oil LAND ROVER DISCOVERY 1999 User Guide

GENERAL INFORMATION
03-2
Safety Instructions
Whenever possible, use a lift or pit when working
beneath vehicle, in preference to jacking. Chock
wheels as well as applying parking brake.
Jacking
Always use the recommended jacking points.
Always ensure that any lifting apparatus has
sufficient load capacity for the weight to be lifted.
Ensure the vehicle is standing on level ground prior
to lifting or jacking.
Apply the handbrake and chock the wheels.
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the
vehicle on safety stands.
Do not leave tools, lifting equipment, spilt oil, etc.
around or on the work bench area. Always keep a
clean and tidy work area.
Brake shoes and pads
Always fit the correct grade and specification of
brake linings. When renewing brake pads and brake
shoes, always replace as complete axle sets.Brake hydraulics
Observe the following recommendations when
working on the brake system:
lAlways use two spanners when loosening or
tightening brake pipe or hose connections.
lEnsure that hoses run in a natural curve and are
not kinked or twisted.
lFit brake pipes securely in their retaining clips
and ensure that the pipe cannot contact a
potential chafing point.
lContainers used for brake fluid must be kept
absolutely clean.
lDo not store brake fluid in an unsealed
container, it will absorb water and in this
condition would be dangerous to use due to a
lowering of its boiling point.
lDo not allow brake fluid to be contaminated with
mineral oil, or put new brake fluid in a container
which has previously contained mineral oil.
lDo not re-use brake fluid removed from the
system.
lAlways use clean brake fluid or a recommended
alternative to clean hydraulic components.
lAfter disconnection of brake pipes and hoses,
immediately fit suitable blanking caps or plugs to
prevent the ingress of dirt.
lOnly use the correct brake fittings with
compatible threads.
lObserve absolute cleanliness when working
with hydraulic components.
Cooling system caps and plugs
Extreme care is necessary when removing
expansion tank caps and coolant drain or bleed
screws when the engine is hot, especially if it is
overheated. To avoid the possibility of scalding,
allow the engine to cool before attempting removal.
Air suspension system
Whilst working on the air suspension system, eye
protection must be worn at all times.

GENERAL INFORMATION
03-3
Environmental Precautions
General
This section provides general information which can
help to reduce the environmental impacts from the
activities carried out in workshops.
Emissions to air
Many of the activities that are carried out in
workshops emit gases and fumes which contribute to
global warming, depletion of the ozone layer and/or
the formation of photochemical smog at ground
level. By considering how the workshop activities are
carried out, these gases and fumes can be
minimised, thus reducing the impact on the
environment.
Exhaust fumes
Running car engines is an essential part of workshop
activities and exhaust fumes need to be ventilated to
atmosphere. However, the amount of time engines
are running and the position of the vehicle should be
carefully considered at all times, to reduce the
release of poisonous gases and minimise the
inconvenience to people living nearby.
Solvents
Some of the cleaning agents used are solvent based
and will evaporate to atmosphere if used carelessly,
or if cans are left unsealed. All solvent containers
should be firmly closed when not needed and
solvent should be used sparingly. Suitable
alternative materials may be available to replace
some of the commonly used solvents. Similarly,
many paints are solvent based and the spray should
be minimised to reduce solvent emissions.
Refrigerant
It is illegal to release any refrigerants into the
atmosphere. Discharge and replacement of these
materials from air conditioning units should only be
carried out using the correct equipment.
Checklist
Always adhere to the following.
Engines:
ldon't leave engines running unnecessarily;
lminimise testing times and check where the
exhaust fumes are being blown.
Materials:
lkeep lids on containers of solvents;
lonly use the minimum quantity;
lconsider alternative materials;
lminimise over-spray when painting. Gases:
luse the correct equipment for collecting
refrigerants;
ldon't burn rubbish on site.
Discharges to water
Most sites will have two systems for discharging
water: storm drains and foul drains. Storm drains
should only receive clean water, foul drains will take
dirty water.
The foul drain will accept many of the normal waste
waters such as washing water, detergents and
domestic type wastes, but oil, petrol, solvent, acids,
hydraulic oil, antifreeze and other such substances
should never be poured down the drain. If in any
doubt speak to the Water Company first.
Every precaution must be taken to prevent spillage of
oil, fuel, solvents etc. reaching the drains. All
handling of such materials must take place well away
from the drains and preferably in an area with a kerb
or wall around it, to prevent discharge into the drain.
If a spillage occurs it should be soaked up
immediately. Having a spill kit available will make
this easier.
Additional precautions
Check whether the surface water drains are
connected to an oil water separator, this could
reduce the pollution if an incident was to occur. Oil
water separators do need regular maintenance to
ensure effectiveness.
Checklist
Always adhere to the following.
Disposal:
lnever pour anything down a drain without first
checking that it is environmentally safe to do so,
and that it does not contravene any local
regulations or bye-laws;
l have oil traps emptied regularly.
Spillage prevention:
lstore liquids in a walled area;
lmake sure that taps on liquid containers are
secure and cannot be accidentally turned on;
lprotect bulk storage tanks from vandalism by
locking the valves;
ltransfer liquids from one container to another in
an area away from open drains;
lensure lids are replaced securely on containers;
lhave spill kits available near to points of storage
and handling of liquids.

