1995 LAND ROVER DISCOVERY electrical

Tdi
1
REPAIR VISCOUS COUPLING, FAN BLADES, PULLEY AND
FAN COWL
Service repair no - 26.25.03/05
Viscous coupling -Remove1to3
Fan blades -Remove1to4
Fan cowl -Remove1to3
Fan pulley -Remove1to6
Remove
WARNING: Disconnect battery negative
terminal to prevent engine being started
before removing or adjusting drive belt.
1.Slacken nut securing viscous coupling/fan blade
assembly to pulley.
NOTE: Nut securing viscous unit to pulley
has a left hand thread. Release by turning
clockwise when viewed from front of
viscous unit.
2.Drop viscous unit and fan assembly into bottom
of cowling
3.Remove two fixings clips from top of cowling and
lift cowling complete with viscous unit and fan
out of lower mountings.
4.Remove fan blades from viscous coupling if
necessary.
5.Remove serpentine drive belt and, if fitted, air
conditioning compressor belt.
6.Remove pulley fixings, remove pulley.
NOTE: The serpentine belt is removed by
using a hexagonal socket and tommy bar
on the auto-tensioning pulley nut. Whilst
tensioning the device the belt can be removed.
7.Reverse removal procedure. Ensure fan blades
are fitted correctly. Fan is marked 'front' and
should be fitted with word 'front' closest to
radiator. Tighten to
30 Nm.
8.Refit drive belt.See ENGINE, Repair, Drive
Belt
THERMOSTAT
Service repair no - 26.45.01
Remove
1.Partially drain cooling system, until coolant level
is below thermostat housing.
2.Disconnect hose from thermostat housing.
3.Disconnect electrical connections to water
temperature switch.
4.Remove outlet elbow.
5.Withdraw thermostat.
Test
6.Note rating of thermostat is 88°C. Place
thermostat in a container half full of water. Heat
water, observe temperature at which thermostat
begins to open. Thermostat is satisfactory if its
open between 85°C and 89°C.
Refit
7.Insert thermostat with jiggle pin/vent hole upper
most (12 o'clock position) .
8.Fit the outlet elbow and new joint washer.
Tighten to
28 Nm.
9.Reverse removal procedure. 1 to 3.
10.Check for coolant leaks around all connections
and joint faces.

V8i
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, Drive Belt -
Check Tension
YES - Continue.
3.Is ignition timing correct?
NO -
See ELECTRICAL, Adjustment,
Ignition Timing
YES - Continue.
4.Is coolant in radiator frozen?
YES - Slowly thaw and drain system.
See
Adjustment, Coolant Requirements
NO - Continue.
5.Is air flow through radiator restricted or blocked?
YES - Apply air pressure from engine side of
radiator to clear obstruction.
NO - Continue.
6.Are there any external leaks, from water pump,
engine gaskets or the heater unit?
YES - Investigate and rectify.
See Adjustment,
Coolant Requirements
NO - Continue.
7.Are fan blades fitted correct way round, concave
side towards engine?
NO - Rectify.
YES - Continue.8.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 11,
otherwise: Continue.
9.Are the air conditioning fans operating correctly?
See Electrical Trouble Shooting Manual.K5
NO - Rectify.
YES - Continue.
10.Is temperature sender and gauge giving
accurate readings?
NO - Substitute parts and compare readings.
YES - Continue.
11.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 the coolant only, or both systems are contaminated,
suspect cylinder head gaskets or radiator.
If only the lubrication stystem is contaminated with
coolant, suspect inlet manifold or front cover gaskets.

26COOLING SYSTEM
2
FAULT DIAGNOSIS ENGINE RUNS COLD
Before conducting any cooling system diagnosis:
See
Description and operation, Engine cooling
1.Check operation of viscous unit.See
Description and operation, Viscous Fan
Is viscous unit operating correctly?
NO -
See Repair, Viscous coupling, fan
blades, pulley and fan cowl
YES - Continue.
2.Is thermostat correct type and operating?
See
Repair, Thermostat
If problem is not diagnosed: Continue.
3.Are the air conditioning fans operating
continuously?
YES -
See Electrical Trouble Shooting
Manual.
NO - Continue.
4.Is temperature sender and gauge giving
accurate readings? Substitute parts and
compare readings. If problem is not diagnosed
repeat tests, starting at 1.

