1995 LAND ROVER DISCOVERY warning

19FUEL SYSTEM
20
REPAIRADD: 09/95 FUEL SYSTEM - DEPRESSURISE - ADVANCED
EVAPS
Service repair no - 19.50.02
WARNING: Fuel pressure of up to 2.5 bar
will be present in the system, even if the
engine has not been run for some time.
Always depressurise the system before
disconnecting any components in the fuel feed
line (between fuel pump and pressure regulator).
The spilling of fuel is unavoidable during this
operation. Ensure that all necessary precautions
are taken to prevent fire and explosion.
NOTE: Fuel pressure can be relieved at
fuel filter unions.
1.Position cloth around relevant union to protect
against fuel spray.
2.Carefully loosen union.
CAUTION: Use two spanners when
loosening or tightening unions.
3.Tighten union once fuel pressure is relieved.
4.Remove cloth.FUEL TANK - ADVANCED EVAPS
Service repair no - 19.55.01
WARNING: Ensure fuel handling
precautions given in section 01
Introduction are strictly adhered to when
carrying out following instructions.
CAUTION: Before disconnecting any part
of fuel system, it imperative that all dust,
dirt and debris is removed from around
components to prevent ingress of foreign matter
into fuel system.
Remove
1.Disconnect battery negative lead.
2.Drain fuel tank completely.
See fuel tank -
draining - advanced evaps
3.Remove 6 screws securing tail door tread strip
and remove tread strip.
4.Remove RH luggage compartment side panel.
See CHASSIS AND BODY, Repair, rear
compartment lower trim panels

SFI
21
REPAIR ADD: 09/95
5.Fold back loadspace carpet and sound
insulation to reveal access panel.
6.Remove 6 screws securing fuel pump access
panel.
7.Remove access panel.8.Disconnect multiplugs from fuel pump and
pressure sensor
9.Noting their fitted positions, disconnect both fuel
connections by pressing the black release
latches on each connector and pushing the
connector back down the line.
10.Care must be taken to catch any excess fuel
which may spill from the fuel lines once
removed.
11.Raise rear of vehicle.
WARNING: Support on safety stands.

19FUEL SYSTEM
24
REPAIRADD: 09/95 Refit
29.Fit NEW pump seal to tank opening.
30.Carefully lower pump into tank opening, pressing
firmly on the pump top flange to allow correct
positioning.
NOTE: Ensure location tag on pump top
flange is engaged correctly to tank
opening lip.
31.Fit locking ring and tighten to
35 Nmusing
service tool LRT-19-009.
32.Fit vent hose to fuel tank clips and connect to
pressure sensor.
33.With assistance, fit fuel tank into position.
34.Fit fuel tank cradle and secure with nuts and
bolts.
35.Align upper fuel tank strap and secure with nut
and bolt.
36.Fit NEW clip to fuel filler neck hose.
37.Connect fuel filler neck internal breather to tank.
38.Connect fuel filler neck hose to tank.
39.Position fuel filler neck hose clip and tighten until
head shears.
40.Connect vent line quickfit connector to
liquid/vapour separator.
41.Connect vent line hose connection.
42.Position anti-roll [sway] bar straps and secure
with nuts and bolts.
43.Remove stand(s) and lower vehicle.
44.Connect both fuel lines to the pump by pushing
the connectors down each line square to the
pump connection until the connectors positively
latches.
45.Connect multiplugs to fuel pump and pressure
sensor.
46.Reconnect battery negative lead.
47.Refill tank with drained fuel.
48.Run the engine to check for any fuel leaks.
49.Fit access panel and secure with screws.
50.Reposition loadspace sound insulation and
carpet.
51.Fit RH luggage compartment side panel.
See
CHASSIS AND BODY, Repair, rear
compartment trim panels
52.Fit tail door tread strip and secure with screws.FUEL TANK - DRAINING - ADVANCED EVAPS
Service repair no - 19.55.02
WARNING: Before removing the fuel tank
it must be drained.
WARNING: Petrol/gasoline vapour is
highly flammable and in confined spaces
is also explosive and toxic. Always have a
fire extinguisher containing FOAM, CO2, GAS or
POWDER close at hand when handling or draining
fuel. See Introduction
CAUTION: Before disconnecting any part
of fuel system, it is imperative that all dust,
dirt and debris is removed from around
components to prevent ingress of foreign matter
into fuel system.
NOTE: Assuming the fuel tank is FULL
drain the following quantities:
Renew Fuel pump = 9 Litres (2.4 US Gallons)
Renew Fuel filler neck = 22 Litres (6 US Gallons)
Renew Fuel tank = COMPLETE DRAIN
1.Depressurise fuel system.
See fuel system -
depressurise - advanced evaps
2.Disconnect battery negative lead.
3.Remove 6 screws securing tail door tread strip
and remove tread strip.
4.Remove RH luggage compartment side panel.
See CHASSIS AND BODY, Repair,

