gearbox LAND ROVER DISCOVERY 1999 User Guide

GENERAL DATA
04-15
Automatic gearbox - ZF4HP22/24
Type ZF4HP22, electro-hydraulic shift control with fluid torque converter
Gears 4 forward, 1 reverse
Gear ratios:
⇒ First 2.480:1
⇒ Second 1.480:1
⇒ Third 1.000:1
⇒ Fourth 0.728:1
⇒ Reverse 2.086:1
Torque converter lock-up Engaged in third and fourth gears above 72 km/h (45 mph)
Input shaft axial end-float 0.2 to 0.4 mm (0.008 to 0.016 in)

IDENTIFICATION NUMBERS
05-2
Vehicle identification number - except NAS and
Canada
Example: SALLTGM87WA600172Vehicle identification number - NAS and Canada
Example: SALTY124OWA600180
Paint and trim colour codes
Paint code (F): a 3 digit code identifying the original
paint colour is stamped on the VIN plate. Refer to
Parts Catalogue for full list of colour codes.
Trim code (G): a code identifying the original trim
type and colour is stamped on the VIN plate. Refer to
the relevant Parts Catalogue for coding details
SALManufacturer's identifier (Land Rover UK)
LTMarque/Model
LT = Discovery
GClass
A = Japan
G = 100 inch
MBody Style
B = 5 door models
8Engine
1 = 4.0 V8 LC Cat
2 = 4.0 V8 HC Cat
3 = 4.0 LC Non Cat
8 = TD5 engine EGR/Cat
9 = TD5 engine EGR/ Non Cat
7Transmission and Steering
3 = RHD automatic gearbox
4 = LHD automatic gearbox
7 = RHD manual gearbox
8 = LHD manual gearbox
WModel Year
W = 1998 Model year
X = 1999 Model year
Y = 2000 Model year
1 = 2001 Model year
2 = 2002 Model year
3 = 2003 Model year
AAssembly plant
A = Solihull
F = KD build
6 figures= Serial number
SALManufacturer's identifier (Land Rover UK)
TMarque/Model
T = Discovery
YClass
Y = 100 inch USA/Canada
N = 100 inch California
1Body Style
1 = 4 door Station Wagon
2Engine
2 = 4.0 V8 HC Cat
4Transmission and Steering
4 = LHD automatic gearbox
OCheck digit
WModel Year
W = 1998 Model year
X = 1999 Model year
Y = 2000 Model year
1 = 2001 Model year
2 = 2002 Model year
3 = 2003 Model year
AAssembly plant
A = Solihull
6 figures= Serial number

IDENTIFICATION NUMBERS
05-3
Identification Number Locations
Engine number
V8 Engine
Td5 Engine
Stamped on the LH side of the cylinder block below
the exhaust manifoldManual gearbox number
Stamped on the RH side of the gearbox casing,
adjacent to the oil drain plug.
Automatic gearbox number
Stamped on a plate attached to the LH side of the
gearbox casing adjacent to the selector mechanism.

TORQUE WRENCH SETTINGS
06-1
TORQUE WRE NCH SETTINGS
Maintenance
TORQUE DESCRIPTION METRIC IMPERIAL
Wheel nuts 140 Nm (103 lbf.ft)
V8 oil drain plug 33 Nm (24 lbf.ft)
Td5 oil drain plug 23 Nm (17 lbf.ft)
Oil filter element, tighten two thirds of a turn by hand or to - 17 Nm (13 lbf.ft)
Manual gearbox oil drain plug 50 Nm (37 lbf.ft)
Manual gearbox oil filler/level plug 30 Nm (22 lbf.ft)
Automatic gearbox oil drain plug 15 Nm (11 lbf.ft)
Automatic gearbox oil drain plug 30 Nm (22 lbf.ft)
Transfer gearbox oil drain plug 30 Nm (22 lbf.ft)
Transfer gearbox oil filler/level plug 25 Nm (18 lbf.ft)
Axle oil drain plug 64 Nm (47 lbf.ft)
Axle oil filler/level plug 10 Nm (7 lbf.ft)