V8i
3
REPAIR THERMOSTAT
Service repair no - 26.45.01
Remove
1.Partially drain cooling system, until coolant level
is below thermostat housing.
2.Disconnect hose from thermostat housing.
3.Disconnect electrical connections to water
temperature switch.
4.Remove outlet elbow.
5.Withdraw thermostat.
Test
6.Note rating of thermostat is 88°C. Place
thermostat in a container half full of water. Heat
water, observe temperature at which thermostat
opens. Thermostat is satisfactory if it opens
between 85°C and 89°C.Refit
7.Insert thermostat with jiggle pin/vent hole
uppermost (12 o'clock position).
8.Fit the outlet elbow and new joint washer.
Tighten to
28 Nm.
9.Reverse removal procedure. 1 to 3.
10.Check for coolant leaks around all connections
and joint faces.

41TRANSFER GEARBOX
2
FAULT DIAGNOSIS PROCEDURE
Prior to road test
1.Check oil level in transfer box is correct.
2.Check tightness of level and drain plugs.
3.Check breather system for blockage. To validate
the system the pipe must be removed,
inspected, rectified as necessary and refitted.
4.Remove all traces of oil from exterior of transfer
box.
Take vehicle for short road test.
5.Identify source of leaks and rectify as follows.
Front or rear output seal leaking:-
1.Drain the oil and remove the leaking output
flange.
2.Inspect the seal track on the flange for surface
damage. If damaged renew component.
3.Remove and discard the oil seal.
4.Inspect the seal locating bore and remove any
sharp edges which may damage the new oil
seal.
5.Fit new seal.
6.Fit the output flange and all the other parts.
7.Add oil to correct level into the gearbox.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids
Cover plate gasket leaking.
1.Drain the oil and remove the leaking cover plate.
2.Remove all traces of joint sealant from both joint
faces.
3.Degrease all components and apply a thin film of
Hylomar sealant, to both joint faces.
4.Apply thread sealant to the bolts which come
into contact with gearbox oil.
5.Refit cover plate.
CAUTION: Care must be taken not to
overtighten the fixings.Leak between the main and transfer gearboxes.
1.Site vehicle onto a ramp [hoist].
2.Select neutral in transfer box and select 4th gear
in the main gearbox.
3.Run engine at 2000 rpm with the clutch/drive
engaged.
4.Observe joint between the main and transfer
boxes.
5.If oil leak is found establish if it is gear oil.
6.If so, the leak is originating from the transfer box.
7.Check the two inner (main/transfer) bolts are oil
tight, as these holes are tapped through into the
main transfer case.
8.Remove the transfer box to inspect the
mainshaft collar seal track condition, and the
front face of the transfer case for porosity.
See
Repair, LT230T Transfer Gearbox
9.If these areas require servicing, the transfer
gearbox input seal must also be renewed.
CAUTION: Avoid damaging the new seal
lip and ensure the seal is fitted flush with
the machined face. Also ensure the new
seal is not damaged when refitting the transfer
gearbox.
10.If red A.T.F type oil is seen leaking during the
workshop test, investigate the main gearbox for
cause of leak.
Detent plug or electrical switch leaks.
1.Detent plugs and electrical switches do not
usually leak. It must be noted that they fit into
open tapped holes in the transfer case and
therefore should be considered when looking for
the source of the leak.

