warning LAND ROVER DISCOVERY 1999 Owner's Manual

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
09-5
Manual
Gearbox -
R380Gate plate bolts STC 50552
Manual
Gearbox -
R380Gear case to
extension housingSTC 4404
Manual
Gearbox -
R380Extension housing
boltsSTC 50552
Manual
Gearbox -
R380Gear change lever
yoke Allen screwSTC 50552
Manual
Gearbox -
R380Gear case to centre
plateSTC 4404
Manual
Gearbox -
R380Detent plugs STC 50552
Manual
Gearbox -
R380Bias spring
adjustment plate
boltsSTC 50552
Transfer Box -
LT230SEBottom cover plate STC 4600
Transfer Box -
LT230SEBottom cover plate
boltsSTC 50552
Transfer Box -
LT230SEFront output
housing core plugSTC 3811
Transfer Box -
LT230SETransfer box to
gear case bolts -
Petrol and Diesel
enginesSTC 50552
Transfer Box -
LT230SETransfer box to
gear case studs -
Petrol and Diesel
enginesSTC 50552
Transfer Box -
LT230SERear cover STC 4600
Transfer Box -
LT230SEDifferential warning
lamp switch(es)STC 50552
Transfer Box -
LT230SEHigh/Low selector
warning lamp
switchSTC 50552
Transfer Box -
LT230SERear output shaft
housingSTC 4600
Transfer Box -
LT230SERear output shaft
housing boltsSTC 50552
Transfer Box -
LT230SEHigh/Low selector
fork set screwSTC 50552
Transfer Box -
LT230SEInterlock solenoid
selector cover - Up
to 03 MYSTC 4600
Transfer Box -
LT230SEInterlock solenoid
circlip - 03 MY
onwardsSTC 50551
Transfer Box -
LT230SENeutral sensor STC 50552
Transfer Box -
LT230SEIntermediate shaft
retaining plate boltSTC 50552Transfer Box -
LT230SESide cover STC 4600
Transfer Box -
LT230SESide cover bolts STC 50552
Transfer Box -
LT230SEDifferential lock
selector shaft
detent plugSTC 50552
Transfer Box -
LT230SEDifferential lock
selector housing
boltsSTC 50552
Transfer Box -
LT230SEFront output shaft
housingSTC 4600
Transfer Box -
LT230SEFront output shaft
housing boltsSTC 50552
Transfer Box -
LT230SEHigh/Low selector
shaft detent plugSTC 50552
Transfer Box -
LT230SEInput gear bearing
housingSTC 4600
Transfer Box -
LT230SERear cover stud nut
and boltSTC 50552
Transfer Box -
LT230SEHigh/Low cross
shaft housingSTC 4600
Transfer Box -
LT230SEHigh/Low cross
shaft housing boltsSTC 50552
Automatic
gearbox -
ZFHP22-24Torque converter
housing to engine
boltsSTC 50553
Rear Axle and
Final DriveDifferential cover to
casingSTC 3811
Rear Axle and
Final DriveDifferential cover to
casing boltsSTC 50552
Front axle Differential cover to
casingSTC 3811
Front axle Differential cover to
casing boltsSTC 50552
Front
suspensionDrive shaft to hub STC 50554
Rear
suspensionDrive shaft to hub STC 50554
Rear
suspensionSLS air compressor
boltsSTC 50552

MAINTENANCE
PROCEDURES 10-5
Lamps, horns and warning indicators
Check
1.Switch on side, head and tail lamps and check
operation.
2.Check headlamp levelling operation.
3.Check turn signals and hazard warning lamps
for correct operation.
4.Press brake pedal and check operation of
brake lamps.
5.Check all exterior lamp lenses for clarity and
condition. Pay particular attention to headlamp
lenses for signs of stone chips or damage.
6.Check horn for loud, clear sound.
7.Switch on headlamps (with ignition switch at 'O'
position) and check light reminder warning
operates when door is opened.
8.Check operation of interior courtesy lights.
9.Check operation of all instrument pack warning
and indicator lights.
Wipers and washers
Check
1. Operate screen washer and switch on wipers.
Ensure washer jets are correctly aimed and
check for smooth, smear free operation of
wiper blades across screen at all speeds
including intermittent.
2.Repeat operation for rear screen washers/
wipers.
3.Check all wiper blades for condition and signs
of splits or damage.
4.Check security of wiper arms.

