bonnet LAND ROVER DISCOVERY 1999 Owner's Manual

STEERING
ADJUSTMENTS 57-25
7.Syphon PAS fluid from reservoir.
8.Position container to collect PAS fluid spillage.
9.Clean steering box pipe pipe housing.
10.Remove bolt securing pipe clip to steering box.
Leaving the feed pipe from PAS reservoir in
place, release clip and PAS cooler pipe from
steering box. Discard lower 'O' ring.
11.Fit LRT-57-041 adaptor to steering box.
12.Fit PAS cooler pipe to LRT-57-041, align
retaining clip and tighten Allen bolt to 25 Nm (18
lbf.ft).
13.Hang pressure gauge in a safe position under
bonnet.
14.Remove PAS reservoir filler cap, fill to level
indicator and refit cap.
15.Connect battery earth lead.
16.Start engine and allow air to bleed from PAS
system by turning steering from lock to lock.
Stop engine and check PAS fluid level.
17.Ensure steering system and test equipment are
free from leaks.
18.Open test valve on LRT-57-001 and start
engine.
19.With the engine at idle, slowly turn the steering
wheel and hold on full lock.
20.Note the pressure reading on LRT-57-005.21.Repeat the pressure check for the opposite full
lock.
22.Test pressure should be between 21 and 62
bar, (300 to 900) psi. Dependant on road
surface.
23.With the engine at idle, centralise the steering
wheel. Pressure should read 7 bar (100 psi) or
below.
24.Pressure outside the above tolerance indicates
a fault.
25.To determine if fault is in steering pump or
steering box, close the valve on LRT-57-001 for
a maximum of 5 seconds. Pump damage may
occur if test valve is closed for longer periods.
26.If gauge does not register between 75 and 103
bar, (1500 psi), (maximum pump pressure), the
pump is faulty.
27.If maximum pump pressure is correct suspect
the steering box.
28.On completion stop engine, disconnect battery
earth lead and syphon fluid from PAS reservoir.
29.Remove test equipment from LRT-57-002.
30.Remove bolt and clip from steering box.
31.Release PAS cooler pipe from LRT-57-041 and
discard 'O' ring. Leaving PAS reservoir oil feed
pipe in place, release LRT-57-041 from
steering box and discard 'O' ring.
32.Fit new 'O' rings to PAS cooler pipe.
33.Fit PAS cooler pipe to steering box, align
retaining clip, fit bolt and tighten to 25 Nm (18
lbf.ft).
34.Remove PAS reservoir filler cap, fill to level
indicator and refit cap.
35.Clean chassis member.
36.Fit splash shield and secure with screws.
37.Connect battery earth lead.
38.Start engine.
39.Start engine and allow air to bleed from PAS
system, by turning steering from lock to lock.
40.Visually check PAS system for leaks.
41.Check power steering fluid, if aerated, wait until
fluid is free from bubbles then top-up reservoir
to 'UPPER' level mark.
42.Visually check PAS system for leaks.
43.Dismantle test equipment.

EXTERIOR FITTINGS
76-2-2 REPAIRS
8.Remove 8 bolts securing wing to body and
remove wing.
Refit
1.Position wing to body.
2.Connect side repeater lamp to multiplug and fit
to wing.
3.Position wing to body, align wing to bonnet and
front door so that the correct gaps are achieved
and tighten bolts to 17 Nm (13 lbf.ft).
4.Check alignment of wing to bonnet and front
door. If necessary, adjust wing to achieve
correct gaps.
5.Fit and tighten nut securing wing to bracket on
sill finisher to 17 Nm (13 lbf.ft).
6.Fit and tighten screw securing wing to
headlamp surround panel.
7.Fit and tighten bolt securing front of wing to
bracket on body to 17 Nm (13 lbf.ft).
8.Fit wheel arch liner extension to bumper and
secure with screws.
9.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - wheel arch - front.
10.Fit front repeater lamp.

+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
Wing - front - from 03MY
$% 76.10.24
Remove
1.Remove the headlamp assembly.

+ LIGHTING, REPAIRS, Headlamp -
from 03MY.
2.Remove the front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - wheel arch - front.
3.Remove screw securing wheel arch liner
extension panel to the inner wing.
4.Remove 6 screws securing wheel arch liner
extension panel to the front bumper and
remove the extension panel.
5.Release side repeater lamp from front wing,
disconnect the multiplug and remove the lamp.

