1995 LAND ROVER DISCOVERY fuel cap release

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...............................................................

12ENGINE
12
REPAIR
12.Ensure service tools LRT-12-010 and
LRT-12-091 are scrupulously clean. Coat seal
guide and oil seal journal with clean engine oil.
CAUTION: Do not handle oilseal lip, check
it is not damaged. Ensure outside diameter
remains clean and dry.
13.Position oil seal guide LRT-12-010 on crankshaft
flange.
NOTE: Lubricant coating must cover seal
guide outer surface completely to ensure
that oil seal lip is not turned back during
assembly. Position oil seal, lipped side towards
engine, on seal guide. Seal outside diameter
MUST be clean and dry.
14.Fit oil seal using tool LRT-12-091. Remove seal
guide.
15.Tighten rear main bearing cap to
90 Nm.
16.Fit sump.
17.Fit flywheel or flexible drive plate and ring gear.ENGINE
Service repair no - 12.41.01
Remove
1.Park vehicle on level ground and apply park
brake.
2.De-pressurise fuel system.
See FUEL
SYSTEM, Repair, Depressurising Fuel
System
3.Remove bonnet [hood].See CHASSIS AND
BODY, Repair, Bonnet [Hood]
4.Remove battery.See ELECTRICAL, Repair,
Battery
5.Remove radiator/oil coolers.See COOLING
SYSTEM, Repair, Radiator/Oil Coolers
6.Place an absorbent cloth around fuel feed hose
at fuel rail and release compression nut.
Remove feed hose from rail, seal end of pipes
with masking tape to prevent ingress of dirt.
7.Release fuel return hose clamp and remove
hose from pressure regulator, seal both
openings with masking tape to prevent ingress of
dirt.
8.Remove vacuum hose from rear of regulator.
9.Manual vehicles: Disconnect throttle cable from
bracket. Automatic vehicles: Detach throttle
bracket from plenum chamber and lay assembly
to one side.
See FUEL SYSTEM, Repair,
Plenum Chamber DO NOT DISTURB KICK
DOWN CABLE SETTING.
10.Remove ram housing.See FUEL SYSTEM,
Repair, Ram Housing
11.Remove air flow sensor.See FUEL SYSTEM,
Repair, Air Flow Sensor
12.Remove air cleaner assembly.See FUEL
SYSTEM, Repair, Air Cleaner Assembly
13.Remove Generator.See ELECTRICAL,
Description and operation, Generator
14.Release air conditioning compressor from its
mounting and lay to one side. DO NOT
discharge air conditioning system.
See AIR
CONDITIONING, Repair, Compressor

4.0 V8
7
REPAIR 171.Route drive belt around pulleys.
172.Pivot tensioner downwards.
173.Align belt to tensioner and release tensioner.
174.Connect battery positive lead and tighten.
175.Secure terminal cover.
176.Align gearbox breather pipe, clip to engine lifting
eye and fit bolt. Tighten to
9 Nm.
177.Align and secure engine harness brackets to
inlet manifold and fit nuts. Tighten to
9 Nm.
178.Connect injector multiplugs.
179.Connect air intake temperature sensor multiplug.
180.Connect fuel temperature sensor multiplug.
181.Connect coolant temperature multiplug.
182.Connect temperature gauge connector.
183.Connect oil pressure switch Lucar.
184.Connect camshaft sensor multiplug and secure
to bracket.
185.Fit ignition coil bracket.
See FUEL SYSTEM
SFI, Repair, Ignition Coils
186.Position heater hose/pipe assembly.
187.Connect hose to inlet manifold.
188.Align pipe to bracket and fit bolt. Tighten to
9
Nm.
189.Tighten hose clip.
190.Connect heater return hose and tighten clip.
191.Remove plugs from fuel feed and return hose
connections.
192.Clean feed unions.
193.Connect return hose and tighten clip.
194.Connect feed hose union and tighten.
195.Remove cloth.
196.Connect purge hose.
197.Connect leads to generator, tighten terminal nuts
and fit cover.
198.Connect sensing Lucar.
199.Connect servo vacuum hose.
200.Position expansion tank and secure with fixings.
201.Connect hose and tighten clip.
202.Lower ramp.
203.Fit mass air flow sensor.
See FUEL SYSTEM
SFI, Repair, Mass Air Flow Sensor (MAF
Sensor)
204.Fit plenum chamber.See FUEL SYSTEM SFI,
Repair, Plenum Chamber
205.Fit radiator.See COOLING SYSTEM, Repair,
Radiator
206.Fit bonnet.See CHASSIS AND BODY, Repair,
Bonnet [Hood]
207.Reconnect battery negative lead.
208.Bleed power steering system.
See STEERING,
Repair, Power Steering System - Bleed
209.Drain engine oil and refill.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids - USA
Vehicles
210.Start engine. Check for fuel, coolant and oil
leaks.FRONT COVER GASKET
Service repair no - 12.65.04 - Front Cover Gasket
Remove
1.Disconnect battery negative lead.
2.Drain cooling system.
See COOLING SYSTEM
V8, Adjustment, Coolant
3.Remove radiatorSee COOLING SYSTEM,
Repair, Radiator
4.Remove water pump pulley.See COOLING
SYSTEM, Repair, Viscous Coupling, Fan
Blades, Pulley and Fan Cowl
5.Slacken bottom hose clip. Remove hose from
water pump.
6.Raise vehicle on ramp.
7.Disconnect oil cooler hoses from front cover and
position aside. Plug hoses and connections.
8.Disconnect Lucar from oil pressure switch.