GENERAL INFORMATION
03-4
Spill kits
Special materials are available to absorb a number of
different substances. They can be in granular form,
ready to use and bought in convenient containers for
storage. Disposal of used spill-absorbing material is
dealt with in 'Waste Management' section.
Land contamination
Oils, fuels and solvents etc. can contaminate any soil
that they are allowed to contact. Such materials
should never be disposed of by pouring onto soil and
every precaution must be taken to prevent spillage
reaching soil. Waste materials stored on open
ground could also leak, or have polluting substances
washed off them that would contaminate the land.
Always store these materials in suitable skips or
other similarly robust containers.
Checklist
Always adhere to the following.
lDon't pour or spill anything onto the soil or bare
ground;
ldon't store waste materials on bare ground, see
'Spillage prevention' list.
Legal compliance
Some sites may have a discharge consent for
effluent discharge to the foul drain for a car wash etc.
It is important to know what materials are allowed in
the drain and to check the results of any monitoring
carried out by the Water Company.
Where paint-spraying operations are carried out it
may be necessary to apply to the Local Authority for
an air emissions licence to operate the plant. If such
a licence is in operation, additional precautions will
be necessary to comply with the requirements, and
the results of any air quality monitoring must be
checked regularly.
Checklist
Always adhere to the following.
lKnow what legal consents and licences apply to
the operations;
lcheck that the emissions and discharges
comply with legal requirements.
Local issues
A number of environmental issues will be of
particular concern to residents and other neighbours
close to the site. The sensitivity of these issues will
depend on the proximity of the site and the layout
and amount of activity carried on at the site.
Noise is a major concern and therefore
consideration should be given to the time spent
carrying out noisy activities and the location of those
activities that can cause excessive noise. Car alarm testing, panel beating, hammering and
other such noisy activities should, whenever
possible, be carried out indoors with doors and
windows shut or as far away from houses as
possible.
Running vehicle engines may be an outside activity
which could cause nuisance to neighbours because
of both noise and smell.
Be sensitive to the time of day when these activities
are carried out and minimise the time of the noisy
operation, particularly in the early morning and late
evening.
Another local concern will be the smell from the
various materials used. Using less solvent, paint
and petrol could help prevent this annoyance.
Local residents and other business users will also be
concerned about traffic congestion, noise and
exhaust fumes, be sensitive to these concerns and
try to minimise inconvenience from deliveries,
customers and servicing operations.
Checklist
Always adhere to the following.
lIdentify where the neighbours who are likely to
be affected are situated;
lminimise noise, smells and traffic nuisance;
lprevent litter by putting waste in the correct
containers;
lhave waste skips emptied regularly.
Use of resource
Another environmental concern is the waste of
materials and energy that can occur in day to day
activities.
Electricity for heating, lighting and compressed air
uses resources and releases pollution during its
generation.
Fuel used for heating, running cars or vans and
mobile plant is another limited resource which
consumes large amounts of energy during its
extraction and refining processes.
Water has to be cleaned, piped to site and disposed
of; all of which creates more potential pollution.
Oil, spares, paint etc., have all produced pollution in
the process of manufacture and they become a
waste disposal problem if discarded.

