1995 LAND ROVER DISCOVERY washer fluid

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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)

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.

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.

10MAINTENANCE
10
MAINTENANCE
CHECK/TOP UP COOLING SYSTEM
1.To prevent corrosion of aluminium alloy engine
parts it is imperative that cooling system is filled
with a solution of water and phosphate free
anti-freeze, winter or summer. Never fill or top up
with plain water.
WARNING: Do not remove filler cap when
engine is hot because cooling system is
pressurised and personal scalding could
result.
2.When removing filler cap, turn cap slowly
anti-clockwise, pause and allow all pressure to
escape.
3.Continue to turn until cap is removed.
4.When engine is cold expansion tank coolant
should be level with top of indicator post, visible
inside tank through filler hole.
5.If necessary, top up cooling system with
premixed coolant. Use soft water whenever
possible, if local water supply is hard, rainwater
should be used.
6.When replacing filler cap it is important that it is
tightened down fully. Failure to tighten filler cap
properly may result in water loss, with possible
damage to engine
The cooling system should be drained and flushed at
2 year intervals or at onset of second winter. Refer to
Coolant Requirements.
See COOLING SYSTEM,
Adjustment, Coolant RequirementsCHECK/ TOP UP POWER STEERING FLUID
RESERVOIR
1.Remove fluid reservoir cap. Check that fluid is
up to high mark on dipstick.
CHECK/ TOP UP CLUTCH AND BRAKE FLUID
RESERVOIRS
CAUTION: Brake fluid can damage
paintwork. If spillage occurs, wash
affected area IMMEDIATELY with a large
quantity of water.
CHECK/TOP UP WASHER RESERVOIR
Top up washer reservoir to within 25 mm of filler neck.
Use a screen washer solvent/anti-freeze solution to
assist removing mud, flies and road film and protect
against freezing.
LUBRICATE ACCELERATOR AND CRUISE
CONTROL LINKAGES
CHECK/ADJUST IGNITION TIMING - V8i
CATALYST
Check ignition timing.See ENGINE TUNING
DATA, Information, Engine 3.9 V8i

MAINTENANCE
13
MAINTENANCE
RENEW AUTOMATIC GEARBOX FLUID AND OIL
SCREEN
1.Site vehicle on lift or level ground. Place
container to drain gearbox fluid into. Disconnect
battery negative lead.
2.Remove gearbox dipstick, located at rear of right
hand rocker cover, to aid oil drainage. Release
plug from bottom of sump and allow fluid to drain
completely.
3.Refit plug using a new sealing washer. Tighten
to
10 Nm
Refill ZF Automatic Gearbox and Check Fluid
Level.
NOTE: The fluid level must checked when
fluid is cold and engine idling in park.
4.Ensure vehicle is on level ground.
5.Refill or top-up with correct quantity and grade of
fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
6.Start and run engine. Apply footbrake, select
position 1 then back to park. Check fluid level,
this must be between the two marks on the
dipstick.
Oil screen replacement ZF automatic gearbox.
See AUTOMATIC GEARBOX, Repair, Oil Screen

33CLUTCH
2
REPAIR BLEED HYDRAULIC SYSTEM
Service repair no - 33.15.01
Procedure
NOTE: During bleed procedure, keep fluid
reservoir topped up to avoid introducing
air to system. For hydraulic fluid
recommendations.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information, Recommended
Lubricants and Fluids
1.Attach suitable tubing to slave cylinder bleed
screw.
2.Place free end of tube in a glass jar containing
clutch fluid.
3.Loosen bleed screw.
4.Pump clutch pedal, pausing at end of each
stroke, until fluid from tubing is free of air.
Keeping free end of tube below surface of fluid.
5.Hold clutch pedal down, tighten bleed screw.
6.Top up fluid reservoir.MASTER CYLINDER
Service repair no - 33.20.01/03
NOTE: All flexible and pipe connections
and joints should be tightened to
15 Nm.
Remove
1.Evacuate hydraulic fluid from system.
2.Disconnect fluid pipe at master cylinder. Plug
master cylinder fluid port and seal end of
hydraulic pipe to prevent ingress of foreign
matter.
3.Lower fascia fuse box panel.
4.Remove master cylinder fixings.
5.Remove retaining washer and clevis pin from
push rod and clutch pedal.
6.Remove master cylinder.

CLUTCH
3
REPAIR Refit
7.Fit the master cylinder and fixings.
8.Fit push-rod to pedal and retain with clevis pin
and washer.
9.Raise fasica fuse box panel.
10.Fit fluid pipe to master cylinder.
11.Bleed system.
See Bleed Hydraulic System
RELEASE BEARING ASSEMBLY
Service repair no - 33.10.07
Remove
1.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
2.Remove clutch slave cylinder.See Slave
Cylinder
3.Withdraw retainer staple.
4.Withdraw bearing and sleeve. If required, press
bearing off sleeve. Fit replacement bearing with
domed face outwards from sleeve.
5.Remove spring clip and fixings.
6.Withdraw release lever assembly.
Refit
7.Smear pivot with grease and fit release lever and
retain with spring clip and bolt.
8.Smear release bearing sleeve inner diameter
with molybdenum disulphide base grease.
9.Reverse removal procedure. 1 to 4.