1995 LAND ROVER DISCOVERY heating

Tdi
1
FAULT DIAGNOSIS ENGINE OVERHEATING
Before conducting any cooling system diagnosis:
See
Description and operation, Engine Cooling
1.Is coolant level correct?
NO - Allow engine to cool, top up level to
expansion tank seam.
YES - Continue.
2.Is drive belt tension correct?
NO -
See ENGINE, Repair, Compressor
Drive Belt
YES - Continue.
3.Is coolant in radiator frozen?
YES - Slowly thaw and drain system.
See
Adjustment, Coolant
NO - Continue.
4.Is air flow through radiator restricted or blocked?
YES - Apply air pressure from engine side of
radiator to clear obstruction.
NO - Continue.
5.Are there any external leaks, from water pump,
engine gaskets, fast idle thermostat or the heater
unit?
YES - Investigate and rectify.
See Adjustment,
Coolant
NO - Continue.
6.Are fan blades fitted correct way round, concave
side towards engine?
NO - Rectify.
YES - Continue
7.Is viscous unit operating correctly?
See
Description and operation, Viscous Fan
NO - Renew.See Repair, Viscous
Coupling, Fan Blades, Pulley and Fan
Cowl
YES - Carry out a pressure test on radiator cap
and system. Check thermostat type,
operation and correct fitting.
See Repair,
Thermostat
If pressure test leads you to suspect coolant
leakage across gaskets, go to check 10,
otherwise: Continue.8.Are the air conditioning fans operating correctly?
See Electrical Trouble Shooting Manual.
NO - Rectify.
YES - Continue.
9.Is temperature sender and gauge giving
accurate readings?
NO - Sustitute parts and compare readings.
YES - Continue.
10.Carry out cylinder pressure test to determine if
pressure is leaking into cooling system causing
over pressurising and loss of coolant.
If problem is not diagnosed, check the coolant system
for engine oil contamination and engine lubrication
system for coolant contamination.
If only the coolant system is contaminated suspect a
cylinder head gasket.
If both systems are contaminated, suspect the
radiator.
If only the lubrication system is contaminated with
coolant, suspect leakage past cylinder liner seals or
cylinder head gasket.

V8i
1
DESCRIPTION AND OPERATION ENGINE COOLING
Description
The V8i engine uses a pressurised cooling system
and cross flow radiator which is supplied from a
separate header tank. The coolant radiator also
incorporates a section at the left hand end for cooling
the transmission oil and a section at the other end for
cooling the engine oil.The belt driven viscous fan and centrifugal water
pump is located in the engine front cover with ports for
circulation of coolant to both banks of cylinders and
cylinder heads. Coolant returns to the top of the
radiator via ports in the inlet manifold where the
thermostat is mounted horizontally.
Coolant also circulates through the vehicle heating
system and is used to heat air entering the inlet
manifold plenum chamber.
Coolant circulation (engine hot)
1. Cross flow radiator
2. Header tank
3. Viscous fan and water pump
4. Heater pipes
5. Plenum chamber connection
6. Thermostat

V8i
3
DESCRIPTION AND OPERATION Plenum chamber heating
Air entering the plenum chamber is heated by a flow
of coolant from the inlet manifold which returns
through a long hose, to the top right corner of the
radiator.
1. Hot water supply
2. Cold return to radiatorVISCOUS FAN
Description
The viscous drive unit for the engine cooling fan,
provides a means of controlling the speed of the fan
relative to the running temperature of the engine. The
viscous unit is a type of fluid coupling, which drives
the fan blades through the medium of a special
'silicone fluid' injected into the unit during
manufacture.
1. Drive in from water pump spindle
2. Drive out to fan blades
3. Bi-metal

