alternator LAND ROVER DISCOVERY 1999 Owner's Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 1999, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 1999Pages: 1529, PDF Size: 34.8 MB
Page 628 of 1529
AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-31
40.Fit suitable strap to retain torque converter.
Refit
1.Clean gearbox to engine mating faces.
2.Remove torque converter retaining strap.
3.With assistance position gearbox to engine.
4.Fit but do not tighten six bolts securing gearbox
housing to engine.
5.Connect multiplug to gearbox and tighten
locking ring.
6.Connect multiplug to inhibitor switch.
7. If fitted: Connect and adjust differential lock
selector cable.
+ TRANSFER BOX - LT230SE,
ADJUSTMENTS, Cable - selector -
differential lock - adjust.
8.Position selector lever to inhibitor switch and
tighten nut to 25 Nm (18 lbf.ft).
9.Position selector cable to gearbox and secure
with 'C' clip.
10.Clean oil pipe unions and fit new 'O' rings.
11.Position and tighten pipe unions to gearbox.
12.Position and tighten oil cooler pipe clamps.
13.Position and tighten oil cooler pipe clips to
engine sump and alternator bracket.
14.Position engine RH and LH rear mountings
and tighten bolts to 85 Nm (63 lbf.ft) and nuts to
85 Nm (63 lbf.ft).
15.Secure gearbox breather pipes to bulkhead
clip.
16. Up to 03 Model Year - If fitted: Connect 2
Lucars to differential lock warning lamp switch
and multiplugs to high/low ratio switch and
neutral sensor.
17. 03 Model Year onwards - If fitted: Connect
differential lock warning lamp switch multiplugs
to main harness.
18.Position cable tie and multiplug to transfer box
bracket.
19.Connect high/low ratio selector cable to
selector lever and secure with clevis pin. 20.Position high/low ratio selector cable to
abutment bracket and secure with 'C' clip.
21. Models fitted with high/low shift interlock
solenoid: Position interlock solenoid harness
to high/low shift cable, fit sleeve around cable
and harness.
22. Models fitted with high/low shift interlock
solenoid: Connect solenoid multiplug to main
harness and secure multiplug to bracket.
23.Position handbrake backplate and tighten bolts
to 75 Nm (55 lbf.ft).
24.Fit hand brake drum and tighten screw.
25.Remove bolts securing tool LRT-99-008A to
gearbox.
26.Rotate engine to align torque converter, fit new
bolts and tighten to 50 Nm (37 lbf.ft).
27.Fit rear propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
28.Fit front propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
29.Fill transfer gearbox with oil.
+ MAINTENANCE, PROCEDURES,
Transfer box.
30.Fill automatic gearbox with oil.
+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
31.Position intermediate silencer and secure to
mounting rubbers.
32.Clean silencer and tail pipe mating faces.
33.Position new gasket to tail pipe and tighten
nuts to 25 Nm (18 lbf.ft).
34.Fit exhaust front pipe.
+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
35.Fit bolt securing closing plate to gearbox
housing and tighten to 7 Nm (5.2 lbf.ft).
36.Fit upper bolts securing gearbox housing to
engine and tighten to 50 Nm (37 lbf.ft).
37.Fit starter motor.
+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
38.Tighten remaining gearbox housing to engine
bolts to 50 Nm (37 lbf.ft).
39.Connect battery earth lead.
40.Fit battery cover and secure with fixings.
41.Check and adjust selector cable.
+ AUTOMATIC GEARBOX - ZF4HP22
- 24, ADJUSTMENTS, Cable - selector.
Page 863 of 1529
BRAKES
70-10 DESCRIPTION AND OPERATION
Vacuum pump (diesel models only)
1Alternator
2Vacuum pump
3Brake servo assembly vacuum connection4Oil feed pipe
5Oil drain pipe
As the diesel engine air inlet system does not produce sufficient depression to operate the brake servo assembly, an
engine driven vacuum pump is installed.
The vacuum pump is integrated with the engine alternator and driven by the auxiliary drive belt. The pump is a rotary
vane type, lubricated and cooled by engine oil supplied through a pipe connected to the engine block and returned
through a pipe connected to the engine oil sump. Air extracted from the brake servo assembly is vented into the oil
sump with returning lubricating oil.
