1995 LAND ROVER DISCOVERY fuel cap

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
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.

MFI
3
FAULT DIAGNOSIS FUEL PRESSURE CHECK
In order to check the fuel pressure it is necessary to
first depressurise the fuel system as follows:
WARNING: Under normal operating
conditions the multiport fuel injection
system is pressurised by a high pressure
fuel pump, operating at up to 2.3 to 2.5 bar. When
engine is stationary pressure is maintained within
system. To prevent pressurised fuel escaping and
to avoid personal injury it is necessary to
depressurise multiport fuel injection system
before any service operations are carried out.
If vehicle has not been run there will be a small
amount of residual pressure in fuel line. The
depressurising procedure must still be carried out
before disconnecting any component within the
fuel system.
The spilling of fuel is unavoidable during this
operation. Ensure that all necessary precautions
are taken to prevent fire and explosion.
A Pressure gauge 18G1500
B Fuel tank and pump
C Fuel filter
D Fuel injectors x 8
E Regulator1.Remove fuel pump relay module.
See Repair,
Multiport Fuel Injection Relay
2.Start and run engine.
3.When sufficient fuel has been used to cause fuel
line pressure to drop, injectors will become
inoperative, resulting in engine stall. Switch off
ignition.
4.Disconnect battery negative lead. .
NOTE: Fuel at low pressure will remain in
system. To remove low pressure fuel,
place absorbent cloth around fuel pipe at
the filter during disconnection.
5.Connect the pressure gauge on the outlet from
the filter, located on the chassis under the right
rear wheel arch.
6.Reconnect the battery and turn the ignition to
position II while observing the pressure gauge.
Results
Expected reading 2,39-2,672 kgf/cm
2
Pressure drop-max 0.7 kgf/cm2in one minute.
If pressure is low check that filter is not blocked
and pump is operating satisfactorily. Then
recheck pressure. If pressure is still low renew
regulator.
See Repair, Fuel Pressure
Regulator

19FUEL SYSTEM
6
REPAIR ENGINE COOLANT TEMPERATURE SENSOR
Service repair no - 19.22.18
Remove
1.Position drain tray to collect coolant spillage.
2.Disconnect multiplug from coolant sensor.
3.Remove sensor from thermostat housing.
4.Remove and discard copper washer.
Refit
5.Fit a new copper washer.
6.Fit sensor and tigten securely.
7.Top-up cooling system.
8.Run engine, check for water leaks around
sensor.DEPRESSURISING FUEL SYSTEM
WARNING: Under normal operating
conditions the Multiport fuel injection
system is pressurised by a high pressure
fuel pump, operating at up to 2.3 to 2.5 bar When
engine is stationary pressure is maintained within
system. To prevent pressurised fuel escaping and
to avoid personal injury it is necessary to
depressurise multiport fuel injection system
before any service operations are carried out.
If vehicle has not been run there will be a small
amount of residual pressure in fuel line. The
depressurising procedure must still be carried out
before disconnecting any component within the
fuel system.
The spilling of fuel is unavoidable during this
operation. Ensure that all necessary precautions
are taken to prevent fire and explosion.
1.Remove fuel pump relay module.
See
Multiport Fuel Injection Relays
2.Start and run engine.
3.When sufficient fuel has been used to cause fuel
line pressure to drop, injectors will become
inoperative, resulting in engine stall. Switch off
ignition.
4.Disconnect battery negative lead.
NOTE: Fuel at low pressure will remain in
system. To remove low pressure fuel,
place absorbent cloth around fuel feed
hose at fuel rail.
5.Disconnect either:
a) Nut and olive at fuel rail
OR
b) Hose at inlet end of fuel filter.
Refit
6.Refit fuel feed hose.
7.Refit fuel pump relay module, reconnect battery.
8.Crank engine (engine will fire in approximately 6
to 8 seconds).