41TRANSFER GEARBOX
4
REPAIR SHIFTLOCK SOLENOID/NEUTRAL SWITCH
Service repair no - 41.10.63/64
This is sited on top of the transfer gearbox. Access to
the component is gained through the transmission
tunnel aperture.
Remove
1.Disconnect battery negative lead.
2.Remove centre console.
See CHASSIS AND
BODY, Repair, Centre Console
3.Remove rear passenger heater air ducts.
4.Remove insulation pad.
5.Remove four screws and remove main gear
lever assembly.
6.Drill out rivets and remove tunnel blanking plate.
7.Disconnect solenoid multiplug.
8.Remove four retaining bolts and remove shiftlock
solenoid cover.
9.Remove solenoid and spring washer.
10.Clean joint sealant from mating faces.
KEY
1. Gearlever
2. Transmission tunnel aperture
3. Transfer gearbox
4. Bolt
5. Switch
6. Solenoid
7. Electrical connectionsRefit
1.Apply Hylosil or equivalent sealant to mating
faces.
2.Ensure solenoid plug lead is located in cover
recess.
3.Reverse removal procedure.
4.Fit four solenoid bolts. Tighten to
9Nm.
Neutral switch, audible alarm
1.Disconnect neutral switch electrical plug.
2.Remove neutral switch from transfer box.
Refit
3.Apply Hylomar PL32/L20 or SL500 sealant to
neutral switch.
4.Reverse removal procedure.
5.Switch - Tighten to
25Nm.

ZF
5
REPAIR Remove
1.Select low range with transfer gear lever.
2.Remove knob and gaiter from transfer gear
lever.
3.Disconnect battery terminals.
4.Remove insulation pad from rocker cover and
inlet manifold.
5.On LH drive vehicles only, disconnect multi-plug
from top of brake fluid reservoir.
6.Release electrical harness from clips along top
of bulkhead and pull over to one side.7.Remove bolt securing transfer and main gearbox
breather pipe clip to rear of cylinder head.
8.Disconnect kick down cable at fuel injection
pump.
9.Drain coolant from cooling system.
10.Disconnect top hose from radiator.
11.Disconnect turbo charger hose from inter-cooler.
12.Remove starter heat shield.

44AUTOMATIC GEARBOX
6
REPAIR 13.Remove starter.
14.Working through starter aperture note position of
torque converter flexible drive plate to facilitate
refitting.
15.Remove the four torque convertor to flexible
drive securing bolts, rotating engine to gain
access to each individual bolt.
16.Raise vehicle on four post ramp [hoist].
17.Drain lubrication oil from transfer and main
gearboxes.
18.Disconnect speedometer cable from transfer
gearbox and disconnect associated clipping.
19.Remove rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
20.Disconnect front propeller shaft at transfer
gearbox and tie to one side.
21.Remove exhaust front pipe.
22.Remove bolts securing front and centre silencer
mounting brackets and tie silencer to one side.
23.Disconnect oil cooler pipes from gearbox.
24.Blank off pipes and union connections.
25.Remove bolt securing retaining bracket to sump
and move cooler pipes aside.
26.Disconnect selector cable from lever on side of
gearbox.
27.Disconnect inhibitor switch multi-plug.
28.Disconnect park brake cable from linkage to park
brake lever.
29.Disconnect electrical connections from
differential lock switch on transfer gearbox.
30.Remove two lower bolts from transfer gearbox
input bearing support plate.
31.Assemble approved support cradle to
transmission hoist.32.Raise hoist and secure cradle to transfer
gearbox input bearing support plate using bolts
removed.
33.Disconnect gearbox mounting brackets from
chassis cross member.
34.Remove chassis cross member.
35.Lower transmission sufficiently to allow access
to items attached to top of gearbox.
36.Remove left hand gearbox mounting bracket
assembly.
37.Remove ties from breather pipes and harness.
38.Remove nut securing gearbox oil filler/dip stick
tube to bell housing.
39.Release union nut at gearbox sump and remove
filler/dipstick tube. Fit blanking plugs.
40.Support engine using a wooden block with a
suitable ramp [hoist] jack.
41.Remove nut securing kick down cable bracket to
bell housing.
42.Remove two bolts securing top of bell housing to
flywheel housing.
43.Remove nuts securing bell housing to flywheel
housing and withdraw transmission assembly
from engine.
44.Fit a suitable torque converter retaining strap to
the bell housing.
45.Remove hoist and transmission from under
vehicle.
46.Fit lifting eyes to transmission.
47.Using suitable chains and lifting tackle take
weight of transmission assembly.
48.Remove bolts securing transmission cradle to
transfer box and withdraw hoist complete with
cradle.
49.Refit bolts to cover plate.