1995 LAND ROVER DISCOVERY light

GENERAL FITTING REMINDERS
7
INFORMATION COTTER PINS
1.Fit new cotter pins throughout when replacing
any unit.
2.Always fit cotter pins where cotter pins were
originally used. Do not substitute spring
washers: there is always a good reason for the
use of a cotter pin.
3.All cotter pins should be fitted as shown unless
otherwise stated.
NUTS
1.When tightening a slotted or castellated nut
never loosen it back to insert cotter pin or locking
wire except in those recommended cases where
this forms part of an adjustment. If difficulty is
experienced, alternative washers or nuts should
be selected, or washer thickness reduced.
2.Where self-locking nuts have been removed it is
advisable to replace them with new ones of the
same type.
NOTE: Where bearing pre-load is involved
nuts should be tightened in accordance
with special instructions.
LOCKING WIRE
1.Fit new locking wire of the correct type for all
assemblies incorporating it.
2.Arrange wire so that its tension tends to tighten
the bolt heads, or nuts, to which it is fitted.SCREW THREADS
1.Both UNF and Metric threads to ISO standards
are used. See below for thread identification.
2.Damaged threads must always be discarded.
Cleaning up threads with a die or tap impairs the
strength and closeness of fit of the threads and
is not recommended.
3.Always ensure that replacement bolts are at
least equal in strength to those replaced.
4.Do not allow oil, grease or jointing compound to
enter blind threaded holes. The hydraulic action
on screwing in the bolt or stud could split the
housing.
5.Always tighten a nut or bolt to the recommended
torque value. Damaged or corroded threads can
affect the torque reading.
6.To check or re-tighten a bolt or screw to a
specified torque value first loosen a quarter of a
turn, then re-tighten to the correct value.
7.Oil thread lightly before tightening to ensure a
free running thread, except in the case of
threads treated with sealant/lubricant, and
self-locking nuts.
UNIFIED THREAD IDENTIFICATION
1. Bolts
A circular recess is stamped in the upper surface
of the bolt head.
2. Nuts
A continuous line of circles is indented on one of
the flats of the hexagon, parallel to the axis of
the nut.
3. Studs, Brake Rods, etc.
The component is reduced to the core diameter
for a short length at its extremity.

MAINTENANCE
19
MAINTENANCE
RESET EMISSION MAINTENANCE REMINDER -
USA
The emission maintenance reminder is designed to
activate at 52,500 and 105,000 miles respectively and
will illuminate a 'Service Engine' red warning light in
instrument binnacle.
The emission maintenance reminder must be reset
after required maintenance has been carried out and
a new tamperproof label fitted by a Land Rover of
North America dealer. This emission maintenance
reminder is part of the Emission Control System
Reset
1.The control unit is located in the passenger
footwell.
2.Identify control unit and remove from plug.
3.Remove tamperproof label to reveal access hole
for resetting.
4.Place a thin metallic probe into access hole and
momentarily electrically short between reset pins
inside unit.RECOMMENDED SERVICE ITEMS
Refer Service Schedule sheets for intervals.
Clean sunroof drain tubes, clean and lubricate guide
rails and slides.
Renew the hydraulic brake fluid.
See BRAKES,
Repair, Brake System Bleed
Renew all hydraulic brake fluid, seals, brake servo
filter and flexible hoses.
All working surfaces of the master cylinder and caliper
cylinders should be examined and renewed where
necessary.
ABS vehicles only - renew hydraulic brake fluid and
flexible hoses examine the working surfaces of the
caliper cylinders and renew the seals or cylinders
where necessary.
Air cleaner - When the vehicle is used in dusty or field
conditions or deep wading, frequent attention to the
air cleaner may be required.
ABS vehicles used extensively in arduous off-road
conditions - check the rear wheel road speed sensor
for abrasive wear.