V8i
1
FAULT DIAGNOSIS ENGINE OVERHEATING
Before conducting any cooling system diagnosis:
See
Description and operation, Engine Cooling
1.Is coolant level correct?
NO - Allow engine to cool, top up level to
expansion tank seam.
YES - Continue.
2.Is drive belt tension correct?
NO -
See ENGINE, Repair, Drive Belt -
Check Tension
YES - Continue.
3.Is ignition timing correct?
NO -
See ELECTRICAL, Adjustment,
Ignition Timing
YES - Continue.
4.Is coolant in radiator frozen?
YES - Slowly thaw and drain system.
See
Adjustment, Coolant Requirements
NO - Continue.
5.Is air flow through radiator restricted or blocked?
YES - Apply air pressure from engine side of
radiator to clear obstruction.
NO - Continue.
6.Are there any external leaks, from water pump,
engine gaskets or the heater unit?
YES - Investigate and rectify.
See Adjustment,
Coolant Requirements
NO - Continue.
7.Are fan blades fitted correct way round, concave
side towards engine?
NO - Rectify.
YES - Continue.8.Is viscous unit operating correctly?
See
Description and operation, Viscous Fan
NO - Renew.See Repair, Viscous
Coupling, Fan Blades, Pulley and Fan
Cowl
YES - Carry out a pressure test on radiator cap
and system. Check thermostat type,
operation and correct fitting
See Repair,
Thermostat
If pressure test leads you to suspect coolant
leakage across gaskets, go to check 11,
otherwise: Continue.
9.Are the air conditioning fans operating correctly?
See Electrical Trouble Shooting Manual.K5
NO - Rectify.
YES - Continue.
10.Is temperature sender and gauge giving
accurate readings?
NO - Substitute parts and compare readings.
YES - Continue.
11.Carry out cylinder pressure test to determine if
pressure is leaking into cooling system causing
over pressurising and loss of coolant.
If problem is not diagnosed, check the coolant system
for engine oil contamination and engine lubrication
system for coolant contamination.
If the coolant only, or both systems are contaminated,
suspect cylinder head gaskets or radiator.
If only the lubrication stystem is contaminated with
coolant, suspect inlet manifold or front cover gaskets.

R380
1
FAULT DIAGNOSIS MANUAL GEARBOX
Symptom - Gear jumps out of engagement (any
forward gear)
1.Check condition and security of transmission
and engine mountings.
2.Check in situ, gear lever and selector
adjustments.
3.In situ, remove gearshift and check selector rail
yoke security.
Also check selector detent spring tension and
both spool retainers.
Suspect internal fault
See remove and overhaul procedure.
4.Check action/operation of main selector rail and
forks.
5.Check condition of synchromesh and gear dog
teeth.
6.Check main and layshaft end floats bearings and
adjustments.
7.Check condition of all gearbox components,
ensure clearances and adjustments are correct
on reassembly.
Symptom - Reverse gear only jumps out of
engagment
1.Check condition and security of transmission
and engine mountings.
2.Check in situ, gear lever and selector
adjustments.
3.In situ, remove gearshift and check selector rail
yoke security.
Also check selector detent spring tension and
both spool retainers.
Suspect internal fault
See remove and overhaul procedure.
4.Check action/operation of main selector rail and
reverse lever.
5.Check condition of reverse gear, angled
bearings and shaft.
6.Check condition of all gearbox components,
ensure clearances and adjustments are correct
on reassembly.Symptom - Excessive force required to engage or
change gear, vehicle stationary or moving.
1.Check lubricant specification and level, if low do
not top up at this stage.
2.In situ, lubricate gear mechanism, and check
selector adjustments.
3.In situ, remove gearshift and check selector rail
is free and that the yoke is secure. Also check
selector detent spring tension and both spool
retainers.
4.Drain lubricant and check for contamination or
metal particles.
Suspect worn synchromesh unit or baulk rings
on affected gears. See remove and overhaul
procedure.
Symptom - Noisy gear engagement, vehicle
stationary.
See CLUTCH, Fault diagnosis, Clutch
Noise - Mechanical Faults
Symptom - Noisy gear selection, vehicle moving.
1.Confirm that clutch operation is satisfactory.
2.Establish which gear/gears is causing noise.
3.Check lubricant specification and level, if low do
not top up at this stage.
4.Drain lubricant and check for contamination or
metal particles.
Suspect worn synchromesh. See remove and
overhaul procedure.
5.Check condition of synchromesh unit, springs
and cones for distortion and wear. Also check
dog teeth for damage and cone mating surface
on gear for signs of overheating.
6.Check condition of all gearbox components,
ensure clearances and adjustments are correct
on reassembly.
Symptom - Noise from gearbox in neutral, which
changes tone or becomes worse when clutch is
depressed.
See CLUTCH, Fault diagnosis, Clutch
Noise - Mechanical Faults

STEERING
1
FAULT DIAGNOSIS INSUFFICIENT POWER ASSISTANCE
1.Is fluid level correct?
YES - go to 3.
NO - Fill/bleed sytem
2.Is problem a leak?
YES - Diagnose.
See Power Steering Fluid
Leaks
NO - continue
3.Is drive belt tension correct?
YES - go to 5.
NO - retension.
See ENGINE, Repair, Drive
Belt
4.Is problem resolved?
YES - end
NO - continue
5.Carry out pressure test at idle and 1000 rev/min.
See Power Steering System - Test
6.Is correct pressure achieved?
YES - steering box defective
Not at any speed go to 9.
Not at idle go to 7.
7.Is idle speed correct?
YES- Goto8.
NO - Correct idle speed -
If 3.9
See ENGINE TUNING DATA,
Information, Engine 3.9 V8i
If TdiSee ENGINE TUNING DATA,
Information, 300 Tdi Engine
If MpiSee ENGINE TUNING DATA,
Information, Engine - Mpi - 2.0 Litre
8.Is problem resolved?
YES - end
NO - go to 9.
9.Bypass steering box using adaptor tap
LRT-57-001
10.Is correct pressure obtained?
YES - defective steering box
NO - defective steering pump
CAUTION: Do not hold steering wheel on
full lock for more than 30 seconds in any
one minute to avoid overheating fluid and
possibly damaging seals.
NOTE: 1. Excessive pressure in the
system is almost always caused by a
faulty relief valve in the PAS pump.
NOTE: 2. Insufficient pressure in the
system is usually caused by low fluid level
or PAS pump drive belt slip, or one of the
following: PAS system leaks, faulty PAS pump
relief valve, fault in steering box valve and worm
assembly, leak at piston in steering box, worn
components in PAS pump or box.