EXTERIOR FITTINGS
REPAIRS 76-2-3
6.Remove bolt securing front wing lower support
bracket to the body.
7.Remove nut securing sill finisher to the front
wing lower support bracket.
8.Remove 3 bolts securing front wing rear edge
to the body and collect the bracket.9.Remove bonnet sealing rubber from the front
wing flange.
10.Remove bolt securing front wing to the front
support bracket.
11.Remove 5 bolts securing front wing to the body
and remove the front wing.
NOTE: Do not carry out further dismantling if
component is removed for access only.
12.Remove nut securing lower support bracket to
the front wing and remove the bracket.
13.Remove the front wing wheel arch finisher.

EXTERIOR FITTINGS
76-2-4 REPAIRS
Refit
1.Clean front wing body mounting brackets.
2.Fit and secure the front wheel arch finisher to
the front wing.
3.Position lower support bracket to the front wing,
fit nut and tighten to 8 Nm (6 lbf.ft).
4.Position front wing to body, fit bracket and bolts
but do not tighten at this stage.
5.Check and adjust alignment of the front wing to
the bonnet and door.
6.Tighten the front wing retaining bolts to 8 Nm (6
lbf.ft).
7.Fit bonnet sealing rubber to the front wing
flange.
8.Fit bolt securing lower support bracket to the
body and tighten to 8 Nm (6 lbf.ft).
9.Fit nut securing sill finisher to the front wing
lower support bracket and tighten to 8 Nm (6
lbf.ft).
10.Fit bolt securing front wing to the front support
bracket and tighten to 8 Nm (6 lbf.ft).
11.Fit side repeater lamp to the front wing and
connect the multiplug.
12.Fit front wheel arch liner extension panel to the
front bumper and secure with screws.
13.Fit and tighten screw securing front wheel arch
liner extension panel to the inner wing.
14.Fit the front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - wheel arch - front.
15.Fit the headlamp assembly.

+ LIGHTING, REPAIRS, Headlamp -
from 03MY.
Rear folding step
$% 76.10.41
Remove
1.Remove 2 bolts securing step and damper
assembly to chassis.
2.Remove step and damper assembly.
3.Remove 2 patch lock nuts securing damper to
step and discard nuts.
4.Remove damper from step.
Refit
1.Fit damper to step and secure with new patch
lock nuts. Tighten nuts to 17 Nm (13 lbf.ft).
2.Position step and damper assembly to chassis
and secure with bolts. Tighten bolts to 45 Nm
(33 lbf.ft).

EXTERIOR FITTINGS
REPAIRS 76-2-9
Bonnet
$% 76.16.01.99
Remove
1.Support bonnet in open position.
2.Fit protection covers to wings and mark hinge
outline on bonnet if bonnet is to be refitted.
3.Disconnect windscreen washer tube at elbow
joint.
4.With assistance, remove bolts securing hinges
to bonnet and remove bonnet.
Refit
1.With assistance, position bonnet to hinges. Fit
and lightly tighten bolts.
2.Connect windscreen washer tube.
3.Close bonnet. Check that bonnet is aligned to
both front wings and that gaps are equal. If
necessary, adjust bonnet alignment and/or
gaps.
4.Finally tighten hinge bolts to 25 Nm (18 lbf.ft).
Cable - bonnet release - up to 03MY
$% 76.16.29
Remove
1.Remove front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.
2.Release LH headlamp from adjuster pin
sockets.
3.Disconnect 2 multiplugs from headlamp and
remove headlamp.
4.Drill out 4 rivets securing bonnet lock shield to
bonnet platform and remove shield.
5.Disconnect bonnet release cable inner and
outer from lock.

EXTERIOR FITTINGS
76-2-10 REPAIRS
6.Remove 4 fasteners securing LH fascia closing
panel to fascia and remove panel.
7.Remove 2 nuts securing bonnet release lever
assembly to body.
8.Remove bonnet release cable from lever
assembly.
9. Diesel models: Pull sound insulation away
from bulkhead for access to bonnet release
cable grommet. 10.Remove grommet from engine bulkhead.
11.Tie a draw string to end of bonnet release
cable in passenger compartment.
12.Pull bonnet release cable, from bonnet lock
end, until whole of cable is released.
13.Untie draw string from bonnet release cable
and remove cable.
14.Remove grommet from cable.
Refit
1.Fit grommet to bonnet release cable.
2.Tie draw string to passenger compartment end
of bonnet release cable.
3.Use draw string to pull bonnet release cable
into position.
4.Fit grommet to engine bulkhead.
5.Untie draw string from bonnet release cable.
6.Position bonnet release lever assembly and
connect bonnet release cable to lever.
7.Fit release lever assembly to body and tighten
nuts to 10 Nm (7 lbf.ft) .
8.Connect bonnet release cable to lock.
9.With assistance, operate bonnet release lever
and check for correct operation of lock.
10.Fit fascia closing panel and secure with
fasteners.
11.Fit bonnet lock shield and secure with rivets.
12.Position headlamp to body, connect multiplugs
and fit headlamp to sockets.
13.Fit front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.

