battery LAND ROVER DISCOVERY 1999 Owner's Manual

ENGINE - V8
12-2-30 REPAIRS
Refit
1.Clean mating faces of engine and gearbox,
dowel and dowel holes.
2.Lubricate splines and bearing surface on first
motion shaft with grease.
3.With assistance position engine in engine bay,
align to gearbox and locate on dowels.
4.Position support brackets, fit bell housing bolts
and tighten to 50 Nm (37 lbf.ft).
5.Position engine mountings, fit nuts and tighten
to 85 Nm (63 lbf.ft).
6.Lower lifting equipment and remove from
engine.
7. Models with automatic gearbox: Align torque
converter to drive plate, fit bolts and tighten to
50 Nm (37 lbf.ft). Fit access plug.
8.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
9.Position oil cooling pipe saddle clamps and
tighten bolts.
10.Position engine harness into foot well.
11.Connect 5 multiplugs to ECM.
12.Fit toe board and secure with trim fixings.
13.Connect engine harness earth to body and
secure with nut.
14.Connect engine harness to main harness
multiplug.
15.Connect multiplug to EVAP purge valve.
16.Connect engine harness multiplugs to fuse
box.
17.Connect starter lead to fuse box and secure
with nut.
18.Connect engine harness positive lead to
battery and tighten nut.
19.Fit fuse box cover.
20.Position engine earth lead and secure with
bolt.
21.Position coolant rail and secure with bolt.
22.Connect harness clips to coolant rail.
23.Connect hose to coolant rail and coolant pump
and secure with clips.
24.Connect PAS pump high and low pressure
pipes and secure with clips.
25.Position oil cooling pipe saddle clamp to PAS
pump housing and secure with bolt.
26.Clean A/C compressor and housing mating
faces, dowels and dowel holes.
27.Position A/C compressor, fit bolts and tighten
to 22 Nm (16 lbf.ft).
28.Connect multiplug to A/C compressor.
29.Clean ACE pump and housing mating faces,
dowels and dowel holes.
30.Position ACE pump, fit bolts and tighten to 22
Nm (16 lbf.ft). 31.Clean all pulley 'V's, fit auxiliary drive belt,
using a 15mm spanner, release belt tensioner
secure belt and re-tension drive belt .
32.Ensure auxiliary drive belt is correctly located
on all pulleys.
33.Fit radiator.

+ COOLING SYSTEM - V8, REPAIRS,
Radiator.
34.Fit top hose and secure with clips.
35.Connect fuel pipe to fuel rail.
36.Position ignition coils and connect ht leads.
37.Fit upper inlet manifold.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
38.Fit new oil filter and refill engine with oil.

+ ENGINE - V8, REPAIRS, Filter - oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - V8 engine.
39.Top up gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.

ENGINE - V8
REPAIRS 12-2-37
Gasket - sump
$% 12.60.38
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove dipstick.
4.Raise the vehicle on a ramp.
5.Drain engine oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - V8 engine.
6.Remove 8 bolts securing cross member and
remove cross member.
7.Raise front of vehicle under body to increase
clearance between engine and front axle.
8.Disconnect and release gearbox oil cooler pipe
and discard 'O' ring. 9.Remove 2 clips securing oil cooler pipes at
front of sump.
10.Remove clip securing oil cooler pipes to side of
sump.
11.Remove clip bracket.
12.Remove 2 forward facing bolts securing sump
to bell housing.
13.Remove 4 rear facing bolts securing sump to
bell housing.
14.Remove 2 bolts in sump recess.
15.Remove 3 nuts securing front of sump.

ENGINE - V8
12-2-38 REPAIRS
16.Remove 12 bolts securing sump flange to
engine.
17.Manoeuvre sump over front axle and remove
sump.
18.Discard sump gasket.
Refit
1.Clean all traces of sealant from the sump and
sump mating faces using a plastic scraper or
solvent.
2.Ensure bolt holes in cylinder block are clean
and dry.
3.Apply a 5 mm (0.2 in) wide bead of sealant, Part
No. STC 50550, across the cylinder block to
front cover joint and across the cylinder block to
rear main bearing joint. Apply a globule of
sealant to cover the ends of the cruciform
seals, (see illustration).
4.Fit new gasket, dry, to sump, ensuring that
locating tags are correctly positioned.
5.Manoeuvre sump into position, fit and lightly
tighten 2 bolts to retain sump in place, then fit
and lightly tighten remainder of bolts.
6.Working in the sequence illustrated, tighten the
sump bolts to 22 Nm (16 lbf.ft).
7.Position side clip bracket, fit and tighten bolt. 8.Position oil cooler pipe clips, fit and tighten
nuts.
9.Clean gearbox oil cooler pipe 'O' ring recess
and mating face.
10.Lubricate and fit new 'O' ring to gearbox oil
cooler pipe.
11.Position pipe and tighten nut.
12.Lower front of vehicle.
13.Position cross member to chassis, fit bolts and
tighten to 25 Nm (18 lbf.ft).
14.Refill engine oil and fit dipstick.
15.Connect battery earth lead.
16.Fit battery cover and retain with fixings.

