1995 LAND ROVER DISCOVERY drain tube

MAINTENANCE
19
MAINTENANCE
RESET EMISSION MAINTENANCE REMINDER -
USA
The emission maintenance reminder is designed to
activate at 52,500 and 105,000 miles respectively and
will illuminate a 'Service Engine' red warning light in
instrument binnacle.
The emission maintenance reminder must be reset
after required maintenance has been carried out and
a new tamperproof label fitted by a Land Rover of
North America dealer. This emission maintenance
reminder is part of the Emission Control System
Reset
1.The control unit is located in the passenger
footwell.
2.Identify control unit and remove from plug.
3.Remove tamperproof label to reveal access hole
for resetting.
4.Place a thin metallic probe into access hole and
momentarily electrically short between reset pins
inside unit.RECOMMENDED SERVICE ITEMS
Refer Service Schedule sheets for intervals.
Clean sunroof drain tubes, clean and lubricate guide
rails and slides.
Renew the hydraulic brake fluid.
See BRAKES,
Repair, Brake System Bleed
Renew all hydraulic brake fluid, seals, brake servo
filter and flexible hoses.
All working surfaces of the master cylinder and caliper
cylinders should be examined and renewed where
necessary.
ABS vehicles only - renew hydraulic brake fluid and
flexible hoses examine the working surfaces of the
caliper cylinders and renew the seals or cylinders
where necessary.
Air cleaner - When the vehicle is used in dusty or field
conditions or deep wading, frequent attention to the
air cleaner may be required.
ABS vehicles used extensively in arduous off-road
conditions - check the rear wheel road speed sensor
for abrasive wear.

Tdi
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Engine block
Bearing cap 133...............................................................................................
Blanking plug, oil gallery, rear 37....................................................................
Oil squirt jet assembly 17................................................................................
Drain plug, cylinder block 25...........................................................................
Oil squirt jet, vacuum pump cam 7.................................................................
Connecting rod to cap 59................................................................................
Oil pick up assembly to bearing cap 9...........................................................
Oil pick up assembly to front cover 25............................................................
Camshaft thrust plate 9..................................................................................
Oil drain pipe to block (internal) 25.................................................................
Oil drain pipe to block (external) 25................................................................
Sump to cylinder block and front cover 25......................................................
Drain plug, oil sump 35...................................................................................
Tappet guide 14..............................................................................................
Breather side cover assembly 25....................................................................
Baffle plate to breather side cover 4..............................................................
Vacuum pump 25............................................................................................
Fuel lift pump 25.............................................................................................
Flywheel housing 45.......................................................................................
Flywheel housing clutch cover stud 10...........................................................
Plug, flywheel housing 12...............................................................................
Rear oil seal assembly 25...............................................................................
Oil filter adaptor 45..........................................................................................
Waxstat adaptor to oil filter adaptor 9............................................................
Oil pressure switch 17.....................................................................................
Oil filter, spin on 13.........................................................................................
Oil cooler unions to filter adaptor 45...............................................................
Oil level tube 25..............................................................................................
Engine mounting foot to cylinder block 85......................................................
Engine mounting foot to flywheel housing 45.................................................
Engine mounting foot rubber to mounting foot (bolt and nut) 85.....................
Flywheel to crankshaft 146..............................................................................
Clutch cover plate to flywheel 34....................................................................
Flex drive plate to crankshaft (auto) 146..........................................................
Flex drive plate to ring gear (auto) 25.............................................................
Flex drive plate to torque converter (auto) 45.................................................

Tdi
3
SPECIFICATIONS, TORQUE Turbo charger oil drain adaptor to block 42....................................................
Oil drain pipe to turbocharger 25....................................................................
Turbocharger oil drain pipe to adaptor 38.......................................................
Turbocharger oil feed pipe adaptor to block 25...............................................
Turbocharger oil feed pipe to adaptor 25........................................................
Oil feed pipe to turbocharger 19.....................................................................
Turbocharger to cylinder head (stud) 10.........................................................
Turbocharger to cylinder head (nut) 45...........................................................
Turbocharger to blanking plate 25..................................................................
Turbocharger to EGR valve 25.......................................................................
EGR delivery tube to valve 25........................................................................
EGR delivery tube to mixing tube 25..............................................................
Fuel lift pump to filter (union) 15.....................................................................
Fuel filter from lift pump (banjo bolt) 33...........................................................
Fuel filter to fuel injection pump (banjo bolt) 33..............................................
Fuel injection pump from fuel filter (banjo bolt) 25..........................................
Injector pipes to injectors and fuel injection pump 29.....................................
Spill rail to injectors (banjo bolt) 10.................................................................
Spill rail to injection pump (banjo bolt) 25.......................................................
Boost pipe injection pump (banjo bolt) 10.......................................................
Plug, rear of injection pump 29.......................................................................
PAS pump to mounting plate 25.....................................................................
PAS pump mounting plate to auxiliaries mounting bracket 25........................
PAS pump pulley to hub 25............................................................................
Generator to auxiliaries mounting bracket 25.................................................
Starter motor (bolt and nut) 45........................................................................
Tachometer electrical connection 4...............................................................
Air conditioning compressor
Compressor mounting bracket to front cover 45.............................................
Compressor to mounting bracket (stud) 8......................................................
Compressor to mounting bracket (nut) 25......................................................
Belt tensioner pulley to tensioner arm 45........................................................
Belt tensioner assembly to front cover plate 25..............................................
Idler pulley to front cover plate 45...................................................................
Compressor belt guard (nut) 25......................................................................
Sensors to water outlet elbow (air/con) 25......................................................
Blanking plug, water outlet elbow (air/con) 25................................................
Generator mounting bracket to front cover 45................................................
Generator to mounting bracket 85..................................................................
Generator pulley to hub 95.............................................................................
Generator belt guard 25..................................................................................

