1995 LAND ROVER DISCOVERY cooling

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Workshop manual
DISCOVERY
This manual covers vehicles from
1995 model year
01 INTRODUCTION
04 GENERAL SPECIFICATION DATA
05 ENGINE TUNING DATA
07 GENERAL FITTING REMINDERS
09 LUBRICANTS, FLUIDS AND CAPACITIES
10 MAINTENANCE
12 ENGINE Tdi
12 ENGINE 3.9 V8
12 ENGINE 4.0 V8
12 ENGINE Mpi
17 EMISSION CONTROL
19 FUEL SYSTEM Tdi
19 FUEL SYSTEM MFI
19 FUEL SYSTEM SFI
19 FUEL SYSTEM Mpi
19 CRUISE CONTROL
26 COOLING SYSTEM Tdi
26 COOLING SYSTEM V8
26 COOLING SYSTEM Mpi
30 MANIFOLD AND EXHAUST SYSTEM
33 CLUTCH
37 MANUAL GEARBOX
41 TRANSFER GEARBOX
44 AUTOMATIC GEARBOX
47 PROPELLER SHAFTS
51 REAR AXLE AND FINAL DRIVE
54 FRONT AXLE AND FINAL DRIVE
57 STEERING
60 FRONT SUSPENSION
64 REAR SUSPENSION
70 BRAKES
74 WHEELS AND TYRES
75 SUPPLEMENTARY RESTRAINT SYSTEM
76 CHASSIS AND BODY
80 HEATING AND VENTILATION
82 AIR CONDITIONING
84 WIPERS AND WASHERS
86 ELECTRICAL
Published by Rover Technical Communication
Ó1996 Rover Group Limited
Publication Part No. LRL 0079 ENG (2nd Edition)

04GENERAL SPECIFICATION DATA
10
INFORMATION COOLING SYSTEM 3.9 V8i
System type Pressurised, spill return, thermostatically controlled.....................................................................
water and anti-freeze mixture. Pump assisted thermo
syphon. Coolant radiator combined with oil cooler.
Fan and viscous coupling assembly 11 blade axial flow 433mm diameter.................................
Pump type Centifugal, impellor, belt driven.........................................................................
Thermostat opening 88 degrees..........................................................
Expansion tank cap pressure 15 p.s.i. (system pressure)............................................
STEERING
Power steering box
Make/type Adwest Varamatic - worm and roller box........................................................................
Ratio Variable: straight ahead 19.3:1 on lock 14.3:1.................................................................................
Steering wheel turns, lock-to-lock 3.375....................................
Steering pump
Make/type -V8i ZF - Unicorn.................................................................
Make/type - Mpi & Tdi Hobourn-Eaton series 500......................................................
Steering geometry
Steering wheel diameter 405mm..................................................
Steering wheel diameter airbag model 400mm.............................
Toe-out measurement 0 to 2mm toe out......................................................
Toe-out included angle 0Ê to 0Ê 16'.....................................................
Camber angle 0Ê.................................................................. Check with vehicle in static..............
unladen condition, that is, vehicle
with water,
Castor angle 3Ê..................................................................... oil and five gallons of fuel. Rock..............
the vehicle up and down at the
front to allow
Swivel pin inclination static 7Ê............................................... it to take up a position..............

04GENERAL SPECIFICATION DATA
20
INFORMATION Lubrication
System Wet sump, pressure fed.............................................................................
Pressure, engine warm at normal operating speeds 25 - 55lbf/in
2= 1,76 - 3,87Kgf cm2........
Oil pump:
- Type G-rotor integral with front cover.......................................................................
- Drive off crankshaft nose.....................................................................
Oil pressure relief valve Non-adjustable....................................................
Relief valve spring:
- Full length 51,6mm......................................................................
- Compressed length at 7.71Kg load 31mm................................
Oil filter Screw-on disposable canister.............................................................................
Engine oil cooler Combined with coolant radiator and intercooler...............................................................
FUEL SYSTEM - 300 Tdi
Fuel lift pump type Mechanical with hand primer............................................................
Fuel lift pump pressure 42 - 55 kpa at 1800 rpm.....................................................
Fuel filter Paper element in disposable canister..........................................................................
Air cleaner Paper element type........................................................................
COOLING SYSTEM - 300 Tdi
System type Pressurised, spill return, thermostatically controlled.....................................................................
water and anti freeze mixture. Pump assisted thermo
syphon. Coolant radiator combined with oil cooler and
turbo intercooler.
Cooling fan 11 blade axial flow 433 mm diameter. 1.29:1 drive.......................................................................
ratio. Viscous coupling.
Pump type Centrifugal, impellor, belt driven.........................................................................
Thermostat opening 88° .........................................................
Expansion tank cap pressure 15lbf/in
2= 1,06Kgf cm2(system pressure) ...........................................
CLUTCH - 300 Tdi
Type Valeo diaphragm spring.................................................................................
Centre plate diameter 235 mm.......................................................
Facing material Verto F202 grooved.................................................................
Release bearing Ball journal...............................................................

