1995 LAND ROVER DISCOVERY wiring

30MANIFOLD AND EXHAUST SYSTEM
2
REPAIR Remove
Catalysts - remove and refit 1 to 5
1.Raise vehicle on a ramp [hoist].
2. Catalyst vehicles only:Disconnect two heated
oxygen sensor wiring connectors.
NOTE: NAS models have four heated
oxygen sensors fitted.
3.Remove two nuts securing rear exhaust
assembly to front exhaust assembly.
4.Remove nuts and release front downpipes from
manifolds. Discard gaskets.
5.Lower front exhaust assembly with catalysts (if
fitted), retain olive.
NOTE: Assistance is required for removing
and refitting rear exhaust assembly.
6.Remove bolts securing three hanger brackets to
chassis. Lower exhaust assembly onto rear axle.
Detach rubbers from hanging brackets.
7.Place extended axle stands underneath chassis,
in front of chassis mounted rear towing brackets.
8.Lower ramp[hoist] until vehicle weight is
supported securely on stands.
9.Lower ramp [hoist] until rear shock absorbers
are ALMOST fully extended.
10.Move rear exhaust to a diagonal position, centre
silencer to right of vehicle.
11.Facing rear of vehicle, twist assembly
anti-clockwise clear of rear axle.
12.Remove rear exhaust assembly from vehicle.
Refit
13.Position rear exhaust assembly over rear axle in
a diagonal position, as for removing.
14.Twist assembly clockwise until it is in mounting
position.
15.Reverse removal procedure. 1. to 9. using new
manifold gaskets and applying exhaust sealer to
system joint.
16.Examine system for leaks, ensuring that system
does not foul underbody components. Rectify if
necessary.EXHAUST MANIFOLD - V8i
Service repair no - Left hand - 30.15.10
Service repair no - Right hand - 30.15.11
Remove
1.Disconnect front exhaust pipe(s) from
manifold(s).
2.Tap back bolt locking tabs and remove eight
bolts, lock tabs and washers.
3.Remove manifold(s) and old gaskets.
Refit
4.Ensure that mating surfaces of cylinder head
and exhaust manifold are clean and smooth.
5.Coat threads of each bolt with anti-seize
compound.
6.Place manifold and new gaskets in position on
cylinder head and fit securing bolts, new
lockplates and plain washers. Plain washers are
fitted between manifold and lockplates.
7.Evenly tighten manifold bolts to
20Nmbend
over lockplate tabs.
8.Reconnect front exhaust pipe, using new
exhaust flange gaskets.

ZF
7
REPAIR Accessories removal/fitting
If fitting a replacement transmission assembly to the
vehicle, remove the following items from the existing
assembly and fit to the replacement.
CAUTION: It is important to remove the
spacer from the extension shaft and fit
onto the replacement unit.
50.Breather pipe union and washers from main
gearbox.
51.Breather pipe, union and washers from transfer
gearbox.
52.Main gearbox selector lever.
53.RH mounting bracket assembly.
54.Oil cooler pipe unions.
55.Fit blanks to all apertures where unions have
been removed and blank off pipe ends.
Refit
1.Fit transmission to cradle and hoist.
2.Locate hoist under vehicle and remove torque
convertor retaining strap.
3.Ensure low range gear is engaged.
4.Apply approved sealant to bell housing face.
5.Carefully raise assembly, align bell housing with
flywheel housing and bring mating faces
together.
6.Fit nuts and bolts to secure transmission to
engine.
7.Locate electrical wiring and breather pipes to
position.
8.Secure kick down cable clip to bell housing.
9.Raise hoist sufficiently to take weight.
10.Remove block and jack from engine sump.
11.Fit filler/dipstick tube to gearbox sump and
secure bracket to bell housing.
12.Apply Loctite to torque convertor bolts
13.Working through starter aperture refit the four
torque convertor to flexible drive securing bolts,
rotating crankshaft to gain access to bolt
locations.
14.Refit starter and heatshield.
15.Secure breather pipes and harness with ties.
16.Fit left hand mounting bracket assembly to
gearbox.
17.Raise transmission and support with a suitable
ramp [hoist] jack.
18.Remove two bolts securing transmission to
cradle, lower hoist and remove from under
vehicle.
19.Apply Loctite to above bolts and fit to transfer
gearbox input bearing support plate.
20.Fit chassis cross member.21.Secure gearbox mounting brackets to chassis
cross member.
22.Remove ramp [hoist] jack.
23.Connect electrical leads to differential lock
switch.
24.Connect inhibitor switch multi-plug.
25.Connect selector cable to lever on side of
gearbox.
26.Connect oil cooler pipes to gearbox and secure
retaining bracket to gearbox sump.
27.Secure silencer to chassis and refit exhaust front
pipe.
28.Refit front propeller shaft to transfer gearbox.
29.Refit rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
30.Connect speedometer cable to transfer gearbox.
31.Refill transfer gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
32.Lower ramp [hoist] to ground level.
33.Reconnect turbo-charger hose to inter-cooler.
34.Reconnect top hose to radiator.
35.Refill cooling system with correct mixture of
coolant.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
36.Reconnect kick down cable to fuel injection
pump.
37.Secure breather pipe clip to rear of cylinder
head.
38.Engage harness with clips along top of
bulkhead.
39.On left hand drive vehicles only, connect
multi-plug to top of brake fluid reservoir.
40.Refit insulation pad to rocker cover and inlet
manifold, secure with oil filler cap.
41.Refit gaiter and knob to transfer gear lever.
42.Select high range gear.
43.Reconnect battery terminals.
44.Refill main gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids

