1995 LAND ROVER DISCOVERY Workshop Manual

19FUEL SYSTEM
8
REPAIR
All glow plugs
5.Remove terminal nut from glow plug, disconnect
wire from glow plug terminal.
6.Remove glow plug.
Refit
7.Clean glow plug and seating.
8.Coat threads of glow plug with suitable anti-seize
compound operational to a temperature of
1000°C.
9.Fit glow plug. Tighten to
23 Nm.
10.Connect wire to glow plug terminal and secure
with nut.
NOTE: Feed wire must be connected to
No. 4 glow plug terminal.
11.
No. 3 glow plug:Lubricate new 'O' ring with
engine oil and fit to Hummel valve. Fit valve and
secure with bolt. Tighten to
15 Nm.
No. 1 glow plug - air conditioning models
12.Position compressor to front cover, fit bolts.
Tighten to
25 Nm.
13.Fit drive belt to compressor pulley and adjust
tension.
See ENGINE, Repair, Drive Belt
Renew
All models
14.Reconnect battery negative lead.EGR VALVE
Service repair no - 19.45.01
Remove
1.Disconnect multiplug from EGR valve.
2.Disconnect vacuum pipe from EGR valve.
3.Remove 2 Allen screws securing EGR valve to
exhaust manifold.
4.Remove 2 bolts securing hose to EGR valve.
5.Remove EGR valve and discard gaskets.
Refit
6.Clean mating faces of EGR valve and exhaust
manifold.
7.Reverse removal procedure. Tighten bolts to
25
Nm.

Tdi
9
REPAIR GLOW PLUG CONTROL UNIT
Service repair no - 19.60.33
Remove
1.Disconnect battery negative lead.
2.Remove nut and bolt securing control unit to
mounting bracket.
3.Disconnect multiplug and remove control unit.
Refit
4.Reverse removal procedure.EGR CONTROL UNIT
Service repair no - 19.45.06
Remove
1.Release 2 glovebox stays from fascia and pivot
glovebox fully downwards.
2.Remove 2 plastic nuts securing control unit to
body.
3.Release control unit from fixings.
4.Disconnect multiplug and remove control unit.
Refit
5.Reverse removal procedure.

19FUEL SYSTEM
10
REPAIR EGR THROTTLE POSITION SENSOR
Service repair no - 19.30.14
Remove
1.Remove 2 screws securing sensor mounting
plate to injection pump.
2.Disconnect sensor multiplug from harness.
3.Remove sensor assembly.
Refit
4.Position sensor assembly on injection pump and
fit and tighten screws.
5.Connect multiplug.
6.Adjust sensor.
See Adjustment, EGR Throttle
Position Sensor
INJECTORS
Service repair no - 19.60.10
Remove
1.Remove oil filler cap and remove sound
deadening pad from top of engine.
2.Remove high pressure pipe from relevant
injector and injection pump.
3.Disconnect spill return hose(s) from injector.
4.Plug pipes and injector connections to prevent
the ingress of dirt and foreign matter.
5.Remove nut securing injector clamp plate to
cylinder head.
6.Remove injector.
Refit
7.Reverse removal procedure. Renew copper
washer on injector. Tighten injector clamp plate
nut to
25 Nm.

Tdi
11
REPAIR FUEL INJECTION PUMP AND TIMING
Service repair no - 19.30.07
NOTE: The following text refers to a Tdi
vehicle with a manual gearbox without
electronic diesel control. Where reference
is made to the timing tool substitute the following
information for automatic and EDC variants.
If manual gearbox:Timing tool LRT-12-044 fits into
the base of the flywheel housing
If manual gearbox with EDC:Timing tool
LRT-12-085 must be used and also fits into the base
of the flywheel housing.
If automatic gearbox:Timing tool LRT-12-044 fits
into the larger bolt hole of coverplate on engine
backplate, sited near to the rear of sump. Pin locates
in ring gear.
Remove
1.Disconnect battery negative lead.
2.Remove injection pipes, pump to injector.
3.Remove oil filler cap from rocker cover.
4.Viewing valve mechanism through filler aperture,
turn crankshaft clockwise until No. 1 cylinder is
just before TDC.
5.Refit oil filler cap.
6.Remove blanking plug from flywheel housing.
7.Fit timing tool LRT-12-044 to flywheel housing,
do not engage centre pin.
8.Continue rotating crankshaft clockwise until
centre pin engages with timing slot in flywheel.
9.Remove injection pump access plate, complete
with gasket, from front cover plate.
10.Fit pin from LRT-12-045 to injection pump gear.
11.Remove drive gear to pump hub fixing bolts and
plate.