Page 896 of 1529
BRAKES
REPAIRS 70-43
Vacuum pump - servo
$% 70.50.19
Remove
1.Remove auxiliary drive belt.
+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Release cover and remove nut securing lead
to alternator.
3.Disconnect alternator multiplug.
4.Remove bolt (LH thread) and remove auxiliary
drive belt tensioner. 5.Remove bolt securing support stay to
alternator.
6.Release clip and disconnect oil drain hose from
vacuum pump.
7.Disconnect vacuum pump oil supply pipe from
cylinder head and discard 'O' ring.
8.Remove bolt securing alternator and release
from mounting bracket.
9.Disconnect vacuum hose from vacuum pump.
10.Remove alternator. Take care not to damage
radiator cooling fins.
11.Remove 4 bolts, and remove vacuum pump
from alternator.
CAUTION: Always fit plugs to open
connections to prevent contamination.
Page 897 of 1529
BRAKES
70-44 REPAIRS
Refit
1.Clean mating faces of alternator and vacuum
pump.
2.Fit vacuum pump to alternator and tighten
bolts to 8 Nm (6 lbf.ft).
3.Position alternator to engine and connect
multiplug.
4.Connect vacuum hose and oil drain hose to
vacuum pump and secure clips.
5.With assistance align alternator to mounting
bracket and fit but do not tighten bolt.
6.Fit bolt securing support stay to alternator and
tighten to 25 Nm (18 lbf.ft) .
7.Tighten bolt securing alternator to mounting
bracket to 45 Nm (33 lbf.ft).
8.Using new 'O' ring, connect oil supply pipe to
cylinder head and tighten to 10 Nm (7 lbf.ft).
9.Connect lead to alternator and tighten nut to 6
Nm (4.4 lbf.ft).
10.Fit auxiliary drive belt tensioner and tighten bolt
to 50 Nm (37 lbf.ft).
11.Fit auxiliary drive belt.
+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
Page 1088 of 1529
PANEL REPAIRS
REPAIRS 77-2-21
REPAIRS
Front bulkhead assembly
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
4.Remove washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
5. Models with A/C: Remove condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
6. Diesel models: Remove gearbox fluid cooler.
7.Remove RH and LH headlamps.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
8.Release headlamp levelling motors and
position aside.
9.Release headlamp wiring and position aside.
10.Remove battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
11.Remove battery tray.
12.Remove air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
13.Remove 2 earth leads from LH of front
bulkhead.
14.Remove RH horn.
+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
15. Models with A/C: Release and remove A/C
pipes.
16.Remove RH and LH crush cans.
17.Remove bonnet release cable.
18.Support bonnet in open position
19.Remove bonnet locking mechanism.
20.Remove VIN plate.
21.Remove 2 bolts securing front bulkhead
assembly to chassis.
22.Remove centre braces.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit centre braces.
2.Fit 2 bolts securing bulkhead to chassis and
tighten to 45 Nm (33 lbf.ft).
3.Fit VIN plate.
4.Fit bonnet locking mechanism.
5.Fit bonnet release cable.
6.Fit crush cans.
7. Models with A/C: Fit A/C pipes.
8.Fit RH horn.
+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
9.Fit 2 earth leads to LH of front bulkhead.
10.Fit air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
11.Fit battery tray.
12.Fit battery. Do not connect leads.
+ CHARGING AND STARTING,
REPAIRS, Battery.
13.Fit headlamp wiring and headlamp levelling
motors.
14.Fit RH and LH headlamps.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
15. Diesel models: Fit gearbox fluid cooler.
16. Models with A/C: Fit condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
17.Fit washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
Page 1089 of 1529
PANEL REPAIRS
77-2-22 REPAIRS
18.Fit front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
19.Connect leads/multiplug to alternator.
20.Connect battery leads, negative lead last.
Page 1090 of 1529
PANEL REPAIRS
REPAIRS 77-2-23
Bonnet locking platform
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front bumper assembly.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
4. Models with A/C: Remove condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
5. Diesel models: Remove gearbox fluid cooler.
6.Remove RH and LH headlamps.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
7.Remove RH and LH repeater lamps.
+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
8.Release headlamp wiring and position aside.