REAR AXLE AND FINAL DRIVE
1
REPAIR REAR AXLE
Service repair no - 51.25.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
the axle when lowering or repositioning
axle.
1.Drain brake system.
2.Support chassis rear.
3.Remove road wheels.
4.Support axle weight with hydraulic jack.
5.Disconnect ABS wiring harness multi-plug at
jump hose bracket, if applicable.
6.Disconnect shock absorbers.
7.Disconnect flexible brake hose at connection
under floor.
8.Disconnect lower links at axle.
9.Mark differential and propeller shaft flanges with
identification marks for assembly. Remove four
nuts and bolts. Lower propeller shaft and tie to
one side.10.Disconnect pivot bracket ball joint at axle
bracket.
11.Release bolts and remove coil spring retaining
plates.
12.Lower axle and remove road springs.
13.Disconnect anti-roll[sway] bar links to axle.
See
REAR SUSPENSION, Repair, Anti-Roll[Sway]
Bar Ball Joint Links
14.Remove axle assembly.
Refit
15.Position axle and fit lower links. Tighten to
176
Nm
16.Reverse removal procedure.
17.Tighten pivot bracket ball joint to axle to
176 Nm.
18.Tighten propeller shaft to differential drive flange
to
47 Nm
19.Bleed brake system.See BRAKES, Repair,
Brake System Bleed

70BRAKES
4
DESCRIPTION AND OPERATION System description
The brake system consists of dual hydraulic circuits in
a front - rear split. That is individual circuits to front
and rear axles.
Wheelspeed signals are provided by the fitting of
exciter rings to axles and speed sensors.
An ABS stop light switch is fitted to provide a braking
signal to the ECU as well as operate the stop lights.
Electrical wiring is provided as necessary with system
relays and fuses. Discovery Electrical Troubleshooting
Manual gives the location and wiring circuits of these
components.
Visual warning of system malfunction is provided via a
warning light in the instrument panel.
Hydraulic circuit ABS
Key
A = Primary hydraulic circuit
B = Secondary hydraulic circuit
C = Pressure reducing valve
D = ABS ModulatorABS System operation
During normal braking the feel of the brake pedal on
vehicles equipped with ABS will be the same as that
on non ABS vehicles. During ABS cycling the driver
will experience feedback in the form of a pulsating
brake pedal and solenoid/pump motor noise from the
Modulator.
The system is fully automatic in operation both on and
off road, and will only act when the ECU detects that
ABS cycling is necessary. The ECU continually
monitors the operation of the system.
When starting the ABS system will go through a series
of self checks, including a check of the solenoid
valves/pump motor.
WARNING LIGHT
The warning light will be on during the self check
(1.3-2 secs). If no faults are stored in the memory the
light goes out for 0.5sec,then comes on again. It will
then remain on until the vehicle is driven faster than 7
kph/5mph. This is the only time that the light will be on
without indicating a problem.
Any faults detected by the ECU will cause the warning
light to illuminate indicating that the vehicle may not
have full ABS control.

