1995 LAND ROVER DISCOVERY Workshop Manual

Mpi
11
REPAIR 43.Remove engine mounting heat shield. Remove
upper nuts from engine L.H. and R.H.
mountings.
44.Release 4 screws and remove spark plug cover.
45.Fit tool LRT-12-056, support engine using
suitable hoist.
46.Raise vehicle.
47.Loosen 2 nuts securing downpipe to silencer.
48.Remove 4 nuts securing downpipe to exhaust
manifold.
49.Release downpipe from exhaust manifold.
50.Collect gasket.

12ENGINE
12
REPAIR 51.Remove engine L.H. and R.H. mounting lower
nuts.
52.Lower vehicle.
53.Raise engine.
54.Remove engine mountings.
55.Lower engine.
56.Remove bell housing top nut.
57.Raise engine and support gearbox.58.Remove 12 remaining bell housing nuts.
59.Remove engine.
Refit
NOTE: For torque values.See
Specifications, torque, Torque Values
1.Using assistance, lower engine into position.
2.Fit bell housing nuts, tighten to the correct
torque.
3.Remove gearbox support.
4.Lower engine.
5.Fit bell housing top nut, tighten to the correct
torque.
6.Raise engine.
7.Position engine mountings, partially tighten nuts.
8.Lower engine.
9.Remove hoist and chains.
10.Tighten L.H. and R.H. mounting nuts to the
correct torque. Fit engine mounting heatshield.
11.Fit new gasket to exhaust downpipe.
12.Fit exhaust manifold to downpipe nuts and
tighten to the correct torque.
13.Tighten exhaust downpipe to silencer box nuts
to the correct torque.
14.Position air conditioning compressor and secure
with bolts. Tighten to the correct torque.
15.Connect coil multiplugs.
16.Connect harness to starter solenoid and secure
with nuts.
17.Connect earth lead to cylinder block and secure
with nut.
18.Position engine harness to manifold, secure with
bolts.

Mpi
13
REPAIR 19.Connect crankshaft sensor, knock sensor, air
conditioning compressor, fuel injector harness,
inlet manifold air temperature and fuel
temperature sensor multiplugs.
20.Connect fuel hose to pressure regulator and
secure with clip.
21.Fit and tighten fuel pipe to fuel rail union.
22.Connect multiplugs to throttle housing.
23.Connect vacuum hose to manifold.
24.Connect oil pressure switch multiplug.
25.Connect brake servo hose to manifold, secure
with clip.
26.Connect throttle cable to cam.
27.Position engine harness and connect breather
hose to inlet manifold, secure with clip.
28.Connect coolant temperature sensor multiplugs,
secure harness with cable tie.
29.Connect oxygen sensor multiplug, secure
harness with cable tie.
30.Connect alternator harness.
31.Connect heater hose to heater rail and secure
with clip.
32.Connect hose to coolant pump and secure with
clip.
33.Connect inlet hose to power steering pump and
secure with clip.
34.Fit and tighten outlet pipe union to power
steering pump.
35.Connect bypass and top hose, secure with clip.
36.Connect air cleaner to throttle housing hose and
secure with clip.
37.Remove engine lifting bracket.
38.Position spark plug cover and secure with
screws.
39.Fill engine with oil.
40.Fit bonnet [hood].
See CHASSIS AND BODY,
Repair, Bonnet [Hood]
41.Fit radiator.See COOLING SYSTEM, Repair,
Radiator - Mpi
42.Adjust throttle cable.See FUEL SYSTEM,
Adjustment, Throttle Cable Adjustment
ENGINE SUMP GASKET
Service repair no - 12.60.43
Remove
1.Drain engine oil.
2.Refit drain plug, use new sealing washer if
necessary, tighten to the correct torque.
3.Remove 18 bolts securing sump.
NOTE: 25mm long bolt is fitted at rear L.H.
corner of sump.
4.Release sump from cylinder block.
5.Discard gasket.

12ENGINE
14
REPAIR Refit
1.Clean sump, remove all traces of gasket from
mating faces of sump and cylinder block.
Visually check sump for damage.
2.Apply beads of RTV sealant to front main
bearing cap.
3.Position new gasket to sump, ensuring that
location pips on gasket are located in sump.
Check gasket lays flat on sump flange.
4.Fit sump. Fit bolts, ensuring that longest bolt is
inserted at position 7.
5.Working around the sump in the sequence
illustrated, tighten the bolts to the stage 1 torque
figure. Then, in the same sequence, tighten the
bolts to the stage 2 torque figure.
NOTE: For torque values.See
Specifications, torque, Torque Values
6.Fill engine with oil.CYLINDER HEAD GASKET
Service repair no - 12.29.01
Remove
1.Disconnect battery negative lead.
2.Position absorbent cloth around fuel pipe to fuel
rail union. Unscrew union to relieve pressure.
CAUTION: Plug the connections.
WARNING: Do not carry out the next
instruction until the coolant is cool to
avoid personal injury from scalding.
3.Release clip and disconnect radiator bottom
hose, allowing coolant to drain into a suitable
container.

