1995 LAND ROVER DISCOVERY fuel cap

12ENGINE
12
REPAIR
12.Ensure service tools LRT-12-010 and
LRT-12-091 are scrupulously clean. Coat seal
guide and oil seal journal with clean engine oil.
CAUTION: Do not handle oilseal lip, check
it is not damaged. Ensure outside diameter
remains clean and dry.
13.Position oil seal guide LRT-12-010 on crankshaft
flange.
NOTE: Lubricant coating must cover seal
guide outer surface completely to ensure
that oil seal lip is not turned back during
assembly. Position oil seal, lipped side towards
engine, on seal guide. Seal outside diameter
MUST be clean and dry.
14.Fit oil seal using tool LRT-12-091. Remove seal
guide.
15.Tighten rear main bearing cap to
90 Nm.
16.Fit sump.
17.Fit flywheel or flexible drive plate and ring gear.ENGINE
Service repair no - 12.41.01
Remove
1.Park vehicle on level ground and apply park
brake.
2.De-pressurise fuel system.
See FUEL
SYSTEM, Repair, Depressurising Fuel
System
3.Remove bonnet [hood].See CHASSIS AND
BODY, Repair, Bonnet [Hood]
4.Remove battery.See ELECTRICAL, Repair,
Battery
5.Remove radiator/oil coolers.See COOLING
SYSTEM, Repair, Radiator/Oil Coolers
6.Place an absorbent cloth around fuel feed hose
at fuel rail and release compression nut.
Remove feed hose from rail, seal end of pipes
with masking tape to prevent ingress of dirt.
7.Release fuel return hose clamp and remove
hose from pressure regulator, seal both
openings with masking tape to prevent ingress of
dirt.
8.Remove vacuum hose from rear of regulator.
9.Manual vehicles: Disconnect throttle cable from
bracket. Automatic vehicles: Detach throttle
bracket from plenum chamber and lay assembly
to one side.
See FUEL SYSTEM, Repair,
Plenum Chamber DO NOT DISTURB KICK
DOWN CABLE SETTING.
10.Remove ram housing.See FUEL SYSTEM,
Repair, Ram Housing
11.Remove air flow sensor.See FUEL SYSTEM,
Repair, Air Flow Sensor
12.Remove air cleaner assembly.See FUEL
SYSTEM, Repair, Air Cleaner Assembly
13.Remove Generator.See ELECTRICAL,
Description and operation, Generator
14.Release air conditioning compressor from its
mounting and lay to one side. DO NOT
discharge air conditioning system.
See AIR
CONDITIONING, Repair, Compressor

4.0 V8
7
REPAIR 171.Route drive belt around pulleys.
172.Pivot tensioner downwards.
173.Align belt to tensioner and release tensioner.
174.Connect battery positive lead and tighten.
175.Secure terminal cover.
176.Align gearbox breather pipe, clip to engine lifting
eye and fit bolt. Tighten to
9 Nm.
177.Align and secure engine harness brackets to
inlet manifold and fit nuts. Tighten to
9 Nm.
178.Connect injector multiplugs.
179.Connect air intake temperature sensor multiplug.
180.Connect fuel temperature sensor multiplug.
181.Connect coolant temperature multiplug.
182.Connect temperature gauge connector.
183.Connect oil pressure switch Lucar.
184.Connect camshaft sensor multiplug and secure
to bracket.
185.Fit ignition coil bracket.
See FUEL SYSTEM
SFI, Repair, Ignition Coils
186.Position heater hose/pipe assembly.
187.Connect hose to inlet manifold.
188.Align pipe to bracket and fit bolt. Tighten to
9
Nm.
189.Tighten hose clip.
190.Connect heater return hose and tighten clip.
191.Remove plugs from fuel feed and return hose
connections.
192.Clean feed unions.
193.Connect return hose and tighten clip.
194.Connect feed hose union and tighten.
195.Remove cloth.
196.Connect purge hose.
197.Connect leads to generator, tighten terminal nuts
and fit cover.
198.Connect sensing Lucar.
199.Connect servo vacuum hose.
200.Position expansion tank and secure with fixings.
201.Connect hose and tighten clip.
202.Lower ramp.
203.Fit mass air flow sensor.
See FUEL SYSTEM
SFI, Repair, Mass Air Flow Sensor (MAF
Sensor)
204.Fit plenum chamber.See FUEL SYSTEM SFI,
Repair, Plenum Chamber
205.Fit radiator.See COOLING SYSTEM, Repair,
Radiator
206.Fit bonnet.See CHASSIS AND BODY, Repair,
Bonnet [Hood]
207.Reconnect battery negative lead.
208.Bleed power steering system.
See STEERING,
Repair, Power Steering System - Bleed
209.Drain engine oil and refill.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids - USA
Vehicles
210.Start engine. Check for fuel, coolant and oil
leaks.FRONT COVER GASKET
Service repair no - 12.65.04 - Front Cover Gasket
Remove
1.Disconnect battery negative lead.
2.Drain cooling system.
See COOLING SYSTEM
V8, Adjustment, Coolant
3.Remove radiatorSee COOLING SYSTEM,
Repair, Radiator
4.Remove water pump pulley.See COOLING
SYSTEM, Repair, Viscous Coupling, Fan
Blades, Pulley and Fan Cowl
5.Slacken bottom hose clip. Remove hose from
water pump.
6.Raise vehicle on ramp.
7.Disconnect oil cooler hoses from front cover and
position aside. Plug hoses and connections.
8.Disconnect Lucar from oil pressure switch.