BRAKES
1
FAULT DIAGNOSIS ABS FAULT DIAGNOSIS
If a fault has occurred, or has been identified by ECU
self diagnostic function and ABS warning light is
illuminated. The system and components must be
checked to locate and rectify fault, using Testbook
diagnostics.
NOTE: If warning lamp has indicated a
fault in system, and no fault code has been
stored in memory, cause of fault is:
a) Failure in electrical supply
b) Bad ECU ground
c) Faulty warning light relay
d) ECU not connected
Before commencing fault diagnosis procedure
following items must be checked:
1.Inspect all exposed cables for damage or
abrasion.
2.Check ground on ABS system.
3.Battery - state of charge.
4.Check hub end-float.
5.All ABS fuses and electrical connections.
Fault rectification
1.Complete harness should be replaced if faults
are found in wiring harness.
2.DO NOT use unspecified cables or connectors,
as this could jeopardise safe function of ABS.
3.DO NOT attempt to open sealed 35 way
connector to ECU.FAULT DIAGNOSIS PROCEDURE
NOTE: If ABS warning light illuminates due
to large sensor air gap, fault will be
retained by the ECU memory. Where wheel
sensors have been pushed fully home prior to
test, The ECU will indicate a fault that has been
rectified.
NOTE: After any steering adjustment,
bearing replacement/adjustment, brake
disc replacement: Check hub end-float and
sensor clearance.
RELAYS AND FUSES ABS
The location and identification of ABS electrical relays
are given in the Electrical Troubleshooting Manual
For location and identification of ABS electrical fuses.
See ELECTRICAL, Repair, Fuse Box - Interioror.
See ELECTRICAL, Repair, Fuse Box - Engine
Compartment

75SUPPLEMENTARY RESTRAINT SYSTEM
2
DESCRIPTION AND OPERATION OPERATION
The airbag supplementary restraint system (SRS) is a
safety device which, when used in conjunction with
the seat belt, is designed to protect the driver and
front passenger.
Two different SRS systems are fitted to Discovery.
The Distributed SRS which has two crash sensors
located in the engine compartment on the chassis
longitudinals and the Single Point Sensing (SPS) SRS
which has a single crash sensor located in the Airbag
diagnostic control unit.
The change from distributed SRS to SPS SRS
occurred at VINs198222and528977.
Distributed SRS
In the event of a frontal impact, when the airbag
diagnostic control unit and one of the airbag crash
sensors senses the impact, the diagnostic control unit
fires igniters. This in turn ignites tablets of sodium
azide which generate a large amount of Nitrogen gas
leading to airbag inflation in approximately 30
milli-seconds.SPS SRS
In the event of a frontal impact, when the airbag
diagnostic control unit senses the impact, the
diagnostic control unit fires igniters. This in turn ignites
tablets of sodium azide which generate a large
amount of Nitrogen gas leading to airbag inflation in
approximately 30 milli-seconds.
All Models
When fully deployed the airbag offers additional
protection to the front seat occupant. As an occupant
moves into the airbag it immediately discharges the
gas to provide progressive occupant deceleration and
reduce risk of injuries. The whole process is
completed in approximately 0.3 seconds.
WARNING: All the airbag system
components, including the wiring harness,
MUST be renewed after the airbags have
deployed.

SUPPLEMENTARY RESTRAINT SYSTEM
1
REPAIR SYSTEM PRECAUTIONS
CAUTION: Before and during any removal
operations within the SRS section, note
routing and position of all harnesses to aid
correct refitting and to avoid accidentally trapping
cables.
CAUTION: During refitting of any item
within the SRS section, always ensure
connectors are fully engaged and latched
before proceeding to the next stage of the
operation.DRIVER'S AIRBAG MODULE
Service repair no - 76.74.01
WARNING: All the airbag system
components, including the wiring harness,
MUST be renewed after the airbags have
deployed.
Remove
1.Turn steering wheel 90Ê from horizontal.
2.Switch off ignition.
3.Disconnect battery negative '-' and then the
positive '+' lead.
CAUTION: Always disconnect both leads.
4.Release 2 turnbuckles and remove dash lower
panel.

SUPPLEMENTARY RESTRAINT SYSTEM
9
REPAIR PASSENGER'S AIRBAG MODULE
Service repair no - 76.74.02
WARNING: All the airbag system
components, including the wiring harness,
MUST be renewed after the airbags have
deployed.
Remove
1.Switch off ignition.
2.Disconnect battery negative lead and then
positive lead.
3.Open glovebox and disconnect harness
connector from airbag module.
4.Use special socket and long extension, remove
2 torx head screws securing front of airbag
module to fascia panel.
5.Use special socket, remove 2 torx head screws
securing rear of airbag module to fascia panel.
6.Release airbag module from fascia panel.
CAUTION: Do not allow the airbag module
to hang by the airbag harness.
7.Carefully and without pulling on connector
remove airbag module.
CAUTION: Store the airbag module in
accordance with the storage procedures
described in Description and Operation.
NOTE: If airbag module is to be replaced
the serial number must be recorded in the
vehicle service record.
Refit
8.Reverse removal procedure.
9.Tighten airbag module securing screws to
8Nm
(6 lbf ft).
CAUTION: Take care not to cross thread
screws.
10.Check Supplementary Restraint System using
Testbook.