air conditioning LAND ROVER DISCOVERY 1999 User Guide

TORQUE WRENCH SETTINGS
06-20
Heating and air conditioning
Wipers and washers
TORQUE DESCRIPTION METRIC IMPERIAL
Heater assembly16 Nm (12 lbf.ft)
Compressor bolts22 Nm (16 lbf.ft)
Blower motor19 Nm (14 lbf.ft)
Compressor to mounting bracket bolts 25 Nm (18 lbf.ft)
A/C pipes to compressor bolts 10 Nm (7 lbf.ft)
Condenser pipe bolt 5 Nm (3.7 lbf.ft)
Receiver drier to bracket bolts 5 Nm (3.7 lbf.ft)
Adaptor block to receiver drier bolt 5 Nm (3.7 lbf.ft)
Evaporator pipe bolts 5 Nm (3.7 lbf.ft)
Dual pressure switch to receiver drier 10 Nm (7 lbf.ft)
Air conditioning pipes to receiver drier bolts 5 Nm (3.7 lbf.ft)
TX valve pressure pipe union 22 Nm (16 lbf.ft)
Evaporator pipe to TXV valve 32 Nm (24 lbf.ft)
Evaporator assembly to body bolts 16 Nm (12 lbf.ft)
High and low pressure pipe, bolts 10 Nm (7 lbf.ft)
Fuel burning heater Torx bolts 25 Nm (18 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Link to motor spindle 7 Nm (5.2 lbf.ft)
Front motor assembly 2.5 Nm (1.8 lbf.ft)
Spindle nut 3 Nm (2.2 lbf.ft)
Wiper arm nut13 Nm (10 lbf.ft)

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
09-2
Fluids
Anti-freeze
Use Havoline Extended Life Coolant (XLC), or any
ethylene glycol based anti-freeze (containing no
methanol) with only Organic Acid Technology (OAT)
corrosion inhibitors, to protect the cooling system
CAUTION: No other anti-freeze should be used
with Havoline Extended Life Coolant.
The cooling system should be drained, flushed and
refilled with the correct amount of anti-freeze solution
at the intervals given on the Service Maintenance
Check Sheet.
After filling with anti-freeze solution, attach a warning
label to a prominent position on the vehicle stating
the type of anti-freeze contained in the cooling
system to ensure that the correct type is used for
topping-up.
Brake/Clutch fluid
Use only DOT 4 brake fluid.
PAS fluid
Use Texaco cold climate power assisted steering
fluid PSF 14315.
ACE fluid
Where ambient temperature falls below -20° C (-4°
F), use only Texaco cold climate power assisted
steering fluid PSF 14315. Where ambient
temperature remains above -20° C (-4° F), use either
Texaco cold climate power assisted steering fluid ,
Dexron 11 or Dexron 111 non-synthetic fluid.
Air conditioning
Use only refrigerant R134a.
Refrigerant oil
Use only Nippon Denso ND-oil 8.
Refrigerant oil absorbs water and must not be stored
for long periods. Do not pour unused oil back into the
container.
NOTE: The total quantity of refrigerant oil in the
system is 180 ml.
CAUTION: Do not use any other type of
refrigerant oil.
Anti-Freeze Concentration
The overall anti-freeze concentration should not fall,
by volume, below 50% to ensure that the anti-
corrosion properties of the coolant are maintained.
Anti-freeze concentrations greater than 60% are not
recommended as cooling efficiency will be impaired.
The following recommended quantities of anti-freeze
will provide frost protection to -48°C (-53°F):
Engine - TD5
Engine - V8
Concentration 50%
Amount of Anti-freeze 4 litres
Concentration 50%
Amount of Anti-freeze 6.5 litres
13.5 pts (US)

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
09-4
Gearbox oil
Manual Gearbox: Use Texaco MTF 94 oil for refill
and topping-up.
Automatic Gearbox: Use Texamatic 9226, ATF
Dexron 11D or Dexron 111 for refill and topping-up
Transfer box
Use Texaco Multi-Gear 75W/90R or oil meeting
specification API GL5.
Front and rear axles
Use Texaco Multi-Gear 75W/90R.
Air Conditioning
Use lubricating oil Nippon Denso ND-8.
General Greasing
Use Multipurpose Lithium Base Grease N.L.G.I.
consistency No. 2.
Bonnet latch
Lubricate cable and latch with oil.
Sealants
The following table lists those sealants which are
used during repair / overhaul procedures covered in
this manual; it is essential that the sealant specified
for a particular procedure is used at all times.
Component Application Land Rover
Part No.
Td5 Engine Timing chain fixed
guide Allen screwSTC 50552
Td5 Engine Camshaft cover
gasket joint lineSTC 50550
Td5 Engine Oil pick-up strainer
Torx screwsSTC 50552
Td5 Engine Oil pump drive
sprocket retaining
boltSTC 50552
Td5 Engine Timing chain cover,
crankshaft rear oil
seal and sump
gasket joint linesSTC 50550
Td5 Engine Oil pressure relief
valve plugSTC 50552
Td5 Engine Camshaft carrier to
cylinder headSTC 4600
Td5 Engine Timing cover STC 50550
V8 Engine Sump gasket to
cylinder blockSTC 50550
V8 Engine 'V' grooves at end
of cylinder head -
Inlet manifold
gasketSTC 50550
V8 Engine Cruciform seal
endsSTC 50550
V8 Engine Dipstick tube STC 50554
V8 Engine Timing cover bolts STC 50552
Engine
Management
System - V8Engine coolant
temperature (ECT)
sensor threadsSTC 50552
Manifolds and
Exhaust
System - V8'V' grooves at end
of cylinder head -
Inlet manifold
gasketSTC 50550
Manual
Gearbox -
R380Gear selector
housingSTC 4404
Manual
Gearbox -
R380Selector housing
boltsSTC 50552
Manual
Gearbox -
R380Input shaft oil seal
housingSTC 4404
Manual
Gearbox -
R380Reverse inhibitor
shaft threadsSTC 50552