ENGINE - V8
REPAIRS 12-2-39
Switch - oil pressure
$% 12.60.50
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
4.Remove fixings and remove underbelly panel.
5.Disconnect multiplug from oil pressure switch.
6.Position container below switch to catch oil
spillage.
7.Remove oil pressure switch and discard
sealing washer.
Refit
1.Clean oil pressure switch threads.
2.Fit new sealing washer to switch.
3.Fit oil pressure switch and tighten to 15 Nm (11
lbf.ft) .
4.Connect multiplug to oil pressure switch.
5.Fit underbelly panel and secure with fixings.
6.Remove stand(s) and lower vehicle.
7.Connect battery earth lead.
8.Fit battery cover and retain with fixings.
9.Top up engine oil.
Cooler - engine oil
$% 12.60.68
Remove
1.Release fixings and remove battery cover.
2.Release fixings and remove cooling fan cowl.
3.Remove front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.
4.Remove 6 scrivets and remove LH and RH air
deflectors from front panel.
5.Remove nut and move LH horn aside.

ENGINE - V8
12-2-40 REPAIRS
6.Remove 2 bolts securing radiator LH and RH
upper mounting brackets to body panel and
remove brackets.
7.Remove 4 screws securing air conditioning
condenser LH and RH upper mounting
brackets to condenser.
8.Remove condenser upper mounting brackets
with rubber mounts from radiator extension
brackets.
9.Remove 2 bolts securing LH and RH extension
brackets to radiator and remove brackets.
10.Position absorbent cloth under each oil cooler
hose connection to collect oil spillage. 11.Push against coupling release rings and
disconnect both hoses from oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
12.Remove screw securing oil cooler to radiator.
13.Release cooler from its location on radiator.
14.Release radiator lower mountings from
location in chassis and carefully move radiator
towards engine sufficiently only to release
engine oil cooler from radiator.
15.Remove engine oil cooler.
Refit
1.Fit engine oil cooler to radiator, engage in
location and secure with screw.
2.Fit radiator to location in chassis.
3.Ensure connections are clean, then secure
hoses to oil cooler.
4.Fit extension brackets to radiator and secure
with bolts.
5.Fit brackets with rubber mounts to extension
brackets and secure to air conditioning
condenser with screws.
6.Fit radiator upper mounting brackets and
secure to body with bolts.
7.Fit LH horn and secure with nut.
8.Fit LH and RH air deflectors to front panel and
secure with scrivets.
9.Fit front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY..
10.Fit cooling fan cowl and secure with fixings.
11.Fit battery cover and secure with fixings.
12.Top up engine oil.

EMISSION CONTROL - V8
DESCRIPTION AND OPERATION 17-2-5
Evaporative emission system control
diagram
1Battery
2Fuse 13 (engine compartment fusebox)
3Inertia switch
4Main relay (engine compartment fusebox)
5Engine Control Module (ECM)
6Purge Valve (black harness connector)
7Canister vent solenoid (CVS) valve – NAS
vehicles with vacuum type EVAP system leak
detection capability only8Leak detection pump – NAS vehicles with
positive pressure type EVAP system leak
detection capability only
9Fuel tank pressure sensor – NAS vehicles with
vacuum type EVAP system leak detection
capability only
10Instrument pack (MIL warning light)
M17 0210
12
3
4
5
6
7
9
8
10

EMISSION CONTROL - V8
17-2-8 DESCRIPTION AND OPERATION
Secondary air injection system control
diagram
1Fuselink 2 (engine compartment fusebox)
2SAI pump relay
3SAI pump
4SAI vacuum solenoid valve
(grey harness connector)5Engine Control Module (ECM)
6Battery
7Fuse 13 (engine compartment fusebox)
8Inertia switch
9Main relay
9
M17 0207
1
2
3
4
5
7
6
8