GENERAL INFORMATION
03-5
Checklist
Always adhere to the following.
Electricity and heating:
lkeep doors and windows closed in the winter;
lswitch off machinery or lights when not needed;
luse energy efficient heating systems;
lswitch off computers and photocopiers when
not needed.
Fuel:
ldon't run engines unnecessarily;
lthink about whether journeys are necessary and
drive to conserve fuel.
Water:
ldon't leave taps and hose pipes running;
lmend leaks quickly, don't be wasteful.
Compressed air:
ldon't leave valves open;
lmend leaks quickly;
ldon't leave the compressor running when not
needed.
Use of environmentally damaging materials:
lcheck whether a less toxic material is available.
Handling and storage of materials:
lhave the correct facilities available for handling
liquids to prevent spillage and wastage as listed
above;
lprovide suitable locations for storage to prevent
frost damage or other deterioration.
Waste Management
One of the major ways that pollution can be reduced
is by the careful handling, storage and disposal of all
waste materials that occur on sites. Legislation
makes it illegal to dispose of waste materials other
than to licensed waste carriers and disposal sites.
This means that it is necessary to not only know what
the waste materials are, but also to have the
necessary documentation and licenses.
Handling and storage of waste
Ensure that waste materials are not poured down the
drain or onto soils. They should be stored in such a
way as to prevent the escape of the material to land,
water or air.
They must also be segregated into different types of
waste e.g. oil, metals, batteries, used vehicle
components. This will prevent any reaction between
different materials and assist in disposal.Disposal of waste
Disposal of waste materials must only be to waste
carriers who are licensed to carry those particular
waste materials and all the necessary
documentation must be completed. The waste
carrier is responsible for ensuring that the waste is
taken to the correct disposal sites.
Dispose of waste in accordance with the following
guidelines.
lFuel, hydraulic fluid, anti-freeze and oil: keep
separate and dispose of to specialist contractor.
lRefrigerant: collect in specialist equipment and
reuse.
lDetergents: safe to pour down the foul drain if
diluted.
lPaint, thinners: keep separate and dispose of
to specialist contractor.
lComponents: send back to supplier for
refurbishment, or disassemble and reuse any
suitable parts. Dispose of the remainder in
ordinary waste.
lSmall parts: reuse any suitable parts, dispose
of the remainder in ordinary waste.
lMetals: can be sold if kept separate from
general waste.
lTyres: keep separate and dispose of to
specialist contractor.
lPackaging: compact as much as possible and
dispose of in ordinary waste.
lAsbestos-containing: keep separate and
dispose of to specialist contractor.
lOily and fuel wastes (e.g. rags, used spill kit
material): keep separate and dispose of to
specialist contractor.
lAir filters: keep separate and dispose of to
specialist contractor.
lRubber/plastics: dispose of in ordinary waste.
lHoses: dispose of in ordinary waste.
lBatteries: keep separate and dispose of to
specialist contractor.
lAirbags - explosives: keep separate and
dispose of to specialist contractor.
lElectrical components: send back to supplier
for refurbishment, or disassemble and reuse
any suitable parts. Dispose of the remainder in
ordinary waste.
lElectronic components: send back to supplier
for refurbishment, or disassemble and reuse
any suitable parts. Dispose of the remainder in
ordinary waste.
lCatalysts: can be sold if kept separate from
general waste
lUsed spill-absorbing material: keep separate
and dispose of to specialist contractor.
lOffice waste: recycle paper and toner and ink
cartridges, dispose of the remainder in ordinary
waste.

GENERAL INFORMATION
03-6
General Fitting Instructions
Component removal
Whenever possible, clean components and
surrounding area before removal.
lBlank off openings exposed by component
removal.
lImmediately seal fuel, oil or hydraulic lines when
apertures are exposed; use plastic caps or
plugs to prevent loss of fluid and ingress of dirt.
lClose the open ends of oilways exposed by
component removal with tapered hardwood
plugs or conspicuous plastic plugs.
lImmediately a component is removed, place it in
a suitable container; use a separate container
for each component and its associated parts.
lClean bench and provide marking materials,
labels and containers before dismantling a
component.
Dismantling
Observe scrupulous cleanliness when dismantling
components, particularly when brake, fuel or
hydraulic system parts are being worked on. A
particle of dirt or a cloth fragment could cause a
serious malfunction if trapped in these systems.
lBlow out all tapped holes, crevices, oilways and
fluid passages with an air line. Ensure that any
'O' rings used for sealing are correctly replaced
or renewed, if disturbed during the process.
lUse marking ink to identify mating parts and
ensure correct reassembly. Do not use a centre
punch or scriber to mark parts, they could
initiate cracks or distortion in marked
components.
lWire together mating parts where necessary to
prevent accidental interchange (e.g. roller
bearing components).
lWire labels on to all parts which are to be
renewed, and to parts requiring further
inspection before being passed for reassembly;
place these parts in separate containers from
those containing parts for rebuild.
lDo not discard a part due for renewal until after
comparing it with a new part, to ensure that its
correct replacement has been obtained.Cleaning components
Always use the recommended cleaning agent or
equivalent. Ensure that adequate ventilation is
provided when volatile degreasing agents are being
used. Do not use degreasing equipment for
components containing items which could be
damaged by the use of this process.
General inspection
All components should be inspected for wear or
damage before being reassembled.
lNever inspect a component for wear or
dimensional check unless it is absolutely clean;
a slight smear of grease can conceal an
incipient failure.
lWhen a component is to be checked
dimensionally against recommended values,
use the appropriate measuring equipment
(surface plates, micrometers, dial gauges etc.).
Ensure the measuring equipment is calibrated
and in good serviceable condition.
lReject a component if its dimensions are
outside the specified tolerances, or if it appears
to be damaged.
lA part may be refitted if its critical dimension is
exactly to its tolerance limit and it appears to be
in satisfactory condition. Use 'Plastigauge' 12
Type PG-1 for checking bearing surface
clearances.

