AUX LAND ROVER DISCOVERY 1999 Owner's Manual

ENGINE - V8
12-2-76 OVERHAUL
19.Attach a DTI to front of cylinder block, move
crankshaft rearwards, position stylus of gauge
on end of crankshaft and zero gauge.
20.Move crankshaft forwards, measure and
record end-float obtained.
l Crankshaft end-float = 0.08 to 0.26 mm
(0.003 to 0.01 in).
21.Fit connecting rod bearings.

+ ENGINE - V8, OVERHAUL, Bearings
- connecting rods.
22.Clean timing chain and gears.
23.Clean ends of crankshaft and camshaft.
24.Lubricate timing chain assembly with clean
engine oil.
25.Align timing marks and fit timing chain
assembly.
26.Fit camshaft gear bolt and tighten to 50 Nm (37
lbf.ft).
27.Fit timing gear cover gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
timing gear cover.
28.Clean crankshaft pulley.
29.Fit crankshaft pulley.
30.Fit crankshaft pulley bolt and tighten to 270 Nm
(200 lbf.ft).
31.Remove tool LRT-12-080 from crankshaft
pulley.
32.Clean oil filter and mating face.
33.Lubricate oil filter seal and fit filter to oil pump.
34.Ensure drive belt pulleys are clean and
damage free.
35.Fit auxiliary drive belt to pulleys.
36.Fit crankshaft rear oil seal.

+ ENGINE - V8, OVERHAUL, Seal -
crankshaft - rear - automatic models.

ENGINE MANAGEMENT SYSTEM - V8
18-2-82 REPAIRS
Sensor - engine coolant temperature
(ECT)
$% 18.30.10
Remove
1.Release turnbuckles and remove battery cover.
2.Disconnect battery earth lead.
3.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
4.Remove 2 bolts securing alternator, release
alternator from support bracket and position
aside. 5.Disconnect multiplug from ECT sensor.
6.Remove sensor from inlet manifold and discard
sealing washer.
Refit
1.Clean sealant from threads in manifold.
2.Apply sealant, Part No. STC 50552 to sensor
threads.
3.Fit new sealing washer to ECT sensor and
tighten sensor to 10 Nm (7 lbf.ft).
4.Connect multiplug to ECT sensor.
5.Position alternator, fit bolts and tighten to 45
Nm (33 lbf.ft).
6.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
7.Top up cooling system.
8.Connect battery earth lead.
9.Fit battery cover and secure with fixings.

COOLING SYSTEM - V8
26-2-8 DESCRIPTION AND OPERATION
Coolant pump
1Pulley flange
2Body
3Impeller4Gallery
5Inlet connection
The coolant pump is attached to the front of the cylinder block with nine bolts and sealed between the pump housing
and the cylinder block with a gasket. The pump comprises a shaft which passes through an alloy housing. The outer
end of the shaft has a flange which allows for the attachment of the pump drive pulley which is secured with three
bolts. The drive pulley is driven by the grooved auxiliary drive belt and rotates at the same speed as the crankshaft.
The inner end of the shaft is fitted with an impeller which draws coolant from the thermostat housing and circulates it
through the galleries in the cylinder block and through the heater matrix.
The shaft is supported on bearings in the housing which are packed with grease and sealed for life. A seal is
positioned in the housing to further protect the bearings from the ingress of coolant. The seal is manufactured from a
synthetic material which will allow for expansion of the casing when hot coolant is present.
The cast alloy housing has a hose connection which provides the attachment for the coolant pump feed hose. The
cast housing connects with galleries in the cylinder block and distributes coolant from the pump impeller into the
galleries and water jackets.

COOLING SYSTEM - V8
REPAIRS 26-2-19
Gasket - coolant pump
$% 26.50.02
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Drain cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
3.Remove 3 bolts securing pulley to coolant
pump and remove pulley.
4.Release clip and disconnect feed hose from
coolant pump. 5.Remove 9 bolts securing coolant pump,
remove pump and discard gasket.
Refit
1.Clean coolant pump and mating face.
2.Fit new gasket and coolant pump to cylinder
block. Fit bolts and tighten to 24 Nm (18 lbf.ft).
3.Connect feed hose to coolant pump and secure
with clip.
4.Ensure mating faces of coolant pump pulley
and flange are clean. Fit pulley and tighten
bolts to 22 Nm (16 lbf.ft).
5.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
6.Refill cooling system.

