1995 LAND ROVER DISCOVERY air condition

10MAINTENANCE
12
MAINTENANCE
EXTERNALLY CHECK INTERCOOLER FOR
OBSTRUCTION - Tdi
Clear any trapped dirt or flies from vanes of
intercooler
CLEAN INTERCOOLER ELEMENT - Tdi
Remove
1.Remove intercooler element.
2.Flush intercooler with ICI 'GENKLENE'or
à oD-SOLVE' propriety cleaner, following the
manufacturer's instructions.
3.Dry the intercooler completely ensuring that no
liquid remains in the element.
Refit
4.Refit intercooler element.UNDER VEHICLE MAINTENANCE
Vehicles operating under severe conditions of dust,
sand, mud and water should have oils changed and
lubrication carried out at more frequent intervals than
is recommended in maintenance schedules.
RENEW ENGINE OIL AND FILTER - Tdi
CAUTION: Serious damage to the
turbocharger will result if engine is run
above idling speed before oil pressure is
restored.
RENEW ENGINE OIL - V8i
RENEW ENGINE OIL AND FILTER - V8i
CAUTION: To prevent an airlock occuring
after removing filter, fill new filter with oil
and fit immediately after removing old
filter. If airlock does occur fill oil pump with
petroleum jelly.
RENEW ENGINE OIL AND FILTER - Mpi
CHECK/TOP UP MANUAL GEARBOX OIL - V8i
1.Site vehicle on lift or level ground.
2.Remove oil filler level plug. If necessary, inject
new oil into the gearbox until it runs out of filler
hole. Fit plug. Tighten to
30 Nm.
RENEW MANUAL GEARBOX OIL - Tdi - Mpi
RENEW MANUAL GEARBOX OIL - V8i

MAINTENANCE
17
MAINTENANCE
CHECK/TIGHTEN FRONT AND REAR AXLE
SUSPENSION LINK FIXINGS, CHECK CONDITION
OF MOUNTING RUBBERS
DRAIN FUEL SEDIMENTER - Tdi
Fuel sedimenter
The sedimenter is attached to left-hand side of
chassis frame near fuel tank. It increases the working
life of the fuel filter by removing larger droplets of
water and larger particles of foreign matter from fuel.
Drain off water
1.Loosen drain plug, allow water to run out.
Tighten plug immediately pure diesel fuel starts
to flow.
RENEW FUEL FILTER
WARNING: Ensure that fuel handling
precautions given in Section 01 -
Introduction regarding fuel handling are
strictly adhered to when carrying out following
instructions.
See INTRODUCTION, Information,
Fuel Handling Precautions
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
1.Depressurise fuel system.
See FUEL SYSTEM,
Repair, Depressurising Fuel System
2.The fuel line filter is located on right hand
chassis side member forward of fuel tank filler
neck. Access to filter is gained through right
hand rear wheel arch.
3.Thoroughly clean area around hose connections
to prevent ingress of foreign matter into fuel
system.
4.Loosen two fuel unions and remove hoses from
filter canister.
5.Release securing bolt and bracket, remove filter
from chassis side member.
6.Fit a new filter observing direction of flow arrow
on canister.
7.Fit inlet and outlet hoses. Tighten to
30 Nm.
8.Refit fuel pump relay.
9.Reconnect battery negative lead.
10.Recode radio.
11.Start engine and inspect hose connections for
fuel leaks.

