1995 LAND ROVER DISCOVERY lock

INTRODUCTION
1
INFORMATION INTRODUCTION
This workshop manual covers vehicles from 1995
model year onwards. Amendments and additional
pages will be issued to ensure that the manual
covers latest models. Amendments and additions
will be identified by the addition of a dated footer
at the bottom of the page.
This Workshop Manual is designed to assist skilled
technicians in the efficient repair and maintenance of
Land Rover vehicles.
Individuals who undertake their own repairs
should have some skill and training, and limit
repairs to components which could not affect the
safety of the vehicle or its passengers. Any
repairs required to safety critical items such as
steering, brakes, suspension or supplementary
restraint system should be carried out by a Land
Rover Dealer. Repairs to such items should
NEVER be attempted by untrained individuals.
WARNINGS, CAUTIONSandNOTESare given
throughout this Manual in the following form:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of personal injury.
CAUTION: This calls attention to
procedures which must be followed to
avoid damage to components.
NOTE: This calls attention to methods
which make a job easier or gives helpful
information.
DIMENSIONS
The dimensions quoted are to design engineering
specification. Alternative unit equivalents, shown in
brackets following the dimensions, have been
converted from the original specification.REFERENCES
References to the left or right hand side in the manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
water pump end of the engine is referred to as the
front.
To reduce repetition, some operations covered in this
Manual do not include reference to testing the vehicle
after repair.
It is essential that work is inspected and tested after
completion and if necessary a road test of the vehicle
is carried out particularly where safety related items
are concerned.
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that Land Rover parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement parts
and accessories: Safety features embodied in the
vehicle may be impaired if other than Land Rover
parts are fitted. In certain territories, legislation
prohibits the fitting of parts not to the vehicle
manufacturer's specification. Torque spanner values
given in the Workshop Manual must be strictly
adhered to. Locking devices, where specified, must be
fitted. If the efficiency of a locking device is impaired
during removal it must be replaced with a new one.
Certain fasteners must not be re-used. These
fasteners are specified in the Workshop Manual.
POISONOUS SUBSTANCES
Many liquids and other substances used are
poisonous and therefore must not be consumed. It is
also advisable to keep all substances away from open
wounds. These substances among others include
anti-freeze, brake fluid, fuel, windscreen washer
additives, air conditioning refrigerant, lubricants and
various adhesives.

01INTRODUCTION
6
INFORMATION 2.Raise front road wheels to enable an axle stand
to be installed under left hand axle tube.
3.Position an axle stand under right hand axle
tube, carefully lower jack until axle sits securely
on both axle stands, remove trolley jack.
4.Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5.Reverse procedure when removing vehicle from
stands.
Raise rear of vehicle
1.Position cup of hydraulic arm under differential
casing.
2.Raise vehicle to enable axle stands to be
installed under left and right hand axle tubes.
3.Lower jack until axle sits securely on axle
stands, remove trolley jack.
4.Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5.Reverse procedure when removing vehicle from
stands.
HYDRAULIC VEHICLE RAMP (FOUR POST)
Use only a 'drive on' type ramp which supports vehicle
by its own road wheels. If a 'wheel-free' condition is
required, use a 'drive on' ramp incorporating a
'wheel-free' system that supports under axle casings.
Alternatively, place vehicle on a firm, flat floor and
support on axle stands.
TWO POST VEHICLE RAMPS
The manufacturer of LAND ROVER VEHICLES
DOES NOT recommend using 'Two Post' ramps
that employ four adjustable support arms. These
are NOT considered safe for Land Rover vehicles.
If vehicle is installed on a Two Post ramp
responsibility for safety of vehicle and personnel
performing service operations is in the hands of
the Service Provider.DYNAMOMETER TESTING - NON ANTI-LOCK
BRAKE VEHICLES
Viscous coupling
The front and rear axles cannot be driven
independently due to the viscous coupling. This
eliminates the need for differential lock by
progressively locking the centre differential
automatically if slip occurs at any wheel.
WARNING: DO NOT attempt to drive
individual wheels with vehicle supported
on floor jacks or stands.
Four wheel dynamometers
Provided that front and rear dynamometer rollers are
rotating at identical speeds and that normal workshop
safety standards are applied, there is no speed
restriction during testing except any that may apply to
the tyres.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
If brake testing on a single axle rig is necessary it
must be carried out with propeller shaft to rear axle
removed, AND neutral selected in BOTH main
gearbox and transfer gearbox. When checking brakes,
run engine at idle speed to maintain servo vacuum.
If checking engine performance, the transfer box must
be in high range and propeller shaft to stationary axle
must be removed.