TORQUE WRENCH SETTINGS
06-2
Engine Td5
TORQUE DESCRIPTION METRIC IMPERIAL
ACE pump bolts25 Nm (18 lbf.ft)
A/C compressor bolts 25 Nm (18 lbf.ft)
Alternator support bracket to cylinder head bolts 25 Nm (18 lbf.ft)
Alternator/vacuum pump oil feed pipe union 10 Nm (7 lbf.ft)
Camshaft cover to camshaft carrier bolts 10 Nm (7 lbf.ft)
Camshaft sprocket to camshaft bolts 37 Nm (27 lbf.ft)
Centrifuge cover bolts 10 Nm (7 lbf.ft)
Centrifuge oil drain pipe to sump bolts (or nuts) 10 Nm (7 lbf.ft)
Centrifuge to oil drain pipe bolts 10 Nm (7 lbf.ft)
Centrifuge to oil cooler housing bolts 25 Nm (18 lbf.ft)
CKP sensor bolt10 Nm (7 lbf.ft)
Coolant pipe bolt50 Nm (37 lbf.ft)
Connecting rod bolts, then a further 80°20 Nm (15 lbf.ft)
Crankshaft pulley bolt 460 Nm (340 lbf.ft)
Crankshaft pulley TV damper bolts 80 Nm (59 lbf.ft)
Crankshaft rear oil seal housing bolts 10 Nm (7 lbf.ft)
Cylinder head bolts initial tighten 30 Nm (22 lbf.ft)
Cylinder head bolts final tighten, then a further 90°, then a further 180° and finally a
further 45°65 Nm (48 lbf.ft)
Dipstick tube to camshaft carrier bolt 10 Nm (7 lbf.ft)
Drive plate (automatic transmission) to crankshaft bolts 115 Nm (85 lbf.ft)
EGR pipe clamp to cylinder head bolt - if fitted 25 Nm (18 lbf.ft)
EGR pipe Allen screws 10 Nm (7 lbf.ft)
Engine mounting (front) to cylinder block bolts 48 Nm (35 lbf.ft)
Engine mounting (front) to chassis nuts 85 Nm (63 lbf.ft)
Engine mounting bracket (rear, LH & RH) to gearbox bolts 85 Nm (63 lbf.ft)
Engine mounting bracket (rear, LH & RH) nuts 45 Nm (33 lbf.ft)
Flywheel to crankshaft (manual transmission) bolts, then a further 90°40 Nm (30 lbf.ft)
Front crossmember bolts 26 Nm (20 lbf.ft)
Fuel connector block bolts 25 Nm (18 lbf.ft)
Fuel cooler to inlet manifold bolts 25 Nm (18 lbf.ft)
Gearbox housing to engine bolts 50 Nm (37 lbf.ft)
Heater pipe to cylinder head bolts 25 Nm (18 lbf.ft)
Main bearing cap bolts then a further 90°33 Nm (24 lbf.ft)
Oil cooler housing to cylinder block bolts 25 Nm (18 lbf.ft)
Oil cooler pipe clip bolts 10 Nm (7 lbf.ft)
Oil filter adaptor housing to oil cooler housing bolts 25 Nm (18 lbf.ft)
Oil pick-up strainer Torx screws + 10 Nm (7 lbf.ft)
Oil pressure switch 15 Nm (11 lbf.ft)
Oil pump drive sprocket bolt + 25 Nm (18 lbf.ft)
Oil pump pressure relief valve plug + 25 Nm (18 lbf.ft)
Oil pump and stiffener assembly to cylinder block bolts 13 Nm (10 lbf.ft)
Oil sump to cylinder block bolts 25 Nm (18 lbf.ft)
Oil sump to gearbox bell housing bolts 13 Nm (10 lbf.ft)
PAS pump bracket bolts 27 Nm (20 lbf.ft)
PAS pump pulley bolts 27 Nm (20 lbf.ft)
Rocker arm adjusting screw locknuts 16 Nm (12 lbf.ft)