9.Remove battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
10.Remove battery tray.
11.Remove air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
12.Remove RH horn.
+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
13.Remove bonnet release cable.
14.Support bonnet in open position
15.Remove bonnet locking mechanism.
16.Remove VIN plate.
17.Remove centre braces.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit centre braces.
2.Fit VIN plate.
3.Fit bonnet locking mechanism.
4.Fit bonnet release cable.
5.Fit RH horn.
+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
6.Fit air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
7.Fit battery tray.
8.Fit battery. Do not connect leads.
+ CHARGING AND STARTING,
REPAIRS, Battery.
9.Fit headlamp wiring.
10.Fit RH and LH repeater lamps.
+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
11.Fit RH and LH headlamps.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
12. Diesel models: Fit gearbox fluid cooler.
13. Models with A/C: Fit condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
14.Fit bumper assembly.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
15.Connect leads/multiplug to alternator.
16.Connect battery leads, negative lead last.
Page 1091 of 1529
PANEL REPAIRS
77-2-24 REPAIRS
Front cross member
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
4. Models with A/C: Remove condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
5. Diesel models: Remove gearbox fluid cooler.
6.Remove RH and LH headlamps.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
7.Release headlamp levelling motors and
position aside.
8.Release headlamp wiring and position aside.
9.Remove RH horn.
+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
10. Models with A/C: Release and remove A/C
pipes.
11.Remove RH and LH crush cans.
12.Remove 2 bolts securing front bulkhead
assembly to chassis.
13.Remove centre braces.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.Refit
1.Fit centre braces.
2.Fit 2 bolts securing bulkhead to chassis and
tighten bolts to 45 Nm (33 lbf.ft).
3.Fit crush cans.
4. Models with A/C: Fit A/C pipes.
5.Fit RH horn.
+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
6.Fit headlamp wiring and headlamp levelling
motors.
7.Fit RH and LH headlamps.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
8. Diesel models: Fit gearbox fluid cooler.
9. Models with A/C: Fit condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
10.Fit washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
11.Connect leads/multiplug to alternator.
12.Connect battery leads, negative lead last.
Page 1092 of 1529
PANEL REPAIRS
REPAIRS 77-2-25
Headlamp mounting panel - RH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front bumper assembly.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
4. Models with A/C: Remove condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
5. Diesel models: Remove gearbox fluid cooler.
6.Remove RH headlamp.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
7.Remove RH repeater lamp.
+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
8.Release headlamp levelling motor and position
aside.
9.Release headlamp wiring and position aside.
10.Remove battery and battery tray.
+ CHARGING AND STARTING,
REPAIRS, Battery.
11.Remove horn.
+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
12.Remove RH crush can.
13.Remove 2 bolts securing front bulkhead
assembly to chassis.
14.Remove RH centre brace.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit centre brace.
2.Fit 2 bolts securing bulkhead to chassis and
tighten bolts to 45 Nm (33 lbf.ft).
3.Fit crush can.
4. Models with A/C: Fit A/C pipes.
5.Fit horn.
+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
6.Fit battery and battery tray. Do not connect
leads.
+ CHARGING AND STARTING,
REPAIRS, Battery.
7.Fit headlamp wiring and headlamp levelling
motors.
8.Fit repeater lamp.
+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
M77 1741A
Page 1093 of 1529
PANEL REPAIRS
77-2-26 REPAIRS
9.Fit headlamp.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
10. Diesel models: Fit gearbox fluid cooler.
11. Models with A/C: Fit condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
12.Fit bumper assembly.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
13.Connect leads/multiplug to alternator.
14.Connect battery leads, negative lead last.
Headlamp mounting panel - LH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
4. Models with A/C: Remove condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
5. Diesel models: Remove gearbox fluid cooler.
6.Remove headlamp.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
7.Remove repeater lamp.
+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
8.Release headlamp levelling motor and position
aside.
9.Release headlamp wiring and position aside.
10.Remove air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
11.Remove 2 earth leads from LH of front
bulkhead.
12.Release and remove A/C pipes.
13.Remove crush can.
14.Remove bonnet release cable.
15.Remove 2 bolts securing front bulkhead
assembly to chassis.
16.Remove centre brace.