ENGINE - V8
REPAIRS 12-2-19
Gasket - rocker cover - LH
$% 12.29.40
Remove
1.Remove upper inlet manifold gasket.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
2. Models with air conditioning: Release 4
clips and remove fan cowl.
3. Models with air conditioning: Release
tension on auxiliary drive belt and remove belt
from air conditioning compressor. Disconnect
compressor multiplug. Remove 4 bolts
securing compressor and position compressor
aside. 4.Release ht leads from rocker cover clips.
5.Remove screw securing dip stick tube.
6.Noting fitted position of 2 long screws or multi-
hex bolts, remove and discard screws/bolts
securing rocker cover; remove rocker cover.
CAUTION: Screws/bolts must be replaced
with new 'patched' multi-hex bolts.
7.Remove and discard rocker cover gasket.

ENGINE - V8
12-2-20 REPAIRS
Refit
1.Clean mating faces of rocker cover and
cylinder head, ensure bolt holes are clean and
dry.
2.Fit a new gasket dry, position rocker cover
ensuring gasket is correctly located.
3.Fit new 'patched' multi-hex rocker cover bolts
ensuring that 2 short bolts are on side of rocker
cover nearest centre of engine.
4.Tighten bolts by diagonal selection to:
lStage 1 - 3 Nm (2.5 lbf.ft)
lStage 2 - 8 Nm (6 lbf.ft)
5.Ensure that outer rim of gasket is correctly
positioned around periphery of rocker cover.
6.Fit and tighten screw securing dip stick tube.
7.Secure ht leads in rocker cover clips.
8. Models with air conditioning: Clean
compressor dowels and dowel holes. Position
compressor, fit bolts and tighten to 22 Nm (16
lbf.ft). Release auxiliary drive belt tensioner
and fit belt to compressor.
9. Models with air conditioning: Position fan
cowl and secure clips.
10.Fit upper inlet manifold.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
Gasket - rocker cover - RH
$% 12.29.41
Remove
1.Drain cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
2.Remove upper inlet manifold gasket.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
3. Models with SAI: Disconnect 2 air manifold
unions from adapters in cylinder head and
remove manifold.
CAUTION: Take care that air manifold pipes
are not damaged during removal of union
nuts.
4.Remove 2 bolts securing coolant rails to inlet
manifold.

ENGINE - V8
12-2-40 REPAIRS
6.Remove 2 bolts securing radiator LH and RH
upper mounting brackets to body panel and
remove brackets.
7.Remove 4 screws securing air conditioning
condenser LH and RH upper mounting
brackets to condenser.
8.Remove condenser upper mounting brackets
with rubber mounts from radiator extension
brackets.
9.Remove 2 bolts securing LH and RH extension
brackets to radiator and remove brackets.
10.Position absorbent cloth under each oil cooler
hose connection to collect oil spillage. 11.Push against coupling release rings and
disconnect both hoses from oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
12.Remove screw securing oil cooler to radiator.
13.Release cooler from its location on radiator.
14.Release radiator lower mountings from
location in chassis and carefully move radiator
towards engine sufficiently only to release
engine oil cooler from radiator.
15.Remove engine oil cooler.
Refit
1.Fit engine oil cooler to radiator, engage in
location and secure with screw.
2.Fit radiator to location in chassis.
3.Ensure connections are clean, then secure
hoses to oil cooler.
4.Fit extension brackets to radiator and secure
with bolts.
5.Fit brackets with rubber mounts to extension
brackets and secure to air conditioning
condenser with screws.
6.Fit radiator upper mounting brackets and
secure to body with bolts.
7.Fit LH horn and secure with nut.
8.Fit LH and RH air deflectors to front panel and
secure with scrivets.
9.Fit front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY..
10.Fit cooling fan cowl and secure with fixings.
11.Fit battery cover and secure with fixings.
12.Top up engine oil.

