ABS LAND ROVER DISCOVERY 1999 Workshop Manual

PANEL REPAIRS
REPAIRS 77-2-29
Refit
1. Models with A/C: Fit A/C pipes and recharge
A/C system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
2.Fit harness to valance.
3.Fit brake pipes to valance.
4.Fit ABS modulator.

+ BRAKES, REPAIRS, Modulator unit
- ABS.
5.Fit PAS/ACE reservoir, refill fluids to correct
levelsand bleed ACE system.

+ FRONT SUSPENSION,
ADJUSTMENTS, ACE hydraulic system
bleeding.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Fluids.
6.Fit air filter assembly.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
7.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
8.Connect leads/multiplug to alternator.
9.Connect battery leads, negative lead last.
Valance upper assembly - RH
In this procedure, the front wing and the valance
outer reinforcement are replaced in conjunction with
the RH valance upper assembly.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
4.Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
5.Remove battery tray.
6.Remove fuse box.
7.Release expansion tank from fixings and
position aside.
8.Release harness from valance and position
aside.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
M77 1692A
M77 1750

PANEL REPAIRS
77-2-30 REPAIRS
Refit
1.Fit harness to valance.
2.Fit and secure expansion tank to fixings.
3.Fit fuse box.
4.Fit battery tray.
5.Fit battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
6.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
7.Connect leads/multiplug to alternator.
8.Connect battery leads, negative lead last.
Valance upper assembly (front section) -
LH
In this procedure, the front wing, the valance outer
reinforcement (front section) and the bonnet alarm
switch mounting bracket are replaced in conjunction
with the LH valance upper assembly (front section).
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
4.Remove air filter assembly.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
5.Remove PAS/ACE reservoir.
6.Remove ABS modulator.

+ BRAKES, REPAIRS, Modulator unit
- ABS.
7.Release harness from valance and position
aside.
8. Models with A/C: Depressurise A/C system
and remove pipes from valance.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.

PANEL REPAIRS
REPAIRS 77-2-31
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.Refit
1. Models with A/C: Fit A/C pipes and recharge
A/C system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
2.Fit harness to valance.
3.Fit ABS modulator.

+ BRAKES, REPAIRS, Modulator unit
- ABS.
4.Fit PAS/ACE reservoir and refill fluids to correct
levels.

+ FRONT SUSPENSION,
ADJUSTMENTS, ACE hydraulic system
bleeding.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Fluids.
5.Fit air filter assembly.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
6.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
7.Connect leads/multiplug to alternator.
8.Connect battery leads, negative lead last.
M77 1744
M77 1689A

PANEL REPAIRS
77-2-34 REPAIRS
Front valance assembly - LH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front bulkhead assembly.

+ PANEL REPAIRS, REPAIRS, Front
bulkhead assembly.
4.Remove ABS modulator unit.

+ BRAKES, REPAIRS, Modulator unit
- ABS.
5. LHD models: Remove brake servo.

+ BRAKES, REPAIRS, Servo - brake.
6.Remove brake pipes from valance assembly.
7.Remove PAS/ACE reservoir.
8. Models with A/C: Remove A/C pipes from
valance assembly.
9.Remove wiring harness from valance
assembly.
10.Remove LH front road wheel.
11.Remove LH front mud flap.
12.Remove insulation pad from engine bulkhead.
13.Remove windscreen side finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.Refit
1.Fit windscreen side finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
2.Fit insulation pad to engine bulkhead.
3.Fit front mud flap.
4.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
5.Fit wiring harness to valance assembly.
6. Models with A/C: Fit A/C pipes to valance
assembly.
7.Fit PAS/ACE reservoir.
8.Fit brake pipes to valance assembly.
9. LHD models: Fit brake servo.

+ BRAKES, REPAIRS, Servo - brake.
10.Fit ABS modulator unit.

+ BRAKES, REPAIRS, Modulator unit
- ABS.
11.Fit front bulkhead assembly.