GENERAL INFORMATION
03-8
Oil Seals
General
Always renew oil seals which have been removed
from their working location (whether as an individual
component or as part of an assembly). NEVER use
a seal which has been improperly stored or handled,
such as hung on a hook or nail.
lCarefully examine seal before fitting to ensure
that it is clean and undamaged.
lEnsure the surface on which the new seal is to
run is free of burrs or scratches. Renew the
component if the original sealing surface cannot
be completely restored.
lProtect the seal from any surface which it has to
pass when being fitted. Use a protective sleeve
or tape to cover the relevant surface.
lLubricate the sealing lips with a recommended
lubricant before use to prevent damage during
initial use. On dual lipped seals, smear the area
between the lips with grease.
lIf a seal spring is provided, ensure that it is fitted
correctly. Place lip of seal towards fluid to be
sealed and slide into position on shaft. Use
fitting sleeve where possible to protect sealing
lip from damage by sharp corners, threads or
splines. If a fitting sleeve is not available, use
plastic tube or tape to prevent damage to the
sealing lip.
lGrease outside diameter of seal, place square
to housing recess and press into position using
great care, and if possible a 'bell piece' to
ensure that seal is not tilted. In some cases it
may be preferable to fit seal to housing before
fitting to shaft. Never let weight of unsupported
shaft rest in seal.lUse the recommended service tool to fit an oil
seal. If the correct service tool is not available,
use a suitable tube approximately 0.4 mm
(0.015 in.) smaller than the outside diameter of
the seal. Use a hammer VERY GENTLY on drift
if a suitable press is not available.
lPress or drift the seal in to the depth of its
housing with the sealing lip facing the lubricant
to be retained if the housing is shouldered, or
flush with the face of the housing where no
shoulder is provided. Ensure that the seal does
not enter the housing in a tilted position.

GENERAL INFORMATION
03-9
Joints and Joint Faces
General
Fit joints dry unless specified otherwise.
lAlways use the correct gaskets as specified.
lWhen jointing compound is used, apply in a thin
uniform film to metal surfaces; take care to
prevent jointing compound from entering
oilways, pipes or blind tapped holes.
lIf gaskets and/or jointing compound is
recommended for use; remove all traces of old
jointing material prior to reassembly. Do not use
a tool which will damage the joint faces and
smooth out any scratches or burrs using an oil
stone. Do not allow dirt or jointing material to
enter any tapped holes or enclosed parts.
lPrior to reassembly, blow through any pipes,
channels or crevices with compressed air.
Locking Devices
General
Always replace locking devices with one of the same
design.
Tab washers
Always release locking tabs and fit new locking
washers. Do not re-use locking tabs.
Locking nuts
Always use a backing spanner when loosening or
tightening locking nuts, brake and fuel pipe unions.
Roll pins
Always fit new roll pins of an interference fit in the
hole.
Circlips
Always fit new circlips of the correct size for the
groove.
Keys and keyways
Remove burrs from edges of keyways with a fine file
and clean thoroughly before attempting to refit key.
Clean and inspect key closely; keys are suitable for
refitting only if indistinguishable from new, as any
indentation may indicate the onset of wear.

