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Workshop manual DISCOVERY 01 04 05 07 09 10 This manual covers vehicles from 1995 model year 01 04 05 07 09 10 12 12 12 12 17 19 19 19 19 19 26 26 26 30 33 37 41 44 47 51 54 57 60 64 70 74 75 76 80 82 84 86 INTRODUCTION GENERAL SPECIFICATION DATA ENGINE TUNING DATA GENERAL FITTING REMINDERS LUBRICANTS, FLUIDS AND CAPACITIES MAINTENANCE ENGINE Tdi ENGINE 3.9 V8 ENGINE 4.0 V8 ENGINE Mpi EMISSION CONTROL FUEL SYSTEM Tdi FUEL SYSTEM MFI FUEL SYSTEM SFI FUEL SYSTEM Mpi CRUISE CONTROL COOLING SYSTEM Tdi COOLING SYSTEM V8 COOLING SYSTEM Mpi MANIFOLD AND EXHAUST SYSTEM CLUTCH MANUAL GEARBOX TRANSFER GEARBOX AUTOMATIC GEARBOX PROPELLER SHAFTS REAR AXLE AND FINAL DRIVE FRONT AXLE AND FINAL DRIVE STEERING FRONT SUSPENSION REAR SUSPENSION BRAKES WHEELS AND TYRES SUPPLEMENTARY RESTRAINT SYSTEM CHASSIS AND BODY HEATING AND VENTILATION AIR CONDITIONING WIPERS AND WASHERS ELECTRICAL Published by Rover Technical Communication © 1996 Rover Group Limited Publication Part No. LRL 0079 ENG (2nd Edition) 12 17 19 26 30 33 37 41 44 47 51 54 57 60 64 74 70 75 76 80 82 84 86 INTRODUCTION 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, CAUTIONS and NOTES are 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. 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. 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. 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. INFORMATION 1 01 INTRODUCTION 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 containing FOAM CO2 GAS, or POWDER close 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 A FUEL VAPOUR warning 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. 2 INFORMATION INTRODUCTION SYNTHETIC RUBBER Many '0' ring seals, flexible pipes and other similar items which appear to be natural rubber are made of synthetic materials called Fluoroelastomers. Under normal operating conditions this material is safe, and does not present a health hazard. However, if the material is damaged by fire or excessive heat, it can break down and produce highly corrosive Hydrofluoric acid which can cause serious burns on contact with skin. Should the material be in a burnt or overheated condition handle only with seamless industrial gloves. Decontaminate and dispose of the gloves immediately after use. If skin contact does occur, remove any contaminated clothing immediately and obtain medical assistance without delay. In the meantime, wash the affected area with copious amounts of cold water or limewater for fifteen to sixty minutes. USED ENGINE OIL WARNING: Prolonged and repeated contact with engine or motor oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. Used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities should be provided. Handling precautions 1. Avoid prolonged and repeated contact with oils, particularly used engine oils. 2. Wear protective clothing, including impervious gloves where applicable. 3. Do not put oily rags in pockets. 4. Avoid contaminating clothes, particularly underwear, with oil. 5. Overalls must be cleaned regularly. Discard unwashable clothing and oil impregnated footwear. 6. First aid treatment must be obtained immediately for open cuts and wounds. 7. Use barrier creams, before each work period, to help the removal of oil from the skin. 8. Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. 9. Do not use gasoline, kerosene, diesel fuel, petrol, thinners or solvents for washing the skin. 10. If skin disorders develop, obtain medical advice. 11. Where practicable, degrease components prior to handling. 12. Where there is a risk of eye contact, eye protection should be worn, for example, goggles or face shields; in addition an eye wash facility should be provided. Disposing of used oils Environmental protection precaution It is illegal to pour used oil onto the ground, down sewers or drains, or into waterways. Dispose of used oil through authorised waste disposal contractors. If in doubt contact your Local Authority for advice on disposal facilities. RECOMMENDED SEALANTS A number of branded products are recommended in this manual for use during maintenance and repair work. These items include: HYLOMAR GASKET AND JOINTING COMPOUND and HYLOSIL RTV SILICON COMPOUND. They should be available locally from garage equipment suppliers. If there is any problem obtaining supplies, contact the following company for advice and the address of the nearest supplier. MARSTON LUBRICANTS LTD. Hylo House, Cale Lane, New Springs, Wigan WN2 1JR Tel 01942 824242 INFORMATION 3 01 INTRODUCTION ACCESSORIES AND CONVERSIONS DO NOT FIT unapproved accessories or conversions, as they could affect the safety of the vehicle. Land Rover will not accept liability for death, personal injury, or damage to property which may occur as a direct result of the fitting of non-approved conversions to the vehicle. SPECIAL SERVICE TOOLS The use of approved special service tools is important. They are essential if service operations are to be carried out efficiently, and safely. Where special tools are specified, only these tools should be used to avoid the possibility of personal injury or damage to the components. Also the amount of time which they save can be considerable. Every special tool is designed with the close co-operation of Land Rover, and no tool is put into production which has not been tested and approved by us. New tools are only introduced where an operation cannot be satisfactorily carried out using existing tools or standard equipment. The user is therefore assured that the tool is necessary and that it will perform accurately, efficiently and safely. Special tools bulletins will be issued periodically giving details of new tools as they are introduced. All orders and enquiries from the United Kingdom should be sent direct to V. L. Churchill. Overseas orders should be placed with the local V. L. Churchill distributor, where one exists. Countries where there is no distributor may order direct from: V. L. Churchill Limited, PO Box 3, Daventry, Northants, England, NN11 4NF. The tools recommended in this Workshop Manual are listed in a multi-language illustrated catalogue, obtainable from: Messers. V. L. Churchill at the above address, or from: Land Rover Merchandising Service, PO Box 534, Erdington, Birmingham, B24 0Q5, WHEELS AND TYRES WARNING: DO NOT replace the road wheels with any type other than genuine Land Rover wheels which are designed for multi-purpose on and off road use and have very important relationships with the proper operation of the suspension system and vehicle handling. Replacement tyres must be of the make and sizes recommended for the vehicle, and all tyres must be the same make, ply rating and tread pattern. STEAM CLEANING To prevent consequential rusting, any steam cleaning within the engine bay MUST be followed by careful re-waxing of the metallic components affected. Particular attention must be given to the steering column, engine water pipes, hose clips and ignition coil clamp. SPECIFICATION The specification details and instructions set out in this Manual apply only to a range of vehicles and not to any one. For the specification of a particular vehicle purchasers should consult their Dealer The Manufacturer reserve the right to vary their specifications with or without notice, and at such times and in such manner as they think fit. Major as well as minor changes may be involved in accordance with the Manufacturer's policy of constant product improvement. Whilst every effort is made to ensure the accuracy of the particulars contained in this Manual, neither the Manufacturer or Dealer, by whom this Manual is supplied, shall in any circumstances be held liable for any inaccuracy or the consequences thereof. COPYRIGHT © Land Rover 1996 All rights reserved. No part of this publication may be produced, stored in a retrieval system or transmitted in any form, electronic, mechanical, recording or other means without prior written permission of Land Rover. 4 INFORMATION INTRODUCTION JACKING The following instructions must be carried out before raising the vehicle off the ground. 1. 2. 3. 4. Use a solid level ground surface. Apply parking brake. Select 'P' or 1st gear in main gearbox. Select Low range in transfer gearbox. Vehicle jack The jack provided with the vehicle is only intended to be used in an emergency, for changing a tyre. Do NOT use the jack for any other purpose. Refer to Owner's Manual for vehicle jack location points and procedure. Never work under a vehicle supported by the vehicle jack. Hydraulic jack CAUTION: To avoid damage occurring to the under body components of the vehicle the following jacking procedures must be adhered to. DO NOT POSITION JACKS OR AXLE STANDS UNDER THE FOLLOWING COMPONENTS. A hydraulic jack with a minimum 1500 kg, 3,300 lbs load capacity must be used. CAUTION: Do not commence work on the underside of the vehicle until suitable axle stands have been positioned under the axle. Body structure Bumpers Fuel lines Brake lines Front radius arms Panhard rod Steering linkage Rear Trailing links Fuel tank Engine sump Gearbox bell housing Jack or support vehicle by axles only. Raise the front of the vehicle 1. Position cup of hydraulic arm under differential casing. NOTE: The differential casing is not central to the axle. Care should be taken when raising the front road wheels off the ground as the rear axle has less sway stiffness. INFORMATION 5 01 INTRODUCTION 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. 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 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. 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. 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. 6 INFORMATION INTRODUCTION 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. 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. 