19FUEL SYSTEM
12
REPAIR 12.Remove pin from pump gear.
13.Fit gear retaining tool LRT-12-045 with an 8 mm
washer, 1.5 to 2 mm thick, under each bolt head
in addition to the existing washer.
14.Remove throttle cable and hand throttle cable if
fitted.15.Disconnect stop control solenoid connector.
16.Remove banjo bolts securing spill return, main
fuel and boost signal pipes, refit banjo bolts after
disconnecting pipes.
17.Remove pump mounting bracket bolts 2 off.
18.Loosen pump support bracket bolts to block,
sufficient for bracket to just move.
19.Remove pump securing nuts at flange and
withdraw pump and gasket.
20.Fit blanks to pipe connections.

Tdi
13
REPAIR Refit
21.Remove blanks from pump.
22.Remove special tool pin from pump.
23.Clean mating faces of pump and front cover.
24.Fit pump to cover with a new gasket and secure
with nuts. Tighten to
25 Nm.
25.Attach pump to bracket and finger tighten nuts
and bolts
26.First tighten bolts securing bracket to block and
then bolts securing pump to bracket.
27.Connect spill return, main fuel pipes. Tighten to
25 Nm.
28.Connect boost signal pipe and secure with banjo
bolts. Tighten to
10 Nm.
29.Connect stop control solenoid lead.
30.Connect throttle cable and where applicable
hand throttle cable.
31.Remove special tool LRT-12-045.
32.Fit gear lock plate.
33.Fit pin from special tool LRT-12-045.
34.Secure gear with bolts.
35.Remove special tool pin.
36.Turn crankshaft two complete revolutions, check
timing pin from LRT-12-045 can be fully and
easily inserted into the pump. At the same time
check flywheel timing pin LST-12-044 can also
be inserted in the flywheel slot.
37.If, with the flywheel timing pin located, the timing
pin cannot be inserted cleanly into the injection
pump, carry out the following:
(a) Ensure flywheel timing pin is disengaged
from slot in flywheel.
(b) Turn the crankshaft the small amount
necessary to enable the timing pin to be
inserted into the pump.
(c) Loosen the three pump gear retaining
bolts.
(d) Turn the crankshaft to T.D.C..
(e) Check that the timing pin is an easy fit in
the pump and that the flywheel timing pin
locates.
(f) Tighten the pump gear retaining bolts to
the correct torque.
(g) Remove the timing pin from the pump and
the timing tool from the flywheel housing.
38.Using antisieze compound, fit the blanking plug
to flywheel housing. Tighten to
12 Nm.
39.Fit access plate with gasket to front cover plate.
Tighten to
25 Nm.
40.Refit injector pipes. Tighten to29 Nm.

19FUEL SYSTEM
14
REPAIR ENGINE CONTROL MODULE (ECM)
Service repair no - 18.30.03
NOTE: The ECM is not a serviceable item,
in the event of failure it must be renewed.
Remove
1.Disconnect battery negative lead.
2.Remove 'A' post trim pad.
3.Loosen multi-plug screw to ECM.
4.Disconnect multi-plug from ECM.
5.Secure multi-plug and harness aside.
6.Remove retaining nuts from ECM.
7.Manoeuvre ECM from its mounted position.
Refit
8.Refitting is the reverse of removal procedure.
9.Reconnect harness plug. Ensure plug is pushed
firmly into location and retaining clip secures
plug in position.
10.Tighten screw securing multi-plug.AIRFLOW METER
Service repair no - 18.30.15
NOTE: The air flow meter is not a
serviceable item, in the event of failure it
must be renewed.
Remove
1.Disconnect battery negative lead.
2.Release vacuum tube from EGR vacuum
capsule.
3.Disconnect airflow meter multi-plug.
4.Loosen air cleaner hose to air flow meter
retaining clip.
5.Disconnect hose from airflow meter.
6.Loosen turbo charger hose to airflow meter
retaining clip.
7.Disconnect hose from airflow meter.
8.Remove meter to mounting bracket bolts.
9.Remove airflow meter.
Refit
10.Reverse removal procedure. Ensure multi-plug is
firmly reconnected and hose clamps are
securely tightened to prevent unmetered air
entering the engine.

Tdi
15
REPAIR BOOST PRESSURE SENSOR
Service repair no - 18.30.63
Remove
1.Disconnect battery negative lead.
2.Disconnect sensor multi-plug.
3.Disconnect pressure tube union.
4.Retrieve and discard union copper washers.
5.Place pressure tube aside.
6.Remove sensor to mounting bracket bolts.
7.Remove sensor.
Refit
8.Renew all copper washers.
9.Reverse removal procedure.
INJECTION TIMING SENSOR
Service repair no - 18.30.64
Remove
1.Disconnect battery negative lead.
2.Disconnect sensor multi-plug.
3.Disconnect spill return pipe to injector.
4.Disconnect injector union.
5.Remove copper washers.
6.Remove injector clamp fixing.
7.Remove clamp.
8.Remove injector.
9.Remove injector copper washers.
Refit
10.Renew all copper washers.
11.Reverse removal procedure.
12.Check for leaks when running.