sensor LAND ROVER DISCOVERY 1999 User Guide

INTRODUCTION
01-4
λLambda
lc Low compression
LCD Liquid Crystal Display
LED Light Emitting Diode
LH Left-Hand
LHD Left-Hand Drive
LVS Liquid Vapour Separator
mMetre
µMicro
MAF Mass Air Flow
MAP Manifold Absolute Pressure
MFU Multi-Function Unit
MFL Multi-Function Logic
max. Maximum
MEMS Modular Engine Management
System
MIL Malfunction Indicator Lamp
min. Minimum
MPa MegaPascal
- Minus (tolerance)
' Minute (angle)
mm Millimetre
mph Miles per hour
MPi Multi-Point injection
MY Model Year
NAS North American Specification
(-) Negative (electrical)
Nm Newton metre
No. Number
NO
2Nitrogen Dioxide
NO
xOxides of Nitrogen
NTC Negative Temperature
Coefficient
OBD On Board Diagnostics
o.dia. Outside diameter
ORM Off-road Mode
ΩOhm
PAS Power Assisted Steering
PCV Positive Crankcase Ventilation
PDC Parking Distance Control
% Percentage
+ Plus (tolerance) or Positive
(electrical)
±Plus or minus (tolerance)
PTC Positive Temperature Coefficient
PTFE Polytetrafluorethylene
PWM Pulse Width Modulation
rRadius
:Ratio
ref Reference
RES Rover Engineering Standards
rev/min Revolutions per minute
RF Radio Frequency
RH Right-Hand
RHD Right-Hand Drive
ROM Read Only Memory
RON Research Octane Number
ROV Roll Over ValveROW Rest Of World
SAE Society of Automotive Engineers
" Second (angle)
SLABS Self Levelling and Anti-Lock
Brake System
SLS Self Levelling Suspension
SOHC Single Overhead Camshaft
sp.gr Specific gravity
SRS Supplementary Restraint System
std. Standard
synchro Synchronizer or synchromesh
TDC Top Dead Centre
TMAP Temperature, Manifold Absolute
Pressure
TP Throttle Position
TPS Throttle Position Sensor
TV Torsional Vibration
TXV Thermostatic Expansion Valve
UK United Kingdom
US United States
V Volt
Var. Variable
VIN Vehicle Identification Number
VIS Variable Intake System
VRS Variable Reluctance Sensor
VSS Vehicle Speed Signal
WWatt

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.

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
06-5
Emission control - Td5
Emission control - V8
TORQUE DESCRIPTION METRIC IMPERIAL
EGR valve pipe Allen screws 10 Nm (7 lbf.ft)
EGR valve to inlet manifold bolts 10 Nm (7 lbf.ft)
EGR intake pipe clip to cylinder head bolts - if fitted 25 Nm (18 lbf.ft)
EGR cooler to cylinder head nut and bolts - if fitted 25 Nm (18 lbf.ft)
EGR valve to flexible mounting nuts 5 Nm (3 lbf.ft)
EGR valve flexible mounting to bracket nuts 5 Nm (3 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
HO
2S Sensors 45 Nm (33 lbf.ft)
SAI air manifold union nuts 25 Nm (18 lbf.ft)
Rubber mountings to SAI pump bracket 10 Nm (7 lbf.ft)
SAI control valve to manifold bolts 10 Nm (7 lbf.ft)
SAI pump to bracket nuts 10 Nm (7 lbf.ft)
SAI pump bracket to body bolt 20 Nm (15 lbf.ft)
Vacuum reservoir to mounting bracket bolt 10 Nm (7 lbf.ft)

TORQUE WRENCH SETTINGS
06-6
Engine management system - Td5
Engine management system - V8
+ Apply sealant, Part No. STC 50552 to threads
TORQUE DESCRIPTION METRIC IMPERIAL
ECT sensor15 Nm (11 lbf.ft)
Fuel tank cradle45 Nm (33 lbf.ft)
CKP sensor10 Nm (7 lbf.ft)
MAP and IAT sensor 10 Nm (7 lbf.ft)
Fuel cooler to inlet manifold - upper bolts 25 Nm (18 lbf.ft)
Turbocharger to exhaust manifold 30 Nm (22 lbf.ft)
Turbocharger drain pipe 10 Nm (7 lbf.ft)
Banjo bolt to oil feed pipe 25 Nm (18 lbf.ft)
Fuel temperature sensor 14 Nm (10 lbf.ft)
Pressure regulator 25 Nm (18 lbf.ft)
Glow plugs16 Nm (12 lbf.ft)
EUI clamp bolts32 Nm (24 lbf.ft)
EGR valve to exhaust manifold 10 Nm (7 lbf.ft)
EGR valve to inlet manifold 10 Nm (7 lbf.ft)
EGR clip25 Nm (18 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Spark plugs20 Nm (15 lbf.ft)
Fuel tank cradle45 Nm (33 lbf.ft)
ECT sensor +10 Nm (7 lbf.ft)
CKP sensor6 Nm (4.4 lbf.ft)
CMP sensor8 Nm (6 lbf.ft)
KS sensor22 Nm (16 lbf.ft)
Throttle body10 Nm (7 lbf.ft)
Plenum chamber22 Nm (16 lbf.ft)
Breather adaptor6 Nm (4.4 lbf.ft)
Throttle cable abutment bracket 10 Nm (7 lbf.ft)
TP sensor 2.2 Nm (1.6 lbf.ft)
IACV sensor8 Nm (6 lbf.ft)
HO
2S sensor45 Nm (33 lbf.ft)
Ignition coils8 Nm (6 lbf.ft)
Fuel rail9 Nm (7 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
06-16
Rear suspension
TORQUE DESCRIPTION METRIC IMPERIAL
Wheel nuts140 Nm (103 lbf.ft)
Wheel hub to axle 100 Nm (74 lbf.ft)
Damper to axle125 Nm (92 lbf.ft)
SLS height sensor link to radius arm 25 Nm (18 lbf.ft)
Radius arm230 Nm (170 lbf.ft)
Transverse links to pivot housing 155 Nm (114 lbf.ft)
Pivot housing to axle bolts 230 Nm (170 lbf.ft)
Transverse link to chassis 140 Nm (103 lbf.ft)
SLS height sensor 6 Nm (4.4 lbf.ft)
SLS compressor25 Nm (18 lbf.ft)
ACE actuator to short arm 185 Nm (136 lbf.ft)
ACE actuator to long arm 48 Nm (35 lbf.ft)
ACE actuator pipe cap nuts 29 Nm (21 lbf.ft)
Anti-roll bar link - upper 50 Nm (37 lbf.ft)
Anti-roll bar link - lower 100 Nm (74 lbf.ft)
ACE long arm to torsion bar 180 Nm (133 lbf.ft)

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