 cm
3........................................................................... 241 cu in
Valve operation Overhead by push-rod................................................................
High Compression Low Compression
Compression ratio 9.35:1............................................................ 8.2:1
Valve operation Overhead by push-rod................................................................
Maximum power: 9.35:1 140kW at 4750 rev/min..............................
8.2:1 132kW at 4750 rev/min................................
Crankshaft
Main journal diameter 63.500 - 63.487 mm....................................................... 2.50 - 2.4995 in
Crankpin journal diameter 55.513 - 55.500 mm................................................ 2.1855 - 2.1850 in
Crankshaft end thrust/end float Taken on thrust washers of centre main bearing........................................
0.10 - 0.20 mm 0.004 - 0.008 in
Main bearings
Number and type 5, Vandervell shells..............................................................
Material Lead bronze with lead-indium overlay............................................................................
Diametrical clearance 0.015 - 0.060 mm....................................................... 0.0006 - 0.0024 in
Connecting rods
Type Horizontally split big-end, plain small-end.................................................................................
Length between centres 155.12 - 155.22 mm................................................... 6.1071 - 6.1110 in
Big-end bearings
Type and material Vandervell VP3 Lead bronze with lead-indium overlay............................................................
Diametrical clearance 0.015 - 0.016 mm....................................................... 0.0006 - 0.0024 in
Piston pins
Length 60.00 - 60.50 mm.............................................................................. 2.3622 - 2.3819 in
Diameter 23.995 - 24.000 mm.......................................................................... 0.9447 - 0.9449 in
Fit-in connecting rod Press fit.........................................................
Clearance in piston 0.015 - 0.006 mm.......................................................... 0.0006 - 0.0002 in
Pistons
Clearance in bore, measured at bottom
of skirt at right angles to piston pin 0.020 - 0.050 mm................................... 0.0008 - 0.0020 in

04GENERAL SPECIFICATION DATA
4
INFORMATION Piston rings
Number of compression rings 2..........................................
Number of control rings 1....................................................
No 1 compression ring Nitrided steel barrel faced.....................................................
No 2 compression ring Tapered spherical barrel marked 'TOP'.....................................................
Width of compression rings 1.478 - 1.49 mm.............................................. 0.0582 - 0.0587 in
(Top) 1.21 - 1.23 mm................................ 0.0476 - 0.0484 in
Compression ring gap 0.40-0.65 mm...................................................... 0.0157 - 0.0256 in
(Top) 0.3 - 0.5 mm................................ 0.0118 - 0.0197 in
Oil control ring type Aclonoform..........................................................
Oil control ring width 3.0 mm......................................................... 0.1181 in
Oil control ring rail gap 0.38-1.40 mm..................................................... 0.0150 - 0.0551 in
Camshaft
Location Central...........................................................................
Bearings Non serviceable...........................................................................
Number of bearings 5..........................................................
Drive Chain 9.52 mm pitch x 54 pitches..................................................................................
Camshaft End Float 0.076 - 0.355 mm......................................................... 0.003 - 0.014 in
TappetsHydraulic self-adjusting ...........................................................................
Valves
Length: Inlet 116.59 - 117.35 mm.................................. 4.590 - 4.620 in
Exhaust 116.59 - 117.35 mm........................... 4.590 - 4.620 in
Seat angle: Inlet 46°-46°25' ..................................
Exhaust 46°-46°25' ...........................
Head diameter: Inlet 39.75 - 40.00 mm.................................. 1.565 - 1.575 in
Exhaust 34.227 - 34.48 mm........................... 1.3475 - 1.3575 in
Stem diameter: Inlet 8.664 - 8.679 mm.................................. 0.3411 - 0.3417 in
Exhaust 8.651 - 8.666 mm........................... 0.3406 - 0.3412 in
Stem to guide clearance: Inlet 0.025 - 0.066 mm.................................. 0.0010 - 0.0026 in
Exhaust 0.038 - 0.078 mm........................... 0.0015 - 0.0031 in
Valve lift (Inlet and Exhaust) 9.94 mm............................................ 0.3913 in
Valve spring length fitted 40.4 mm (1.59 in) at pressure of 29.5 kg (65 lb)..................................................
Lubrication
System type Wet sump, pressure fed.....................................................................
Oil pump type Rotor...................................................................
Oil pressure 2.11 to 2.81 kg/cm
2(30 to 40 psi) at 2400 rev/min with ......................................................................
engine warm
Oil filter-internal Wire screen, pump intake filter in sump................................................................
Oil filter-external Full flow, self-contained cartridge...............................................................