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.

17EMISSION CONTROL
4
DESCRIPTION AND OPERATION REV: 09/95 Evaporative emission control system - pre
advanced EVAPS.
The system is designed to prevent harmful fuel vapour
from escaping to the atmosphere. The system
consists of a vapour separator tank, connected to the
fuel tank and located between the body inner and
outer panels on the right hand side of the vehicle near
the rear wheel arch. An adsorbtion canister,
containing activated charcoal, is positioned in the
engine compartment attached to the front right
valance. The two components are connected by a
pipe running the length of the chassis.
A Pressure relief to atmosphere.
B From fuel tank to separator.
C To adsorbtion canister.
D Pressure relief valve.
E Pressure relief valve.
F Shut-off valve.
G "Speed Fit" connectors.A pressure relief valve is fitted in the hose which is
open to atmosphere. This valve acts as a safety valve
should a build-up of pressure occur in the system, for
example if a hose became blocked or kinked. The
volume of vapour emitted, in such an instance, would
be acceptable.
A pressure relief valve is also fitted in the hose
connected to the adsorbtion canister and releases
vapor to the canister when the pressure in the
separator reaches between 5 and 7 Kpa.
In the top of the separator a shut-off valve is
incorporated in the vapor exit port to prevent the
possible presence of any liquid fuel being transmitted
to the adsorbtion canister should the vehicle roll over.
The adsorbtion canister, which is connected by a hose
to the plenum chamber, absorbs and stores the fuel
vapour from the fuel tank while the engine is not
running. When the engine is started, the vapour is
purged from the canister by air drawn through an
orifice in the base of the canister and by the influence
of vacuum at the top. The vapour drawn into the
plenum chamber through a solenoid operated purge
valve is finally burnt in the combustion chambers.
The purge valve, which is attached to the adsorbtion
canister support bracket, is controlled by the Engine
Control Module ECM which determines the most
emission acceptable time at which purging should
take place. This will normally be at engine speeds
above idle and when the vehicle is in motion. A signal
from the ECM to the purge valve operates the
solenoid and opens the valve to purge the canister of
fuel vapour.

17EMISSION CONTROL
8
DESCRIPTION AND OPERATION ADD: 09/95 System operation
The system is designed to prevent fuel vapour
escaping to atmosphere, and consists of four roll-over
valves fitted internally in the fuel tank, connected to
the liquid/vapour separator by a nylon line. The
separator is mounted to the side of the filler neck. An
EVAP canister is positioned in the engine
compartment mounted on the right front side valance.
The liquid/vapour separator and EVAP canister are
connected by a nylon line which runs the length of the
chassis.
Pressure/vacuum relief valves are incorporated into
the fuel filler cap and are designed to protect the fuel
tank from permanent deformation in the event of
system pressure or vacuum exceeding the system
operating parameters. There are no other relief or
one-way valves in the system.
A vent line flow restrictor known as an anti-trickle fill
valve is fitted to the filler pipe in the line between the
tank and EVAP canister. The function of this valve is
to prevent overfilling the tank by trickling fuel in,
thereby preserving the vapour space in the tank to
allow for fuel expansion during hot weather.
The valve achieves this by blocking the vent line
during the fuel filling process. The valve is operated
by the action of inserting the filler gun so that when
the fuel in the tank reaches the level of the filling
breather, flow cut off occurs due to fuel filling the filler
pipe.During normal vehicle operation and when the engine
is switched off, the venting system between the fuel
tank and EVAP canister is open to allow the free
passage of vapour.
The EVAP canister, which is connected by a nylon
hose to the plenum chamber, absorbs and stores the
fuel vapour from the fuel tank when the engine is not
running. With the engine running, vapour is purged
from the EVAP canister by allowing outside air to be
drawn through the EVAP canister vent solenoid and
link pipe by the influence of manifold vacuum to the
EVAP canister purge connection on the canister.
Filter pads are fitted above and below the charcoal
and in the EVAP canister vent solenoid to prevent the
ingress of foreign matter into the purge line.
The EVAP canister purge valve, which is fitted in the
line from the EVAP canister to the plenum, is
controlled by the ECM which determines the most
emission acceptable time at which purging should
take place. This will normally be at engine speeds
above idle and when the vehicle is in motion.
The EVAP canister vent solenoid is mounted on the
side of the EVAP canister bracket and is connected to
the EVAP canister by a length of large bore hose. The
ECVS is controlled by the ECM and is normally open.
The function of the ECVS is to block the air intake
side of the EVAP canister. When the system receives
an ECM signal the valve closes; this allows the
system leak check to take place. The leak check only
occurs when pre-determined vehicle operating
conditions are met.