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

MANIFOLDS AND EXHAUST SYSTEMS - V8
30-2-10 REPAIRS
Heat shield - brake servo - With
Secondary Air Injection
$% 30.10.48
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove nut securing heat shield bracket to
valance.
4.Remove 2 bolts securing heat shield and
remove heat shield.
Refit
1.Fit heat shield, tightening bolts to 25 Nm (18
lbf.ft) and nut to 10 Nm (7 lbf.ft).
2.Connect battery earth lead.
3.Fit battery cover and secure with fixings.
Gasket - inlet manifold - lower
$% 30.15.08
Remove
1.Remove both rocker covers.
l

+ ENGINE - V8, REPAIRS, Gasket
- rocker cover - LH.
l

+ ENGINE - V8, REPAIRS, Gasket
- rocker cover - RH.
2.Release and disconnect LH injector harness
and multiplugs.
3.Release 3 clips securing top hose and remove
top hose.
4.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.

MANIFOLDS AND EXHAUST SYSTEMS - V8
REPAIRS 30-2-11
5.Remove 3 bolts securing ACE pump, release
pump and position aside.
6.Remove 2 bolts securing alternator and
remove alternator. 7.Remove 3 bolts securing PAS pump pulley and
remove pulley.
8.Remove jockey pulley.
9.Position tray to catch spillage, release PAS
pump high pressure pipe.
CAUTION: Always fit plugs to open
connections to prevent contamination.
10.Remove bolt securing oil cooling pipe and
release bracket from auxiliary housing.
11.Remove two bolts securing PAS pump.
12.Remove 5 bolts and one nut securing auxiliary
housing. Pull housing forward, release PAS
pump and remove housing.

MANIFOLDS AND EXHAUST SYSTEMS - V8
REPAIRS 30-2-13
20.Remove inlet manifold gasket.
21.Remove gasket seals.
Refit
1.Clean all traces of sealant from cylinder head
and cylinder block notches.
2.Clean mating faces of cylinder block, cylinder
head and inlet manifold.
3.Apply sealant, Part No. STC 50550 to cylinder
head and cylinder block notches.
4.Fit new gasket seals, ensuring ends engage
correctly in notches.
5.Fit new inlet manifold gasket.
6.Position gasket clamps and fit bolts, but do not
tighten at this stage.
7.Position inlet manifold to engine. Fit manifold
bolts and, working in the sequence shown,
tighten bolts initially to 10 Nm (7 lbf.ft) then to
51 Nm (38 lbf.ft).
8.Tighten gasket clamp bolts to 18 Nm (13 lbf.ft).
9.Connect fuel pipe.
10.Clean top hose outlet pipe mating faces.
11.Fit new 'O' ring to outlet pipe.
12.Position outlet pipe, fit bolts and tighten to 22
Nm (16 lbf.ft).
13.Position alternator, fit bolts and tighten to 45
Nm (33 lbf.ft).
14.Position PAS pump to auxiliary housing and
locate housing on engine. Fit bolts and tighten
to 40 Nm (30 lbf.ft).15.Fit and tighten auxiliary housing nut to 10 Nm (7
lbf.ft).
16.Fit bolts securing PAS pump and tighten to 22
Nm (16 lbf.ft).
17.Position oil cooling pipe bracket fit bolt and
tighten to 22 Nm (16 lbf.ft).
18.Fit and tighten PAS pump high pressure pipe.
19.Position jockey pulley and tighten bolt to 50 Nm
(37 lbf.ft).
20.Clean PAS pump pulley mating faces.
21.Position PAS pump pulley, fit bolts and tighten
to 22 Nm (16 lbf.ft).
22.Clean ACE pump dowels and dowel holes.
23.Position ACE pump, fit bolts and tighten to 22
Nm (16 lbf.ft).
24.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
25.Secure injector harness and connect injector
multiplugs.
26.Position top hose and secure clips.
27.Fit rocker covers.
l

+ ENGINE - V8, REPAIRS, Gasket
- rocker cover - LH.
l

+ ENGINE - V8, REPAIRS, Gasket
- rocker cover - RH.
28.Check and top up PAS fluid

