clutch LAND ROVER DISCOVERY 1999 User Guide

GENERAL DATA
04-12
Clutch - V8
Type Diaphragm spring, hydraulically operated with self-centering,
preloaded release bearing
Clutch plate friction material APTEC 385
Drive plate diameter 267 mm (10.5118 in)
Pressure plate diameter 268 mm (10.5512 in)
Clutch plate thickness (clamped state)
⇒ New 8.4-8.9 mm (0.33-0.35 in)
⇒ Service limit 7.1 mm (0.28 in)
Rivet depth:
⇒ New 1.73 mm (0.07 in)
⇒ Service limit 0.25 mm (0.01 in)
Clutch plate runout:
⇒ New 0.5 mm (0.02 in)
⇒ Service limit 0.5 mm (0.02 in)

TORQUE WRENCH SETTINGS
06-9
Clutch
TORQUE DESCRIPTION METRIC IMPERIAL
Clutch bleed screw 9 Nm (7 lbf.ft)
Clutch cover nuts Td5 25 Nm (18 lbf.ft)
Clutch cover bolts V8 40 Nm (30 lbf.ft)
Clutch master cylinder to pedal box 25 Nm (18 lbf.ft)
Hydraulic pipe union 18 Nm (13 lbf.ft)
Clutch release bearing pivot point bolt 8 Nm (6 lbf.ft)
Slave cylinder25 Nm (18 lbf.ft)

TORQUE WRENCH SETTINGS
06-10
Manual gearbox - R380
+ Apply sealant, Part No. STC 50552 to threads
TORQUE DESCRIPTION METRIC IMPERIAL
Bias spring adjustment plate bolts + 25 Nm (18 lbf.ft)
Gearbox to engine bolts 45 Nm (33 lbf.ft)
Coolant pipe housing bolts 25 Nm (18 lbf.ft)
Breather pipe banjo bolt 15 Nm (11 lbf.ft)
Gear lever extension clamp bolt 25 Nm (18 lbf.ft)
Gearbox mounting bolts 85 Nm (63 lbf.ft)
Gearbox mounting nuts 48 Nm (37 lbf.ft)
Seal housing bolts 18 Nm (13 lbf.ft)
Bearing sleeve bolts 25 Nm (18 lbf.ft)
Fork bolt7 Nm (5.2 lbf.ft)
Reverse light switch 24 Nm (18 lbf.ft)
Extension housing bolts + 25 Nm (18 lbf.ft)
Gear selector housing bolts + 25 Nm (18 lbf.ft)
Oil pump to housing Torx screws 6 Nm (4.4 lbf.ft)
Gear change lever yoke Allen screw + 25 Nm (18 lbf.ft)
5th gear stake nut 350 Nm (258 lbf.ft)
Spool retainer bolts 8 Nm (6 lbf.ft)
Centre plate detent spring and ball Torx screw 25 Nm (18 lbf.ft)
Selector lever to housing bolts + 25 Nm (18 lbf.ft)
Clutch \ Bell housing bolts 73 Nm (54 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)

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
10-12 PROCEDURES
Fluid reservoirs
Check/top-up — Brake/Clutch reservoir
1.Check fluid level in brake/clutch fluid reservoirs.
2.Clean area around filler cap, remove cap.
3.Top-up if necessary to correct level on reservoir
using recommended fluid.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Fluids.
4.Fit filler cap.
Check/top-up — PAS/ACE reservoirs
1.Check fluid level in PAS and ACE fluid
reservoirs.
2.Clean area around filler cap, remove cap.
3.Top-up if necessary to correct level on reservoir
using recommended fluid.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Fluids.
4.Fit filler cap.Check/top-up — Washer reservoir
1.Check fluid level in windscreen washer
reservoir.
2.Clean area around filler cap, remove cap.
3.Top-up if necessary to correct level on reservoir
using recommended fluid.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Fluids.
4.Fit filler cap.

MAINTENANCE
10-24 PROCEDURES
Brake hose, brake, fuel, ACE, clutch
pipes and unions/electrical harnesses
Check – General
1.Check brake servo hose for cracks, leaks and
chafing.
2.Check brake, clutch pipes and unions for
chafing, leaks and corrosion and that all pipes
and hoses are correctly routed and secure.
3.Check electrical harnesses for chafing and
damage.
Check – V8 engine fuel pipes
1.Check fuel pipes and unions for chafing, leaks
and corrosion and that all pipes and hoses are
correctly routed and secure. Check – Diesel engine fuel pipes
1.Check fuel pipes and unions for chafing, leaks
and corrosion and that all pipes and hoses are
correctly routed and secure.
Power steering, suspension
ACE pipes
1.Check for fluid leaks from power steering and
suspension systems.
2.Check ACE pipes and unions for chafing, leaks
and corrosion and that all pipes and hoses are
correctly routed and secure.

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
REPAIRS 12-2-31
Flywheel
$% 12.53.07
Remove
1.Remove gearbox

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
2.Restrain flywheel.
3.Working in sequence, progressively slacken 6
bolts securing clutch cover to flywheel.
Remove bolts.
4.Remove clutch cover.
5.Remove clutch plate.
6.Release crankshaft sensor multiplug from
bracket.
7.Remove 2 bolts securing crankshaft sensor
cover. 8.Remove crankshaft sensor cover.
9.Remove 2 nuts securing crankshaft sensor.
10.Remove crankshaft sensor.
11.Remove 6 bolts securing flywheel.
12.Remove flywheel.
On early engines, balance weights are on
engine side of flywheel; replacement flywheels
will have balance weights on clutch side of
flywheel.
Refit
1.Clean mating faces of flywheel and crankshaft,
dowel and dowel hole. Ensure bolt holes in
crankshaft are clean and dry.
2.Fit flywheel to crankshaft and tighten bolts to
78 Nm (58 lbf.ft).
3.Clean crankshaft sensor and mating face.
4.Fit crankshaft sensor and tighten nuts to 6 Nm
(4.4 lbf.ft).
5.Fit crankshaft sensor cover and tighten bolts to
6 Nm (5 lbf.ft).
6.Fit crankshaft sensor multiplug to bracket.
7.Clean clutch cover, drive plate and spigot bush
in end of crankshaft. Renew worn components
as necessary.
8.If refitting existing drive plate, apply 'Molycote
FB 180' to splines.