ENGINE MANAGEMENT SYSTEM - V8
DESCRIPTION AND OPERATION 18-2-7
The ECM controls the following outputs:
lFuel injectors (1 per cylinder).
lIgnition coils/ high tension leads/ spark plugs.
lFuel pump relay.
lIdle air control valve.
lHeated oxygen sensors.
lEVAP canister purge valve.
lEVAP canister vent solenoid (CVS) valve (where fitted).
lMalfunction Indicator Lamp (MIL)/ service engine soon lamp (where fitted).
lHill descent control (via SLABS interface).
lEVAP system fuel leak detection pump (where fitted)
lSecondary air injection pump (where fitted)
The ECM also interfaces with the following:
lDiagnostics via diagnostic connector with TestBook.
lController Area Network (CAN) link to EAT ECU.
lAir conditioning system.
lSelf Levelling & Anti-lock Braking System (SLABS) ECU.
lImmobilisation system via the body control unit (BCU).
lInstrument cluster.
lCruise control ECU
lActive Cornering Enhancement (ACE) ECU

ENGINE MANAGEMENT SYSTEM - V8
18-2-36 DESCRIPTION AND OPERATION
Idle Air Control Valve (IACV) (C0641)
The IACV is located on the side of the air inlet pipe on top of the engine. The IACV is used to maintain good quality
idle speed under all operating conditions.
When an engine is running at idle it is subject to a combination of internal and external loads that can affect idle speed.
These loads include engine friction, water pump, alternator operation, and air conditioning.
The IACV acts as an air bypass valve. The ECM uses the IACV to enable the closed loop idle speed calculation to be
made by the ECM. This calculation regulates the amount of air flow into the engine at idle, therefore compensating
for any internal or external loads that may affect idle speed.
The IACV utilises two coils that use opposing PWM signals to control the position of opening/closing of a rotary valve.
If one of the circuits that supply the PWM signal fails, the ECM closes down the remaining signal preventing the IACV
from working at its maximum/ minimum setting. If this should occur, the IACV automatically resumes a default idle
position. In this condition, the engine idle speed is raised and maintained at 1200 rev/min with no load placed on the
engine.
The idle speed in cold start condition is held at 1200 rev/min in neutral for 20 seconds and ignition timing is retarded
as a catalyst heating strategy. The cold start idle speed and the default idle position give the same engine speed 1200
rev/min, and although they are the same figure they must not be confused with each other as they are set separately
by the ECM.
Note that the rotary valve must not be forced to move by mechanical means. The actuator can not be
serviced; if defective, the entire IACV must be replaced.
Input/Output
The input to the IACV is a 12 volt signal from fuse 2 located in the engine compartment fuse box. The output earth
signal to open and close the actuator is controlled by the ECM as follows:
lIACV (open signal) - via pin 42 of connector C0636 of the ECM
lIACV (closed signal) - via pin 43 of connector C0636 of the ECM
The IACV can fail the following ways or supply incorrect signal:
lActuator faulty.
lRotary valve seized.
lWiring loom fault.
lConnector fault.
lIntake system air leak.
lBlocked actuator port or hoses.
lRestricted or crimped actuator port or hoses.
In the event of an IACV signal failure any of the following symptoms may be observed:
lEither low or high idle speed.
lEngine stalls.
lDifficult starting.
lIdle speed in default condition.

ENGINE MANAGEMENT SYSTEM - V8
DESCRIPTION AND OPERATION 18-2-45
Malfunction Indicator Lamp (MIL)/ service engine soon warning lamp
The MIL/ service engine soon warning lamp is located in the instrument cluster. It illuminates to alert the driver to
system malfunctions. Service engine soon warning lamp is the name for this warning lamp in NAS only, it is called
MIL in all other markets.
During ignition a self-test function of the lamp is carried out. The lamp will illuminate for 3 seconds then it will
extinguish if no faults exist.

+ INSTRUMENTS, DESCRIPTION AND OPERATION, Description.
Input/Output
The MIL is supplied with battery voltage from the instrument cluster. When the ECM detects a fault, it provides an
earth path to illuminate the MIL. Output to the MIL is via pin 20 of connector C0637 of the ECM.
Air Temperature Control (ATC) request
The ATC request comes via the ATC switch located in the facia panel. When the driver operates the switch it acts as
a request from the ATC ECU to engage the ATC clutch to drive the system.
During periods of high driver demand such as hard acceleration or maximum rev/min the ATC clutch will be disabled
for a short time. This is to reduce the load on the engine.

+ AIR CONDITIONING, DESCRIPTION AND OPERATION, Description.

ENGINE MANAGEMENT SYSTEM - V8
18-2-46 DESCRIPTION AND OPERATION
Input/Output
The operation of the ATC request is via a switch being connected to earth. Voltage is supplied via pin 38 of connector
C0637 of the ECM, at the point at when the switch is pressed the connection is made and the ATC clutch is engaged.
The ATC request can fail as follows:
lOpen circuit.
lShort circuit to voltage supply.
lShort circuit to vehicle earth.
lWiring loom fault.
In the event of an ATC request failure, the ATC system does not work.
Should a malfunction of the component occur the following fault codes may be evident and can be retrieved by
TestBook.
P Code J2012 Description Land Rover Description
P1535 Air conditioning compressor request
malfunctionATC requested when not in standby mode