19FUEL SYSTEM
26
REPAIRADD: 09/95 FUEL FILLER NECK - ADVANCED EVAPS
Service repair no - 19.55.07
WARNING: Ensure that fuel handling
precautions given in 1 - Introduction are
strictly adhered to when carrying out
following instructions.
CAUTION: Before disconnecting any part
of fuel system, it is imperative that all dust,
dirt and debris is removed from around
components to prevent ingress of foreign matter
into fuel system.
Remove
1.Depressurise fuel system.
See fuel system -
depressurise - advanced evaps
2.Disconnect battery negative lead.
3.Check the amount of fuel in the tank. If the tank
is full drain 6 US gallons (22 litres) minimum.
See fuel tank - draining.
4.Remove 6 screws securing tail door tread strip
and remove tread strip.
5.Remove RH luggage compartment side panel.
See CHASSIS AND BODY, Repair, rear
compartment trim panels
6.Fold back loadspace carpet and sound
insulation to gain access to RH mudflap fixing.
7.Raise rear of vehicle.
WARNING: Support on safety stands.
8.Remove nut and bolt securing filler neck support
bracket to mud flap bracket.
NOTE: This fixing also retains the filler
neck earth strap.
9.Remove 5 nuts and bolts securing mud flap to
body.
10.Remove mud flap.

Mpi
5
DESCRIPTION AND OPERATION
Fuel pump
The electric fuel pump, located inside the fuel tank, is
a self-priming centrifugal 'wet' pump, the motor and
pump are filled with fuel.
The fuel pump supplies more fuel than the maximum
load requirement for the engine, so that pressure in
the fuel system can be maintained under all
conditions.
Fuel pressure regulator
The pressure regulator is a mechanical device
controlled by manifold depression and is mounted in
the fuel rail. The regulator ensures that fuel rail
pressure is maintained at a constant pressure
difference to that in the inlet manifold, as manifold
depression increases the regulated fuel pressure is
reduced in direct proportion.
When pressure exceeds the regulator setting excess
fuel is spill returned to the fuel tank swirl pot which
contains the fuel pick-up strainer.
Relay module
The relay module contains the main relay, fuel pump
relay, starter relay and oxygen sensor relay and is
mounted on the ECM mounting bracket.
The main relay is energised when the ignition is
switched on and supplies current to the ECM
The fuel pump relay is energised by the ECM for a
short period when the ignition is switched on, during
cranking and while the engine is running.
The starter relay is energised by the cranking signal
from the ignition switch.
This oxygen sensor relay is energised when the
ignition is switched on and supplies current to the
ECM
Intake air temperature sensor
The intake air temperature sensor is fitted in the side
of the inlet manifold and sends the ECM a signal
relating to air temperature. The ECM uses this signal
in its calculations on air flow.
Inertia switch
The fuel pump circuit incorporates an inertia switch
which in the event of sudden deceleration isolates the
power supply to the fuel pump. The inertia switch is
situated in the engine compartment on the bulkhead
and can, if tripped, be reset by depressing the central
plunger.
WARNING: Check the integrity of the fuel
system before the inertia switch is reset.
Diagnostic connector
A diagnostic connector is provided to enable
diagnosis to be carried out without disturbing the
system electrical connections and to allow the ECM's
ability to store certain faults to be utilised.
Oxygen sensor - Closed-loop emission control
The MEMS Mpi system operates a closed loop
emission system to ensure the most efficient level of
exhaust gas conversion.
An oxygen sensor fitted in the exhaust manifold
monitors the exhaust gases. It then supplies a small
voltage proportional to exhaust oxygen content to the
ECM As the air/fuel mixture weakens, the exhaust
oxygen content increases and so the voltage to the
ECM decreases. If the mixture becomes richer so the
oxygen content decreases and the voltage increases.
The ECM uses this signal voltage to determine the
air/fuel mixture being delivered to the engine, and
adjusts the injector duration to maintain the ratio
necessary for efficient gas conversion by the catalyst.
The oxygen sensor has an integral heating element to
ensure an efficient operating temperature is quickly
reached from cold. The electrical supply for the heater
element is controlled by the oxygen sensor relay.
Fuel temperature sensor
The fuel temperature sensor is inserted in the fuel rail
and measures fuel and fuel rail temperatures. During
engine cranking at high temperatures, the ECM
increases fuel supply, and opens the throttle disc via
the stepper motor to aid hot starting.