Mpi
15
REPAIR 4.Release clip and disconnect hose from heater
rail.
5.Disconnect 2 coolant temperature sensor
multiplugs.
6.Release clips and disconnect the bypass hose
and top hose.
7.Release harness from cable tie.
8.Disconnect oxygen sensor multiplug.
9.Release harness lead from cable tie.
10.Release throttle cable from abutment bracket.
11.Release throttle cable from cam. Also remove
coolant bypass hose from throttle housing.
12.Disconnect stepper motor and throttle
potentiometer multiplugs.
13.Release clip and disconnect hose, air cleaner to
throttle housing.

12ENGINE
16
REPAIR 14.Release clip and disconnect brake servo hose
from manifold.
15.Disconnect fuel temperature sensor multiplug.
16.Remove 3 bolts securing engine harness to
manifold.
17.Disconnect fuel injection harness multiplug.
18.Disconnect inlet manifold air temperature sensor
multiplug.
19.Release clip and disconnect fuel hose from
pressure regulator.
CAUTION: Plug the connections
20.Release clips and disconnect 3 hoses from
manifold.
21.Remove bolt securing dipstick tube to coolant
rail.

Mpi
17
REPAIR 22.Raise vehicle
23.Remove 4 nuts securing downpipe to exhaust
manifold.
24.Release downpipe from exhaust manifold.
25.Collect gasket.
26.Release 4 screws and remove spark plug cover.
27.Release spark plug leads from spark plugs and
release from clips. Place aside.
28.Remove camshaft covers.
29.Remove timing belt.
See Camshaft Front Oil
Seal
30.Progressively loosen and remove 10 cylinder
head bolts in sequence shown.
31.Remove cylinder head complete with manifold,
place on blocks to prevent damage.
32.Remove and discard cylinder head gasket.
33.Remove location dowels from cylinder block.
34.Inspect cylinder head for damage, cracks and
burning.
35.Inspect cylinder block. Ensure that the oil
restrictor is clear and fitted below the block face.
36.Clean all traces of gasket material from head
and block mating faces, using release agent and
plastic scraper.
37.Check cylinder head and block faces for
warpage:
Longitudinal warp = 0.1 mm max.
Transverse warp = 0.1 mm max.
Diagonal warp = 0.1 mm max.
38.Decarbonize cylinder head and pistons if
necessary.
39.Clean cylinder head bolt threads with a wire
brush, check for damage, replace if necessary.
40.Check cylinder block threads by running bolts
into threads using fingers only. Clean any tight
threads using M11 x 1.5 mm tap. Remove all
traces of oil from bolt holes.

12ENGINE
18
REPAIR Refit
1.Fit location dowels to cylinder head.
2.Fit cylinder head gasket to cylinder block.
3.Using assistance fit cylinder head to cylinder
block.
4.Lubricate cylinder head bolts.
5.Fit and tighten cylinder head bolts to the correct
torque and in the correct sequence.
NOTE: For torque values.See
Specifications, torque, Torque values
6.Fit timing belt.
7.Fit camshaft covers.
8.Fit spark plug leads to spark plugs and secure to
clips.
9.Fit spark plug cover and secure with screws.
10.Fit new gasket and secure downpipe to exhaust
manifold with nuts.
11.Fit bolt securing dipstick tube to coolant rail.
12.Connect 3 vacuum hoses to inlet manifold.
13.Connect fuel to pressure regulator, secure with
clip.
14.Connect fuel injection harness, inlet manifold air
temperature sensor and fuel temperature sensor
multiplugs.
15.Secure engine harness to manifold with bolts.
16.Connect brake servo hose to manifold, secure
with clip.
17.Connect air cleaner hose to throttle housing,
secure with clip.
18.Connect stepper motor and throttle
potentiometer multiplugs.
19.Fit and adjust throttle cable.
20.Connect oxygen sensor multiplug, secure with
cable tie.
21.Connect the bypass and top hose, secure with
clips.
22.Connect coolant temperature sensor multiplugs,
secure with cable tie.
23.Connect hose to heater rail and secure with clip.
24.Connect radiator bottom hose and secure with
clip.
25.Tighten fuel pipe to fuel rail union.
26.Reconnect battery negative lead.