EMISSION CONTROL - V8
DESCRIPTION AND OPERATION 17-2-21
If the purge valve breaks or becomes stuck in the open or closed position, the EVAP system will cease to function
and there are no default measures available. The ECM will store the fault in memory and illuminate the MIL warning
lamp if the correct monitoring conditions have been achieved (i.e. valve status unchanged for 45 seconds after engine
has been running for 15 minutes). If the purge valve is stuck in the open position, a rich air:fuel mixture is likely to
result at the intake manifold, this could cause the engine to misfire and the fuelling adaptions will change.
The following failure modes are possible:
lSticking valve
lValve blocked
lConnector or harness wiring fault (open or short circuit)
lValve stuck open
If the purge valve malfunctions, the following fault codes may be stored in the ECM diagnostic memory, which can be
retrieved using TestBook/T4:
Canister Vent Solenoid (CVS) Unit – (NAS with vacuum type, fuel evaporation leak detection system only)
1CVS unit
2Mounting bracket3Spring clips to pipe from EVAP canister
4Harness connector
The canister vent solenoid (CVS) valve is mounted on a slide-on bracket which is riveted to the cruise control bracket
at the right hand side of the engine compartment. The vent pipe from the EVAP canister is connected to a stub pipe
on the CVS unit via a hose and plastic pipe combination. A two-pin connector links to the engine management ECM
via the engine harness for solenoid control; one of the wires is the supply feed from fuse No.2 in the engine
compartment fusebox, the other wire is the valve drive line to the ECM. The solenoid is operated when the ECM
grounds the circuit.
P-code Description
P0440Purge valve not sealing
P0444Purge valve open circuit
P0445Purge valve short circuit to ground
P0443Purge valve short circuit to battery voltage

EMISSION CONTROL - V8
17-2-22 DESCRIPTION AND OPERATION
The valve is normally open, allowing any build up of air pressure within the evaporation system to escape, whilst
retaining the environmentally harmful hydrocarbons in the EVAP canister. When the ECM is required to run a fuel
system test, the CVS valve is closed to seal the system. The ECM is then able to measure the pressure in the fuel
evaporative system using the fuel tank pressure sensor.
The ECM performs electrical integrity checks on the CVS valve to determine wiring or power supply faults. The ECM
can also detect a valve blockage if the signal from the fuel tank pressure sensor indicates a depressurising fuel tank
while the CVS valve should be open to atmosphere.
The following failure modes are possible:
lConnector or harness wiring fault (open or short circuit)
lValve stuck open or shut
lValve blocked
If the CVS valve malfunctions, the following fault codes may be stored in the ECM diagnostic memory, which can be
retrieved using TestBook/T4:
Fuel Tank Pressure Sensor (NAS vehicles with vacuum type leak detection system only)
1Ambient pressure
2Tank pressure3Sensor cell
The fuel tank pressure sensor is located in the top flange of the fuel tank sender / fuel pump module and is a non-
serviceable item (i.e. if the sensor becomes defective, the complete fuel tank sender unit must be replaced). The fuel
tank pressure sensor connector is accessible through the fuel pump access hatch in the boot area floor of the vehicle.
The pressure sensor is a piezo-resistive sensor element with associated circuitry for signal amplification and
temperature compensation. The active surface is exposed to ambient pressure by an opening in the cap and by the
reference port. It is protected from humidity by a silicon gel. The tank pressure is fed up to a pressure port at the back
side of the diaphragm.
P-code Description
P0446CVS valve / pipe blocked
P0447CVS valve open circuit
P0448CVS valve short circuit to ground
P0449CVS valve short circuit to battery voltage

EMISSION CONTROL - V8
DESCRIPTION AND OPERATION 17-2-23
For systems utilising the vacuum method for determining evaporation leaks, the sensor is used to monitor for a drop
in vacuum pressure. The evaporation system is sealed by the CVS valve and purge valve after a vacuum has been
previously set up from the intake manifold while the purge valve is open and the CVS valve is closed. If any holes or
leaks are present at the evaporation system joints, the vacuum pressure will gradually drop and this change in
pressure will be detected by the fuel tank pressure sensor. This system is capable of determining leaks down to 1 mm
(0.04 in.) in diameter.
The fuel tank pressure sensor is part of the NAS OBD system, a component failure will not be noticed by the driver,
but if the ECM detects a fault, it will be stored in the diagnostic memory and the MIL light will be illuminated on the
instrument pack. Possible failures are listed below:
lDamaged or blocked sensor
lHarness / connector faulty
lSensor earthing problem
lOpen circuit
lShort circuit to battery voltage
lShort circuit to ground
lECM fault
Possible failure symptoms of the fuel tank pressure sensor are listed below:
lFuel tank pressure sensor poor performance
lFuel tank pressure sensor low range fault
lFuel tank pressure sensor high range fault
If the fuel tank pressure sensor should malfunction, the following fault codes may be stored in the ECM diagnostic
memory, which can be retrieved using TestBook/T4:
P-code Description
P0451Fuel tank pressure signal stuck high within range
P0452Fuel tank pressure signal short circuit to battery voltage (out of range - High)
P0453Fuel tank pressure signal short circuit to ground or open circuit (out of range - Low)