V8i
15
REPAIR OIL SUMP
Service repair no - 12.60.44
Remove
1.Drain engine oil
See SECTION 10,
Maintenance, Under Vehicle Maintenance
2.Fit drain plug. Tighten to40 Nm.
3.If fitted, disconnect low oil level sensor multiplug.
4.Remove bolt securing dipstick tube to rocker
cover.
5.Working form the centre outwards, progressively
loosen and remove 17 bolts securing sump.
Remove sump.
6.Remove all traces of sealant from mating
surfaces of sump, cylinder block and front cover,
using a suitable solvent or plastic scraper.
7.Degrease mating surfaces of sump, cylinder
block and front cover.Refit
8.Apply RTV Hylosil White sealant to mating
surface of sump.
9.Position sump, tighten bolts finger tight.
10.Tighten bolts progressively in sequence shown.
Tighten to
18 Nm.
11.Fit bolt securing dipstick tube to rocker cover.
12.If fitted, connect low oil level sensor multiplug.

12ENGINE
4
DESCRIPTION AND OPERATION CYLINDER BLOCK COMPONENTS
1. Cylinder block
2. Knock sensor
3. Crankshaft sensor
4. Bolt - crankshaft sensor
5. Locating dowel - cylinder head
6. Bolt - connecting rod
7. Piston
8. Piston ring - top compression
9. Piston ring - 2nd compression
10. Piston ring - oil control
11. Gearbox adapter plate
12. Bearing shell - big end - upper
13. Flywheel
14. Bolt - flywheel
15. Torx screw - gearbox adapter plate
16. Blanking plate
17. Bolt - blanking plate
18. Gasket
19. Bolt - crankshaft rear oil seal housing
20. Crankshaft rear oil seal and housing
21. Bolt - coolant pump cover
22. Coolant pump cover
23. Impeller
24. Sealing rings
25. 'O' ring
26. Bolts - coolant pump
27. 'O' ring
28. Coolant pump body
29. Thrust washer halves - upper
30. Bearing shell - main bearing - upper
31. Locating dowel - oil pump
32. Locating dowel - flywheel
33. Gudgeon pin34. Crankshaft
35. Bearing shell - big end - lower
36. Bearing cap - big end
37. Nut - big end bearing cap
38. Locating dowel - main bearing cap
39. Bearing caps - main bearings
40. Bolt - main bearing cap
41. Thrust washer halves - lower
42. Bearing shell - main bearing - lower
43. Woodruff keys
44. Dipstick
45. Bolt - dipstick tube
46. Dipstick tube
47. Bolts - sump
48. Gasket - sump
49. 'O' ring
50. Oil strainer
51. Bolts - oil strainer
52. Sump
53. Washer - drain plug
54. Drain plug
55. Oil filter element
56. Crankshaft front oil seal
57. Bolts - oil pump
58. Gasket - oil pump
59. Oil pump
60. Oil pressure switch
61. Crankshaft spigot bush
62. Crankshaft spigot bearing
63. Locating dowel - coolant pump
64. Connecting rod
65. Bolts belt tensioner mounting plate
66. Belt tensioner mounting plate
67. Bolt - gearbox adapter plate

44AUTOMATIC GEARBOX
2
REPAIR 1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead.
3.Remove fan cowl securing screws and release
cowl from radiator.
4.Loosen securing clip and disconnect air flow
hose from plenum chamber.
5.Disconnect stepper motor hose from top of
plenum chamber.
6.Disconnect kickdown cable from throttle linkage
and release from clipping.7.Release two gearbox breather pipes from clip
located on lifting eye at rear of right hand
cylinder head.
8.Remove dipstick from main gearbox oil filler
tube.
9.Working inside vehicle detach transfer gear lever
gaiter from console, unscrew knob and withdraw
gaiter and knob.
10.Raise vehicle on ramp [hoist].
11.Remove drain plugs and drain oil from transfer
gearbox and main gearbox. Refit plugs.
12.Detach heat shield at front exhaust pipe to
manifold.
13.Disconnect electrics to Lambda sensors.
14.Remove catalytic converter assembly.
15.Remove chassis cross-member from under
gearbox.16.Remove heat shield from speedometer cable at
transfer gearbox.
17.Remove clamp and disconnect speedometer
cable from transfer gearbox. Tie cable to one
side.
18.Mark for reassembly propeller shaft to transfer
gearbox mating flanges.

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.

ZF
9
REPAIR OIL SUMP
Service repair no - 44.24.05
Remove
1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead.
3.Raise vehicle.
4.Drain oil and refit plug with new seal.
5.Detach heat shield at front exhaust pipe to
manifold.
6.Disconnect electrics from Lambda sensors.
7.Remove catalytic converter assembly.
8.Remove chassis cross-member from under
gearbox.
9.Disconnect dipstick tube at oil sump. Loosen
securing bolt at bell housing and move dipstick
aside.
10.Remove clamps securing oil sump. Note their
locations for refit and withdraw sump.
11.Remove gasket and clean gasket mating faces.Refit
12.Refit oil sump using a new gasket.
13.Connect dipstick tube to oil sump and tighten
bolt at bell housing.
14.Refit chassis cross member.
15.Refit catalytic converter assembly
16.Connect electrics to Lambda sensors.
17.Connect heat shield front pipe to manifold.
18.Connect battery.
19.Refill gearbox using correct grade of oil.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids