User manual LAND ROVER DISCOVERY WORKSHOP MANUAL

[. . . ] 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. [. . . ] CHECK 16 At approximately 88 kph (55 mph) depress throttle to kickdown - gearbox should change down to 2nd release throttle to re-engage 4th direct drive clutch continue to accelerate gently. CHECK 17 At approximately 128 kph (80 mph) depress throttle to kickdown - gearbox should change down to 3rd release throttle to re-engage 4th direct drive clutch and continue to accelerate gently. CHECK 23 With 1 selected 2nd gear engaged continue to de-accelerate and at 45 kph (28 mph) the box should automatically downshift to 1st gear after which no upshifts will occur in this selector position. END OF ROADTEST At 128 kph (80 mph) select 2nd no downshift should occur. CHECK 21 At 104 kph (65 mph) an automatic downshift into 2nd gear should occur. De-accelerate to approximately 47 kph (30 mph) depress throttle to kickdown - geabox should downshift to 1st gear, continue accelerating at full throttle until 3rd gear is attained. To do this you will have repeated check 2 of Test 1. FAULT DIAGNOSIS 3 44 AUTOMATIC GEARBOX AUTOMATIC GEARBOX ASSEMBLY ILLUSTRATED 1. 4. Gearbox assembly Inhibitor switch assembly Control unit assembly Filter and sump assembly 4 FAULT DIAGNOSIS ZF 1. Governor and adaptor housing assembly FAULT DIAGNOSIS 5 44 AUTOMATIC GEARBOX 1. C, C' and D Clutch assembly FAULT DIAGNOSIS 7 44 AUTOMATIC GEARBOX 1. Freewheel and fourth gear assembly 8 FAULT DIAGNOSIS ZF 1. E and F Clutch assembly FAULT DIAGNOSIS 9 44 AUTOMATIC GEARBOX FAULT SYMPTOMS SYMPTOM 1 - Intermittent drive and high pitched noise FAULT - Low fluid level or restricted filter SYMPTOM 2 - No drive in reverse Select 'D' oe No drive FAULT - Continue with Symptom 3 oe Drives forward FAULT - Reverse gear interlock valve seized Select '1' oe No engine braking FAULT - Clutch brake 3 SYMPTOM 3 - No drive from rest with 'D' selected Select '1' oe Vehicle drives FAULT - No 2 freewheel oe No drive Carry out main line pressure check oe Normal pressure FAULT - Clutch A oe No pressure FAULT - Blocked filter or pump failure oe Low pressure FAULT - Restricted filter or sticking primary regulator SYMPTOM 4 - Slip in all forward gears Carry out main line pressure check oe No pressure FAULT - Blocked filter or pump failure oe Low pressure FAULT - Restricted filter or sticking primary regulator oe Normal pressure FAULT - Clutch 'A' SYMPTOM 5 - Harsh engagement 'N' to 'D' Check engine idle speed Carry out main line pressure check oe High pressure FAULT - Primary regulator stuck oe Normal pressure FAULT - Clutch 'A' or damper for clutch'A' SYMPTOM 6 - Fierce shift or flare 1st to 2nd shift Check engine idle speed Carry out mainline pressure check oe High pressure FAULT - Continue with symptom 5 oe Normal pressure FAULT - Modulator valve or dampers for clutch brake CB1 and/or clutch brake CB2 FAULT - Clutch brake CB1 and/or clutch brake CB2 SYMPTOM 7 - Fierce shift or flare 2nd to 3rd Carry out mainline pressure check oe High pressure FAULT - Continue with symptom 5 oe Normal pressure FAULT - Modulator valve or clutch 'B' damper FAULT - Clutch 'B' SYMPTOM 8 - No 3rd gear FAULT - 2-3 shift valve FAULT - Clutch 'B' SYMPTOM 9 - No 4th gear 'D' selected FAULT - 4th to 3rd downshift valve stuck or 3rd to 4th upshift valve stuck FAULT - Clutch brake 4 10 FAULT DIAGNOSIS ZF SYMPTOM 10 - None or harsh engagement of direct drive clutch NOTE: The direct drive clutch will only engage if 4th gear is engaged at 40 to 45 mph. Carry out road test pressure check with gauge connected to torque converter. oe Normal pressure FAULT - Failed direct drive clutch oe Pressures correct but remains high FAULTS POSSIBLE Direct drive clutch and torque converter control valve stuck Hysteresis valve stuck Direct drive clutch control valve stuck SYMPTOM 11 - Direct drive clutch shift point incorrect or at low speed NOTE: Direct drive clutch engagement at low speed will cause vibration in the torque converter Carry out mainline and torque converter pressure check oe Normal pressure FAULT - Governor valve sticking oe Low or incorrect pressure FAULTS POSSIBLE Direct drive clutch and torque converter control valve sticking. SYMPTOM 12 - Drives in 'D' but immediately upshifts to 3rd FAULT - 2nd to 3rd shift valve stuck. SYMPTOM 13 - With 'D' selected vehicle starts in 2nd FAULTS POSSIBLE 1st and 2nd shift valve stuck. SYMPTOM 14 - With 'D' selected vehicle starts in 3rd FAULTS POSSIBLE 1st to 2nd and 2nd to 3rd shift valves stuck. Governor sleeve sticking. SYMPTOM 15 - No kickdown 4th to 3rd FAULT - 4th to 3rd kickdown valve stuck. SYMPTOM 16 - Upshifts/downshifts and kickdown shifts at incorrect road speeds Check throttle kickdown cable adjustment Carry out main line pressure check oe Normal pressure FAULT - Governor valve sticking oe Incorrect pressure FAULTS POSSIBLE Incorrect throttle valve adjustment Primary regulator sticking SYMPTOM 17 - No upshifts at light throttle FAULTS POSSIBLE Governor valve sticking Shift valves sticking SYMPTOM 18 - No engine braking '3' selected 3rd gear FAULT - Clutch 'C' SYMPTOM 19 - Delayed or no downshift occurs when making a manual selection from '3' to '2' FAULTS POSSIBLE 2nd and 3rd upshift valve sticking. SYMPTOM 20 - At speeds below 28 mph when making a manual selection from '2' to '1', downshift is delayed or does not occur FAULTS POSSIBLE Governor sticking. SYMPTOM 21 - '1' Selected 1st gear no engine braking FAULT - Clutch brake 3 SYMPTOM 22 - '2' Selected 2nd gear no engine braking FAULT - Clutch brake 1 SYMPTOM 23 - Vehicle drives forward in 'N' FAULT - Clutch 'A' stuck FAULT DIAGNOSIS 11 ZF KICKDOWN CABLE ADJUSTMENT 1. Remove split pin, withdraw clevis pin and disconnect kickdown cable from lever. [. . . ] Temporarily fit camshaft timing gear, fit and tighten bolt sufficiently to pull gear fully on to camshaft. Attach a magnetic base DTI to front of cylinder block with stylus of gauge contacting machined face of gear adjacent to gear teeth. Pull camshaft fully forwards and check that end-float is between 0. 1 and 1. 2 mm. If end-float exceeds 0. 2 mm with new thrust plate fitted, camshaft must be replaced. [. . . ]