SFI
11
DESCRIPTION AND OPERATION ADD: 09/95 Fuel Filler Neck Assembly
The filler neck consists of a stainless steel upper
section and a convolute nylon lower section. The
nylon lower is joined at one end to the tank and at the
other to the stainless upper section where both joints
utilise a short piece of rubber hose. The joint at the
fuel tank is secured using a spring assisted hose clip
which has a shear off cap.
NOTE: The spring assisted clip must never
be re-used, if removed a new clip of the
same type must be fitted.
Tank vent connections are achieved using serviceable
plastic quickfit connectors. The filler cap is tethered to
the body of the vehicle. Only a cap of this type must
be used as a replacement.Fuel Lines
The fuel lines consist of two coated steel lines fitted
along the length of the chassis from the fuel pump at
the rear of the vehicle to the connections at the fuel
rail on the engine, via a fuel filter on the feed line.
Connections at the pump are metal quickfits, while
those at the filter and fuel rail are threaded unions
utilising "O" rings for effective sealing.
NOTE: When the fuel filter is serviced or
the fuel rail joints are disconnected, new
"O" rings must always be fitted.
Connections at the fuel rail are made using "Saginaw"
screw thread type connectors with "O" rings as the
sealing medium. The fuel lines in the engine
compartment are made from a braided nylon material.
NOTE: This material must not be clamped
or kinked as this impairs its performance.

19FUEL SYSTEM
22
REPAIRADD: 09/95
12.Mark location of anti-roll [sway] bar straps.
13.Remove nuts and bolts securing anti-roll [sway]
bar straps, and allow bar to swing down clear of
tank.14.Disconnect pressure sensor breather pipe
connection.
15.Disconnect vent line quickfit connector from
liquid/vapour separator.
16.Remove torque screw cap from hose to tank
filler neck clip.
17.Loosen clip screw securing hose to tank filler
neck.
18.Release hose from filler neck and internal filler
neck breather hose from fuel tank.
19.Remove and discard fuel filler neck clip.

SFI
27
REPAIR ADD: 09/95
11.Disconnect vent line quickfit connector from
liquid/vapour separator.
12.Remove torque screw cap from hose to tank
filler neck clip.
13.Loosen clip screw securing hose to tank filler
neck.
14.Release hose from filler neck and internal filler
neck breather hose from fuel tank.
15.Remove and discard fuel filler neck clip.
16.Disconnect the pressure sensor breather pipe
connection.
17.Disconnect the vent line hose connection.
18.Fit ignition key to fuel filler flap lock and open
flap.
19.Release fuel filler cap from filler neck.
20.Remove filler neck assembly from vehicle.
Do not carry out further dismantling if
component is removed for access only.
21.Remove torque screw cap from hose to filler
neck clip.
22.Loosen clip screw securing hose to filler neck.
23.Remove hose from filler neck.
24.Remove and discard fuel filler hose clip.
25.Remove vent line from filler neck.

19FUEL SYSTEM
28
REPAIRADD: 09/95 Refit
26.Fit vent line to filler neck.
27.Fit NEW clip to filler neck hose.
28.Fit hose to filler neck.
29.Position filler neck hose clip and tighten until
head shears.
30.Fit filler neck assembly to vehicle.
NOTE: To aid fitment of filler neck through
body grommet apply a soap solution to lip
of grommet.
31.Fit NEW clip to fuel filler neck hose.
32.Connect fuel filler neck internal breather to tank.
33.Connect fuel filler neck hose to tank.
34.Position fuel filler neck hose clip and tighten until
head shears.
35.Connect vent line quickfit connector to
liquid/vapour separator.
36.Connect the pressure sensor breather pipe
connection.
37.Connect the vent line hose connection.
38.Fit mud flap and secure with nuts and bolts.
39.Position filler neck support bracket and earth
strap to mud flap bracket and secure with nut
and bolt.
40.Remove stand(s) and lower vehicle.
41.Reposition loadspace sound insulation and
carpet.
42.Fit RH luggage compartment side panel.
See
CHASSIS AND BODY, Repair,
43.Fit tail door tread strip and secure with screws.
44.Refill tank with drained fuel.
45.Fit fuel filler cap to filler neck.
46.Close filler flap, lock with ignition key and
remove key.
47.Reconnect battery negative lead.FUEL TANK FILLER CAP - ADVANCED EVAPS
Service repair no - 19.55.08
Remove
1.Fit ignition key to fuel filler flap lock and open
flap.
2.Remove screw securing cap retaining strap to
body.
3.Remove fuel filler cap.
Refit
4.Fit fuel filler cap.
5.Position cap retaining strap to body and secure
with screw.
6.Close filler flap, lock with ignition key and
remove key.