INTRODUCTION
7
INFORMATION DYNAMOMETER TESTING - VEHICLES WITH
ANTI-LOCK BRAKES (ABS)
WARNING: Do not attempt to test ABS
function on a dynamometer
Four wheel dynamometers
NOTE: Before testing a vehicle on a four
wheel dynamometer disconnect the valve
relay.
See Electrical Trouble Shooting
Manual.
The ABS function will not work, the ABS warning
light will illuminate. Normal braking will be
available.
Provided that front and rear rollers are rotating at
identical speeds and that normal workshop safety
standards are applied, there is no speed restriction
during testing except any that may apply to the tyres.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
NOTE: ABS will not function on a two
wheel dynamometer. The ABS light will
illuminate during testing. Normal braking
will be available.
If brake testing on a single rig is necessary it must be
carried out with propeller shaft to the rear axle
removed, AND neutral selected in BOTH main and
transfer boxes.
If checking engine performance, the transfer box must
be in high range and drive shaft to stationary axle
removed.
TOWING
CAUTION: The vehicle has permanent
four-wheel drive. The following towing
instructions must be adhered to:
Towing the vehicle on all four wheels with driver
operating steering and brakes.
1.Turn ignition key turn to position '1' to release
steering lock.
2.Select neutral in main gearbox and transfer
gearbox.
3.Secure tow rope, chain or cable to towing eye.
4.Release the parking brake.
CAUTION: The brake servo and power
assisted steering system will not be
functional without the engine running.
Greater pedal pressure will be required to apply
the brakes, the steering system will require
greater effort to turn the front road wheels.
The vehicle tow connection should be used only
in normal road conditions, 'snatch' recovery
should be avoided.
Suspended tow by breakdown vehicle
CAUTION: To prevent vehicle damage,
front or rear propeller shaft MUST BE
removed, dependent upon which axle is
being trailed.
1.Mark propeller shaft drive flanges at transfer
gearbox and axles with identification lines to
enable the propeller shaft to be refitted in its
original position.
2.Remove the propeller shaft fixings, remove the
shaft from the vehicle.
3.If the front axle is to be trailed turn ignition key to
position '1' to release steering lock.
CAUTION: The steering wheel and/or
linkage must be secured in a straight
ahead position. DO NOT use the steering
lock mechanism for this purpose.

INTRODUCTION
13
INFORMATION European vehicle identification number (VIN)
Stamped on the right hand side chassis forward of
rear wheel.
Federal (USA) vehicle identification number
Stamped on a plate rivetted to the upper left hand 'A' -
post, visible through the front screen of the vehicle.Vehicle identification number (VIN)
An adhesive label containing the Vehicle Identification
Number, date of manufacture and gross axle weight
ratings is fixed to the lock face of the front left hand
door. The information includes wheel and tyre sizes
and tyre pressures at gross axle weight ratings.
Key to vehicle identification label
A.Month and year of manufacture
B.Gross vehicle weight rating
C.Gross axle weight rating for front axle
D.Gross axle weight rating for rear axle
E.Vehicle identification number (17 digits)
F.Vehicle identification number - bar code

01INTRODUCTION
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INFORMATION LOCATION OF IDENTIFICATION NUMBERS
Engine serial number - 300Tdi Engine
The 300Tdi engine number is stamped on the cylinder
block on the right hand side of the engine above the
camshaft front cover plate.
Engine serial number - Mpi engine
Stamped on the R.H. face of the cylinder block
adjacent to the gearbox.
Engine serial number - V8i engine
Stamped on a cast pad on the cylinder block, between
numbers 3 and 5 cylinders.
NOTE: The appropriate engine
compression ratio is stamped above the
serial number.
Main gearbox R380
Stamped on a cast pad on the bottom right hand side
of the gearbox.
Transfer gearbox LT230
The serial number is stamped on the left hand side of
the gearbox casing below the mainshaft rear bearing
housing adjacent to the bottom cover.
Front and rear axles
Serial number is stamped on top of the left hand axle
tube.

