belt LAND ROVER DISCOVERY 1999 User Guide

TORQUE WRENCH SETTINGS
06-4
Engine V8
* New bolts must be fitted
+ Apply sealant, Part Number STC 50552 to threads
TORQUE DESCRIPTION METRIC IMPERIAL
Engine mounting bolts (rear, LH & RH) to gearbox bolts 85 Nm (63 lbf.ft)
Engine mounting (rear, LH & RH) nuts 45 Nm (33 lbf.ft)
Cylinder head bolts tighten, then 90°, then a further 90° * 20 Nm (15 lbf.ft)
Rocker shaft bolts 40 Nm (30 lbf.ft)
Alternator mounting bracket 40 Nm (30 lbf.ft)
Auxiliary drive belt tensioner 45 Nm (33 lbf.ft)
Engine earth lead 22 Nm (16 lbf.ft)
Rocker cover screws/bolts * 8 Nm (6 lbf.ft)
Torque converter to drive plate 50 Nm (37 lbf.ft)
A/C compressor 22 Nm (16 lbf.ft)
ACE pump 22 Nm (16 lbf.ft)
Flywheel to crankshaft 78 Nm (58 lbf.ft)
Crankshaft sensor 6 Nm (5 lbf.ft)
Crankshaft sensor cover 6 Nm (5 lbf.ft)
Spacer and hub to crankshaft - Early engines 85 Nm (63 lbf.ft)
Drive plate and clamp ring - Early engines 45 Nm (33 lbf.ft)
Drive plate to crankshaft Allen bolts - Later engines 85 Nm 63 lbf.ft)
Oil pick up strainer 10 Nm (7 lbf.ft)
Filter head adaptor 13 Nm (10 lbf.ft)
Filter head 8 Nm (6 lbf.ft)
Sump bolts 22 Nm (16 lbf.ft)
Oil pressure switch 15 Nm (11 lbf.ft)
Timing gear cover to cylinder block + 22 Nm (16 lbf.ft)
Oil cooler pipe to timing gear cover 15 Nm (11 lbf.ft)
Crankshaft pulley bolt 270 Nm (200 lbf.ft)
Coolant outlet elbow 22 Nm (16 lbf.ft)
Auxiliary housing 40 Nm (30 lbf.ft)
Jockey pulley 50 Nm (37 lbf.ft)
Camshaft gear 50 Nm (37 lbf.ft)
Rocker shaft bolts 40 Nm (30 lbf.ft)
Connecting rod bolts
Final torque - turn through 80°°20 Nm
80°(15 lbf.ft)
80°
Initial torque - all main bearing cap bolts and side bolts 13.5 Nm (10 lbf.ft)
Final torque - main bearing cap side bolts 11 to 15 45 Nm (33 lbf.ft)
Final torque - main bearing cap bolts 1 to 8 72 Nm (53 lbf.ft)
Final torque - main bearing cap bolts 9 and 10 92 Nm (68 lbf.ft)
Final torque - main bearing cap side bolts 16 to 20 45 Nm (33 lbf.ft)
Viscous fan nut 45 Nm (33 lbf.ft)
Camshaft thrust plate bolts 22 Nm (16 lbf.ft)
Secondary Air Injection adapters 33 Nm (24 lbf.ft)

TORQUE WRENCH SETTINGS
06-18
Restraint systems
TORQUE DESCRIPTION METRIC IMPERIAL
Front seat belt upper anchorage 32 Nm (24 lbf.ft)
Front seat belt reel 50 Nm (37 lbf.ft)
Front seat belt lower anchorage to seat 32 Nm (24 lbf.ft)
Second row upper anchorage 50 Nm (37 lbf.ft)
Second row seat belt reel 32 Nm (24 lbf.ft)
Second row lower anchorage 32 Nm (24 lbf.ft)
Third row upper anchorage 50 Nm (37 lbf.ft)
Third row seat belt reel 50 Nm (37 lbf.ft)
Third row lower anchorage 32 Nm (24 lbf.ft)
'B' post adjustable seat belt mounting 22 Nm (16 lbf.ft)
Seat belt pre-tensioners 32 Nm (24 lbf.ft)
Driver's side air bag 9 Nm (7 lbf.ft)
Passenger side air bag 8 Nm (6 lbf.ft)
SRS DCU10 Nm (7 lbf.ft)

TORQUE WRENCH SETTINGS
06-21
Electrical
TORQUE DESCRIPTION METRIC IMPERIAL
Alternator support stay 25 Nm (18 lbf.ft)
Alternator lead - Td5 6 Nm (4.4 lbf.ft)
Auxiliary drive belt tensioner bolt 50 Nm (37 lbf.ft)
Alternator pulley80 Nm (59 lbf.ft)
Alternator B+ nut - V8 18 Nm (13 lbf.ft)
Alternator B+ nut - V8 5 Nm (3.7 lbf.ft)
Starter motor - Td5 27 Nm (20 lbf.ft)
Starter motor solenoid 10 Nm (7 lbf.ft)
Starter motor - V8 44 Nm (32 lbf.ft)
Alternator45 Nm (33 lbf.ft)
Starter motor heat shield - V8 10 Nm (7 lbf.ft)
Horn13 Nm (10 lbf.ft)
Battery carrier bolts 28 Nm (21 lbf.ft)