GENERAL INFORMATION
03-10
Split pins
Always fit new split-pins of the correct size for the
hole in the bolt or stud.
Screw Threads
General
Metric threads to ISO standards are used.
Damaged nuts, bolts and screws must always be
discarded. Cleaning damaged threads with a die or
tap impairs the strength and fit of the threads and is
not recommended.
Always ensure that replacement bolts are at least
equal in strength to those replaced. Castellated nuts
must not be loosened to accept a split-pin, except in
recommended cases when this forms part of an
adjustment.
Do not allow oil or grease to enter blind threaded
holes. The hydraulic action on screwing in the bolt or
stud could split the housing.
Always tighten a nut or bolt to the recommended
torque figure. Damaged or corroded threads can
affect the torque reading.
To check or re-tighten a bolt or screw to a specified
torque figure, first loosen a quarter of a turn, then
retighten to the correct torque figure.
Oil thread lightly before tightening to ensure a free
running thread, except in the case of threads treated
with sealant/lubricant, and self-locking nuts.

GENERAL INFORMATION
03-11
Bolt and Nut Identification
Bolt identification
An ISO metric bolt or screw made of steel and larger
than 6 mm in diameter can be identified by either of
the symbols ISO M or M embossed or indented on
top of the bolt head.
In addition to marks identifying the manufacturer, the
top of the bolt head is also marked with symbols
indicating the strength grade, e.g. 8.8; 10.9; 12.9;
14.9. As an alternative, some bolts and screws have
the M and strength grade symbol stamped on the
flats of the hexagon.Encapsulated bolts and screws
Encapsulated bolts and screws have a micro-
encapsulated locking agent pre-applied to the
thread. They are identified by a coloured section
which extends 360° around the thread. The locking
agent is released and activated by the assembly
process and is then chemically cured to provide the
locking action.
Unless a specific repair procedure states otherwise,
encapsulated bolts may be re-used providing the
threads are undamaged and the following procedure
is adopted:
lRemove loose adhesive from the bolt and
housing threads.
lEnsure threads are clean and free of oil and
grease.
lApply an approved locking agent.
An encapsulated bolt may be replaced with a bolt of
equivalent specification provided it is treated with an
approved locking agent.

GENERAL INFORMATION
03-17
Electrical Precautions
General
The following guidelines are intended to ensure the
safety of the operator while preventing damage to the
electrical and electronic components fitted to the
vehicle. Where necessary, specific precautions are
detailed in the individual procedures of this manual.
Equipment
Prior to commencing any test procedure on the
vehicle ensure that the relevant test equipment is
working correctly and any harness or connectors are
in good condition. It is particularly important to check
the condition of the lead and plugs of mains operated
equipment.
Polarity
Never reverse connect the vehicle battery and
always ensure the correct polarity when connecting
test equipment.
High voltage circuits
Whenever disconnecting live ht circuits always use
insulated pliers and never allow the open end of the
ht lead to contact other components, particularly
ECU's. Exercise caution when measuring the voltage
on the coil terminals while the engine is running, high
voltage spikes can occur on these terminals.Connectors and harnesses
The engine compartment of a vehicle is a particularly
hostile environment for electrical components and
connectors:
lAlways ensure electrically related items are dry
and oil free before disconnecting and
connecting test equipment.
lEnsure disconnected multiplugs and sensors
are protected from being contaminated with oil,
coolant or other solutions. Contamination could
impair performance or result in catastrophic
failure.
lNever force connectors apart using tools to
prise apart or by pulling on the wiring harness.
lAlways ensure locking tabs are disengaged
before disconnection, and match orientation to
enable correct reconnection.
lEnsure that any protection (covers, insulation
etc.) is replaced if disturbed.
Having confirmed a component to be faulty:
lSwitch off the ignition and disconnect the
battery.
lRemove the component and support the
disconnected harness.
lWhen replacing the component keep oily hands
away from electrical connection areas and push
connectors home until any locking tabs fully
engage.
Battery disconnection
Before disconnecting the battery, disable the alarm
system and switch off all electrical equipment. If the
radio is to be serviced, ensure the security code has
been deactivated.
CAUTION: To prevent damage to electrical
components, always disconnect the battery
when working on the vehicle's electrical system.
The ground lead must be disconnected first and
reconnected last.
CAUTION: Always ensure that battery leads are
routed correctly and are not close to any
potential chafing points.
Battery charging
Only recharge the battery with it removed from the
vehicle. Always ensure any battery charging area is
well ventilated and that every precaution is taken to
avoid naked flames and sparks.