charging LAND ROVER DISCOVERY 1999 Owner's Manual

STEERING
57-42 REPAIRS
Pump - power steering - diesel
$% 57.20.14
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Remove 3 bolts securing PAS pump pulley and
remove pulley.
3.Position tray to catch spillage, release PAS
pump pressure pipe.
4.Remove clip and release PAS pump inlet hose.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove 4 bolts and remove PAS pump.
6.Remove bolt, and remove mounting bracket
from PAS pump.
7.Remove 2 bolts, remove low pressure adaptor
pipe and discard 'O' ring. Refit
1.Clean PAS pump and adaptor pipe.
2.Fit new 'O' ring to adaptor pipe, fit pipe and
tighten bolts to 10 Nm (7 lbf.ft).
3.Position mounting bracket to PAS pump, fit but
do not tighten bolt.
4.Position PAS pump and align pump drive to
coolant pump. Fit and tighten bolts to 25 Nm
(18 lbf.ft).
5.Tighten mounting plate bolt to 25 Nm (18 lbf.ft).
6.Clean PAS pump and pipe union.
7.Fit and tighten PAS pump pressure pipe to 20
Nm (15 lbf.ft).
8.Fit PAS pump inlet hose and secure with clip.
9.Clean PAS pump and pulley mating faces.
10.Position PAS pump pulley, fit and tighten bolts
to 10 Nm (7 lbf.ft).
11.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
12.Bleed power steering system.

+ STEERING, ADJUSTMENTS,
Hydraulic system - bleed.

FRONT SUSPENSION
REPAIRS 60-41
Pump - ACE - V8
$% 60.60.10
CAUTION: The ACE hydraulic system is
extremely sensitive to the ingress of dirt or
debris. The smallest amount could render the
system unserviceable. It is imperative that the
following precautions are taken.
lACE components are thoroughly cleaned
externally before work commences;
lall opened pipe and module ports are
capped immediately;
lall fluid is stored in and administered
through clean containers.
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Loosen 3 clips securing air intake hose.
Release air intake hose and position aside.
Note: Pre 03 MY air intake hose illustrated.3.Position container to catch spillage.
4.Release clip on pump suction hose and
disconnect hose.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove banjo bolt and disconnect pressure
pipe from ACE pump. Discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Remove 3 bolts securing ACE pump to
mounting and remove ACE pump.
7.Restrain pulley, remove 3 securing bolts and
remove pulley from ACE pump.

FRONT SUSPENSION
60-42 REPAIRS
Refit
1.Clean mating faces of pulley and ACE pump.
2.Position pulley to ACE pump and fit bolts.
Restrain pulley and tighten bolts to 25 Nm (18
lbf.ft).
3.Clean mating faces of ACE pump and
mounting.
4.Connect suction hose to ACE pump and secure
with clip.
5.Ensure there is sufficient fluid in ACE/PAS
reservoir to prime ACE pump.
6.Position ACE pump below level of ACE/PAS
reservoir, with suction hose uppermost, and
allow fluid from ACE/PAS reservoir to
completely fill ACE pump.
7.Position ACE pump to mounting, fit bolts and
tighten to 25 Nm (18 lbf.ft).
8.Rotate ACE pump clockwise (viewed from
pulley end) until a steady flow of fluid runs from
outlet port.
9.Connect pressure pipe to ACE pump with banjo
bolt and new sealing washers. Tighten banjo
bolt to 28 Nm (21 lbf.ft).
10.Position air intake hose and secure clips.
11.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
12.Renew ACE high pressure filter.

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.
Pump - ACE - diesel
$% 60.60.10
CAUTION: The ACE hydraulic system is
extremely sensitive to the ingress of dirt or
debris. The smallest amount could render the
system unserviceable. It is imperative that the
following precautions are taken.
lACE components are thoroughly cleaned
externally before work commences;
lall opened pipe and module ports are
capped immediately;
lall fluid is stored in and administered
through clean containers.
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Disconnect multiplugs from mass air flow
sensor and ambient air pressure sensor.
3.Release clips and disconnect mass air flow
sensor from air cleaner.
4.Loosen hose clip, disconnect inlet air hose
from turbo charger and move hose aside.

FRONT SUSPENSION
60-44 REPAIRS
Refit
1.Clean mating faces of pulley and ACE pump.
2.Position pulley to ACE pump and fit bolts.
Restrain pulley and tighten bolts to 25 Nm (18
lbf.ft).
3.Clean mating faces of ACE pump and
mounting.
4.Connect suction hose to ACE pump and secure
with clip.
5.Ensure there is sufficient fluid in ACE/PAS
reservoir to prime ACE pump.
6.Position ACE pump below level of ACE/PAS
reservoir, with suction hose uppermost, and
allow fluid from ACE/PAS reservoir to
completely fill ACE pump.
7.Position ACE pump to mounting, fit bolts and
tighten to 25 Nm (18 lbf.ft).
8.Rotate ACE pump clockwise (viewed from
pulley end) until a steady flow of fluid runs from
outlet port.
9.Connect pressure pipe to ACE pump with banjo
bolt and new sealing washers. Tighten banjo
bolt to 28 Nm (21 lbf.ft).
10.Connect hose to intercooler and secure with
clip.
11.Fit ACE/PAS reservoir into mounting bracket.
12.Connect air hose to turbo charger and secure
with clip.
13.Fit mass air flow sensor to air filter and secure
with clips.
14.Connect multiplugs to mass air flow sensor and
ambient air pressure sensor.
15.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
16.Renew ACE high pressure filter.

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.
Valve block - ACE
$% 60.60.20
CAUTION: The ACE hydraulic system is
extremely sensitive to the ingress of dirt or
debris. The smallest amount could render the
system unserviceable. It is imperative that the
following precautions are taken.
lACE components are thoroughly cleaned
externally before work commences;
lall opened pipe and module ports are
capped immediately;
lall fluid is stored in and administered
through clean containers.
Remove
1.Raise vehicle on a ramp.
2.Disconnect 4 multiplugs from valve block.
3.Position container underneath valve block to
collect fluid spillage.

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.

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.

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.

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.

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

PANEL REPAIRS
77-2-28 REPAIRS
Valance upper assembly - LH
In this procedure, the front wing, the valance outer
reinforcement and the bonnet alarm switch mounting
bracket are replaced in conjunction with the LH
valance upper 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.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
4.Remove air filter assembly.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
5.Remove PAS/ACE reservoir.
6.Remove ABS modulator.

+ BRAKES, REPAIRS, Modulator unit
- ABS.
7.Remove brake pipes from valance.
8.Release harness from valance and position
aside.
9. Models with A/C: Depressurise A/C system
and remove pipes from valance.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.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.
M77 1743
M77 1690A