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. INFORMATION 7 01 INTRODUCTION TRANSPORTING THE VEHICLE BY TRAILER Lashing eyes are provided on front and rear of the chassis side members, to facilitate the securing of the vehicle to a trailer or other means of transportation. CAUTION: Underbody components must not be used as lashing points. Install vehicle on trailer and apply park brake. Select neutral in main gearbox. Selecting 'N' will prevent damage to parking pawl of the automatic gearbox. FRONT OF CHASSIS JUMP STARTING WARNING: Hydrogen and oxygen gases are produced during normal battery operation. This gas mixture can explode if flames, sparks or lighted tobacco are brought near battery. When charging or using a battery in an enclosed space, always provide ventilation and shield your eyes. Keep out of reach of children. Batteries contain sulphuric acid. Avoid contact with skin, eyes, or clothing. Also, shield eyes when working near battery to protect against possible splashing of acid solution. In case of acid contact with skin, eyes, or clothing, flush immediately with water for a minimum of fifteen minutes. If acid is swallowed, drink large quantities of milk or water, followed by milk of magnesia, a beaten egg, or vegetable oil. SEEK MEDICAL AID IMMEDIATELY. To Jump Start - Negative Ground Battery WARNING: To avoid any possibility of injury use particular care when connecting a booster battery to a discharged battery. 1. Position vehicles so that jump leads will reach, ensuring that vehicles DO NOT TOUCH, alternatively a fully charged slave battery may be positioned on floor adjacent to vehicle. 2. Ensuring that ignition and all electrical accessories are switched off, that parking brake is applied and neutral is selected on a manual gearbox, with an automatic gearbox select neutral (N) or park (P) and then connect the jump leads as follows; A. Connect one end of first jumper cable to positive (+) terminal of booster battery. B. Connect other end of first jumper cable to positive (+) terminal of discharged battery. C. Connect one end of second jumper cable to negative terminal of booster battery. REAR OF CHASSIS 8 INFORMATION INTRODUCTION D. Connect other end of second jumper cable to a good earth point on the engine, NOT TO NEGATIVE TERMINAL OF DISCHARGED BATTERY. Keep jumper lead away from moving parts, pulleys, drive belts and fan blade assembly. WARNING: Making final cable connection could cause an electrical arc which if made near battery could cause an explosion. 3. If booster battery is installed in another vehicle, start engine and allow to idle. 4. Start engine of vehicle with discharged battery, following starting procedure in Owners' Manual. CAUTION: If vehicle fails to start within a maximum time of 12 seconds, switch ignition off and investigate cause. Failing to follow this instruction could result in irrepairable damage to catalysts. 5. Remove negative (-) jumper cable from the engine and then terminal of booster battery. 6. Remove positive (+) jumper cable from positive terminals of booster battery and discharged battery. INFORMATION 9 01 INTRODUCTION ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL Across flats (bolt size) ............................................ AF After bottom dead centre ................................... ABDC After top dead centre ......................................... ATDC Alternating current ................................................. a.c. Ampere ................................................................ amp Ampere hour .................................................... amp hr Before bottom dead centre ................................ BBDC Before top dead centre ...................................... BTDC Bottom dead centre ............................................. BDC Brake horse power ................................................ bhp British Standards .................................................... BS Carbon monoxide .................................................. CO Centimetre ............................................................. cm Centigrade (Celsius) ................................................ C Cubic centimetre ................................................... cm3 Cubic inch ............................................................... in3 Degree (angle) ............................................... deg or ° Degree (temperature) ..................................... deg or ° Diameter ............................................................... dia. Direct current ......................................................... d.c. Electronic Control Unit ........................................ ECU Electronic Fuel Injection ........................................ EFI Fahrenheit ................................................................. F Feet ........................................................................... ft Feet per minute .................................................. ft/min Fifth ........................................................................ 5th First ........................................................................ 1st Fluid ounce .......................................................... fl oz Foot pounds (torque) ............................................ lbf ft Fourth ..................................................................... 4th Gramme (force) ........................................................ gf Gramme (mass) ........................................................ g Gallons ................................................................... gal Gallons (US) ..................................................... US gal High tension (electrical) ........................................ H.T. Internal diameter ................................................... I.D. Inches of mercury .............................................. in. Hg Inches ...................................................................... in Kilogramme (force) ................................................. kgf Kilogramme (mass.) ................................................ kg Kilogramme centimetre (torque) ....................... kgf.cm Kilogramme per square millimetre ................. kgf/mm2 Kilogramme per square centimetre ................. kgf/cm2 Kilogramme metres (torque) .............................. kgf.m Kilometres .............................................................. km Kilometres per hour ............................................. km/h Kilovolts ................................................................... kV Left-hand ................................................................ LH Left-hand steering ............................................. LHStg Left-hand thread ............................................... LHThd Litres ..................................................................... litre Low tension ............................................................. l.t. Maximum ............................................................ max. Metre ........................................................................ m Millilitre .................................................................... ml Millimetre ............................................................... mm Miles per gallon .................................................... mpg Miles per hour ...................................................... mph Minute (angle) ............................................................ ' Minus (of tolerance) ................................................... Negative (electrical) ................................................... Newton metres (torque) ........................................ Nm Number ................................................................. No. Ohms ................................................................... ohm Ounces (force) ....................................................... ozf Ounces (mass) ........................................................ oz Ounce inch (torque) .......................................... ozf.in. Outside diameter ................................................. O.D. Part number ................................................... Part No. Percentage ............................................................... % Pints ......................................................................... pt Pints (US) ........................................................... US pt Plus (tolerance) ......................................................... + Positive (electrical) .................................................... + Pound (force) .......................................................... lbf Pounds inch (torque) .......................................... in.lbf. Pound (mass) ........................................................... lb Pounds per square inch ..................................... P.S.I. Ratio ........................................................................... : Reference .............................................................. ref. Revolution per minute ..................................... rev/min Right-hand ............................................................. RH Second (angle) ........................................................... " Second (numerical order) ...................................... 2nd Specific gravity ................................................... sp.gr. Square centimetres ............................................... cm2 Square inches ......................................................... in2 Standard wire gauge ......................................... s.w.g. Synchroniser/Synchromesh .......................... synchro. Third ....................................................................... 3rd Top dead centre .................................................. TDC United Kingdom ...................................................... UK Vehicle Identification Number ............................... VIN Volts ......................................................................... V Watts ....................................................................... W SCREW THREADS American Standard Taper Pipe ......................... NPTF British Standard Pipe ........................................... BSP Unified Coarse .................................................... UNC Unified Fine ......................................................... UNF 10 INFORMATION INTRODUCTION CROSS REFERENCE OF EMISSION SYSTEM TERMINOLOGY NEW TERM (ACRONYM) OLD TERM (ACRONYM) Accelerator pedal ................................................. (AP) Air cleaner .......................................................... (ACL) Air conditioning .................................................... (AC) Battery positive voltage ........................................ (B+) Closed loop .......................................................... (CL) Closed throttle position ...................................... (CTP) Canister purge valve .................................... (CANPV) Data link connector ........................................... (DLC) Diagnostic trouble code ..................................... (DTC) Distributor ignition ................................................. (DI) Engine control module ...................................... (ECM) Engine coolant level ........................................... (ECL) Engine coolant temperature .............................. (ECT) Engine coolant temperature sensor ................ (ECTS) Engine speed .................................................... (RPM) Evaporative emission system .......................... (EVAP) Engine fuel temperature sensor ...................... (EFTS) 4th gear, 3rd gear etc. .............................. (4GR, 3GR) Fuel pump ............................................................ (FP) Fan control module ........................................... (FCM) Generator .......................................................... (GEN) Ground .............................................................. (GND) Heated oxygen sensor .................................... (H02S) Idle air control ...................................................... (IAC) Idle air control valve ......................................... (IACV) Ignition control module ....................................... (ICM) Inertia fuel shutoff ................................................ (IFS) Inertia fuel shutoff switch .................................. (IFSS) Intake air temperature ......................................... (IAT) Malfunction indicator lamp .................................. (MIL) Manifold vacuum zone ...................................... (MVZ) Mass air flow sensor ....................................... (MAFS) Multiport fuel injection ........................................ (MFI) On board diagnostic .......................................... (OBD) Open loop ............................................................ (OL) Park/neutral position ......................................... (PNP) Park/neutral position switch ............................ (PNPS) Programmable read only memory .................. (PROM) Relay module ...................................................... (RM) Service reminder indicator .................................. (SRI) Solid state relay module ................................. (SSRM) Three way catalytic converter .......................... (TWC) Throttle body ........................................................ (TB) Throttle position sensor ...................................... (TPS) Torque converter clutch .................................... (TCC) Transmission range .............................................. (TR) Transmission range selector ............................. (TRS) Vehicle speed sensor ........................................ (VSS) Wide open throttle ............................................ (WOT) Throttle pedal .......................................................... (-) Air cleaner ............................................................... (-) Air conditioning .................................................... (AC) Battery plus, bat +, bat feed ................................. (B+) Closed loop ............................................................. (-) Closed throttle, idle position .................................... (-) Charcoal canister purge valve ................................. (-) Serial link ................................................................ (-) Fault code ............................................................... (-) Electronic ignition .................................................... (-) Electronic control unit ........................................ (ECU) Coolant level ........................................................... (-) Coolant temperature ......................................... (temp) Coolant temperature thermistor .............................. (-) Engine speed ................................................ (rev/min) Evaporative loss system ................................... (ELC) Fuel temperature thermistor .................................... (-) Fourth gear, 3rd gear .............................................. (-) Fuel pump ............................................................... (-) Condenser fan timer ................................................ (-) Alternator ................................................................ (-) Ground, earth ........................................................ (B-) Lambda (02) sensor ................................................ (-) Idle speed control ................................................ (ISC) Stepper motor ......................................................... (-) Ignition module ........................................................ (-) Inertia switch ........................................................... (-) Inertia switch ........................................................... (-) Intake temperature/ambient temperature ................ (-) EFI warning lamp .................................................... (-) Manifold depression, vacuum ................................. (-) Air flow meter .......................................................... (-) Electronic fuel injection ....................................... (EFI) Fault code display unit ............................................ (-) Open loop ............................................................... (-) Park or neutral ......................................................... (-) Start inhibit switch ................................................... (-) Chip, PROM ................................................... (PROM) Relay ....................................................................... (-) Check engine light ................................................... (-) Control unit .............................................................. (-) Catalyst, catalytic converter .............................. (CAT) Throttle housing ...................................................... (-) Throttle potentiometer ............................................. (-) Direct drive clutch .............................................. (DDC) Transmission gear ................................................... (-) Shift lever, shifter .................................................... (-) Road speed transducer ........................................... (-) Full throttle, wide open throttle ......................... (WOT) INFORMATION 11 01 INTRODUCTION VEHICLE IDENTIFICATION NUMBER (VIN) The Vehicle Identification Number and the recommended maximum vehicle weights are stamped on a plate located under the bonnet [hood] riveted to the front of the engine compartment. Vehicle Identification Number Plate (UK, Australia, R.O.W., Europe) Vehicle Identification Number Plate (Saudi Arabia) A. B. C. D. E. F. Year of manufacture Month of manufacture Maximum vehicle weight Maximum road weight-front axle Maximum road weight-rear axle VIN (17 digits) A. B. C. D. E. F. Build date (Australia). Type approval VIN (17 digits) Maximum permitted laden weight for vehicle Maximum vehicle and trailer weight Maximum road weight-front axle Maximum road weight-rear axle The vehicle identification number identifies the manufacturer, model range, wheel base, body type, engine, steering, transmission, model year and place of manufacture. The following example shows the coding process. SAL LH LJ G B F V 8 7 M A World manufacturer identifier Range Rover or Discovery Class 100 inch 2 door 300 Tdi or V8i Petrol 5 speed LHD or 5 speed RHD 1995 MY Solihull site The number is also stamped on the right side of the chassis forward of the spring mounting turret. 12 INFORMATION INTRODUCTION European vehicle identification number (VIN) 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. Stamped on the right hand side chassis forward of rear wheel. Federal (USA) vehicle identification number Key to vehicle identification label A. B. C. D. E. F. Month and year of manufacture Gross vehicle weight rating Gross axle weight rating for front axle Gross axle weight rating for rear axle Vehicle identification number (17 digits) Vehicle identification number - bar code Stamped on a plate rivetted to the upper left hand 'A' post, visible through the front screen of the vehicle. INFORMATION 13 01 INTRODUCTION 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. 14 INFORMATION INTRODUCTION Automatic gearbox Stamped on a plate riveted to the bottom left hand side of the gearbox casing. INFORMATION 15 01 INTRODUCTION FAULT DIAGNOSTIC EQUIPMENT TESTBOOK Todays Land Rover Vehicles are equipped with a large amount of electronics to provide the best performance of the vehicles systems. Diagnostic equipment named TESTBOOK is available to expand the diagnostic abilities of the dealer workshop. This repair manual is produced with Testbook in mind. Features of Testbook include :- Fully upgradable support for the technician. Structured diagnostics to accommodate all skill levels. Touch screen operation. Direct print out of screen information and test results. READING THIS MANUAL This manual is divided into sections shown on the contents page, alongside a range of icons, familiar to service technicians. Relevant information is contained within each of these sections. These are further divided into the following sub-sections which appear at the foot of each page :Description and operation. Fault diagnosis. Adjustment. Repair. Overhaul. Specifications, Torque. Service tools. To avoid repeating information through the sections, where part of the repair operation impacts on another section, a cross reference is given to direct the reader to where the information is sited. For example: The maintenance section states the need to renew V8i drive belt. A cross reference sites this information in: Section: V8i Engine - Sub-section: Repairs - Heading: Drive belt renew. Sections that contain derivatives such as engines are further separated within that section. American terminology. A few words used in this manual differ to words used in America. Where this occurs the American word is placed inside brackets. For example: bonnet [hood], wing [fender], ramp [hoist]. ELECTRICAL TROUBLESHOOTING MANUAL The Electrical Troubleshooting Manual is a separate publication that is intended for use by trained Land Rover technicians as an aid to diagnosing electrical concerns. It provides circuit diagrams, system diagnosis flow charts, electrical component location tables, electrical component location views and circuit operation details. 16 INFORMATION GENERAL SPECIFICATION DATA ENGINE 3.9 V8i Type ................................................................................. Number of cylinders ......................................................... Bore ................................................................................. Stroke ............................................................................... Capacity ........................................................................... Compression ratio ............................................................ Valve operation ................................................................ Maximum power - 8.13:1 ............................ - 9.35:1 ............................ Crankshaft Main journal diameter ....................................................... Minimum regrind diameter ............................................... Crankpin journal diameter ................................................ Minimum regrind diameter ............................................... Crankshaft end thrust/(end float) ...................................... V8i Eight, two banks of four 94,00 mm 71,12 mm 3950 cc 8.13:1 or 9.35:1 Overhead by push-rod 127kW at 4550 rev/min 134kW at 4750 rev/min 58,409-58,422 mm 57,393-57,406 mm 50,800-50,812 mm 49,784-49,797 mm Taken on thrust washers of centre main bearing 0,10-0,20 mm Main bearings Number and material ........................................................ 5, Lead-indium Diametrical clearance ....................................................... 0,010-0,048 mm Undersize bearing shells .................................................. 0,254 mm, 0,508 mm Connecting rods Type ................................................................................. Horizontally split big-end, plain small-end Length between centres ................................................... 143,81-143,71 mm Big-end bearings Type and material ............................................................ Diametrical clearance ....................................................... End-float crankpin ............................................................ Undersize bearing shells .................................................. Piston pins Length .............................................................................. Diameter .......................................................................... Fit-in connecting rod ......................................................... Clearance in piston .......................................................... 72,67-72,79 mm 22,215-22,220 mm Press fit 0,002-0,007 mm Lead-indium 0,015-0,055 mm 0,15-0,36mm 0,254 mm, 0,508 mm INFORMATION 1 04 Pistons GENERAL SPECIFICATION DATA Clearance in bore, measured at bottom of skirt at right angles to piston pin ................................... 0,018-0,041 mm Piston rings Number of compression rings .......................................... Number of control rings .................................................... No 1 compression ring ..................................................... No 2 compression ring ..................................................... Width of compression rings .............................................. Compression ring gap ...................................................... Oil control ring width ......................................................... Oil control ring rail gap ..................................................... Camshaft Location ........................................................................... Bearings ........................................................................... Number of bearings .......................................................... Drive ................................................................................. Central Tin - aluminium 5 Chain 9,52 mm pitch x 54 pitches. 2 1 Molybdenum barrel faced Tapered and marked 'T' or 'TOP' 1,478-1,49 mm 0,40-0,65 mm 3,0 mm 0,38-1,40 mm Tappets ........................................................................... Hydraulic-self-adjusting Valves Inlet .................................. Exhaust ........................... Seat angle: Inlet .................................. Exhaust ........................... Head diameter: Inlet .................................. Exhaust ........................... Stem diameter: Inlet .................................. Exhaust ........................... Stem to guide clearance: Inlet .................................. Exhaust ........................... Valve lift (Inlet and Exhaust) ............................................ Valve spring length fitted .................................................. Lubrication System type ..................................................................... Wet sump, pressure fed Oil pump type ................................................................... Eccentric rotor Oil pressure ...................................................................... 2.75 bar (40 lb/in2) at 2500 rev/min with engine at running temperature Oil filter-internal ................................................................ Wire screen, pump intake filter. Oil filter-external ............................................................... Full flow, self-contained cartridge Length: 116,59-117,35 mm 116,59-117,35 mm 45°to 45 1/2° 45°to 45 1/2° 39,75-40,00 mm 34,226-34,480 mm 8,664-8,679 mm 8,651-8,666 mm 0,025-0,066 mm 0,038-0,078 mm 9,49 mm 40,4 mm at pressure of 29,5 kg 2 INFORMATION GENERAL SPECIFICATION DATA ENGINE 4.0 V8 Type ................................................................................. Number of cylinders ......................................................... Bore ................................................................................. Stroke ............................................................................... Capacity ........................................................................... Valve operation ................................................................ Compression ratio ............................................................ Valve operation ................................................................ Maximum power: 9.35:1 .............................. 8.2:1 ................................ 4.0 litre V8 Eight, two banks of four 94.00 mm 71.12 mm 3950 cm3 Overhead by push-rod High Compression 9.35:1 Overhead by push-rod 140kW at 4750 rev/min 132kW at 4750 rev/min 3.70 in 2.80 in 241 cu in Low Compression 8.2:1 Crankshaft Main journal diameter ....................................................... 63.500 - 63.487 mm 2.50 - 2.4995 in Crankpin journal diameter ................................................ 55.513 - 55.500 mm 2.1855 - 2.1850 in Crankshaft end thrust/end float ........................................ Taken on thrust washers of centre main bearing 0.10 - 0.20 mm 0.004 - 0.008 in Main bearings Number and type .............................................................. 5, Vandervell shells Material ............................................................................ Lead bronze with lead-indium overlay Diametrical clearance ....................................................... 0.015 - 0.060 mm 0.0006 - 0.0024 in Connecting rods Type ................................................................................. Horizontally split big-end, plain small-end Length between centres ................................................... 155.12 - 155.22 mm 6.1071 - 6.1110 in Big-end bearings Type and material ............................................................ Vandervell VP3 Lead bronze with lead-indium overlay Diametrical clearance ....................................................... 0.015 - 0.016 mm 0.0006 - 0.0024 in Piston pins Length .............................................................................. Diameter .......................................................................... Fit-in connecting rod ......................................................... Clearance in piston .......................................................... 60.00 - 60.50 mm 23.995 - 24.000 mm Press fit 0.015 - 0.006 mm 2.3622 - 2.3819 in 0.9447 - 0.9449 in 0.0006 - 0.0002 in Pistons Clearance in bore, measured at bottom of skirt at right angles to piston pin ................................... 0.020 - 0.050 mm 0.0008 - 0.0020 in INFORMATION 3 04 GENERAL SPECIFICATION DATA Piston rings Number of compression rings .......................................... Number of control rings .................................................... No 1 compression ring ..................................................... No 2 compression ring ..................................................... Width of compression rings .............................................. (Top) ................................ Compression ring gap ...................................................... (Top) ................................ Oil control ring type .......................................................... Oil control ring width ......................................................... Oil control ring rail gap ..................................................... Camshaft Location ........................................................................... Bearings ........................................................................... Number of bearings .......................................................... Drive ................................................................................. Camshaft End Float ......................................................... 2 1 Nitrided steel barrel faced Tapered spherical barrel marked 'TOP' 1.478 - 1.49 mm 0.0582 - 0.0587 in 1.21 - 1.23 mm 0.0476 - 0.0484 in 0.40-0.65 mm 0.0157 - 0.0256 in 0.3 - 0.5 mm 0.0118 - 0.0197 in Aclonoform 3.0 mm 0.1181 in 0.38-1.40 mm 0.0150 - 0.0551 in Central Non serviceable 5 Chain 9.52 mm pitch x 54 pitches. 0.076 - 0.355 mm 0.003 - 0.014 in Tappets ........................................................................... Hydraulic self-adjusting Valves Length: Inlet .................................. Exhaust ........................... Seat angle: Inlet .................................. Exhaust ........................... Head diameter: Inlet .................................. Exhaust ........................... Stem diameter: Inlet .................................. Exhaust ........................... Stem to guide clearance: Inlet .................................. Exhaust ........................... Valve lift (Inlet and Exhaust) ............................................ Valve spring length fitted .................................................. 116.59 - 117.35 mm 4.590 - 4.620 in 116.59 - 117.35 mm 4.590 - 4.620 in 46°- 46°25' 46°- 46°25' 39.75 - 40.00 mm 1.565 - 1.575 in 34.227 - 34.48 mm 1.3475 - 1.3575 in 8.664 - 8.679 mm 0.3411 - 0.3417 in 8.651 - 8.666 mm 0.3406 - 0.3412 in 0.025 - 0.066 mm 0.0010 - 0.0026 in 0.038 - 0.078 mm 0.0015 - 0.0031 in 9.94 mm 0.3913 in 40.4 mm (1.59 in) at pressure of 29.5 kg (65 lb) Lubrication System type ..................................................................... Wet sump, pressure fed Oil pump type ................................................................... Rotor Oil pressure ...................................................................... 2.11 to 2.81 kg/cm2 (30 to 40 psi) at 2400 rev/min with engine warm Oil filter-internal ................................................................ Wire screen, pump intake filter in sump Oil filter-external ............................................................... Full flow, self-contained cartridge 4 INFORMATION GENERAL SPECIFICATION DATA FUEL SYSTEM 3.9 V8i Fuel system type .............................................................. Lucas 14CUX hot wire system electronically controlled Fuel pump-make/type ...................................................... ACX delco high pressure electrical, immersed in the fuel tank Fuel pump delivery pressure ............................................ 2.4-2.6 bar (34-37 lbf/in2) Fuel filter .......................................................................... Bosch in-line filter 'canister' type Airflow Sensor Make and type ................................................................. Lucas 'Hot Wire' 5AM Injectors Make and type ................................................................. Lucas 8NJ Electronic Control Unit Make and type ................................................................. Lucas 14CUX Fuel pressure regulator Make and type ................................................................. Lucas 8RV Fuel temperature sensor Make and type ................................................................. Lucas 6TT Coolant temperature sensor Make and type ................................................................. Lucas 3TT Bypass Airvalve (Stepper motor) Make and type ................................................................. Lucas 2ACM Throttle potentiometer Make and type ................................................................. Lucas 215SA Lambda sensor - catalyst vehicles Make and type ................................................................. Lucas 3LS INFORMATION 5 04 GENERAL SPECIFICATION DATA FUEL SYSTEM (GEMS) 4.0 V8 ENGINE Type ................................................................................. Sagem - Lucas Gems 8 hot wire system electronically controlled Fuel pump-make/type ...................................................... High pressure electrical, immersed in the fuel tank Fuel pump delivery pressure ............................................ 2.4-2.6 bar (34-37 lbf/in2) Fuel filter .......................................................................... Bosch in-line filter 'canister' type Mass airflow sensor Make and type ................................................................. Lucas 'Hot Wire' 20AM Injectors Make and type ................................................................. Lucas D1000 Electronic Control Module Make and type ................................................................. Lucas GEMS 8.3 Fuel pressure regulator Make and type ................................................................. Lucas 8RV Coolant temperature sensor Make and type ................................................................. Lucas 8TT Bypass Air valve (Stepper motor) Make and type ................................................................. Lucas 3ACM Throttle position sensor Make and type ................................................................. Lucas 3TP Heated oxygen sensor - catalyst vehicles Make and type ................................................................. Lucas 4LS Camshaft position sensor Make and Land Rover part no. ......................................... Lucas ERR6170 Crankshaft position sensor Make and type ................................................................. Lucas 3VRS, Honeywell ERR6049 Knock sensor Make and type ................................................................. Lucas 2KS Intake air temperature sensor Make and type ................................................................. Lucas 10TT Ignition coils Make and type ................................................................. Lucas 2DIS2 Fuel temperature sensor Make and type ................................................................. Lucas 6TT 6 INFORMATION GENERAL SPECIFICATION DATA SHIFT SPEED AUTOMATIC ZF ON 3.9 V8i OPERATION SELECTOR POSITON VEHICLE SPEED APPROX ENGINE SPEED APPROX (RPM) KICKDOWN MPH KD4 - 3 KD3 - 2 KD2 - 1 KD3 - 4 KD2 - 3 KD1 - 2 D 3(D) 2(D,3) D D(3) D(3,2) 84 - 92 57 - 62 27 - 34 N/A 60 - 63 34 - 40 KPH 136 - 150 91 - 99 44 - 56 N/A 96 - 104 56 - 64 4750 - 5200 4600 - 5250 FULL THROTTLE FT4 - 3 FT3 - 2 FT3 - 4 FT2 - 3 FT1 - 2 D 3(D) D D(3) D(3,2) 61 - 67 40 - 46 74 - 80 55 - 60 29 - 34 98 - 108 64 - 73 119 - 129 88 - 96 48 - 56 3980 - 4330 4350 - 4800 3950 - 4650 PART THROTTLE PT4 - 3 PT3 - 2 PT2 - 1 D D(3) D(3,2) 47 - 54 29 - 37 10 - 12 75 - 86 48 - 59 16 - 19 LIGHT THROTTLE LT3 - 4 LT2 - 3 LT1 - 2 D D(3) D(3,2) 26 - 30 18 - 22 9 - 10 43 - 49 29 - 35 14 - 16 1430 - 1650 1420 - 1820 1180 - 1220 ZERO THROTTLE ZT4 - 3 ZT3 - 2 ZT2 - 1 D D(3) D(3,2) 19 - 25 12 - 15 6-7 31 - 41 19 - 24 10 - 11 TORQUE CONVERTER Lock up (IN) Unlock (OUT) D D 51 - 54 49 - 52 81 - 86 78 - 83 1875 - 2000 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. INFORMATION 7 04 GENERAL SPECIFICATION DATA SHIFT SPEED AUTOMATIC ZF ON Tdi ENGINE OPERATION SELECTOR POSITON VEHICLE SPEED APPROX ENGINE SPEED APPROX (RPM) KICKDOWN MPH KD4 - 3 KD3 - 2 KD2 - 1 KD3 - 4 KD2 - 3 KD1 - 2 D 3(D) 2(D,3) D D(3) D(3,2) 62 - 72 43 - 49 23 - 36 64 - 76 46 - 51 26 - 29 KPH 99 - 115 69 - 78 37 - 58 102 - 122 74 - 82 42 - 46 3400 - 4000 3600 - 3900 3500 - 3800 PART THROTTLE PT4 - 3 PT3 - 2 PT2 - 1 D D(3) D(3,2) 39 - 45 24 - 30 18 - 20 62 - 72 38 - 48 29 - 32 LIGHT THROTTLE LT3 - 4 LT2 - 3 LT1 - 2 D D(3) D(3,2) 24 - 28 21 - 23 13 - 14 38 - 45 34 - 37 21 - 22 1300 - 1400 1700 - 1800 1700 - 1900 ZERO THROTTLE ZT4 - 3 ZT3 - 2 ZT2 - 1 D D(3) D(3,2) 22 - 27 18 - 22 9 - 11 35 - 43 29 - 35 14 - 18 TORQUE CONVERTER Lock up (IN) Unlock (OUT) D D 46 - 49 45 - 48 74 - 78 72 - 77 1600 - 1850 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. 8 INFORMATION GENERAL SPECIFICATION DATA 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 ................................................................................. Front - Catalyst vehicles ................................................... Rear ................................................................................. Universal joints ................................................................. 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 Tubular 51mm diameter Solid bar 28.6mm diameter Tubular 51mm diameter Open type Hookes O3EHD INFORMATION 9 04 GENERAL SPECIFICATION DATA COOLING SYSTEM 3.9 V8i System type ..................................................................... Pressurised, spill return, thermostatically controlled water and anti-freeze mixture. Pump assisted thermo syphon. Coolant radiator combined with oil cooler. Fan and viscous coupling assembly ................................ 11 blade axial flow 433mm diameter. Pump type ........................................................................ Centifugal, impellor, belt driven. Thermostat opening ......................................................... 88 degrees. Expansion tank cap pressure ........................................... 15 p.s.i. (system pressure). STEERING Power steering box Make/type ........................................................................ Adwest Varamatic - worm and roller box Ratio ................................................................................. Variable: straight ahead 19.3:1 on lock 14.3:1 Steering wheel turns, lock-to-lock .................................... 3.375 Steering pump Make/type -V8i ................................................................. ZF - Unicorn Make/type - Mpi & Tdi ...................................................... Hobourn-Eaton series 500 Steering geometry Steering wheel diameter .................................................. Steering wheel diameter airbag model ............................. Toe-out measurement ...................................................... Toe-out included angle ..................................................... Camber angle .................................................................. 405mm 400mm 0 to 2mm toe out 0° to 0° 16' 0° .............. Check with vehicle in static unladen condition, that is, vehicle with water, Castor angle ..................................................................... 3° .............. oil and five gallons of fuel. Rock the vehicle up and down at the front to allow Swivel pin inclination static ............................................... 7° .............. it to take up a position 10 INFORMATION GENERAL SPECIFICATION DATA SUSPENSION Type ................................................................................. Coil springs controlled by telescopic dampers front and rear. Front ................................................................................. Lateral location of axle by Panhard rod, and longitudinal location by two radius arms. Rear ................................................................................. Lateral location of axle by a centrally positioned 'A' frame bolted at the apex to a ball joint mounting. Longitudinal location of axle by two tubular trailing links. ROAD SPRING DATA V8i - Mpi LEFT HAND DRIVE Left hand front Right hand front Left/Right hand rear Part No NRC 4306 572315 ANR 3477 or ANR 4352 Part No 572315 572315 ANR 3477 or ANR 4352 Colour Code Blue/White Blue Brown/Green Orange/Orange * Colour Code Blue Blue Brown/Green Orange/Orange * RIGHT HAND DRIVE Left hand front Right hand front Left/Right hand rear Tdi Diesel RIGHT HAND DRIVE Left hand front Right hand front Left/Right hand rear Part No ANR 1975 or ANR 4350 ANR 1976 or ANR 4351 ANR 3477 or ANR 4352 Part No ANR 1976 or ANR 4351 ANR 1975 or ANR 4350 ANR 3477 or ANR 4352 Colour Code Blue/Pink/Red Brown/Brown ** Blue/Pink/Yellow Grey/Grey ** Brown/Green Orange/Orange * Colour Code Blue/Pink/Yellow Grey/Grey ** Blue/Pink/Red Brown/Brown ** Brown/Green Orange/Orange * LEFT HAND DRIVE Left hand front Right hand front Left/Right hand rear * VIN 119534 onwards ** VIN 116461 onwards INFORMATION 11 04 GENERAL SPECIFICATION DATA SHOCK ABSORBERS Type ................................................................................. Telescopic, double-acting non-adjustable Bore diameter ................................................................... 35.47mm BRAKES Front service brake Type ................................................................................. Outboard discs with four piston calipers Operation ......................................................................... Hydraulic, servo assisted self-adjusting Pad material ..................................................................... non asbestos Rear service brake Type ................................................................................. Outboard discs with two piston calipers Operation ......................................................................... Hydraulic, servo assisted, self-adjusting Pad material ..................................................................... non asbestos Parking brake Type ................................................................................. Mechanical-cable operated drum brake on the rear of the transfer gearbox output shaft Lining material .................................................................. non asbestos Servo/master cylinder non ABS Manufacturer .................................................................... Lucas Servo type ........................................................................ LSC 115 Master cylinder type ......................................................... AS/AS Anti-lock brake system Manufacturer/type ............................................................ Wabco 4 wheel sensed add on anti-lock brake system. Servo/master cylinder ABS Manufacturer .................................................................... Lucas Master cylinder type ......................................................... CV/CV 12 INFORMATION GENERAL SPECIFICATION DATA AIR CONDITIONING System ............................................................................. Compressor ..................................................................... Refrigerant ....................................................................... Charge quantity ................................................................ Charge quantity with rear air conditioning ........................ Nippon Denso Nippon Denso 10 PA 17 R134a 0.9Kg 1.15Kg WIPER MOTORS Tailgate wiper motor Make/type ........................................................................ IMOS (non-serviceable) Running current, wet screen at 20°C ambient ................. 1.0 to 2.8 amps Wiper speed, wet screen at 20°C ambient ....................... 37 to 43 cycles per minute Windscreen wiper motor Make/type ........................................................................ Delco AMR 1514/5 Running current (Link disconnected) ............................... 1.5 amps at 39 to 45 rev/min (normal speed) Rotary link speed ............................................................. 60 to 73 rev/min (high speed) ELECTRICAL System ............................................................................. 12 volt, negative ground Battery Make/type - basic ............................................................. Land Rover Parts and Equipment/Lucas maintenance free 9-plate-YGD 10017 Make/type - heavy duty .................................................... Land Rover Parts and Equipment/Lucas maintenance free 14-plate-YGD 10015 Generator Manufacturer .................................................................... Type ................................................................................. Polarity ............................................................................. Brush length New ......................................................................... Worn, minimum free protrusion from moulding ....... Brush spring pressure flush with moulding ...................... Regulator voltage ............................................................. Nominal output Generator speed ..................................................... Control voltage ........................................................ Amp ......................................................................... Magnetti Marelli A127i 100amp Negative ground 17 mm 5 mm 1.3N to 2.7N 13.6 to 14.4 volts 6000 rev/min 14 volt 100 amp INFORMATION 13 04 Coil GENERAL SPECIFICATION DATA Make/type ........................................................................ Bosch 0221 122 392 Distributor Make/type ........................................................................ Firing angles .................................................................... Application ....................................................................... Pick-up air gap adjustment (Pick-up limb/reluctor tooth) ............................................. Pick-up winding resistance ............................................... Fuses Type ................................................................................. Autofuse (blade type) blow ratings to suit individual circuits Horns Make/type ........................................................................ Klamix (Mixo) TR99 Starter motor Make and type ................................................................. Bosch 12v Lucas 35 DLM8 0°- 45°- 90°(every 45°) ± 1° 12V Negative ground 0.20 mm to 0.35 mm 2k to 5k ohms 14 INFORMATION GENERAL SPECIFICATION DATA BULBS REPLACEMENT BULBS TYPE Exterior lights Headlamps Headlamps - France amber Auxiliary driving lamps Sidelamps Tail lamps Reverse lamps Stop lamps Direction indicator lamps Rear side marker lamps Number plate lamps Interior lights Instrument panel lamps and warning lamps Ignition warning lamp (Instrument panel) Interior roof lamps Clock illumination Cigar lighter illumination Door shut face/puddle lamps Auxiliary switch panel illumination (green) Heated rear screen warning lamp (amber) Hazard warning lamp Automatic graphics illumination Heater/air conditioning graphics illumination Differential lock warning lamp Column switch illumination 12V 12V 12V 12V 12V 12V 12V 12V 12V 12V 12V 12V 12V 1.2W 2W 10W 1.2 1.2W 5W 1.2W 1.2W 1.2W 5W 1.2W 1.2W 1.2W bulb/holder unit capless 'Festoon' capless capless capless capless capless capless capless bulb/holder unit bulb/holder unit capless 12V 12V 12V 12V 12V 12V 12V 12V 12V 12V 60/55W 60/55W 55W H3 5W 5/21W 21W 21W 21W 5W 5W (Halogen) (Halogen) (Halogen) bayonet bayonet bayonet bayonet bayonet capless capless CAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damage to vehicle wiring and switches. INFORMATION 15 04 GENERAL SPECIFICATION DATA VEHICLE WEIGHTS AND PAYLOAD When loading a vehicle to its maximum (Gross Vehicle Weight), consideration must be taken of the unladen vehicle weight and the distribution of the payload to ensure that axle loadings do not exceed the permitted maximum values. It is the customer's responsibility to limit the vehicle's payload in an appropriate manner such that neither maximum axle loads nor Gross Vehicle Weight are exceeded. Maximum EEC kerb weight and distribution - all optional equipment VEHICLE WEIGHTS - Mpi 3 Door Front axle ......................................................................... 930 kg Rear axle .......................................................................... 1010 kg Total ................................................................................. 1940 kg Maximum axle weights Front axle ......................................................................... 1110 kg Rear axle .......................................................................... 1650 kg Gross vehicle weight ........................................................ 2720 kg 5 Door 930 kg 1055 kg 1985 kg VEHICLE WEIGHTS - V8i Front axle ......................................................................... 970 kg Rear axle .......................................................................... 1010 kg Total ................................................................................. 1980 kg Maximum axle weights Front axle ......................................................................... 1100 kg Rear axle .......................................................................... 1650 kg Gross vehicle weight ........................................................ 2720 kg 970 kg 1055 kg 2025 kg VEHICLE WEIGHTS - 300 Tdi Front axle ......................................................................... 1040 kg Rear axle .......................................................................... 1015 kg Total ................................................................................. 2055 kg Maximum axle weights Front axle ......................................................................... 1200 kg Rear axle .......................................................................... 1650 kg Gross vehicle weight ........................................................ 2720 kg EEC kerb weight = Unladen weight + Full fuel tank + 75 kg driver. 1040 kg 1060 kg 2100 kg 16 INFORMATION GENERAL SPECIFICATION DATA TYRE PRESSURES Pressures: Check with tyres cold 205R16 Radial bars lbf/in2 kgf/cm2 Normal on and off-road use. All speeds and loads Front 1.9 28 2.0 Rear 2.6 38 2.7 Off-road 'emergency' soft use maximum speed of 40 kph (25 mph) Front 1.2 17 1.2 Rear 1.8 25 1.8 WARNING: Vehicles fitted with tubeless alloy road wheels as original equipment, note that these wheels DO NOT accept inner tubes and tubed tyres MUST NOT be fitted. NOTE: Emergency soft pressures should only be used in extreme conditions where extra floatation is required. Max speed 40km/h (25mph). WHEELS AND TYRES Type and size ................................................................... Alloy 7.00J X 16 Tyre size .......................................................................... 