04GENERAL SPECIFICATION DATA
22
INFORMATION ENGINE - Mpi - 2.0 LITRE
Type 20 T4 - 16 valve twin overhead camshaft.................................................................................
Cylinder arrangement 4 in line.......................................................
Bore 84.45 mm.................................................................................
3.325 in
Stroke 89.00 mm...............................................................................
3.504 in
Capacity 1994 cm
3...........................................................................
121.68 in3
Firing order 1-3-4-2.......................................................................
Compression ratio 10 : 1............................................................
Oil pump
Outer rotor to body clearance 0.05 to 0.10 mm..........................................
Inner rotor tip clearance 0.025 to 0.12 mm...................................................
Outer rotor end float 0.03 to 0.08 mm.........................................................
Oil pressure relief valve
Spring free length 42.0 mm.............................................................
Cooling system
Starts to open 82 to 86°C ...................................................................
Thermostat fully open 88°C .......................................................
Open travel A 9 mm...................................................................
Camshaft
Camshaft end-float 0.06 to 0.25 mm...........................................................
Bearing clearance 0.060 to 0.094 mm............................................................
Service limit 0.15 mm.............................................................
Timing belt tensioner
Spring free length 57.5 to 58.5 mm.............................................................
Cylinder head
Longitudinal warp - maximum 0.1 mm.................................
Transverse warp - maximum 0.1 mm...................................
Diagonal warp - maximum 0.1 mm......................................
Cylinder head height 135.0 to 135.1 mm...............................................
Valve springs
Free length 46.25 mm.......................................................................
Fitted length 37.0 mm.....................................................................
Load at fitted length 255±12 N ..........................................................
Load at valve open length 560±22.5 N ................................................

04GENERAL SPECIFICATION DATA
24
INFORMATION FUEL SYSTEM - Mpi
Electronic fuel injection data
See ENGINE TUNING DATA, Information, Engine............................................
- Mpi - 2.0 Litre
Fuel Pump:
Make/Type A.C. Rochester/Electric immersible.......................................................................
Pump pressure 3.2 bar.................................................................
Delivery at 3 bar pressure & 12V (min) 64 litre/h............................
Regulated pressure range 3.0 ñ 0.2 bar................................................
Fuel pump delivery pressure 2.3 - 2.5 kgf/cm
2............................................
Fuel filter Bosch in-line filter 'canister' type..........................................................................
COOLING SYSTEM - Mpi
Pressure cap 15lbf/in
2(1.03 bar) (system pressure) ....................................................................
Thermostat 88 ÊC.......................................................................
CLUTCH - Mpi
Type Diaphragm spring, hydraulically operated.................................................................................
Adjustment Self adjusting.......................................................................
Clutch plate diameter 215.13 mm.......................................................
TRANSMISSION - Mpi
Manual gearbox
Type R380 Single helical constant mesh.......................................................................
Speeds 5 forward 1 reverse all synchromesh.............................................................................
Transfer box
Type LT230T Two speed reduction on main gearbox output. Front....................................................................
and rear drive permanently engaged via a lockable
differential
Overall ratios (final drive): In high transfer In low transfer
Fifth 4.146:1.................................................................................. 9.761:1
Fourth 4.989:1............................................................................... 11.746:1
Third 7.518:1................................................................................. 17.701:1
Second 11.479:1............................................................................. 27.109:1
First 17.884:1.................................................................................. 42.109:1
Reverse 18.463:1............................................................................ 43.472:1