10MAINTENANCE
18
MAINTENANCE
ABS VEHICLES - CHECK ROAD WHEEL SPEED
SENSOR ELECTRICAL HARNESS FOR DAMAGE
RENEW OXYGEN SENSORS
See EMISSION CONTROL, Repair, Heated
Oxygen Sensor (HO2S)
RENEW CATALYTIC CONVERTERS
See MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust System Complete
REPORT ANY UNUSUAL FEATURES OF VEHICLE
CONDITION AND ADDITIONAL WORK REQUIREDCARRY OUT ROAD TEST
For details of dynamometer testing.See
INTRODUCTION, Information, Dynamometer
Testing - Non Anti-lock brake vehicles See
INTRODUCTION, Information, Dynamometer
Testing - Vehicles with Anti-lock brakes (ABS)
Check following items:
1.Inhibitor switch only operates in P and N.
2.Engine for excessive noise.
3.Clutch for slip, judder or spin.
4.Automatic gear selection/shift speeds.
5.Gear selection/noise - high/low range.
6.Steering for abnormal noise/effort.
7.Steering for free play.
8.All instruments, gauges and warning indicators.
9.Heater and air conditioning systems.
10.Heated rear screen.
11.Shock absorbers - ride irregularities.
12.Foot brake, on emergency stop, pulling to one
side, binding, pedal effort.
13.Parkbrake efficiency.
14.Seat reclining and latching.
15.Fully extend seat belt, check operation of
retraction and latching. Inertia belts lock when
snatched or vehicle on slope.
16.Road wheel balance.
17.Transmission for vibrations.
18.Body noises, squeaks and rattles.
19.Excessive exhaust smoke.
20.Engine idle speed.
21.Endorse service record.
22.Report any unusual features of vehicle condition
and additional work required.
ENDORSE SERVICE RECORD

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.

Tdi
1
REPAIR DRIVE BELT INFORMATION
A single 'serpentine drive belt' drives all the
ancilliaries bar the air conditioning compressor, which
has a separate drive belt. It is essential that the belts
are fitted exactly as shown. It should also be noted
that the water pump/viscous fan is driven in a
clockwise direction.
A drive belt tensioner automatically tensions the drive
belt, eliminating the need for tensioning individual
drive belts. Turning the tensioner pulley in a clockwise
direction will release drive belt tension.
Under normal highway use the belt must be changed
at 160,000 kilometres, 96,000 miles or eight years
whichever occurs first.
The drive belt must be examined at every service and
replaced if necessary.Off road driving
Regular examination of the drive belt is essential if the
vehicle is used off road. The vehicle driver should be
requested to identify the type of mileage the vehicle
has covered.
After every off road session the owner should inspect
the belt for cuts and possible damage caused by
stones. If belt has jumped, reposition belt correctly. A
new belt must be fitted at the next service or before,
dependant on the type of damage sustained.
Fan cowl
To ensure easy access to the drive belt the top portion
of the fan cowl is detachable.
Check condition
Check condition of drive belt. Renew a belt that shows
signs of wear, splitting or oil contamination.

Tdi
3
REPAIR ENGINE
Service repair no - 12.41.01
Remove
CAUTION: Seal all exposed pipe ends
against ingress of dirt after disconnection.
1.Park vehicle on level ground and apply park
brake.
2.Disconnect battery negative lead.
3.Remove bonnet [hood].
See CHASSIS AND
BODY, Repair, Bonnet [Hood]
4.If air conditioning is fitted, remove RH footwell
side trim panel and disconnect harness multiplug
from relay.
5.Disconnect the two engine harness multiplugs
on LH side of footwell.
6.Remove engine harness grommet from
bulkhead and move harness into engine bay.
7.Release battery positive lead from retaining clip
at base of suspension turret.
8.Remove Radiator Assembly.
See COOLING
SYSTEM, Repair, Radiator
9.Discharge air conditioning system.See AIR
CONDITIONING, Adjustment, Refrigerant
Recovery Recycling Recharging
Remove retaining bolts and disconnect both pipe
adaptors from rear of compressor.
10.Remove rocker cover insulation.
11.Disconnect cyclone hose from air cleaner hose.
12.Remove air cleaner hose from turbocharger.
13.Remove feed pipe/hose from turbocharger and
intercooler.
14.Disconnect heater hoses from cylinder head and
heater rails.
15.Remove bolt securing transmission breather
pipe clip to cylinder head; move breather pipes
aside.
16.Disconnect inlet and outlet hoses from power
steering pump.
17.Disconnect bypass hose from thermostat
housing.
18.Release bypass hose from retaining clips on
front timing cover.
19.Remove split pin securing inner throttle cable to
injector pump.
20.Depress tags on outer cable adjusting nut,
remove cable from mounting bracket, and move
aside.
21.If automatic transmission is fitted, release
kickdown cable from injector pump and mounting
bracket.

