1995 LAND ROVER DISCOVERY roof

01INTRODUCTION
2
INFORMATION FUEL HANDLING PRECAUTIONS
The following information provides basic precautions
which must be observed if fuel is to be handled safely.
It also outlines the other areas of risk which must not
be ignored.
This information is issued for basic guidance only, and
in any case of doubt, appropriate enquiries should be
made of your local Fire Officer or Fire Department.
Fuel vapour is highly flammable and in confined
spaces is also very explosive and toxic.
When fuel evaporates it produces 150 times its own
volume in vapour, which when diluted with air
becomes a readily ignitable mixture. The vapour is
heavier than air and will always fall to the lowest level.
It can readily be distributed throughout a workshop by
air current, consequently, even a small spillage of fuel
is very dangerous.
Always have a fire extinguisher containingFOAM CO
2
GAS,orPOWDERclose at hand when handling fuel,
or when dismantling fuel systems and in areas where
fuel containers are stored.
WARNING: lt is imperative that the battery
is not disconnected during fuel system
repairs as arcing at the battery terminal
could ignite fuel vapour in the atmosphere.
Always disconnect the vehicle battery BEFORE
carrying out work on the fuel system.
Whenever fuel is being handled, transferred or
stored, or when fuel systems are being dismantled
all forms of ignition must be extinguished or
removed, any leadlamps used must be flame proof
and kept clear of spillage.
No one should be permitted to repair components
associated with fuel without first having had fuel
system training.Hot fuel handling precautions
WARNING: Before commencing any
operation requiring fuel to be drained from
the fuel tank, the following procedure must
be adhered to:
1.Allow sufficient time for the fuel to cool, thus
avoiding contact with hot fuels.
2.Vent the system by removing the fuel filler cap in
a well ventilated area. Refit the filler cap until the
commencement of fuel drainage.
Fuel transfer
WARNING: Fuel must not be extracted or
drained from any vehicle while it is
standing over a pit.
The transfer of fuel from the vehicle fuel tank must be
carried out in a well ventilated area. An approved
transfer tank must be used according to the transfer
tank manufacturer's instructions and local regulations,
including attention to grounding of tanks.
Fuel tank removal
AFUEL VAPOURwarning label must be attached to
the fuel tank upon removal from the vehicle.
Fuel tank repair
Under no circumstances should a repair to any tank
be attempted.

GENERAL SPECIFICATION DATA
15
INFORMATION BULBS
REPLACEMENT BULBS TYPE
Exterior lights
Headlamps 12V 60/55W (Halogen)
Headlamps - France amber 12V 60/55W (Halogen)
Auxiliary driving lamps 12V 55W H3 (Halogen)
Sidelamps 12V 5W bayonet
Tail lamps 12V 5/21W bayonet
Reverse lamps 12V 21W bayonet
Stop lamps 12V 21W bayonet
Direction indicator lamps 12V 21W bayonet
Rear side marker lamps 12V 5W capless
Number plate lamps 12V 5W capless
Interior lights
Instrument panel lamps and warning lamps 12V 1.2W bulb/holder unit
Ignition warning lamp (Instrument panel) 12V 2W capless
Interior roof lamps 12V 10W 'Festoon'
Clock illumination 12V 1.2 capless
Cigar lighter illumination 12V 1.2W capless
Door shut face/puddle lamps 12V 5W capless
Auxiliary switch panel illumination (green) 12V 1.2W capless
Heated rear screen warning lamp (amber) 12V 1.2W capless
Hazard warning lamp 12V 1.2W capless
Automatic graphics illumination 12V 5W capless
Heater/air conditioning graphics illumination 12V 1.2W bulb/holder unit
Differential lock warning lamp 12V 1.2W bulb/holder unit
Column switch illumination 12V 1.2W capless
CAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damage
to vehicle wiring and switches.