205R16 (tubeless) Type and size ................................................................... Steel 6.00JK X 16 Tyre size .......................................................................... 205R16 (tubed) 'Freestyle' choice tyre specification Tyre size .......................................................................... 235/70 R16 Front Tyre pressure ................................................................... 26 lbf/in2 NOTE: Petrol vehicles must be fitted with 'S' or 'T' rated tyres. Rear 34 lbf/in2 INFORMATION 17 04 GENERAL SPECIFICATION DATA 300 Tdi ENGINE Type ................................................................................. Number of cylinders ......................................................... Bore ................................................................................. Stroke ............................................................................... Capacity ........................................................................... Compression ratio ............................................................ Valve operation ................................................................ Crankshaft Main bearing journal diameter .......................................... 63,475 - 63,487 mm Regrind dimensions ......................................................... 63,2333 - 63,246 mm Use 0.010 in U/S bearings Crankpin journal diameter ................................................ 58,725 - 58,744 mm Regrind dimensions ......................................................... 58,4708 - 58,48985 mm Use 0.010 in U/S bearings Crankshaft end thrust ....................................................... Taken on thrust washers at centre main bearing Crankshaft end float ......................................................... 0,05 - 0,15 mm Main bearings Number and type .............................................................. 5 halved shells with oil grooves Diametrical clearance ....................................................... 0,0792 - 0,0307 mm Connecting rods Length between centres ................................................... 175,38 - 175,43 mm Diametrical clearance (big-end bearings) ........................ 0,025 - 0,075 mm End float on crankpin ....................................................... 0,15 - 0,356 mm Pistons Type ................................................................................. Aluminium alloy, combustion chamber in crown. Graphite coating on sidewalls. Skirt diametrical clearance (at right angle to gudgeon pin) ......................................... 0,025 - 0,05 mm Maximum height above combustion face ......................... 0,8 mm Gudgeon pins Type ................................................................................. Fit in piston ....................................................................... Diameter .......................................................................... Clearance in connecting rod ............................................ Floating Hand push fit 30,1564 - 30,1625 mm 0,0025 - 0,0163 mm Direct injection, turbocharged, intercooled 4 90,47 mm 97,00 mm 2495 cc 19.5:1 ± 0.5:1 O.H.V. pushrod operated 18 INFORMATION GENERAL SPECIFICATION DATA Piston rings Type: - Top ........................................................................ - Second .................................................................. - Oil control .............................................................. Gap in bore: - Top ........................................................................ - Second .................................................................. - Oil control .............................................................. Clearance in piston grooves: - Second .................................................................. - Oil control .............................................................. Camshaft Drive ................................................................................. Location ........................................................................... End float ........................................................................... Number of bearings .......................................................... Material ............................................................................ Valves Tappet clearance: - Inlet and exhaust ................................................... Seat angle: - Inlet ....................................................................... - Exhaust ................................................................. Head diameter: - Inlet ....................................................................... - Exhaust ................................................................. Stem diameter: - Inlet ....................................................................... - Exhaust ................................................................. Valve lift: - Inlet ....................................................................... - Exhaust ................................................................. Cam lift: - Inlet ....................................................................... - Exhaust ................................................................. Valve head stand down - Inlet ....................................................................... - Exhaust ................................................................. Valve springs Type ................................................................................. Single coil Length, free ...................................................................... 46,28 mm Length, under 21 kg load ................................................. 40,30 mm 30 mm wide dry toothed belt Right hand side (thrust side) 0,1 - 0,2 mm 4 Steel shell, white metal lined Barrel edge, chrome plated Taper faced Expander and rails 0,40 - 0,60 mm 0,30 - 0,50 mm 0,3 - 0,6 mm 0,050 - 0,085 mm 0,050 - 0,085 mm 0,20 mm 30° 45° 38,75 - 39,05 mm 36,35 - 36,65 mm 7,960 - 7,975 mm 7,940 - 7,960 mm 9,67 mm 9,97 mm 6,81 mm 7,06 mm 0,81 - 1,09 mm 0,86 - 1,14 mm INFORMATION 19 04 Lubrication GENERAL SPECIFICATION DATA System ............................................................................. Pressure, engine warm at normal operating speeds ........ Oil pump: - Type ...................................................................... - Drive ..................................................................... Oil pressure relief valve .................................................... Relief valve spring: - Full length ...................................................................... - Compressed length at 7.71Kg load ................................ Oil filter ............................................................................. Engine oil cooler ............................................................... Wet sump, pressure fed 25 - 55lbf/in2 = 1,76 - 3,87Kgf cm 2 G-rotor integral with front cover. off crankshaft nose Non-adjustable 51,6mm 31mm Screw-on disposable canister Combined with coolant radiator and intercooler FUEL SYSTEM - 300 Tdi Fuel lift pump type ............................................................ Fuel lift pump pressure ..................................................... Fuel filter .......................................................................... Air cleaner ........................................................................ Mechanical with hand primer 42 - 55 kpa at 1800 rpm Paper element in disposable canister 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/in2 = 1,06Kgf cm 2 (system pressure) CLUTCH - 300 Tdi Type ................................................................................. Centre plate diameter ....................................................... Facing material ................................................................. Release bearing ............................................................... Valeo diaphragm spring 235 mm Verto F202 grooved Ball journal 20 INFORMATION GENERAL SPECIFICATION DATA TRANSMISSION - 300 Tdi Manual gearbox Type R380 ....................................................................... Single helical constant mesh Speeds ............................................................................. 5 forward 1 reverse all synchromesh 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 INFORMATION 21 04 GENERAL SPECIFICATION DATA ENGINE - Mpi - 2.0 LITRE Type ................................................................................. 20 T4 - 16 valve twin overhead camshaft Cylinder arrangement ....................................................... 4 in line Bore ................................................................................. 84.45 mm 3.325 in Stroke ............................................................................... 89.00 mm 3.504 in Capacity ........................................................................... 1994 cm3 121.68 in3 Firing order ....................................................................... 1-3-4-2 Compression ratio ............................................................ 10 : 1 Oil pump Outer rotor to body clearance .......................................... 0.05 to 0.10 mm Inner rotor tip clearance ................................................... 0.025 to 0.12 mm Outer rotor end float ......................................................... 0.03 to 0.08 mm Oil pressure relief valve Spring free length ............................................................. 42.0 mm Cooling system Starts to open ................................................................... 82 to 86°C Thermostat fully open ....................................................... 88°C Open travel A ................................................................... 9 mm Camshaft Camshaft end-float ........................................................... 0.06 to 0.25 mm Bearing clearance ............................................................ 0.060 to 0.094 mm Service limit ............................................................. 0.15 mm Timing belt tensioner Spring free length ............................................................. 