lock LAND ROVER DISCOVERY 1999 Workshop Manual

ENGINE MANAGEMENT SYSTEM - V8
18-2-88 REPAIRS
Cable - throttle
$% 19.20.06
Remove
1.Release 3 fasteners and remove drivers side
closing panel and move aside.
2.Release inner cable from throttle pedal.
3.Release outer cable from bulkhead. 4.Release outer cable from clip, loosen lock nuts
and remove outer cable from abutment
bracket.
5.Release inner cable from operating lever and
remove cable.
Refit
1.Position cable, secure to bulkhead and
connect inner cable to throttle pedal.
2.Position inner cable to operating lever and
connect outer cable to abutment bracket and
retaining clip.
3.Position closing panel and secure fasteners.
4.Adjust throttle cable.

+ ENGINE MANAGEMENT SYSTEM -
V8, ADJUSTMENTS, Cable - throttle.

ENGINE MANAGEMENT SYSTEM - V8
18-2-96 REPAIRS
Cable - cruise control
$% 19.75.10
Remove
1.Release clip and disconnect inner cable from
actuator.
2.Release outer cable from actuator mounting
bracket.
3.Loosen cable locknuts, release outer cable
from abutment bracket and retaining clip.
4.Release inner cable from operating lever and
remove cable.
Refit
1.Position cable and connect to operating lever.
2.Position cable to abutment bracket.
3.Position outer cable to actuator mounting
bracket and connect inner cable to actuator.
4.Adjust cruise control cable.

+ ENGINE MANAGEMENT SYSTEM -
V8, ADJUSTMENTS, Cable - cruise control.
Switch - cruise control (on/off)
$% 19.75.30
Remove
1.Carefully remove switch from instrument cowl.
2.Disconnect multiplug and remove switch.
Refit
1.Position new switch and connect multiplug.
2.Carefully push switch into instrument cowl.

FUEL DELIVERY SYSTEM - V8
DESCRIPTION AND OPERATION 19-2-1
FUEL DELIVERY SYST EM - V8 DESCRIPTION AND OPERAT ION
Fuel delivery system
1Fuel pressure regulator (hidden)
2Schraeder valve
3Fuel rail
4Injectors
5Engine block6Fuel feed pipe
7Coarse filter
8Fine filter
9Fuel pump and fuel gauge sender assembly

FUEL DELIVERY SYSTEM - V8
19-2-2 DESCRIPTION AND OPERATION
Fuel tank and breather components (all
except NAS)
1Fuel filler cap
2Relief valve
3Vent to EVAP canister
4Tank breather connection
5Fuel pump, regulator and fuel gauge sender
assembly
6Seal
7Locking ring
8Fuel feed connection
9Fuel gauge sender float
10Fuel tank and breather assembly
11Heat shield
12Scrivet 2 off13Stud plate
14Nut 2 off
15Cradle
16Bolt 2 off
17Nut plate 2 off
18Hose clip 2 off
19Hose
20Vent hose
21Vent hose coupling
22Hose clip 2 off
23Hose
24Filler tube
25Liquid Vapour Separator (LVS)

FUEL DELIVERY SYSTEM - V8
DESCRIPTION AND OPERATION 19-2-3
Fuel tank and breather components
(NAS)
1Fuel filler cap
2Filler tube
3OBD pressure sensor atmospheric pipe
4Vent pipe to EVAP canister
5Fuel pump, regulator and fuel gauge sender
assembly
6OBD pressure sensor (vacuum type, EVAP
system leak detection capability only)
7Seal
8Locking ring
9Fuel feed connection
10Fuel gauge sender float
11Fuel tank and breather assembly12Heat shield
13Scrivet 2 off
14Stud plate
15Nut 2 off
16Cradle
17Bolt 2 off
18Nut plate 2 off
19Hose clip
20LVS vent pipe
21Tank breather connection
22Liquid vapour separator (LVS)
23Anti-trickle fill valve

FUEL DELIVERY SYSTEM - V8
19-2-4 DESCRIPTION AND OPERATION
Description
General
The fuel delivery system comprises a fuel tank, fuel pump and regulator and eight injectors. The system is controlled
by the Engine Control Module (ECM) which energises the fuel pump relay and controls the operation and timing of
each injector solenoid.