05ENGINE TUNING DATA
4
INFORMATION 300 Tdi ENGINE
Type2.5 Litre Turbo diesel intercooled .................................................................................
Firing order1-3-4-2 .....................................................................
Injection timing1,54 mm lift at T.D.C. ...............................................................
Injection timing with electronic EGR1,40 mm lift at T.D.C. ............................
Injection timing with EDC0,45 mm lift at T.D.C. ..............................................
Timing marks:
Valve timing - manual Slot for pin in flywheel and TDC mark on front pulley........................................................
Valve timing - automatic Slot for pin in ring gear. Access through rear engine...................................................
plate. TDC mark on front pulley
Injection timing Timing pin (service tool).................................................................
Tappet clearances inlet and exhaust 0,20 mm cold...............................
Valve timing: Inlet Exhaust
- Opens 16°B.T.D.C. ............................................................................ 51°B.B.D.C.
- Closes 42°A.B.D.C. ............................................................................ 13°A.T.D.C.
- Peak 103°A.T.D.C. ............................................................................... 109°B.T.D.C.
- Lift 9,67 mm.................................................................................. 9,97 mm
Maximum governed speeds:
- No load (neutral/full throttle) 4600 + 40 - 120 rev/min...........................................
- Idle speed at running temperature 720±20 rev/min .................................
- Die-down time 4 seconds................................................................
INJECTION PUMP
Make & type - standard Bosch rotary R509 type with boost control and two....................................................
speed mechanical governor with auto advance and
solenoid electrical shut-off. Tamper proof sealing on,
no load governed speed and fuel adjustment screws.
Constant volume delivery valves
Make & type - Electronic EGR Bosch rotary R509/1 type with boost control and two.........................................
speed mechanical governor with auto advance and
solenoid electrical shut-off. Tamper proof sealing on
flight speed and fuel adjustment screws. Constant
volume delivery valves. Throttle position sensor for
EGR control.
Make & type - Electronic diesel control - EDC Bosch rotary R500 type with full electronic control of.................
fuelling and timing. Constant pressure delivery valves.

07GENERAL FITTING REMINDERS
2
INFORMATION PREPARATION
1.Before removing a component, clean it and its
surrounding areas as thoroughly as possible.
2.Blank off any openings exposed by component
removal, using greaseproof paper and masking
tape.
3.Immediately seal fuel, oil or hydraulic lines when
separated, using plastic caps or plugs, to
prevent loss of fluid and entry of dirt.
4.Close open ends of oilways, exposed by
component removal, with tapered hardwood
plugs or readily visible plastic plugs.
5.Immediately a component is removed, place it in
a suitable container; use a separate container for
each component and its associated parts.
6.Before dismantling a component, clean it
thoroughly with a recommended cleaning agent;
check that agent is suitable for all materials of
component.
7.Clean bench and provide marking materials,
labels, containers and locking wire before
dismantling a component.
DISMANTLING
1.Observe scrupulous cleanliness when
dismantling components, particularly when
brake, fuel or hydraulic system parts are being
worked on. A particle of dirt or a cloth fragment
could cause a dangerous malfunction if trapped
in these systems.
2.Blow out all tapped holes, crevices, oilways and
fluid passages with an air line. Ensure that any
O-rings used for sealing are correctly replaced or
renewed, if disturbed.
3.Use marking ink to identify mating parts, to
ensure correct reassembly. If a centre punch or
scriber is used they may initiate cracks or
distortion of components.
4.Wire together mating parts where necessary to
prevent accidental interchange (e.g. roller
bearing components).
5.Wire labels on to all parts which are to be
renewed, and to parts requiring further
inspection before being passed for reassembly;
place these parts in separate containers from
those containing parts for rebuild.
6.Do not discard a part due for renewal until after
comparing it with a new part, to ensure that its
correct replacement has been obtained.INSPECTION-GENERAL
1.Never inspect a component for wear or
dimensional check unless it is absolutely clean;
a slight smear of grease can conceal an incipient
failure.
2.When a component is to be checked
dimensionally against figures quoted for it, use
correct equipment (surface plates, micrometers,
dial gauges, etc.) in serviceable condition.
Makeshift checking equipment can be
dangerous.
3.Reject a component if its dimensions are outside
limits quoted, or if damage is apparent. A part
may, however, be refitted if its critical dimension
is exactly limit size, and is otherwise satisfactory.
4.Use 'Plastigauge' 12 Type PG-1 for checking
bearing surface clearances. Directions for its
use, and a scale giving bearing clearances in
0,0025 mm steps are provided with it.