57.5 to 58.5 mm Cylinder head Longitudinal warp - maximum ................................. Transverse warp - maximum ................................... Diagonal warp - maximum ...................................... Cylinder head height ............................................... Valve springs Free length ....................................................................... Fitted length ..................................................................... Load at fitted length .......................................................... Load at valve open length ................................................ 0.1 mm 0.1 mm 0.1 mm 135.0 to 135.1 mm 46.25 mm 37.0 mm 255 ± 12 N 560 ± 22.5 N 22 INFORMATION GENERAL SPECIFICATION DATA Valves Valve stem diameter: Inlet ......................................................................... Exhaust ................................................................... Valve head diameter: Inlet ......................................................................... Exhaust ................................................................... Valve installed height - maximum .................................... Valve stem to guide clearance: Inlet ......................................................................... Service limit ............................................................. Exhaust ................................................................... Service limit ............................................................. 7.09 to 7.10 mm 7.07 to 7.09 mm 31.7 to 31.95 mm 29.2 to 29.43 mm 43.4 mm 0.04 to 0.06 mm 0.09 mm 0.06 to 0.07 mm 0.10 mm Valve guides Internal diameter - Inlet and Exhaust ............................... 7.137 to 7.162 mm Overall length: Inlet ......................................................................... 48.5 mm Exhaust ................................................................... 52.9 mm Valve seats Valve seat angle - Inlet and Exhaust ................................ 45° Valve seat width - Inlet and Exhaust ................................ 1.5 to 2.0 mm Valve face angle: Inlet and Exhaust ............................................................. 45°to 45°15' Crankshaft End-float ........................................................................... Thrust washer halves thickness ....................................... Main journal diameter ....................................................... Maximum out of round ............................................ Main bearing diametric clearance .................................... Big-end journal diameter .................................................. Maximum out of round ............................................ Big-end bearing diametric clearance ................................ Piston rings New ring to groove clearance: Top compression ............................................................. 2nd compression .............................................................. Oil control rails - expander fitted ...................................... Ring fitted gap: Top compression ............................................................. 2nd compression .............................................................. Oil control rails ................................................................. 0.03 to 0.2 mm 2.31 to 2.36 mm 54.005 to 54.026 mm 0.010 mm 0.03 to 0.07 mm 47.648 to 47.661 mm 0.010 mm 0.04 to 0.08 mm 0.06 to 0.09 mm 0.05 to 0.07 mm 0.03 to 0.05 mm 0.25 to 0.35 mm 0.3 to 0.5 mm 0.38 to 1.14 mm Pistons Piston diameter: Grade A ................................................................... 84.409 to 84.422 mm Grade B ................................................................... 84.423 to 84.436 mm Clearance in bore ............................................................. 0.01 to 0.03 mm Cylinder bore Grade A ................................................................... 84.442 to 84.455 mm Grade B ................................................................... 84.456 to 84.469 mm INFORMATION 23 04 GENERAL SPECIFICATION DATA FUEL SYSTEM - Mpi Electronic fuel injection data ............................................ See ENGINE TUNING DATA, Information, Engine - Mpi - 2.0 Litre Fuel Pump: Make/Type ....................................................................... Pump pressure ................................................................. Delivery at 3 bar pressure & 12V (min) ............................ Regulated pressure range ................................................ Fuel pump delivery pressure ............................................ Fuel filter .......................................................................... A.C. Rochester/Electric immersible 3.2 bar 64 litre/h 3.0 æ 0.2 bar 2.3 - 2.5 kgf/cm2 Bosch in-line filter 'canister' type COOLING SYSTEM - Mpi Pressure cap .................................................................... 15lbf/in2 (1.03 bar) (system pressure) Thermostat ....................................................................... 88 °C CLUTCH - Mpi Type ................................................................................. Diaphragm spring, hydraulically operated Adjustment ....................................................................... Self adjusting Clutch plate diameter ....................................................... 215.13 mm TRANSMISSION - Mpi Manual gearbox Type R380 ....................................................................... Single helical constant mesh Speeds ............................................................................. 5 forward 1 reverse all synchromesh Transfer box Type LT230T .................................................................... Two speed reduction on main gearbox output. Front and rear drive permanently engaged via a lockable differential Overall ratios (final drive): Fifth .................................................................................. Fourth ............................................................................... Third ................................................................................. Second ............................................................................. First .................................................................................. Reverse ............................................................................ In high transfer 4.146:1 4.989:1 7.518:1 11.479:1 17.884:1 18.463:1 In low transfer 9.761:1 11.746:1 17.701:1 27.109:1 42.109:1 43.472:1 24 INFORMATION GENERAL SPECIFICATION DATA VEHICLE DIMENSIONS Dimensions Overall length (including spare wheel) ............................. Overall length (including tow hitch) .................................. Overall width .................................................................... Overall height ................................................................... Wheelbase ....................................................................... Track front/rear ................................................................. Width between wheel boxes ............................................ Seating capacity ............................................................... Performance Tyre size fitted .................................................................. Tyre size fitted .................................................................. Max. gradient (EEC kerb weight) ..................................... Approach angle (EEC kerb weight) .................................. Departure angle with tow hitch (EEC kerb weight) ........... Departure angle without tow hitch (EEC kerb weight) ............................................................ Ramp break over angle .................................................... Min. ground clearance (unladen) ..................................... Wading depth ................................................................... Towing weights On road 750 kg 2750 kg 3500 kg 4000 kg Off road 500 kg 1000 kg 1000 kg 1000 kg 205 R16 radial 235/70 R16 radial 45° 35° 20° 29° 33° 204 mm 500 mm 4538 mm 4581 mm 2189 mm 1914 mm 2540 mm 1486 mm 1080 mm 5 to 7 Unbraked trailers .............................................................. Trailers with overrun brakes - Mpi .................................... Trailers with overrun brakes - V8i & Tdi ........................... 4 wheel trailers with coupled brakes (FULLY BRAKED)* .......................................................... NOTE: * Only applies to vehicles modified to accept coupled brakes. NOTE: All weight figures are subject to local restrictions. INFORMATION 25 ENGINE TUNING DATA ENGINE 3.9 V8i Type ................................................................................. 3.9 Litre V8i Firing order ..................................................................... 1-8-4-3-6-5-7-2 Cylinder Numbers Left bank .......................................................................... 1-3-5-7 Right bank ........................................................................ 2-4-6-8 No 1 Cylinder location ................................................... Pulley end of left bank Timing marks .................................................................. On crankshaft vibration damper Spark plugs Make/type(8.13:1 Compression) ...................................... Gap .................................................................................. Make/type(9.35:1 Compression) ...................................... Gap .................................................................................. Champion RN11YCC 0.84-0.96mm Champion RN11YCC 0.84-0.96mm Coil Make/type ........................................................................ Bosch 0-221-122-392, Compression ratio ......................................................... 8.13:1 or 9.35:1 Fuel injection system ..................................................... Lucas 14 CUX Hot-wire air flow sensor system electronically controlled Valve Timing Opens .............................................................................. Closes .............................................................................. Duration ........................................................................... Valve peak ....................................................................... Idle speed - controlled by MFI system - all loads off in