+ ENGINE MANAGEMENT SYSTEM - V8, DESCRIPTION AND OPERATION, Description - engine
management.
The multiport fuel injection system is a returnless system with the fuel pressure maintained at a constant level by a
fuel pressure regulator. The regulator is located in the fuel pump housing and returns excess fuel directly from the
pump to the tank.
An electrically operated fuel pump is located in the top of the fuel tank and supplies fuel at pressure to two fuel rails
via a flexible hose. The hose is attached to the feed pipe on the fuel rail at the rear of the engine and the fuel pump
with sealed quick release couplings.
A moulded fuel tank is located at the rear underside of the vehicle between the chassis longitudinals. The tank
provides the attachment for the fuel pump and fuel gauge sender unit which is located inside the tank. The fuel system
is pressurised permanently with pressurised fuel vapour venting to an EVAP canister.

+ EMISSION CONTROL - V8, DESCRIPTION AND OPERATION, Emission Control Systems.
Fuel tank and breather
The fuel tank and breather system is a major part of the fuel delivery system. The fuel tank and breathers are located
at the rear of the vehicle between the chassis longitudinals.
Fuel tank
The moulded fuel tank is made from High Molecular Weight (HMW) High Density Polyethylene (HDPE). Continuous
layers of nylon additive are used during the moulding process. The nylon layers give an improved limit of fuel
permeation through the tank wall and are also resistant to alcohol based fuels used in the NAS market.
The tank is retained in position by a metal cradle which is secured to the chassis with two nut plates and bolts at the
rear and a stud plate and two nuts at the front. A strap above the tank is bolted to the chassis and restrains the tank
from moving upwards. The fuel tank has a useable capacity of approximately 95 litres (25 US Gallons).
An aperture in the top surface of the tank allows for the fitment of the fuel pump, regulator and fuel gauge sender unit
which is retained with a locking ring.
A reflective metallic covering is attached to the tank with two scrivets to shield the tank from heat generated by the
exhaust system.
The fuel filler is located in the right hand rear quarter panel, behind an access flap. The flap is opened electrically
using a switch on the fascia.
The filler is closed by a threaded plastic cap which screws into the filler neck. The cap has a ratchet mechanism to
prevent over tightening and seals against the filler neck to prevent the escape of fuel vapour. The filler cap has a valve
which relieves fuel pressure to atmosphere at approximately 0.12 to 0.13 bar (1.8 to 2.0 lbf.in
2) and opens in the
opposite direction at approximately 0.04 bar (0.7 lbf.in2) vacuum.
All markets except NAS: A moulded filler tube, made from HMW HDPE with no additional additives, connects the
filler to the tank via a flexible rubber hose. The filler tube is connected at its top end behind the filler flap.
NAS markets: A fabricated filler tube, made from stainless steel, connects the filler to the tank via a flexible rubber
hose. The filler tube is connected at it's top end behind the filler flap.
On all vehicles that use unleaded fuel, the filler neck is fitted with an inhibitor. The inhibitor is a tapered nozzle in the
mouth of the filler neck which will only allow the use of a standard unleaded fuel filler gun. A spring loaded flap valve
prevents the incorrect fuel from being trickle filled from an incorrect filler gun.

FUEL DELIVERY SYSTEM - V8
19-2-6 DESCRIPTION AND OPERATION
Fuel pump, regulator and fuel gauge sender
1Electrical connector
2Fuel feed pipe coupling
3Pump feed pipe
4Fuel regulator return pipe
5Fuel gauge sender unit
6Float
7Gauze filter
8Swirl pot
9Pump electrical connections10Pump
11Spring 2 off
12OBD pressure sensor (NAS vehicles with
vacuum type EVAP system leak detection
capability only)
13Fuel pressure regulator
14'O' ring
15'O' ring
The fuel pump is a 'self priming' wet type pump which is immersed in fuel in the tank. The fuel pump operates at all
times when the ignition switch is in position II. If the engine is not started, the ECU will 'time-out' after 2 seconds and
de-energise the fuel pump relay to protect the pump. The pump receives a feed from the battery via fuse 10 in the
engine compartment fusebox and the fuel pump relay. The relay is energised by the ECM when the ignition switch is
moved to position II.
The fuel pump is retained with a locking ring and sealed with a rubber seal. The locking ring requires a special tool
for removal and fitment. An access panel for the fuel pump is located in the loadspace floor below the loadspace
carpet. The access panel is sealed to the floor with a rubber seal and retained by six self-tapping screws.
The fuel gauge sender is integral with the fuel pump. The sender is submerged in the fuel and is operated by a float
which moves with the fuel level in the tank.

