weight LAND ROVER DISCOVERY 1999 Owner's Manual

MANUAL GEARBOX - R380
37-18 REPAIRS
22.Ensure gear lever is released from grommet
and no wires or pipes are trapped when
gearbox is lowered.
23.Remove clevis pin and 'C' washer securing low
ratio selector cable to lever and release cable
from lever housing.
24.Remove 2 cable ties securing cable to fuel
pipes. 25.Disconnect 2 Lucars from oil temperature
sensor and disconnect reverse lamp switch
multiplug.
26.Remove banjo bolts securing breather pipes
and discard sealing washers.
27.Remove bolt securing breather pipe 'P' clip and
release breather pipes.
28. If fitted: Disconnect 2 Lucars from differential
lock switch, release and disconnect transfer
box neutral sensor multiplug. Release harness
from 2 retaining clips.
29.Position container to catch oil spillage
30.Remove 2 bolts securing oil cooling pipe
housing to gearbox, release housing and
discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
31.Using a second jack support the weight of the
engine.

STEERING
ADJUSTMENTS 57-19
5.Adjust drag link so that taper joint is centralised
in drop arm, then tighten drag link clamp bolts:
Tighten M8 bolts to 22 Nm (16 lbf.ft) and M10
bolts to 33 Nm (24 lbf.ft).
6.Connect drag link to drop arm and tighten nut to
80 Nm (59 lbf.ft).
7.Remove steering box centralising bolt.
8.Remove stand(s) and lower vehicle.
9.Road test the vehicle and check that the
steering wheel is centralised. If steering wheel
is not centralised, proceed as follows.
10.Slacken drag link adjuster clamp bolts.
11.Without disconnecting drag link from drop arm,
adjust the length of the drag link to bring the
steering wheel to the central position.
CAUTION: Repositioning the steering wheel
on its splines cannot correct small (less
than 5°) errors in steering wheel alignment.
Always rectify small errors in alignment by
adjusting the drag link as detailed above,
ensuring that steering box centralisation is
maintained.
12.Tighten drag link clamp bolts: Tighten M8 bolts
to 22 Nm (16 lbf.ft) and M10 bolts to 33 Nm (24
lbf.ft)
Wheel alignment - front
$% 57.65.01
The following is the only wheel alignment equipment
which has been approved.
lBeissbarth ML 4600 wheel alignment computer
(6 sensor).
lBeissbarth ML 4600-8 wheel alignment
computer (8 sensor).
lBeissbarth ML 4000 wheel alignment computer
(8 sensor wireless).
lHunter S411-14.
Check
1.Ensure tyre pressures are correct and vehicle
is at kerbside weight.
2.Roll vehicle backwards and forwards to relieve
stresses in steering and suspension.
3.Ensure road wheels are positioned straight
ahead.
4.Ensure that wheel alignment equipment is
properly calibrated.
5.Following the equipment manufacturer's
instructions, measure the front wheel
alignment. Compare with the figures given in
General Data.

+ GENERAL DATA, Steering.
Adjust
1.Loosen track rod and adjuster clamp bolts.
2.Rotate adjuster to obtain correct alignment.

+ GENERAL DATA, Steering.
3.Tighten track rod and adjuster clamp bolts:
Tighten M8 bolts to 22 Nm (16 lbf.ft) and M10
bolts to 33 Nm (24 lbf.ft).
4.Recheck front wheel alignment.