12ENGINE
6
REPAIR CRANKSHAFT PULLEY
Service repair no - 12.21.01
Remove
1.Disconnect battery negative lead.
2.Drain coolant.
3.Remove top hose from radiator.
4.Remove intercooler to induction manifold hose.
5.Remove viscous fan and coupling.
See
COOLING SYSTEM, Repair, Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
6.Remove fan cowl.
7.Remove drive belt.
See Drive Belt Renew
8.Fit crankshaft pulley retainer LRT-12-080 and
secure with four bolts.
9.Remove crankshaft pulley retaining bolt using
socket and suitable long bar.
10.Remove pulley retainer.
11.Remove pulley, if necessary using extractor
LRT-12-049 with thrust pad from LRT-12-031.Refit
12.Refit in reverse order, lightly greasing pulley
spigot. Tighten to
80 Nm + 90°.

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.

12ENGINE
4
DESCRIPTION AND OPERATION Lubrication system
The V8i full flow lubrication system uses a gear type oil pump which is driven from the front of the crankshaft. The
oil pump gears are housed in the front cover and the pressure relief valve, warning light switch and filter are also
fitted to the front cover.
Oil drawn through the centrally located steel gauze strainer in the sump, is pumped under pressure through oil
cooler located in the lower half of the main coolant radiator. The cooled oil then passes through the filter, before
being distributed from the main gallery via drillings, to the various components in the engine.
Lubrication to the thrust side of the cylinders is by oil grooves machined in each connecting rod big end joint face,
which are timed to align with holes in the big end journals on the power and exhaust strokes.
Lubrication system
1. Oil to cooler
2. Oil from cooler

V8i
5
DESCRIPTION AND OPERATION Distributor and timing chain lubrication
The distributor and timing chain are lubricated from
the camshaft front bearing. The feed to the timing
chain is channelled along the camshaft sprocket, key
and spacer where it sprays onto the chain.
1. Bearing
2. Camshaft
3. Key
4. Camshaft timing chain sprocket
5. Spacer
6. Distributor drive gearHydraulic tappets
1. Clip
2. Pushrod seat
3. Inner sleeve
4. Upper chamber
5. Non-return ball valve
6. Spring
7. Outer sleeve
8. Lower chamber - high pressure
The purpose of the hydraulic tappet is to provide
maintenance free and quiet operation of the inlet and
exhaust valves. It achieves its designed purpose by
utilizing engine oil pressure to eliminate the
mechanical clearance between the rockers and the
valve stems.
During normal operation, engine oil pressure present
in the upper chamber 4, passes through the
non-return ball valve 5 and into the lower (high
pressure) chamber 8.
When the cam begins to lift the outer sleeve 7, the
resistance of the cylinder valve spring felt through the
pushrod seat 2, causes the inner sleeve 3, to move
downwards inside the outer. This slight downward
movement of the inner sleeve closes the ball valve 5
and increases the hydraulic pressure in the high
pressure chamber, sufficient to ensure that the push
rod opens the valve fully.
As the tappet assembly moves off the peak of the cam
the ball valve 5 opens to equalize the pressure in both
chambers which ensures that the valve fully closes
when the tappet is on the back of the cam.