12ENGINE
14
REPAIR Refit
1.Clean sump, remove all traces of gasket from
mating faces of sump and cylinder block.
Visually check sump for damage.
2.Apply beads of RTV sealant to front main
bearing cap.
3.Position new gasket to sump, ensuring that
location pips on gasket are located in sump.
Check gasket lays flat on sump flange.
4.Fit sump. Fit bolts, ensuring that longest bolt is
inserted at position 7.
5.Working around the sump in the sequence
illustrated, tighten the bolts to the stage 1 torque
figure. Then, in the same sequence, tighten the
bolts to the stage 2 torque figure.
NOTE: For torque values.See
Specifications, torque, Torque Values
6.Fill engine with oil.CYLINDER HEAD GASKET
Service repair no - 12.29.01
Remove
1.Disconnect battery negative lead.
2.Position absorbent cloth around fuel pipe to fuel
rail union. Unscrew union to relieve pressure.
CAUTION: Plug the connections.
WARNING: Do not carry out the next
instruction until the coolant is cool to
avoid personal injury from scalding.
3.Release clip and disconnect radiator bottom
hose, allowing coolant to drain into a suitable
container.

17EMISSION CONTROL
4
DESCRIPTION AND OPERATION REV: 09/95 Evaporative emission control system - pre
advanced EVAPS.
The system is designed to prevent harmful fuel vapour
from escaping to the atmosphere. The system
consists of a vapour separator tank, connected to the
fuel tank and located between the body inner and
outer panels on the right hand side of the vehicle near
the rear wheel arch. An adsorbtion canister,
containing activated charcoal, is positioned in the
engine compartment attached to the front right
valance. The two components are connected by a
pipe running the length of the chassis.
A Pressure relief to atmosphere.
B From fuel tank to separator.
C To adsorbtion canister.
D Pressure relief valve.
E Pressure relief valve.
F Shut-off valve.
G "Speed Fit" connectors.A pressure relief valve is fitted in the hose which is
open to atmosphere. This valve acts as a safety valve
should a build-up of pressure occur in the system, for
example if a hose became blocked or kinked. The
volume of vapour emitted, in such an instance, would
be acceptable.
A pressure relief valve is also fitted in the hose
connected to the adsorbtion canister and releases
vapor to the canister when the pressure in the
separator reaches between 5 and 7 Kpa.
In the top of the separator a shut-off valve is
incorporated in the vapor exit port to prevent the
possible presence of any liquid fuel being transmitted
to the adsorbtion canister should the vehicle roll over.
The adsorbtion canister, which is connected by a hose
to the plenum chamber, absorbs and stores the fuel
vapour from the fuel tank while the engine is not
running. When the engine is started, the vapour is
purged from the canister by air drawn through an
orifice in the base of the canister and by the influence
of vacuum at the top. The vapour drawn into the
plenum chamber through a solenoid operated purge
valve is finally burnt in the combustion chambers.
The purge valve, which is attached to the adsorbtion
canister support bracket, is controlled by the Engine
Control Module ECM which determines the most
emission acceptable time at which purging should
take place. This will normally be at engine speeds
above idle and when the vehicle is in motion. A signal
from the ECM to the purge valve operates the
solenoid and opens the valve to purge the canister of
fuel vapour.

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.

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.