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.

19FUEL SYSTEM
2
FAULT DIAGNOSIS BASE IDLE SPEED SETTING
NOTE: Base idle speed is set at factory. It
should not require further adjustment
unless plenum chamber is changed. The
adjustment screw is sealed with a plug to prevent
unauthorised alteration. Check ignition timing
before attempting following procedure, since this
will affect idle speed.
Equipment required
Two blanking hoses.these are manufactured using
a new air by-pass valve hose - Part No.ETC7874. Cut
two equal pieces 90mm long from hose and seal one
end of each, using 13mm diameter bar. Use a suitable
clamp to ensure an air tight seal.
Checking procedure
1.Drive vehicle at least two miles until engine and
transmission are hot. Switch off engine.
2.Check all electrical loads are OFF, including air
conditioning.
3.Remove air by-pass valve hose.
4.Fit blanking hoses to both plenum chamber and
air by-pass valve. Ensure hoses are securely
fitted to prevent air leaks. Note throttle cable and
cruise control actuator have been omitted from
illustration.5.Start engine and check idle speed is within
limits.
See ENGINE TUNING DATA,
Information, Engine 3.9 v8i
Adjusting base idle speed
6.Drill tamper proof plug and insert a self tapping
screw to enable plug to be extracted.
7.Start engine, adjust idle screw clockwise to
decrease or counter-clockwise to increase idle
speed.
8.Stop engine, remove blanking hoses. Reconnect
hose to plenum.
9.Fit new tamper proof plug.

SFI
1
ADJUSTMENT ENGINE TUNING
Service repair no - 19.22.13
The position of the Idle Air Control (IAC) valve can be
checked using TestBook and adjusted if necessary
through the by-pass screw in the plenum chamber.
The bypass screw is covered by a tamper proof plug
which can be extracted using a self tapping screw.
All vehicles:
1.Ensure air conditioning and all electical loads are
off. Vehicle must be in neutral or park with air
suspension in kneel and disabled.
2.Carry out tuning or base idle setting procedure
as applicable using TestBook.

V8i
1
ADJUSTMENT COOLANT REQUIREMENTS
Frost precautions and engine protection.
Cooling systemMUST ALWAYSbe filled and
topped-up with solution of water and anti-freeze,
winter and summer.NEVERuse water alone, this
may corrode aluminium alloy.
CAUTION: Do not use salt water otherwise
corrosion will occur. In certain territories
where only available natural water supply
has some salt content use only rain or distilled
water.
Recommended solutions
Anti-freeze:Universal anti-freeze or permanent type
ethylene base, without methanol, containing a suitable
inhibitor for aluminium engines and engine parts.
Use one part of anti-freeze to one part of water.
Anti-freeze can remain in the cooling system and will
provide adequate protection for two years provided
that specific gravity of coolant is checked before onset
of second winter and topped-up with new anti-freeze
as required.
Vehicles leaving factory have cooling system filled
with 50% solution of anti-freeze and water. This gives
protection against frost down to minus 36°C (minus
33°F). Vehicles so filled are identified by a label
affixed to radiator.
NOTE: Should ambient temperatures be
below that stated above refer to
Anti-Freeze Data in Recommended
Lubricants, Fluids and Capacities in Section 09.
Instructions in chart must be strictly adhered to
before driving vehicle.
After the second winter the system should be drained
and thoroughly flushed. Before adding new anti-freeze
examine all joints and replace defective hoses to
make sure that the system is leakproof.
See the 'Recommended Lubricants Fluids and
Capacities' for protection quantities.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids
COOLANT
Service repair no - 26.10.01
Draining
WARNING: Do not remove expansion tank
filler cap when engine is hot. The cooling
system is pressurised and personal
scalding could result.
See coolant requirements before refilling system.
1.Remove expansion tank filler cap by slowly
turning it anti-clockwise, pause to allow pressure
to escape. Continue turning it in same direction
and remove.
2.Remove radiator filler plug and 'O' ring to assist
drainage.