STEERING
REPAIRS 57-33
21.With assistance remove 2 nuts and bolts
securing RH engine mounting to chassis.
22.Support the engine weight on a jack.
CAUTION: To prevent damage to
components, cushion the jack pad with a
block of wood or hard rubber.
23.Raise the engine sufficiently to allow the
steering box to clear the sump.
24. Models with ACE: Position ACE control arms
to access steering box bolts. 25.With assistance remove 4 bolts securing
steering box and remove steering box.
26.Remove centralising bolt from steering box.
Refit
1.Fit centralising bolt to steering box.
2.With assistance, position steering box, fit bolts
and tighten to 90 Nm (66 lbf.ft).
3.Lower the engine onto its mountings. Fit engine
mounting bolts and tighten to 85 Nm (63 lbf.ft).
4. Models with ACE: Ensure washer is in place
on lower ball joint of anti-roll bar link, then
connect lower ball joint to axle. Tighten nut to
100 Nm (74 lbf.ft).
5.Position drag link, fit nut and tighten to 80 Nm
(59 lbf.ft).
6.Position Panhard rod, fit bolt and nut and
tighten to 230 Nm (170 lbf.ft).
7.Position coolant rail and secure with clips and
bolt.
8.Fit coolant hoses and secure with clips.
9. Models with ACE: Fit and tighten bolt
securing ACE pipes to chassis.
10.Clean PAS pipe ends and 'O' ring recess.
11.Lubricate new 'O' rings for PAS pipes with clean
PAS fluid.
12.Fit 'O' rings to PAS pipes and position pipes in
steering box. Fit PAS pipe bracket and tighten
bolt to 22 Nm (16 lbf.ft).
13.Ensure steering wheel is centralised. Fit
universal joint between steering box and
intermediate shaft and tighten bolts to 25 Nm
(18 lbf.ft).
14.Remove centralising bolt from steering box.
15.Fit intercooler to turbo hose and secure with
clips.
16.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft).
17.Remove stand(s) and lower vehicle.
18.Connect battery earth lead.
19.Fit battery cover.
20.Refill cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
21.Bleed PAS system.

+ STEERING, ADJUSTMENTS,
Hydraulic system - bleed.
22.Centralise steering linkage

+ STEERING, ADJUSTMENTS,
Steering linkage - centralise.

FRONT SUSPENSION
REPAIRS 60-27
REPAIRS
Bushes - Panhard rod
$% 60.10.07
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove 2 nuts and bolts securing Panhard rod
to axle and chassis.
3.Remove Panhard rod from vehicle.
4.Use tool LRT-60-013 fitted with LRT-60-013/1
and LRT-60-013/3 to press out bushes from
Panhard rod. Refit
1.Clean bush locations in Panhard rod.
2.Use tool LRT-60-013 fitted with LRT-60-013/1
and LRT-60-013/2 to press new bushes into
Panhard rod. Ensure pressure is applied to
the outer edge of the bush, not the rubber
inner.
3.Position Panhard rod to axle and chassis.
4.Fit bolts securing Panhard rod but do not
tighten at this stage.
5.Remove stand(s) and lower vehicle.
6.Tighten bolts securing Panhard rod to 230 Nm
(170 lbf.ft).
CAUTION: Nuts and bolts must be tightened
with weight of vehicle on suspension.

FRONT SUSPENSION
60-32 REPAIRS
Road spring - front
$% 60.20.11
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Support vehicle under chassis.
3.Remove front road wheels.
4.Support weight of front axle.
5.Remove 2 nuts securing anti-roll bar links to
front axle and disconnect links from axle.
6.Remove 2 bolts securing each damper to front
axle.
WARNING: Make sure the axle cannot move
when the damper is disconnected. The
damper limits the downward movement of
the axle. If the axle is not restrained,
disconnecting the damper will allow
unrestricted movement which may cause
personal injury or damage to equipment.
7.Lower front axle.
CAUTION: Ensure brake hoses and ABS
sensor harnesses are not damaged when
lowering front axle.
8.Release and remove front spring from damper.Refit
1.Clean front spring seats.
2.Position front spring, with close coil uppermost,
over damper and locate in cut out in lower
spring seat.
3.Ensure both front springs are correctly located
in spring seats and raise front axle. Fit bolts
securing both dampers to front axle and tighten
to 45 Nm (33 lbf.ft).
4.Ensure washer is in place on lower ball joint of
each anti-roll bar link, then connect lower ball
joints to axle. Tighten nuts to 100 Nm (74 lbf.ft).
5.Fit front road wheels and tighten nuts to 140
Nm (103 lbf.ft).
6.Remove stands and lower vehicle.

FRONT SUSPENSION
60-38 REPAIRS
10.Using LRT-60-011/1 and LRT-60-011/2 press
out bush from rear end of radius arm.
11.Using a suitable piece of tubing, press out
bushes from axle end of radius arm.Refit
1.Clean and lubricate bush and radius arm
mating faces.
2.Using LRT-60-011/1,LRT-60-011/2 and LRT-
60-011/3, press bush into rear end of radius
arm.
3.Using a suitable piece of tubing press front
radius arm bush into radius arm.
4.Repeat above operation for remaining bush.
5.Position radius arm to vehicle and fit securing
nuts and bolts, do not tighten at this stage.
CAUTION: Nuts and bolts must be tightened
with weight of vehicle on suspension.
6.Fit cable tie to secure axle breather.
7.Fit track rod to steering knuckle and secure with
nut, tighten to 125 Nm (92 lbf.ft).
8.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
9.Remove stand(s) and lower vehicle.
10.Tighten radius arm nuts and bolts to 230 Nm
(170 lbf.ft).