TORQUE WRENCH SETTINGS
06-4
Engine V8
* New bolts must be fitted
+ Apply sealant, Part Number STC 50552 to threads
TORQUE DESCRIPTION METRIC IMPERIAL
Engine mounting bolts (rear, LH & RH) to gearbox bolts 85 Nm (63 lbf.ft)
Engine mounting (rear, LH & RH) nuts 45 Nm (33 lbf.ft)
Cylinder head bolts tighten, then 90°, then a further 90° * 20 Nm (15 lbf.ft)
Rocker shaft bolts 40 Nm (30 lbf.ft)
Alternator mounting bracket 40 Nm (30 lbf.ft)
Auxiliary drive belt tensioner 45 Nm (33 lbf.ft)
Engine earth lead 22 Nm (16 lbf.ft)
Rocker cover screws/bolts * 8 Nm (6 lbf.ft)
Torque converter to drive plate 50 Nm (37 lbf.ft)
A/C compressor 22 Nm (16 lbf.ft)
ACE pump 22 Nm (16 lbf.ft)
Flywheel to crankshaft 78 Nm (58 lbf.ft)
Crankshaft sensor 6 Nm (5 lbf.ft)
Crankshaft sensor cover 6 Nm (5 lbf.ft)
Spacer and hub to crankshaft - Early engines 85 Nm (63 lbf.ft)
Drive plate and clamp ring - Early engines 45 Nm (33 lbf.ft)
Drive plate to crankshaft Allen bolts - Later engines 85 Nm 63 lbf.ft)
Oil pick up strainer 10 Nm (7 lbf.ft)
Filter head adaptor 13 Nm (10 lbf.ft)
Filter head 8 Nm (6 lbf.ft)
Sump bolts 22 Nm (16 lbf.ft)
Oil pressure switch 15 Nm (11 lbf.ft)
Timing gear cover to cylinder block + 22 Nm (16 lbf.ft)
Oil cooler pipe to timing gear cover 15 Nm (11 lbf.ft)
Crankshaft pulley bolt 270 Nm (200 lbf.ft)
Coolant outlet elbow 22 Nm (16 lbf.ft)
Auxiliary housing 40 Nm (30 lbf.ft)
Jockey pulley 50 Nm (37 lbf.ft)
Camshaft gear 50 Nm (37 lbf.ft)
Rocker shaft bolts 40 Nm (30 lbf.ft)
Connecting rod bolts
Final torque - turn through 80°°20 Nm
80°(15 lbf.ft)
80°
Initial torque - all main bearing cap bolts and side bolts 13.5 Nm (10 lbf.ft)
Final torque - main bearing cap side bolts 11 to 15 45 Nm (33 lbf.ft)
Final torque - main bearing cap bolts 1 to 8 72 Nm (53 lbf.ft)
Final torque - main bearing cap bolts 9 and 10 92 Nm (68 lbf.ft)
Final torque - main bearing cap side bolts 16 to 20 45 Nm (33 lbf.ft)
Viscous fan nut 45 Nm (33 lbf.ft)
Camshaft thrust plate bolts 22 Nm (16 lbf.ft)
Secondary Air Injection adapters 33 Nm (24 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
06-11
Transfer box - LT230SE
† New nut must be fitted
* New Patchlok nut must be fitted
+ Apply sealant, Part No. STC 50552 to threads
TORQUE DESCRIPTION METRIC IMPERIAL
High/low selector cable 30 Nm (22 lbf.ft)
Bottom cover plate bolts + 25 Nm (18 lbf.ft)
Transfer box to gearbox bolts - Petrol and diesel + 45 Nm (33 lbf.ft)
Rear cover plate stud nut/bolts + 25 Nm (18 lbf.ft)
Differential lock warning lamp switch locknut - Up to 03 MY 11 Nm (8 lbf.ft)
Differential lock warning lamp switches - 03 MY onwards + 25 Nm (18 lbf.ft)
Drive flange nut 148 Nm (109 lbf.ft)
Output shaft housing bolts + 45 Nm (33 lbf.ft)
Oil temperature sensor - If fitted + 25 Nm (18 lbf.ft)
Inhibitor switch to transfer box 26 Nm (19 lbf.ft)
Intermediate shaft nut † 88 Nm (65 lbf.ft)
Intermediate shaft retaining plate bolt + 25 Nm (18 lbf.ft)
Differential bearing retaining nut * 72 Nm (53 lbf.ft)
Output flange nut 162 Nm (119 lbf.ft)
High/Low selector housing bolts + 25 Nm (18 lbf.ft)
Bearing housing/cover bolts + 25 Nm (18 lbf.ft)
Blanking plug + 25 Nm (18 lbf.ft)
High/Low selector warning lamp switch 25 Nm (18 lbf.ft)
Differential lock selector housing bolts + 25 Nm (18 lbf.ft)
Neutral sensor 25 Nm (18 lbf.ft)
Interlock solenoid bolts - Up to 03 Model Year 10 Nm (7 lbf.ft)