+ PANEL REPAIRS, REPAIRS, Front
bulkhead assembly.
12.Connect leads/multiplug to alternator.
13.Connect battery leads, negative lead last.
M77 1742

CORROSION PREVENTION AND SEALING
77-4-22 SEALING
Water leaks
Where water leakage is involved, always adopt a logical approach to the problem using a combination of skill,
experience and intuition. Do not reach a conclusion based only on visual evidence, such as assuming that a wet
footwell is caused by a leak emanating from the windscreen. It will often be found that the source of the leak is
elsewhere. Use of the correct procedure will increase the chance of locating a leak, however obscure it may seem.
Tools and equipment
The following tools and equipment are recommended for the purpose of detection and rectification of water leaks:
1Garden sprayer (hand-operated)
2Wet/dry vacuum cleaner
3Dry, absorbent cloths
4Battery torch
5Small mirror
6Weatherstrip locating tool
7Trim panel remover
8Small wooden or plastic wedges
9Dry compressed air supply
10Hot air blower
11Sealer applicators
12Ultrasonic leak detector
During leak detection, the vehicle should be considered in three basic sections:
lThe front interior space;
lThe rear passenger space;
lThe loadspace or boot.
Testing
From the information supplied by the customer it should be possible for the bodyshop operator to locate the starting
point from which the leak may be detected. After the area of the leak has been identified, find the actual point of entry
into the vehicle.
A simple and effective means in the first instance is an ordinary garden spray with provision for pressure and jet
adjustment, which will allow water to be directed in a jet or turned into a fine spray. Use a mirror and a battery-powered
torch (NOT a mains voltage inspection lamp) to see into dark corners.
The sequence of testing is particularly important. Start at the lowest point and work slowly upwards, to avoid testing
in one area while masking the leak in another. For example, if testing started at the level of the windscreen, any water
cascading into the plenum chamber could leak through a bulkhead grommet and into the footwells. Even at this point
it could still be wrongly assumed that the windscreen seal was at fault.
Another important part of identifying a water leak is by visual examination of door aperture seals, grommets and
weatherstrips for damage, deterioration or misalignment, together with the fit of the door itself against the seals.
Sealing
When the point of the leak has been detected, it will then be necessary to rectify it using the following procedure:
1Renew all door aperture seals and weatherstrips which have suffered damage, misalignment or deterioration
2Check all body seals to ensure that they are correctly located on their mounting flanges/faces using a lipping
tool if necessary
3Dry out body seams to be treated using compressed air and/or a hot air blower as necessary
4Apply sealant on the outside of the joint wherever possible to ensure the exclusion of water
5When rectifying leaks between a screen glass and it's weatherstrip (or in the case of direct glazing, between the
glass and bodywork), avoid removing the glass if possible. Apply the approved material at the appropriate
location (i.e. glass to weatherstrip or glass to body)

AIR CONDITIONING
82-4DESCRIPTION AND OPERATION
Refrigerant system
Schematic of air conditioning system
1Evaporator
2Thermostatic expansion valve
3Low pressure servicing connection
4Outlet to rear A/C system (where fitted)
5Dual pressure switch
6Receiver drier
7Cooling fan
8Condenser
9Compressor10Inlet from rear A/C system (where fitted)
11High pressure servicing connection
12Air flows
aAmbient air
bCooled air
cAmbient air through condenser
13Refrigerant
aLiquid
bVapour
The refrigerant system transfers heat from the vehicle interior to the outside atmosphere to provide the heater
assembly with dehumidified cool air. The system comprises a compressor, condenser, receiver drier, thermostatic
expansion valve and evaporator, joined together by refrigerant lines. The system is a sealed, closed loop, filled with
a charge weight of R134a refrigerant as the heat transfer medium. Oil is added to the refrigerant to lubricate the
internal components of the compressor.
To accomplish the transfer of heat, the refrigerant is circulated around the system, where it passes through two
pressure/temperature regimes. In each of the pressure/temperature regimes, the refrigerant changes state, during
which process maximum heat absorption or release occurs. The low pressure/temperature regime is from the
thermostatic expansion valve, through the evaporator to the compressor; the refrigerant decreases in pressure and
temperature at the thermostatic expansion valve, then changes state from liquid to vapour in the evaporator, to absorb
heat. The high pressure/temperature regime is from the compressor, through the condenser and receiver drier to the
thermostatic expansion valve; the refrigerant increases in pressure and temperature as it passes through the
compressor, then releases heat and changes state from vapour to liquid in the condenser.