MAINTENANCE
PROCEDURES 10-1
MAINTENANCE PROCEDURES
V8 engine underbonnet view
1Brake/clutch fluid reservoir filler caps
2Engine oil filler cap
3Spark plug
4Engine oil dipstick
5Coolant header tank6Battery
7Auxiliary drive belt
8ACE/PAS fluid reservoirs
9Windscreen washer reservoir

MAINTENANCE
10-2 PROCEDURES
Diesel underbonnet view
1Coolant header tank
2Brake/clutch fluid reservoir filler caps
3Engine oil dipstick
4Engine oil filler cap
5ACE/PAS fluid reservoirs6Battery
7Auxiliary drive belt
8Air cleaner
9Windscreen washer reservoir

MAINTENANCE
PROCEDURES 10-3
Seats and seat belts
Check
Front seat
Rear seat rear fixings
Rear seat front fixings1.Check seat frames are secured to floor and
show no signs of movement.
2.Check operation of seat slide and tilt
mechanisms, ensuring there is no excessive
play between seat cushion and seat back.
3.Fully extract seat belt and allow it to return
under its own recoil mechanism. Repeat for
other belts.
4. Check entire length of seat belt webbing for
signs of fraying or damage. Repeat for other
belts.

MAINTENANCE
10-4 PROCEDURES
5. Check security of seat belt upper mountings.
6. Check for correct operation of seat belt height
adjusters.
7.Check security of seat belt buckle mountings.
8.Connect each belt to the correct buckle, check
seat buckle and tongue are secure. Release
seat belt buckle and check for correct
operation.9.Check tightness of accessible seat belt fixings.
10.Check tightness of accessible seat belt
mountings.

MAINTENANCE
PROCEDURES 10-11
Auxiliary drive belt
Check
TD5 auxiliary belt
V8 auxiliary belt
1Tensioner pulley
2Alternator
3A/C compressor
4ACE pump
5Idler pulley - V8 only
6PAS pump
7Viscous fan pulley
8Crankshaft pulley
9Idler pulley - V8 only
1.Check auxiliary drive belt for signs of splits,
fraying, oil contamination and wear.
Auxiliary drive belt - V8 engine
1.Replace auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
Auxiliary drive belt - diesel engine
Replace
1.Replace auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.

MAINTENANCE
PROCEDURES 10-31
Road/roller test
WARNING: Roller test must be restricted to 3
mph (5 km/h). If 2 wheel rolling road is to be used,
disconnect propeller shaft from the transfer box
output shaft driving the axle which is NOT on the
rolling road.
Testing
1. 2 wheel rolling road: Engage differential lock
using a 10 mm open ended spanner on flats
machined on differential lock selector
shaft.Switch on ignition and check that the
differential lock, electronic brake
distribution and hill descent warning lamps
are illuminated.
2.Check for correct operation of starter switch,
ensure engine starts correctly; leave the engine
running.
3.Check for correct operation of starter switch,
ensure engine starts correctly; leave the engine
running.
4.With vehicle stationary, turn steering from lock
to lock. Check for smooth operation and ensure
there is no undue noise from power steering
pump or drive belt.
5.Depress clutch and select all gears in turn,
check for smooth, notch free engagement.6. Check all vehicle systems for correct
operation.
7.Check for unusual engine, gearbox and
suspension noises.
8.Check braking system operation.
9.Check for smooth gear engagement.
10.Check engine performance.
11.Check operation of all instruments and warning
devices where practicable.
12.Where possible, check for correct operation of
hill descent control (HDC) mechanism. This
should not be carried out if excessive journey
time is required.
13.After road/roller test, carry out a final inspection
of vehicle, with vehicle on a ramp.
14.Check all fluid levels and top-up if necessary.
15. 2 wheel rolling road: Ensure differential lock is
disengaged and propeller shaft is connected on
completion of test. Switch on ignition and
check that differential lock, electronic brake
distribution and hill descent warning lamps
are extinguished.

ENGINE - V8
12-2-16 REPAIRS
17.Using new gaskets, position exhaust manifold
to cylinder head, fit bolts and using sequence
shown, tighten initially to 15 Nm (11 lbf.ft), then
finally to 36 Nm (28 lbf.ft).
18. LH drive models: Fit brake servo heat shield.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Heat shield -
brake servo - Without Secondary Air
Injection.
19.Fit engine harness bolt and tighten to 22 Nm
(16 lbf.ft).
20.Connect ht leads to spark plugs in their correct
fitted order.
21.Fit inlet manifold gasket.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - lower.
Gasket - cylinder head - RH
$% 12.29.03
Remove
1.Remove inlet manifold gasket.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - lower.
2.Remove bolt securing auxiliary drive belt
tensioner and remove tensioner.
3.Remove 4 bolts securing alternator mounting
bracket and remove bracket.
4.Noting their fitted order, disconnect ht leads
from spark plugs.
5.Remove bolt securing engine earth lead.