REAR SUSPENSION
REPAIRS 64-29
Road spring - rear
$% 64.20.01
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Support vehicle under chassis.
3.Remove road wheel.
4.Support weight of axle on a jack.
5.Remove bolt securing damper to axle.
WARNING: Make sure the axle cannot move
when the damper is disconnected. The
damper limits the downward movement of
the axle. If the axle is not restrained,
disconnecting the damper will allow
unrestricted movement which may cause
personal injury or damage to equipment.
6.Remove clip securing brake pipe to bracket.
7.Release ABS sensor lead from bracket.
8.Lower axle on jack and remove spring.Refit
1.Ensure spring seats are clean.
2.Fit spring with close coil uppermost.
3.Ensure spring is correctly located on spring
seats and raise axle. Fit and tighten bolt
securing damper to axle to 124 Nm (91 lbf.ft).
4.Fit clip to secure brake pipe to bracket.
5.Fit ABS sensor lead to bracket.
6.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
7.Remove stand(s) and lower vehicle.

REAR SUSPENSION
REPAIRS 64-31
Damper - rear
$% 64.30.02
Remove
1.Raise rear of vehicle and support under
chassis.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel.
3.Support weight of axle on a jack.
4.Remove 2 bolts securing damper to axle and
chassis.
WARNING: Make sure the axle cannot move
when the damper is disconnected. The
damper limits the downward movement of
the axle. If the axle is not restrained,
disconnecting the damper will allow
unrestricted movement which may cause
personal injury or damage to equipment.
5.Compress damper and remove from vehicle.
Refit
1.Locate damper in axle and fit lower bolt, extend
damper to chassis and fit top bolt.
2.Tighten damper bolts to 125 Nm (92 lbf.ft).
3.Lower axle and remove jack.
4.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
5.Remove stand(s) and lower vehicle.
Bushes - radius arm
$% 64.35.29
Models with SLS:
WARNING: Ensure the air suspension system is
made safe before commencing work. Otherwise
the chassis may lower onto the bump stops
during repair.
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel(s).
3. Models with SLS: Remove nut and bolt
securing height sensor link to radius arm.
4.Remove nut and bolt securing radius arm to
chassis.
5.Remove 2 nuts securing radius arm to axle.
6.Remove rear bolt and lower radius arm.

REAR SUSPENSION
REPAIRS 64-33
4.Position LRT-60-034/2 over radius arm and
locate bush to aperture.
5.With assistance, press bush into aperture.
6.Repeat above operation for remaining bush.
7.Position radius arm to vehicle and fit securing
nuts and bolts, do not tighten at this stage.
CAUTION: Nuts and bolts must be tightened
with the weight of the vehicle on the
suspension.
8. Models with SLS: Position height sensor link
to radius arm and tighten nut and bolt to 25 Nm
(18 lbf.ft).
9.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
10.Remove stands and lower vehicle.
11.Tighten radius arm nuts and bolts to 230 Nm
(170 lbf.ft).

REAR SUSPENSION
64-34 REPAIRS
Bushes - Watts linkage
$% 64.35.35
Models with SLS:
WARNING: Ensure the air suspension system is
made safe before commencing work. Otherwise
the chassis may lower onto the bump stops
during repair.
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove 3 nuts and bolts securing Watts
linkage to axle and chassis and remove Watts
linkage.
3.Remove 2 nuts and bolts securing transverse
links to pivot housing and remove links from
pivot housing. 4.Use LRT-60-010/1 and LRT-60-010/3 to press
bushes from transverse links and pivot
housing.
Refit
1.Clean bush locations in transverse links and
pivot housing.
2.Using LRT-60-010/1 and LRT-60-010/2press
new bushes into transverse links and pivot
housing.
3.Position transverse links to pivot housing and
tighten bolts to 155 Nm (114 lbf.ft).
4.Position Watts linkage to axle and chassis. Fit
bolts but do not tighten at this stage.
5.Remove stand(s) and lower vehicle.
6.Tighten bolts securing pivot housing to axle to
230 Nm (170 lbf.ft). Tighten bolts securing
transverse links to chassis to 140 Nm (103
lbf.ft).
CAUTION: Nuts and bolts must be tightened
with weight of vehicle on suspension.