12ENGINE
2
FAULT DIAGNOSIS ENGINE NOISES
Excessive or obtrusive noise from the engine
compartment originates from three main sources:
A. The exhaust system, which makes an
unmistakable and easy to diagnose noise.
B. External components emit the greatest variety of
noises, but are also easy to diagnose by simply
removing the drive belt.
C. Engine internal mechanical noises which can
vary in volume and pitch and may be a
combination of, tapping - knocking or rumbling,
are the most difficult to diagnose. The following
is therefore a guide to diagnosis of engine
internal mechanical noises only.
Engine internal mechanical noises.
Single or multiple, light tapping noise, particularly
when engine is cold.
See Description and
operation, Description
1.Is engine oil level correct?
NO - Top up to correct level.
See
LUBRICANTS, FLUIDS AND
CAPACITIES, Information,
Recommended Lubricants and Fluids
YES - Continue.
2.Is the lubricating pressure correct?
NO -
See Engine Oil Pressure Test
YES - Suspect valve operating mechanism.
3.To confirm diagnosis, remove the rocker covers
and with the engine idling, insert a feeler gauge
of 0,015mm between each rocker and valve
stem. A faulty valve operating mechanism will
emit a different noise when the feeler gauge is
inserted.
See Repair, Rocker Shaft Renew
Heavy knocking noise (particularly on load and
when engine is hot).
See Description and
operation, Description
1.Is engine oil level correct?
NO - Top up to correct level.
See
LUBRICANTS, FLUIDS AND
CAPACITIES, Information,
Recommended Lubricants and Fluids
YES - Continue.
2.Is the lubricating pressure correct?
NO -
See Engine Oil Pressure Test
YES - Drain engine oil and filter, and examine
for metallic contamination.
3.Is the oil contaminated with metal particles?
YES - Suspect faulty big end bearings. To
confirm diagnosis, short out the ignition to
each spark plug in turn. The noise will
disappear or be reduced when the
cylinder with the faulty big end is shorted
out.
4.If noise is not conclusively diagnosed, check the
security of the flywheel and crankshaft front
pulley. Temporarily release the drive belt to
reduce general noise level and use a
stethoscope to locate source of noise.
Heavy rumbling noise (particularly during hard
acceleration).
See Description and operation,
Description
1.Is engine oil level correct?
NO - Top up to correct level.
See
LUBRICANTS, FLUIDS AND
CAPACITIES, Information,
Recommended Lubricants and Fluids
YES - Continue.
2.Is the lubricating pressure correct?
NO -
See Engine Oil Pressure Test
YES - Drain engine oil and filter, and examine
for metallic contamination.
3.Is the oil contaminated with metal particles?
YES - Suspect faulty main bearings. If noise is
not conclusively diagnosed, check the
security of the flywheel and crankshaft
front pulley. Temporarily release the drive
belt to reduce general noise level and use
a stethoscope to locate source of noise.

12ENGINE
4
REPAIR CYLINDER HEAD GASKETS - RENEW
Service repair no - 12.29.01
1.Drain cooling system.
See COOLING SYSTEM,
Adjustment, Coolant
2.Remove inlet manifold.See FUEL SYSTEM,
Repair, Intake Manifold
3.Remove generator.
4.If fitted, remove compressor.
See AIR
CONDITIONING, Repair, Compressor
5.Remove rocker shafts.See Rocker Shaft
Renew
6.Remove push rods.
7.Remove both exhaust manifolds.
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust Manifold - V8i
8.Remove air cleaner assembly.See FUEL
SYSTEM, Repair, Air Cleaner Assembly
9.Remove air flow sensor.See FUEL SYSTEM,
Repair, Air Flow Sensor
10.Remove ground leads from rear of left hand
cylinder head
11.Right hand cylinder head - remove breather pipe
from lifting bracket.
12.Loosen cylinder head bolts, reversing tightening
sequence.
13.Remove cylinder heads.
14.Remove cylinder head gaskets.
15.Clean exhaust mating faces.
16.Clean head and block faces.
17.Fit new cylinder head gaskets, word TOP
uppermost. DO NOT use sealant.
18.Oil cylinder bores.
19.Clean threads of head bolts and lightly oil.
20.Locate cylinder heads on block.
21.Locate cylinder head bolts in position illustrated.
96 mm long bolts - 2, 4, 6, 7, 8, 9, 10
66 mm long bolts - 1, 3, 5
NOTE: There are no bolts fitted in the four
lower holes in each cylinder head.
NOTE: Left hand cylinder head illustrated,
arrow points to front of vehicle.
22.Tighten bolts progressively in sequence, shown
to
20 Nmthen a further 180°±5°
23.Reverse removal procedure. 1 to 11.