coolant LAND ROVER DISCOVERY 1999 User Guide

TORQUE WRENCH SETTINGS
06-8
Manifolds and exhaust systems - Td5
Manifolds and exhaust systems - V8
TORQUE DESCRIPTION METRIC IMPERIAL
Front pipe to turbocharger 27 Nm (20 lbf.ft)
Inlet manifold25 Nm (18 lbf.ft)
Tail pipe25 Nm (18 lbf.ft)
Fuel cooler25 Nm (18 lbf.ft)
EGR valve10 Nm (7 lbf.ft)
Exhaust manifold25 Nm (18 lbf.ft)
Exhaust manifold heatshield (M6) bolts 10 Nm (7 lbf.ft)
Exhaust manifold heatshield (M8) bolts 25 Nm (18 lbf.ft)
EGR pipe Allen screws 10 Nm (7 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Intermediate pipe/silencer nuts 25 Nm (18 lbf.ft)
Inlet manifold bolts - initial tighten 10 Nm (7 lbf.ft)
Inlet manifold gasket clamp bolts 18 Nm (13 lbf.ft)
Inlet manifold bolts - final tighten 51 Nm (38 lbf ft)
Tail pipe25 Nm (18 lbf.ft)
Coolant outlet pipe 22 Nm (16 lbf.ft)
Front pipe flange nuts 30 Nm (22 lbf.ft)
Exhaust manifold55 Nm (40 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)

TORQUE WRENCH SETTINGS
06-14
Steering
TORQUE DESCRIPTION METRIC IMPERIAL
Drag link to drop arm 80 Nm (59 lbf.ft)
Track rod to steering knuckle 125 Nm (92 lbf.ft)
Tension collet to steering knuckle 5 Nm (3.7 lbf.ft)
Steering damper125 Nm (92 lbf.ft)
Steering knuckle to axle yoke upper ball joint 110 Nm (81 lbf.ft)
High pressure pipe union 20 Nm (15 lbf.ft)
Drag link/track rod M8 bolts 22 Nm (16 lbf.ft)
Drag link/track rod M10 bolts 33 Nm (24 lbf.ft)
Steering box90 Nm (66 lbf.ft)
Universal joint to intermediate shaft 25 Nm (18 lbf.ft)
Panhard rod230 Nm (170 lbf.ft)
Steering box output shaft 88 Nm (65 lbf.ft)
Drop arm240 Nm (177 lbf.ft)
Auxiliary housing bolts 40 Nm (30 lbf.ft)
Auxiliary housing nut 10 Nm (7 lbf.ft)
PAS pump - V822 Nm (16 lbf.ft)
PAS pump pipe bracket bolt 22 Nm (16 lbf.ft)
Jockey pulley bolt 50 Nm (37 lbf.ft)
PAS pump adaptor pipe 10 Nm (7 lbf.ft)
PAS pump to coolant pump bolts - Td5 25 Nm (18 lbf.ft)
Steering column to fascia 25 Nm (18 lbf.ft)
Universal joint to steering box 25 Nm (18 lbf.ft)
Ball joint to swivel hub 77 Nm (57 lbf.ft)
PAS pump pulley22 Nm (16 lbf.ft)
Steering wheel nut 43 Nm (32 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

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
PROCEDURES 10-9
Air suspension intake filter
Check
1.Check condition of filter and that filter is clean,
replace if necessary.

+ REAR SUSPENSION, REPAIRS,
Filter - intake - SLS.
Anti-freeze
Replace
1.Replace anti-freeze.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
Cooling system
Check
1.Check cooling, intercooler and heating systems
for leaks; hoses and oil pipes for security and
condition.
2.Check accessible hose clips for tightness.
3.Check coolant level, top-up if necessary.
Top-up
1.With engine cold, remove expansion tank filler
cap.
2.Top-up with recommended mixture of coolant
until level reaches mark on expansion tank.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Anti-Freeze
Concentration.
3.Fit expansion tank filler cap.

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
REPAIRS 12-2-21
5.Release coolant rail from inlet manifold and
discard 'O' ring.
6.Remove nuts securing alternator cables and
release cables from alternator.
7.Disconnect multiplugs from RH bank of
injectors and release harness from fuel rail.
8.Release ht leads from clips on rocker cover.
9.Noting fitted position of 2 long screws or multi-
hex bolts, remove and discard screws/bolts
securing rocker cover; remove rocker cover.
10.Remove and discard rocker cover gasket. 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.Secure ht leads in rocker cover clips.
7.Secure injector harness to fuel rail and connect
multiplugs to injectors.
8.Position alternator cables, and tighten terminal
B+ nut to 18 Nm (13 lbf.ft) and terminal D+ nut
to 5 Nm (3 lbf.ft).
9.Clean coolant rail 'O' ring recess.
10.Lubricate and fit new 'O' ring to coolant rail,
position coolant rails, fit bolts and tighten to 22
Nm (16 lbf.ft).
11. Models with SAI: Apply a small amount of
engine oil to top of air manifold union nuts and
around air manifold pipes.
12. Models with SAI:Position air manifold and
finger tighten both air manifold union nuts.
CAUTION: Finger tighten union nuts as far
as possible, damage to air manifold pipes or
adapters may result if this is not done.
13. Models with SAI: Tighten both union nuts to
25 Nm (18 lbf.ft).
CAUTION: Ensure that air manifold pipes
are not distorted during tightening
operation.
14.Fit upper inlet manifold.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
15.Refill cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.