GENERAL SPECIFICATION DATA
7
INFORMATION SHIFT SPEED AUTOMATIC ZF ON 3.9 V8i
OPERATION SELECTOR VEHICLE SPEED ENGINE SPEED
POSITON APPROX APPROX (RPM)
KICKDOWN
MPH KPH
KD4 - 3 D 84 - 92 136 - 150
KD3 - 2 3(D) 57 - 62 91 - 99
KD2 - 1 2(D,3) 27 - 34 44 - 56
KD3 - 4 D N/A N/A
KD2 - 3 D(3) 60 - 63 96 - 104 4750 - 5200
KD1 - 2 D(3,2) 34 - 40 56 - 64 4600 - 5250
FULL THROTTLE
FT4 - 3 D 61 - 67 98 - 108
FT3 - 2 3(D) 40 - 46 64 - 73
FT3 - 4 D 74 - 80 119 - 129 3980 - 4330
FT2 - 3 D(3) 55 - 60 88 - 96 4350 - 4800
FT1 - 2 D(3,2) 29 - 34 48 - 56 3950 - 4650
PART THROTTLE
PT4 - 3 D 47 - 54 75 - 86
PT3 - 2 D(3) 29 - 37 48 - 59
PT2 - 1 D(3,2) 10 - 12 16 - 19
LIGHT THROTTLE
LT3 - 4 D 26 - 30 43 - 49 1430 - 1650
LT2 - 3 D(3) 18 - 22 29 - 35 1420 - 1820
LT1 - 2 D(3,2) 9 - 10 14 - 16 1180 - 1220
ZERO THROTTLE
ZT4 - 3 D 19 - 25 31 - 41
ZT3 - 2 D(3) 12 - 15 19 - 24
ZT2 - 1 D(3,2) 6 - 7 10 - 11
TORQUE CONVERTER
Lock up (IN) D 51 - 54 81 - 86 1875 - 2000
Unlock (OUT) D 49 - 52 78 - 83 1825 - 1930
NOTE: The speeds given in the above chart are approximate and only intended as a guide. Maximum shift
changes should take place within these tolerance parameters.

04GENERAL SPECIFICATION DATA
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INFORMATION SHIFT SPEED AUTOMATIC ZF ON Tdi ENGINE
OPERATION SELECTOR VEHICLE SPEED ENGINE SPEED
POSITON APPROX APPROX (RPM)
KICKDOWN
MPH KPH
KD4 - 3 D 62 - 72 99 - 115
KD3 - 2 3(D) 43 - 49 69 - 78
KD2 - 1 2(D,3) 23 - 36 37 - 58
KD3 - 4 D 64 - 76 102 - 122 3400 - 4000
KD2 - 3 D(3) 46 - 51 74 - 82 3600 - 3900
KD1 - 2 D(3,2) 26 - 29 42 - 46 3500 - 3800
PART THROTTLE
PT4 - 3 D 39 - 45 62 - 72
PT3 - 2 D(3) 24 - 30 38 - 48
PT2 - 1 D(3,2) 18 - 20 29 - 32
LIGHT THROTTLE
LT3 - 4 D 24 - 28 38 - 45 1300 - 1400
LT2 - 3 D(3) 21 - 23 34 - 37 1700 - 1800
LT1 - 2 D(3,2) 13 - 14 21 - 22 1700 - 1900
ZERO THROTTLE
ZT4 - 3 D 22 - 27 35 - 43
ZT3 - 2 D(3) 18 - 22 29 - 35
ZT2 - 1 D(3,2) 9 - 11 14 - 18
TORQUE CONVERTER
Lock up (IN) D 46 - 49 74 - 78 1600 - 1850
Unlock (OUT) D 45 - 48 72 - 77 1700 - 1800
NOTE: The speeds given in the above chart are approximate and only intended as a guide. Maximum shift
changes should take place within these tolerance parameters.

GENERAL SPECIFICATION DATA
9
INFORMATION TRANSMISSION 3.9 V8i
Manual gearbox
Type R380 Single helical constant mesh.......................................................................
Speeds 5 forward 1 reverse all synchromesh.............................................................................
Clutch
Make and type Borg and beck diaphram type..................................................................
Clutch plate diameter 266.5mm........................................................
Automatic gearbox
Type ZF4HP Four speed and reverse with fluid torque converter.....................................................................
Transfer box
Type LT230T Two speed reduction on main gearbox output, front....................................................................
and rear drive permanently engaged via a lockable
differential.
Propeller shafts
Type
Front Tubular 51mm diameter.................................................................................
Front - Catalyst vehicles Solid bar 28.6mm diameter...................................................
Rear Tubular 51mm diameter.................................................................................
Universal joints Open type Hookes O3EHD.................................................................
Rear axle
Type Spiral bevel, fully floating shafts.................................................................................
Ratio 3.54:1.................................................................................
Front axle
Type Spiral bevel, enclosed constant velocity joints, fully.................................................................................
floating shafts
Angularity of universal joint on full lock 32° ............................
Ratio 3.54:1.................................................................................