FUEL DELIVERY SYSTEM - V8
19-2-14 REPAIRS
9.Remove 6 screws securing fuel pump access
panel to floor.
10.Remove access panel.
11.Clean fuel pump hose connections.
12.Position absorbent cloth to absorb fuel spillage.
13.Disconnect multiplug and fuel hose from fuel
pump housing.
CAUTION: Always fit plugs to open
connections to prevent contamination.
14. NAS models: Disconnect pressure sensor
pipe from fuel pump housing.
CAUTION: Always fit plugs to open
connections to prevent contamination.
15.Use LRT-19-009 to remove locking ring from
fuel pump housing.
16.Remove fuel pump and discard sealing ring. Refit
1.Clean fuel pump housing and mating face on
fuel tank.
2.Fit new seal to mating face on fuel tank.
3.Fit fuel pump assembly to fuel tank and use
LRT-19-009 to fit locking ring.
4.Connect multiplug and fuel hose to fuel pump
housing.
5. NAS models: Connect pressure sensor pipe to
fuel pump housing.
6.Fit fuel pump access panel and secure with
screws.
7.Reposition carpet.
8.Fit carpet finisher and secure with screws.
9.Fit screw cover.
10. Models with third row seats: Fit and secure
third row seat latch finishers.
11.Fit right hand rear lower quarter trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
12. Models with third row seats: Fit RH third row
seat.

+ SEATS, REPAIRS, Seat - third row.
13.Connect battery earth lead.
14.Fit battery cover and secure with fixings.

COOLING SYSTEM - V8
26-2-6 DESCRIPTION AND OPERATION
Description
General
The cooling system used on the V8 engine is a pressure relief by-pass type system which allows coolant to circulate
around the cylinder block and the heater circuit when the thermostat is closed. With coolant not passing through the
radiator, this promotes faster heater warm-up which in turn improves passenger comfort.
A coolant pump is located in a housing at the front of the engine and is driven by a drive belt. The pump is connected
into the coolant passages cast in the cylinder block and pumps coolant from the radiator through the cylinder block.
A viscous fan is attached by means of a nut to the coolant pump pulley drive spindle. The fan draws air through the
radiator to assist in cooling when the vehicle is stationary. The fan rotational speed is controlled relative to the running
temperature of the engine by a thermostatic valve regulated by a bi-metallic coil.
The cooling system uses a 50/50 mix of anti-freeze and water.
Thermostat housing
A plastic thermostat housing is located behind the radiator. The housing has three connections which locate the
radiator bottom hose, top hose and coolant pump feed hose. The housing contains a wax element and a spring loaded
by-pass flow valve.
Thermostat - Main valve
The thermostat is used to maintain the coolant at the optimum temperature for efficient combustion and to aid engine
warm-up. The thermostat is closed at temperatures below approximately 82°C (179°F). When the coolant
temperature reaches approximately 82°C the thermostat starts to open and is fully open at approximately 96°C
(204°F). In this condition the full flow of coolant is directed through the radiator.
The thermostat is exposed to 90% hot coolant from the engine on one side and 10% cold coolant returning from the
radiator bottom hose on the other side.
Hot coolant from the engine passes from the by-pass pipe through four sensing holes in the flow valve into a tube
surrounding 90% of the thermostat sensitive area. Cold coolant returning from the engine, cooled by the radiator,
conducts through 10% of the sensitive area.
In cold ambient temperatures, the engine temperature is raised by approximately 10°C (50°F) to compensate for the
heat loss of 10% exposure to the cold coolant returning from the bottom hose.
By-pass flow valve
The by-pass flow valve is held closed by a light spring. It operates to further aid heater warm-up. When the main valve
is closed and the engine speed is at idle, the coolant pump does not produce sufficient flow and pressure to open the
valve. In this condition the valve prevents coolant circulating through the by-pass circuit and forces the coolant through
the heater matrix only. This provides a higher flow of coolant through the heater matrix to improve passenger comfort
in cold conditions.
When the engine speed increases above idle the coolant pump produces a greater flow and pressure than the heater
circuit can take. The pressure acts on the flow valve and overcomes the valve spring pressure, opening the valve and
limiting the pressure in the heater circuit. The valve modulates to provide maximum coolant flow through the heater
matrix and yet allowing excess coolant to flow into the by-pass circuit to provide the engine's cooling needs at higher
engine rev/min.