EXTERIOR FITTINGS
REPAIRS 76-2-11
Cable - bonnet release - from 03MY
$% 76.16.29
Remove
1.Remove the front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - from 03MY.
2.Drill out 4 rivets securing bonnet lock shield to
the bonnet locking platform and remove the
shield.
3.Disconnect bonnet release cable from the
bonnet lock.
4.Disconnect bonnet release cable from the front
panel retaining clip.5.Remove 2 nuts securing bonnet release lever
to the 'A' post.
6.Disconnect bonnet release cable from the
bonnet release lever.
7.Remove bonnet release cable grommet from
the bulkhead.
8.Remove the bonnet release cable.
9.Remove grommet from the bonnet release
cable.
Refit
1.Fit grommet to the bonnet release cable.
2.Position bonnet release cable to body and
connect to the bonnet release lever.
3.Position bonnet release lever to 'A' post, fit nuts
and tighten to 10 Nm (7 lbf.ft).
4.Fit bonnet release cable grommet to the
bulkhead.
5.Connect bonnet release cable to the bonnet
lock.
6.Align timing mark on bonnet release cable to
retaining clip and secure to the clip.
7.With assistance operate bonnet release lever
and check for the correct operation of the lock.
8.Fit bonnet lock shield and secure with rivets
9.Fit the front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - from 03MY.
M76 4573
M76 3029B
M76 4574

EXTERIOR FITTINGS
REPAIRS 76-2-17
Grille - front - from 03MY
$% 76.55.03
Remove
1.Remove 3 scrivets securing front grille to
bonnet locking platform.
2.Remove front grille.
NOTE: Do not carry out further dismantling if
component is removed for access only.
3.Remove motif from front grille.
Refit
1.Clean front grille to motif mating face.
2.Fit and secure motif to front grille.
3.Fit front grille and secure with scrivets.

CHASSIS AND BODY DIMENSIONS
BODY DIMENSIONS 77-1-7
Front end information
I.D Description X Y Z
A Grille mounting slot -3190.5 413.9 303
(-125.610) (16.295) (11.929)
B Headlamp mounting panel, -3124 686.6 335
slot (-122.992) (27.031) (13.188)
C Bonnet locking platform, jig -3065.8 611 584.7
location hole (-120.700) (24.055) (23.019)
D Valance upper, jig location -2789.4 770.5 507.1
hole (-109.818) (30.334) (19.964)
E First wing fixing hole -3064.8 768 650.4
(-120.661) (30.236) (25.606)
F Second wing fixing hole -2787.9 778.7 686.1
(-109.759) (30.657) (27.011)
G Third wing fixing hole -2523.9 785.4 704.5
(-99.366) (30.921) (27.736)
H Fourth wing fixing hole -2259 789.6 718.4
(-88.937) (31.086) (28.283)
J Fifth wing fixing hole -1993.9 793 728.9
(-78.5) (31.220) (28.696)
M77 1753
B
C
D
E
F
G
H
J
A

CHASSIS AND BODY DIMENSIONS
77-1-8 BODY DIMENSIONS
Front end/side information
I.D Description X Y Z
A Bonnet hinge fixing, top hole -1906.3 706 742.9
(-75.051) (27.795) (29.248)
B Windscreen finisher, top slot -1508.9 715 1229
(-59.405) (28.147) (48.385)
C 'A' post top, top hinge fixing -1859 809.6 584.7
hole (-120.700) (24.055) (23.019)
D 'A' post bottom, top hinge -1859 809.6 289.1
fixing hole (-120.700) (24.055) (11.381)
E 'B/C' post top, top hinge -860.5 809.8 680.5
fixing (-33.877) (31.881) (26.791)
F 'B/C' post top, jig location -841.5 809.8 644.5
hole (-33.129) (31.881) (25.374)
G 'B/C' post bottom, top hinge -860.5 809.8 290.3
fixing hole (-33.877) (31.881) (11.429)
H 'B/C' post bottom, jig location -841.5 809.8 254.2
hole (-33.129) (31.881) (10.007)
J 'D' post, door striker fixing, -75.4 782.3 619.1
top hole (-2.968) (30.799) (24.374)
M77 1755A
B
C
H
F
D
J
A
E
G