STEERING
57-12 DESCRIPTION AND OPERATION
PAS pump - V8
1Bolt 2 off
2Nut
3Stud
4Auxiliary housing
5PAS pump6Outlet
7Inlet
8Bolt 3 off
9Drive pulley
The PAS pump is located on the auxiliary housing and is attached by two bolts, the bolts go through flanged bushes
in the auxiliary housing. A stud passes through the PAS pump and through a flanged bush in the auxiliary housing,
the auxiliary housing and PAS pump are secured by a nut. As the two bolts and nut are tightened the bushes move
slightly and the flange of each bush clamps the PAS pump. A drive pulley is attached to the pump drive shaft with
three bolts, and is belt driven at a ratio of 1.4 crankshaft revolutions to 1 of the drive pulley. Fluid is drawn into the
PAS pump inlet from the reservoir through a flexible hose at low (suction) pressure. Fluid at high pressure from the
PAS pump outlet is supplied to the rotary control valve on the steering box.
The PAS pump is a roller vane type and has an internal pressure regulator and flow control valve. The roller vanes
can move in slots in the pumps rotor and are moved outwards by centrifugal force as the pump rotates. The pump
rotor rotates in the pump housing, the internal shape of the housing forms a 'cam' shape. Due to the 'cam' shape the
volume of the housing decreases between the inlet and outlet ports.
As the pump rotor rotates towards the pump inlet the volume between the roller vanes and the pump housing
increases, this action causes a depression in the chamber between the pump roller vanes and the housing. As the
rotation continues the chamber is opened to the pump inlet, and the depression in the chamber causes fluid to be
drawn in. The roller vanes continue past the inlet port, closing off the inlet port and trapping the fluid in the chamber
between the rollers and the pump housing.

STEERING
57-14 DESCRIPTION AND OPERATION
PAS pump - diesel
1Drive pulley
2Mounting bracket
3Bolt 2 off
4Bolt
5PAS pump
6Coupling7Auxiliary housing
8Outlet
9Inlet adaptor pipe and seal
10Bolt 2 off
11Bolt 2 off
12Bolt 3 off
The PAS pump is located on the auxiliary housing, two bolts go through the PAS pump, mounting bracket and into
the auxiliary housing. One bolt also attaches the mounting bracket to the PAS pump, two bolts secure the mounting
bracket to the auxiliary housing. An inlet adaptor pipe with a seal is secured to the bottom of the pump with two bolts.
A drive pulley is attached to the pump drive shaft with three bolts, and is belt driven at a ratio of 1.35 crankshaft
revolutions to 1 of the drive pulley. A coupling on the rear of the PAS pump rotates the water pump impeller located
in the auxiliary housing. Fluid is supplied to the PAS pump inlet from the reservoir through a flexible hose at low
(suction) pressure. Fluid at high pressure from the PAS pump outlet is supplied to the rotary control valve on the
steering box.
The PAS pump is a roller vane type and has an internal pressure regulator and flow control valve. The roller vanes
can move in slots in the pumps rotor and are moved outwards by centrifugal force as the pump rotates. The pump
rotor rotates in the pump housing, the internal shape of the housing forms a 'cam' shape. Due to the 'cam' shape the
volume of the housing decreases between the inlet and outlet ports.

STEERING
REPAIRS 57-39
Refit
1.Clean seal recess, output shaft, end cover and
mating face.
2.Lubricate new end cover 'O' ring with clean
PAS fluid. Fit 'O' ring to end cover.
3.Position output shaft, fit bolts and tighten to 88
Nm (65 lbf.ft).
4.Tighten rack adjuster one turn, align marks and
secure with Allen screw.
5.Lubricate new output shaft seal with clean PAS
fluid.
6.Fit seal using LRT-57-504.
7.Fit spacer, circlip and seal shield.
8.Clean drop arm and steering box splines.
9.Ensure steering box is in the central position.
Align and fit drop arm to output shaft and
secure with new lock washer and nut. Tighten
nut to 240 Nm (177 lbf.ft).
10.Secure lock washer to drop arm nut.
11.Fit steering box.
lFor V8 models:

+ STEERING, REPAIRS, Power
steering box - V8.
lFor LHD diesel models:

+ STEERING, REPAIRS, Power
steering box - LHD - diesel.
lFor RHD diesel models:

+ STEERING, REPAIRS, Steering
box - RHD - diesel.
Pump - power steering - V8
$% 57.20.14
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Remove cable tie securing harness to air intake
hose.
3.Loosen 3 clips securing air intake hose, release
and remove hose.
Note: Pre 03 MY air intake hose illustrated.
4. Models with ACE: Remove 3 bolts securing
ACE pump, release pump and position aside.