57STEERING
2
FAULT DIAGNOSIS POWER STEERING SYSTEM - TEST
NOTE: If steering lacks power assistance.
Check pressure of hydraulic pump before
fitting new components. Use fault
diagnosis chart to assist in tracing faults.
A. Steering box.
B. Steering pump.
C. Existing hose, steering box to pump.
D. Hose LRT-57-030.
E. Test adaptor LRT-57-001.
F. Pressure gauge LRT-57-005.
G. Thread adaptor LRT-57-004.
H. Thread adaptor LRT-57-022.Procedure
1.A hydraulic pressure gauge and test adaptor is
used to test power steering system. This gauge
is able to measure 140 kgf/cm
2. The maximum
power steering system pressure is 77 kgf/cm2.
2.Some fault conditions of hydraulic pump may
obtain pressures up to 105 kgf/cm
2. Pressure on
gauge is same pressure being exerted upon
steering wheel. When testing, turn steering
wheel gradually while reading pressure gauge.
3.Check and maintain maximum fluid level of
reservoir.
4.Examine power steering units and connections
for leaks. All leaks must be rectified before
attempting to test the system.
5.Check steering pump drive belt tension.
See
ENGINE, Repair, Drive Belt
6.Assemble test equipment and fit to vehicle, as
shown in RR3959M.
7.Open tap of adaptor.
8.Bleed system, take care not to overload
pressure gauge.
9.With system in good condition, pressures should
be:
(A) Steering wheel held on full lock and engine
running at 1,000 rev/min, 70 to 77 kgf/cm
2.
(B) Steering wheel held on full lock and engine
idling, 28 kgf/cm
2.
Checks should be carried out on both full lock
positions.
CAUTION: Do not maintain this pressure
for more than 30 seconds in any one
minute to avoid overheating fluid and
possibly damaging seals.
10.Release steering wheel and with engine idling.
Pressure should read below 7 kgf/cm
2.
11.If pressures differ to those given a fault exists.
12.To determine if fault is steering box or pump.
Close adaptor tap for a maximum five seconds.
13.If gauge does not register specified pressure,
pump is faulty.
14.Fit a new pump, bleed system and repeat test. If
low pressure or a substantial imbalance exists,
fault is in steering box valve and worm
assembly.

57STEERING
4
REPAIR
Refit
15.Position steering box to chassis side member,
ensuring locating peg is engaged. Tighten bolts
to
81 Nm.
16.Fit pinch bolt and nut securing universal joint to
power steering box. Tighten to
25 Nm.
17.Position tie bar, tighten bolts and nut to81 Nm,
starting with tie bar to mounting nut, then
loosen nut and bolts by one complete turn.
18.Check steering box, adjust if necessary.See
Adjustment, Power Steering Box
19.Refit drag link to drop arm tighten nut to40 Nm.
20.Fit undertray.
21.Lower vehicle to ground.
22.Remove plugs and refit pipes to steering box.
Tighten 16mm thread to
20 Nm.
14mm thread to15 Nm.
23.Remove filler cap. Fill reservoir to oil level mark
on dipstick. Use recommended fluid.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids
and bleed power steering system.See
Power Steering System - Bleed
24.Recheck fluid level and replace cap.
25.With engine running, test steering system for
leaks by holding steering in both full lock
directions.
CAUTION: Do not maintain this pressure
for more than 30 seconds in any one
minute, to avoid oil overheating and
possible seal damage.
26.Test drive vehicle: using both full lock directions,
to settle steering components. If possible, drive
vehicle over speed bumps and include harsh
braking.
WARNING: Do not test drive vehicle on
public highway.
27.Drive vehicle in a straight line on level ground
and stop.
28.Tighten tie bar to mounting nut to
110 Nm.
29.Tighten bolts securing tie bar to81 Nm.
30.Ensure steering wheel is correctly aligned when
wheels are positioned straight ahead.
31.If necessary reposition steering wheel.
See
Steering Wheel
32.Road test vehicle.