CRUISE CONTROL
1
FAULT DIAGNOSIS ROAD TEST
CAUTION: Do not engage cruise control
when vehicle is being used in low transfer
gear or reverse.
WARNING: The use of cruise control is not
recommended on winding, snow covered
or slippery roads or in heavy traffic
conditions where a constant speed cannot be
maintained.
1.Start engine, depress main control switch to
actuate cruise control system. Accelerate to
approximately 50 km/h, (30 mph), operate
'set/acc'switch, immediately release switch,
remove foot from accelerator pedal. Vehicle
should maintain speed at which'set/acc'switch
was operated.
2.Operate'set/acc'switch and hold at that
position, vehicle should accelerate smoothly until
switch is released. Vehicle should now maintain
new speed at which'set/acc'switch was
released.
3.Momentarily touch and release'set/acc'switch,
vehicle speed should increase 1.6 km/h (1 mph)
for each touch. Note that five touches will
increase speed 8 km/h (5 mph).
4.Apply'res/decel'switch while vehicle is in cruise
control mode, cruise control should disengage.
Slow to approximately 55 km/h, (35 mph)
operate'res/decel'switch, immediately release
switch and remove foot from accelerator, vehicle
should smoothly accelerate to previously set
speed. Increase speed using accelerator pedal,
release pedal, vehicle should return to previously
set speed.
NOTE: The cruise control system fitted to
the diesel engine is not as responsive as
that fitted to the petrol engine, due to the
characteristics of diesel engines. Therefore, at
speeds below approx. 65 km/h (40 mph), the
vehicle speed may drop when cruise is selected
and then slowly regain the 'set' speed.5.Operate brake pedal, cruise control system
should immediately disengage returning vehicle
to driver control at accelerator pedal. Operate
'res/decel'switch, vehicle should accelerate to
previously set speed without driver operation of
accelerator pedal.
6.Operate'res/decel'switch and allow vehicle to
decelerate to below 42 km/h, (26 mph). Operate
'res/decel'switch, cruise control system should
remain disengaged.
7.Operate'set/acc'switch below 40 km/h, (28
mph), cruise control system should remain
disengaged. Accelerate, using accelerator pedal
to above 45 km/h, (28 mph), operate'res/decel'
switch, and remove foot from accelerator pedal,
vehicle should smoothly adjust to previously
memorised speed.
8. Automatic vehicles- select neutral, system
should disengage.Manual vehicles- depress
clutch, system should disengage.
9.Cruise at 80 km/h (50 mph), declutch, select
neutral, remove foot from clutch. Operate
'res/decel'switch. Engine should rev to 5000
rev/min, cruise control disengages, engine
returns to idle.
10.Engage forward gear. Operate'res/decel'
switch. Remove foot from accelerator. Speed
should accelerate to previous set speed.
11.Depress main control switch in control system
should immediately disengage and erase
previously set speed from ECU memory.
See
Electrical Trouble Shooting Manual.
ELECTRICAL TESTS
Electrical functionality can be checked using
TestBook.
CABLE SETTING - TDi AUTOMATIC MODELS
1.An incorrectly adjusted kickdown cable can
prevent correct operation of the cruise control
system.
See AUTOMATIC GEARBOX,
Adjustment, kickdown cable adjustment.

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.

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.