12ENGINE
14
REPAIR FLYWHEEL
Service repair no - 12.53.07
Remove
1.Disconnect battery negative lead.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
Assembly
4.Fit two long 8mm bolts into the clutch bolt holes,
diametrically opposite, to use as handles when
lifting the flywheel off the crankshaft.
5.Remove fan cowl
6.Fit crankshaft pulley retainer LRT-12-080 and
secure with four bolts, to restrain crankshaft
while removing flywheel retaining bolts.
7.Remove the bolts and lift off flywheel.
NOTE: To prevent excessive flywheel
run-out, ensure that the mating faces of
the flywheel and crankshaft are clean.Refit
8.Locate the flywheel on the crankshaft and
secure with new patched retaining bolts,
progressively tighten to
147 Nm.
9.Check the flywheel for possible run-out by
mounting a dial test indicator with the stylus in a
loaded condition resting on the flywheel face at a
radius of 114mm from the centre.
10.Turn the flywheel and check that run-out does
not exceed 0,05 to 0,07mm. Should run-out be
excessive, remove the flywheel and check again
for irregularities on the crankshaft and flywheel
mating faces and the dowel.
11.Reverse removal procedure. 1 to 6.

Tdi
3
SPECIFICATIONS, TORQUE Turbo charger oil drain adaptor to block 42....................................................
Oil drain pipe to turbocharger 25....................................................................
Turbocharger oil drain pipe to adaptor 38.......................................................
Turbocharger oil feed pipe adaptor to block 25...............................................
Turbocharger oil feed pipe to adaptor 25........................................................
Oil feed pipe to turbocharger 19.....................................................................
Turbocharger to cylinder head (stud) 10.........................................................
Turbocharger to cylinder head (nut) 45...........................................................
Turbocharger to blanking plate 25..................................................................
Turbocharger to EGR valve 25.......................................................................
EGR delivery tube to valve 25........................................................................
EGR delivery tube to mixing tube 25..............................................................
Fuel lift pump to filter (union) 15.....................................................................
Fuel filter from lift pump (banjo bolt) 33...........................................................
Fuel filter to fuel injection pump (banjo bolt) 33..............................................
Fuel injection pump from fuel filter (banjo bolt) 25..........................................
Injector pipes to injectors and fuel injection pump 29.....................................
Spill rail to injectors (banjo bolt) 10.................................................................
Spill rail to injection pump (banjo bolt) 25.......................................................
Boost pipe injection pump (banjo bolt) 10.......................................................
Plug, rear of injection pump 29.......................................................................
PAS pump to mounting plate 25.....................................................................
PAS pump mounting plate to auxiliaries mounting bracket 25........................
PAS pump pulley to hub 25............................................................................
Generator to auxiliaries mounting bracket 25.................................................
Starter motor (bolt and nut) 45........................................................................
Tachometer electrical connection 4...............................................................
Air conditioning compressor
Compressor mounting bracket to front cover 45.............................................
Compressor to mounting bracket (stud) 8......................................................
Compressor to mounting bracket (nut) 25......................................................
Belt tensioner pulley to tensioner arm 45........................................................
Belt tensioner assembly to front cover plate 25..............................................
Idler pulley to front cover plate 45...................................................................
Compressor belt guard (nut) 25......................................................................
Sensors to water outlet elbow (air/con) 25......................................................
Blanking plug, water outlet elbow (air/con) 25................................................
Generator mounting bracket to front cover 45................................................
Generator to mounting bracket 85..................................................................
Generator pulley to hub 95.............................................................................
Generator belt guard 25..................................................................................