COOLING SYSTEM - V8
DESCRIPTION AND OPERATION 26-2-7
Inlet manifold - Cooling connections
Coolant leaves the cylinder block via an outlet pipe attached to the front of the air intake manifold. The pipe is
connected to the thermostat housing and the radiator by a branch hose off the radiator top hose.
Hot coolant from the engine is also directed from the inlet manifold via pipes and hoses into the heater matrix. Coolant
is circulated through the heater matrix at all times when the engine is running.
A further tapping from the inlet manifold supplies coolant to the throttle housing via a hose. The coolant circulates
through a plate attached to the bottom of the housing and is returned through a plastic bleed pipe to an expansion
tank. The hot coolant heats the air intake of the throttle housing preventing ice from forming.
An Engine Coolant Temperature (ECT) sensor is fitted in the inlet manifold adjacent to the manifold outlet pipe. The
sensor monitors coolant temperature emerging from the engine and sends signals to the ECM for engine
management and temperature gauge operation.

+ ENGINE MANAGEMENT SYSTEM - V8, DESCRIPTION AND OPERATION, Description - engine
management.
Expansion tank
The expansion tank is located in the engine compartment. The tank is made from moulded plastic and attached to
brackets on the right hand inner wing. A maximum coolant when cold level is moulded onto the tank.
Excess coolant created by heat expansion is returned to the expansion tank from the radiator bleed pipe at the top of
the radiator. An outlet pipe is connected into the pump feed hose and replaces the coolant displaced by heat
expansion into the system when the engine is cool.
The expansion tank is fitted with a sealed pressure cap. The cap contains a pressure relief valve which opens to allow
excessive pressure and coolant to vent through the overflow pipe. The relief valve opens at a pressure of 1.4 bar (20
lbf.in
2) and above.
Heater matrix
The heater matrix is fitted in the heater assembly inside the passenger compartment. Two pipes pass through the
bulkhead into the engine compartment and provide coolant flow to and from the matrix. The pipes from the bulkhead
are connected to the matrix, sealed with 'O' rings and clamped with circular rings.
The matrix is constructed from aluminium with two end tanks interconnected with tubes. Aluminium fins are located
between the tubes and conduct heat away from the hot coolant flowing through the tubes. Air from the heater
assembly is warmed as it passes through the matrix fins. The warm air is then distributed into the passenger
compartment as required.

+ HEATING AND VENTILATION, DESCRIPTION AND OPERATION, Description.When the engine is
running, coolant from the engine is constantly circulated through the heater matrix.
Radiator
The 45 row radiator is located at the front of the vehicle. The cross-flow type radiator is manufactured from aluminium
with moulded plastic end tanks interconnected with tubes. Aluminium fins are located between the tubes and conduct
heat from the hot coolant flowing through the tubes, reducing the cooling temperature as it flows through the radiator.
Air intake from the front of the vehicle when moving carries heat away from the fins. When the vehicle is stationary,
the viscous fan draws air through the radiator fins to prevent the engine from overheating.
Two connections at the top of the radiator provide for the attachment of the top hose and bleed pipe. A connection at
the bottom of the radiator allows for the attachment of the bottom hose to the thermostat housing.
Two smaller radiators are located in front of the cooling radiator. The lower radiator provides cooling of the gearbox
oil and the upper radiator provides cooling for the engine oil.

+ MANUAL GEARBOX - R380, DESCRIPTION AND OPERATION, Description.

+ AUTOMATIC GEARBOX - ZF4HP22 - 24, DESCRIPTION AND OPERATION, Description.

+ ENGINE - V8, DESCRIPTION AND OPERATION, Description.
Pipes and hoses
The coolant circuit comprises flexible hoses and metal formed pipes which direct coolant into and out of the engine,
radiator and heater matrix. Plastic pipes are used for the bleed and overflow pipes to the expansion tank.
A bleed screw is installed in the radiator top hose and is used to bleed air during system filling. A drain plug is fitted
to each cylinder bank in the cylinder block. These are used to drain the block of coolant.