TORQUE WRENCH SETTINGS
06-12
Automatic gearbox - ZF4HP22
+ Apply sealant, Part No. STC 50553 to threads
TORQUE DESCRIPTION METRIC IMPERIAL
Selector lever to selector shaft nut 26 Nm (19 lbf.ft)
Starter inhibitor switch bolts 10 Nm (7 lbf.ft)
Engine to torque converter bolts - Td5 & V8 + 50 Nm (37 lbf.ft)
Closing plate to gearbox housing bolt - V8 7 Nm (5.2 lbf.ft)
Fluid pump to intermediate plate bolts 10 Nm (7 lbf.ft)
Intermediate plate Allen plugs (M14) 40 Nm (30 lbf.ft)
Intermediate plate Allen plugs (M20) 50 Nm (37 lbf.ft)
Oil cooler adaptors42 Nm (31 lbf.ft)
Extension housing bolts 25 Nm (18 lbf.ft)
Oil sump to gearbox housing bolts 8 Nm (6 lbf.ft)
Oil filter Torx screws8 Nm (6 lbf.ft)
Oil pick-up tube Torx screw 8 Nm (6 lbf.ft)
Parking pawl guide Torx screw 10 Nm (7 lbf.ft)
Pressure regulator to valve body assembly 8 Nm (6 lbf.ft)
Lock-up solenoid valve, retaining fork Torx screw 8 Nm (6 lbf.ft)
Lock-up solenoid valve assembly to valve body Torx screws 8 Nm (6 lbf.ft)
Gearbox bell housing (intermediate plate and converter housing to gearbox casing) bolts 46 Nm (34 lbf.ft)
Speed sensor bracket screws 8 Nm (6 lbf.ft)

TORQUE WRENCH SETTINGS
06-13
Propeller shafts
Axles
+ Apply sealant, Part No. STC 50552 to bolt threads
TORQUE DESCRIPTION METRIC IMPERIAL
Propeller shaft to transfer gearbox 47 Nm (35 lbf.ft)
Propeller shaft to differential 47 Nm (35 lbf.ft)
Propeller shaft to flexible coupling 76 Nm (56 lbf.ft)
Flexible coupling to differential 76 Nm (56 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Front and rear differential to axle bolts + 55 Nm (40 lbf.ft)
Hub to axle bolts100 Nm (74 lbf.ft)
Pinion flange bolt 100 Nm (74 lbf.ft)
Drive shaft nut490 Nm (360 lbf.ft)