1995 LAND ROVER DISCOVERY radiator

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.

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
6
REPAIR FUEL FILTER ELEMENT
Service repair no - 19.25.07
Remove
1.Disconnect battery negative lead.
2.Clean area around filter head.
3.Place a suitable container beneath filter bowl to
collect any spillage.
4.Loosen bleed screw.
5.Loosen drain tap, allow fuel to drain into
container.
6.Unscrew filter element, discard element.
Refit
7.Clean seal and seating in filter head.
8.Lubricate filter element seal with fuel.
9.Position filter element to filter head and hand
tighten.
10.Reconnect battery negative lead.
11.Crank engine until fuel is drawn through the
system and starts.INTERCOOLER
Service repair no - 19.42.15
Remove
1.Disconnect battery negative lead.
2.Release 2 clips securing fan cowl to radiator top
cover.
3.Remove 4 bolts securing radiator top cover,
remove top cover.
4.Remove nut, bolt and washers securing
intercooler side cover bracket to bonnet [hood]
platform.
5.Release bracket from side cover lug, position
bracket and power steering reservoir aside.
6.Position side cover away from intercooler.
7.Loosen 2 clips and disconnect top hose from
intercooler.
8.Loosen 2 clips and disconnect bottom hose from
intercooler.

19FUEL SYSTEM
14
REPAIR RAM HOUSING
Service repair no - 19.70.04
Remove
1.Disconnect battery negative lead.
2.Remove plenum chamber.
See Plenum
Chamber
3.Release hoses from ram housing.
4.Remove six through bolts (with plain washers)
securing ram housing to intake manifold.
5.Remove ram housing from intake manifold.
6.Place a protective cover over inlet bores to
prevent ingress of dirt.
Refit
7.Clean all mating faces.
8.Apply 'Hylomar' sealant to intake manifold face.
9.Fit ram housing. Tighten bolts, working from two
centre bolts, diagonally towards outer four bolts.
10.Tighten to
26 Nm.
INTAKE MANIFOLD
Service repair no - 30.15.08
Remove
1.Depressurise fuel system.
See Depressurising
Fuel System
2.Disconnect battery negative lead.
3.Drain cooling system.
See COOLING SYSTEM,
Repair, Radiator
4.Remove plenum chamber.See Plenum
chamber
5.Remove ram housing.See Ram Housing
CAUTION: Place a protective cover over
intake manifold openings to prevent the
ingress of dirt.
6.Disconnect the fuel temperature sensor and
injector multiplugs.
7.Remove fuel pressure regulator.
See Fuel
Pressure Regulator
8.Disconnect multiplug from coolant temperature
sensor.
9.Disconnect instrument pack temperature
thermistor.
10.Disconnect coolant sensor multiplug.

19FUEL SYSTEM
16
REPAIR Refit
1.Clean mating faces of cylinder heads, cylinder
block and intake manifold.
2.Locate NEW seals in position with ends
engaged in notches formed between the cylinder
heads and block.
3.Apply RTV sealant between ends of seals,
cylinder head and block.
4.Fit intake manifold gasket with the word
'FRONT'to the front and open bolts hole to the
front RH side.
5.Fit gasket clamps and tighten bolts finger tight.
6.Locate intake manifold onto cylinder heads,
clean threads of manifold securing bolts.
7.Allow 10 minutes for RTV sealant to cure.
8.Fit manifold bolts finger tight. Working in the
sequence shown tighten the bolts to
38 Nm.
9.Tighten the gasket clamp bolts to18 Nm.
10.Reverse removal procedure.
11.Fill cooling system.
See COOLING SYSTEM,
Repair, Radiator
12.Start engine check for water and fuel leaks.