Tdi
1
DESCRIPTION AND OPERATION DESCRIPTION
Air intake
The air cleaner is positioned to the right of the engine
and connected by hoses to a cold air intake duct and
the turbocharger inlet. A crankcase breather hose is
fitted between the air cleaner and the separator.
A single stage turbocharger, fitted between the
exhaust manifold and exhaust pipe, is connected by
hoses to the air cleaner and to an intercooler mounted
on the right of the radiator. The intercooler is
connected by a hose to the inlet manifold.
Fuel system
A 89 litre fuel tank is mounted at the rear of the
vehicle beneath the load space floor. The tank is
vented by a 2 way valve in the filler cap.
A mechanical lift pump, driven by the camshaft, is
mounted on the side of the engine.
A fuel filter, fitted with a replaceable element and
incorporating a water separator, is positioned on the
LH side of the bulkhead.
A Bosch Type injection pump, incorporating a cold
start advance unit and a high idle setting is mounted
on the LH side of the engine and is directly driven by
gears from the crankshaft. The pump meters and
distributes fuel to 4 pintle type injectors located in
pre-combustion chambers in the cylinder heads.
A return line passes excess fuel from the injection
pump and injectors back to the fuel tank.
Glow plugs
Four glow plugs are located in the cylinder head,
directly below each injector.Exhaust gas recirculation (EGR)
Exhaust gas recirculation is controlled by the EGR
control unit mounted in the passenger compartment
on the RH 'A' post behind the fascia and receives the
following inputs:
a. Engine temperature from coolant temperature
transmitter in No. 4 cylinder head.
b. Throttle position from the sensor on the injection
pump.
c. Engine speed from the tachometer.
d. EGR valve lift position.
When all correct signals are received, the EGR
solenoid allows vacuum to open the EGR valve and
recirculate a portion of the exhaust gas.

19FUEL SYSTEM
2
ADJUSTMENT LOW AND HIGH IDLE SPEED
Adjust
The high idle speed (cold start idle) is
automatically set by the setting of the low idle
speed and can not be adjusted individually.
1.Check and adjust throttle cable.
2.Start engine and run it until normal operating
temperature is reached.
3.Using a suitable tachometer, check the engine
idle speed.
See ENGINE TUNING DATA,
Information, 300 Tdi Engine
4.If adjustment is necessary, loosen the locknut on
the injector pump.
5.Turn the adjustment screw either clockwise to
increase the engine speed or anti-clockwise to
decrease the speed. Run the engine at an
increased speed for a few seconds then check
the idle speed again.
6.When the correct speed has been achieved,
hold the adjuster screw steady while tightening
the locknut.
NOTE: The low idle speed control is the
only permitted adjustment in service. Any
additional adjustments required must be
entrusted to authorised Bosch agents.CHECK TURBOCHARGER BOOST PRESSURE
For boost pressure.
See ENGINE TUNING DATA,
Information, 300 Tdi Engine
1.Disconnect, from turbocharger, hose to actuator.
Insert into a suitable "T" piece.
2.Connect a short length of suitable hose to
turbocharger and connect other end to "T" piece.
3.Connect a further length of hose to third leg of
the "T" piece and other end to a pressure gauge
capable of reading in excess of 61 cm Hg. The
pressure gauge hose must be capable of
reaching passenger compartment so that gauge
may be observed.
4.To check maximum boost pressure, drive
vehicle normally but in such a manner that full
throttle can be maintained whilst climbing a hill
with engine speed held steady between 2,500
and 3,000 rev/min.

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.