LUBRICANTS, FLUIDS AND CAPACITIES
3
INFORMATION Propeller shaft Front
and RearNLGI - 2 Multi-purpose Lithium based GREASE
Lubrication nipples
(hubs, ball joints
etc.)
Seat slides
Door lock striker
Brake and clutch
reservoirsBrake fluids having a minimum boiling point of 260°C (500°F) and complying with
FMVSS 116 DOT4
Engine coolant Use an ethylene glycol based anti-freeze (containing no methanol)
V8i, Tdi, Mpi with non-phosphate corrosion inhibitors suitable for use in aluminium engines to ensure
the protection of the cooling system against frost and corrosion in all seasons. Use one
part anti-freeze to one part water for protection down to -36°C (-33°F).
IMPORTANT: Coolant solution must not fall below proportions one part
anti-freeze to three parts water, i.e. minimum 25% anti-freeze in coolant otherwise
damage to engine is liable to occur. Or a maximum of 60%.
Battery lugs, Petroleum jelly.
Earthing surfacesNOTE: Do not use Silicone Grease
where paint has
been removed
Air Conditioning
System Refrigerant Use only refrigerant R134a
Compressor Oil Nippon Denso ND-oil8 Unipart ND-oil8
ABS Sensor Silicone grease: Staborags NBU - Wabco 830 502,0634
bush-rear Wacker chemie 704 - Wabco 830 502,0164
Kluber GL301
LUBRICATION PRACTICE
Use a high quality oil of the correct viscosity range and service classification in the engine during maintenance and
when topping up. The use of oil not to the correct specification can lead to high oil and fuel consumption and
ultimately to damaged components.
Oil to the correct specification contains additives which disperse the corrosive acids formed by combustion and
prevent the formation of sludge which can block the oilways. Additional oil additives should not be used. Always
adhere to the recommended servicing intervals.
WARNING: Many liquids and other substances used in motor vehicles are poisonous. They must
not be consumed and must be kept away from open wounds. These substances, among others,
include anti-freeze windscreen washer additives, lubricants and various adhesives.

09LUBRICANTS, FLUIDS AND CAPACITIES
4
INFORMATION CAPACITIES
The following capacity figures are approximate and are provided as a guide only.
Capacities (approx.)* Litres Imp.Unit US unit
Engine sump oil
- 300Tdi models 5,8...................................................... 10.20 pt 12.30 pt
- V8i petrol models 3.9 6,1............................................ 10.70 pt 12.90 pt
- Mpi petrol models 4,90.................................................. 8.70 pt 10.40 pt
Extra when refilling after fitting new filter
- 300Tdi models 0,85...................................................... 1.50 pt 1.80 pt
- V8i petrol models 0,56.................................................. 1.00 pt 1.20 pt
- Mpi 0,4........................................................................ 0.70 pt 0.85 pt
Manual gearbox 2,67............................................................... 4.70 pt 5.70 pt
Automatic gearbox 9,1........................................................... 16.00 pt 19.20 pt
Transfer gearbox oil 2,30......................................................... 4.00 pt 4.90 pt
Front differential 1,70............................................................... 3.00 pt 3.60 pt
Rear differential 1,70................................................................ 3.00 pt 3.60 pt
Power steering box and reservoir LHD 2,90............................ 5.00 pt 6.00 pt
Power steering box and reservoir RHD 3,40............................ 6.00 pt 7.20 pt
Swivel pin housing oil (each) 0,35............................................ 0.60 pt 0.75 pt
Fuel tank usable fuel 89,0........................................................ 19.5 gall 23 gall
Cooling system
- 300Tdi models 11,50...................................................... 20.20 pt 24.30 pt
- V8i petrol models 11,30.................................................. 20.00 pt 23.90 pt
- Mpi 10,00........................................................................ 17.60 pt 21.00 pt
Washer bottle 7,0................................................................... 12.30 pt 14.80 pt
NOTE: * All levels must be checked by dipstick or level plugs as applicable. When draining oil
from the ZF automatic gearbox, oil will remain in the torque converter, refill to high level on
dipstick only.

LUBRICANTS, FLUIDS AND CAPACITIES
5
INFORMATION ANTI-FREEZE
ENGINE TYPE MIXTURE STRENGTH PERCENTAGE PROTECTION
CONCENTRATION LOWER
TEMPERATURE
LIMIT
V8i Engine One part anti-freeze
Diesel Engine One part water 50%
Complete protection-33°F
Vehicle may be driven away immediately from cold - 36°C
Safe limit protection-41°C
Coolant in mushy state. Engine may be started and driven away after warm-up
period-42°F
Lower protection-47°C
Prevents frost damage to cylinder head, block and radiator. Thaw out before
starting engine-53°F
CAUTION: Anti-freeze content must never be allowed to fall below 25% otherwise damage to the
engine is liable to occur. Also, anti-freeze content should not exceed 60% as this will greatly
reduce the cooling effect of the coolant.
FUEL REQUIREMENTS
Catalyst vehicles
Vehicles equipped with catalytic converter are designed to use ONLY unleaded fuel. Unleaded fuel must be used
for the emission control system to operate properly. Its use will also reduce spark plug fouling, exhaust system
corrosion and engine oil deterioration.
Using fuel that contains lead will result in damage to the emission control system and could result in loss of
warranty coverage. The effectiveness of the catalysts in the catalytic converters will be seriously impaired if leaded
fuel is used. The vehicle is equipped with an electronic fuel injection system, which includes two oxygen sensors.
Leaded fuel will damage the sensors, and will deteriorate the emission control system.
Regulations require that pumps delivering unleaded fuel be labelledUNLEADED.Only these pumps have nozzles
which fit the filler neck of the vehicle fuel tank.