Tdi
1
DESCRIPTION AND OPERATION ENGINE COOLING
Description
The Tdi engine uses a pressurized cooling system
and cross flow radiator which is supplied from a
separate header tank. The radiator assembly is in
three sections. The largest section is for engine
coolant and the other two sections which are cast in
aluminium, are the engine oil cooler and the turbo
charger intercooler.
A belt driven viscous fan and centrifugal water pump
is located in the front of the cylinder block. Hot coolant
is supplied to the heater through hoses. Two small
diameter air purge hoses connect the top of the
radiator and cylinder head water gallery, to the header
tank.
Coolant circulation (engine cold)
1. Cross flow radiator
2. Header tank
3. Viscous fan
4. Heater hoses
5. By pass hose and engine thermostat
6. Air purge hoses
7. Coolant pumpCOOLANT CIRCULATION
Operation
When the engine is started from cold the thermostat
prevents any coolant circulation through the radiator
by closing off the top hose. During the engine warm
up period, the water pump, pumps coolant towards
the rear of the cylinder block around each of the
cylinders. Coolant as it is heated rises through ports in
the cylinder block and head gasket, into the cylinder
head.The coolant flows forwards to the thermostat,
by-pass port and radiator top hose connection.
Start from cold (thermostat closed)
While the thermostat is closed, coolant circulates
around the cylinder block and cylinder head via the
by-pass.
Engine warm (thermostat open)
When the engine reaches normal running temperature
the thermostat closes off the by-pass and opens the
flow to the top of the radiator.

Tdi
1
FAULT DIAGNOSIS ENGINE OVERHEATING
Before conducting any cooling system diagnosis:
See
Description and operation, Engine Cooling
1.Is coolant level correct?
NO - Allow engine to cool, top up level to
expansion tank seam.
YES - Continue.
2.Is drive belt tension correct?
NO -
See ENGINE, Repair, Compressor
Drive Belt
YES - Continue.
3.Is coolant in radiator frozen?
YES - Slowly thaw and drain system.
See
Adjustment, Coolant
NO - Continue.
4.Is air flow through radiator restricted or blocked?
YES - Apply air pressure from engine side of
radiator to clear obstruction.
NO - Continue.
5.Are there any external leaks, from water pump,
engine gaskets, fast idle thermostat or the heater
unit?
YES - Investigate and rectify.
See Adjustment,
Coolant
NO - Continue.
6.Are fan blades fitted correct way round, concave
side towards engine?
NO - Rectify.
YES - Continue
7.Is viscous unit operating correctly?
See
Description and operation, Viscous Fan
NO - Renew.See Repair, Viscous
Coupling, Fan Blades, Pulley and Fan
Cowl
YES - Carry out a pressure test on radiator cap
and system. Check thermostat type,
operation and correct fitting.
See Repair,
Thermostat
If pressure test leads you to suspect coolant
leakage across gaskets, go to check 10,
otherwise: Continue.8.Are the air conditioning fans operating correctly?
See Electrical Trouble Shooting Manual.
NO - Rectify.
YES - Continue.
9.Is temperature sender and gauge giving
accurate readings?
NO - Sustitute parts and compare readings.
YES - Continue.
10.Carry out cylinder pressure test to determine if
pressure is leaking into cooling system causing
over pressurising and loss of coolant.
If problem is not diagnosed, check the coolant system
for engine oil contamination and engine lubrication
system for coolant contamination.
If only the coolant system is contaminated suspect a
cylinder head gasket.
If both systems are contaminated, suspect the
radiator.
If only the lubrication system is contaminated with
coolant, suspect leakage past cylinder liner seals or
cylinder head gasket.

Tdi
1
ADJUSTMENT COOLANT
Service repair no - 26.10.01
Draining
WARNING: Do not remove any caps or
plugs when the engine is hot. The cooling
system is pressurised and personal
scalding could result.
1.Remove expansion tank filler cap.
2.Disconnect bottom hose from radiator and allow
coolant to drain into a container. Ensure
container is clean if reusing coolant.
NOTE: When expansion tank has emptied,
remove thermostat housing plug to assist
drainage. Similarly when coolant level is
below top of radiator, remove radiator plug.
3.Reconnect hose after draining and tighten hose
clamp.
Refit
CAUTION: In order to expel ALL air from
the cooling system, follow the procedures
carefully.
NOTE: Refill procedure is slow but can be
accelerated by squeezing hoses to assist
removal of air from the system.
4.Add correct mix of coolant into expansion tank
until radiator is full (as seen through plug hole on
top of radiator).
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information, Anti-Freeze
CAUTION: Take care to avoid excess
coolant spillage from radiator.
5.Fit radiator plug.
6.Continue adding coolant into expansion tank
until coolant appears in thermostat housing.
CAUTION: Take care to avoid excess
coolant spillage from thermostat housing.
7.Fit thermostat housing plug.
8.Check coolant in expansion tank is level with
indicator post. Add more coolant if necessary.
9.Start engine and run for 5 minutes.
10.Allow engine to cool, check coolant level in
expansion tank; top up to level indicator post if
necessary.
11.Fit expansion tank filler cap.