AIR CONDITIONING
82-6DESCRIPTION AND OPERATION
Condenser
1Condenser matrix
2Outlet connection
3Inlet connection
The condenser transfers heat from the refrigerant to the surrounding air.
The condenser is installed immediately in front of the oil coolers. Rubber mounting bushes are used to mount the
condenser to the chassis sidemembers and brackets on the headlamp panels.
Ambient air, passing through the condenser matrix due to ram effect and/or the cooling fan, absorbs heat from the
refrigerant, which changes state from a vapour to a liquid.

AIR CONDITIONING
DESCRIPTION AND OPERATION 82-7
Receiver drier
1Dual pressure switch
2Inlet connection
3Housing
4Outlet connection5Outlet tube
6Screen
7Desiccant
The receiver drier removes moisture and solid impurities from the refrigerant and also acts as a refrigerant reservoir.
The receiver drier is clamped to a bracket in front of the condenser. The receiver drier housing is manufactured in
aluminium and contains a desiccant to absorb moisture. A mesh screen in the housing removes solid impurities. Inlet,
outlet and dual pressure switch connections are located in the top of the housing.
Liquid refrigerant enters the receiver drier, passes through the desiccant and mesh screen, and through a tube to the
outlet connection.

AIR CONDITIONING
82-8DESCRIPTION AND OPERATION
Thermostatic expansion valve
Thermostatic expansion valve and evaporator
1Refrigerant outlet
2Refrigerant inlet3Thermostatic expansion valve
4Evaporator
The thermostatic expansion valve meters the flow of refrigerant into the evaporator to match the refrigerant flow with
the heat load of the air passing through the evaporator matrix.
The thermostatic expansion valve is installed in the heater assembly, in the refrigerant inlet line to the evaporator.
Liquid refrigerant flows through the valve to the evaporator. The restriction across the valve reduces the pressure and
temperature of the refrigerant and changes it to a fine spray, which improves the evaporation process. Valve opening
is controlled by the pressure in a capillary tube containing a temperature sensitive fluid. One end of the capillary tube
is connected to a diaphragm housing on the thermostatic expansion valve, the other end of the capillary tube is sealed
and attached to the refrigerant outlet line of the evaporator. As the temperature of the refrigerant leaving the
evaporator changes, a corresponding change of capillary tube pressure and valve opening are produced. The warmer
the refrigerant leaving the evaporator becomes, the greater the volume of refrigerant allowed through the valve.
Evaporator
The evaporator is installed in the air inlet of the heater assembly and absorbs heat from the exterior or recirculated
inlet air. Low pressure, low temperature refrigerant changes from liquid to vapour in the evaporator, absorbing large
quantities of heat as it changes state.
Refrigerant lines
To maintain similar flow velocities around the system, the diameter of the refrigerant lines varies to suit the two
pressure/temperature regimes. The larger diameters are installed in the low pressure/temperature regime and the
smaller diameters are installed in the high pressure/temperature regime. Low and high pressure charging connections
are incorporated into the refrigerant lines for system servicing. Where rear AC is installed, connections for the rear
refrigerant lines are incorporated next to the charging connections.

AIR CONDITIONING
82-24DESCRIPTION AND OPERATION
Rear evaporator/blower assembly
1Resistor pack
2Thermostatic expansion valve
3Rear blower relay
4Air outlet
5Evaporator6Capillary tube
7Housing
8Condensate drain outlet
9Refrigerant lines
10Blower
The rear evaporator/blower assembly cools and dehumidifies air from the cabin and supplies it to the rear distribution
system. The unit is installed on the left side of the loadspace, behind the quarter trim. A grille in the quarter trim allows
air to flow from the loadspace into the evaporator/blower. Refrigerant lines for the evaporator and a condensate drain
tube are attached to the rear floor.
The evaporator and blower are installed in a common housing, which also incorporates the resistor pack for the
blower. A thermostatic expansion valve is integrated into the inlet refrigerant line. A rear blower relay is attached to
the top of the housing.
Evaporator
The evaporator absorbs heat from the recirculated air being supplied to the distribution ducts.
Thermostatic expansion valve
The thermostatic expansion valve meters the flow of refrigerant into the evaporator to match the heat load of the air
passing through the evaporator matrix. A capillary tube, attached to the outlet pipe of the evaporator and connected
to the thermostatic expansion valve, automatically adjusts the valve opening in relation to the refrigerant temperature
at the evaporator outlet.