MAINTENANCE
10-14 PROCEDURES
Intercooler - diesel engine
Remove
1.Remove intercooler.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
Flush
1.Flush intercooler element using Flushing
Solvent Part No. STC 9713, following the
manufacturer's instructions.
2.Thoroughly dry intercooler ensuring that no
trace of solvent remains in the element.
3.Refit intercooler on completion.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
Engine oil - V8 engine
WARNING: Avoid excessive skin contact with
used engine oil. Used engine oil contains
potentially harmful contaminants which may
cause skin cancer or other serious skin
disorders.
Replace
1.Position suitable container beneath sump.
2.Clean area around oil drain plug.
3.Remove oil drain plug, discard sealing washer.
4.Allow oil to drain.
5.Fit new sealing washer to oil drain plug.
6.Fit engine drain plug and tighten to 33 Nm (24
lbf.ft).
7.Fill engine with recommended grade of oil to
correct mark on dipstick.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.

MAINTENANCE
PROCEDURES 10-15
Engine oil - diesel engine
WARNING: Avoid excessive skin contact with
used engine oil. Used engine oil contains
potentially harmful contaminants which may
cause skin cancer or other serious skin
disorders.
Replace
1.Release fixings, remove underbelly panel.
2.Position suitable container beneath sump.
3.Clean area around drain plug.
4.Remove oil drain plug, discard sealing washer.
5.Allow oil to drain.
6.Fit new sealing washer to oil drain plug.
7.Fit engine drain plug and tighten to 23 Nm (17
lbf.ft).
8.Fill engine with recommended grade of oil to
correct mark on dipstick.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
9.Fit front underbelly panel, secure fixings.
Centrifuge rotor – diesel engine
Replace
1.Replace centrifuge rotor.

+ ENGINE - Td5, REPAIRS, Rotor -
centrifuge.

MAINTENANCE
10-16 PROCEDURES
Engine oil filter - diesel engine
Replace
1.Replace oil filter.

+ ENGINE - Td5, REPAIRS, Filter - oil.
Engine oil filter – V8 engine
WARNING: Avoid excessive skin contact with
used engine oil. Used engine oil contains
potentially harmful contaminants which may
cause skin cancer or other serious skin
disorders.
Replace
1.Disconnect battery.
2.Position suitable container beneath oil filter.
3.Using a strap type filter wrench, remove filter
element, discard element.
4.Smear sealing ring of replacement filter
element with engine oil.
5.Fit filter element, tighten two thirds of a turn by
hand or to 17 Nm (13 lbf.ft).
6.Top-up engine with recommended grade of oil
to correct mark on dipstick.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
7.Connect battery.
8.Run engine and check for oil leaks from filter.
9.Stop engine, wait for oil to return to sump.
10.Re-check oil level and top-up if necessary.

MAINTENANCE
PROCEDURES 10-17
Manual gearbox
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Check/top-up oil level
1.Release fixings, remove rear underbelly panel.
2.Clean area around oil filler/level plug.
3.Remove oil filler/level plug.
4.Check that oil level is to bottom of oil filler/level
plug hole.
5.Top-up level (if required) with recommended oil
to bottom of filler/level plug hole.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
6.Remove all traces of sealant from threads of oil
filler/level plug.
7.Apply Loctite 290 to threads of oil filler/level
plug.
8. Fit manual gearbox filler/level plug and tighten
to 30 Nm (22 lbf.ft).
9.Remove all traces of oil from gearcase.
10.Fit rear underbelly panel, secure fixings.Replace oil
1.Release fixings, remove rear underbelly panel.
2.Place a suitable container beneath gearbox
drain plug.
3.Clean area around oil filler/level and drain
plugs.
4.Remove oil filler/level plug.
5.Remove oil drain plug, remove and discard
sealing washer.
6.Allow oil to drain.
7.Clean magnet in oil drain plug.
8.Fit new sealing washer to oil drain plug.
9.Fit manual gearbox drain plug and tighten to 50
Nm (37 lbf.ft).
10.Fill gearbox with recommended oil to bottom of
filler/level plug hole.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
11.Remove all traces of sealant from threads of oil
filler/level plug.
12.Apply Loctite 290 to threads of oil filler/level
plug.
13. Fit manual gearbox filler/level plug and tighten
to 30 Nm (22 lbf.ft).
14.Remove all traces of oil from gearcase.
15.Fit rear underbelly panel, secure fixings.

MAINTENANCE
10-18 PROCEDURES
Automatic gearbox
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Replace oil filter
1.Replace oil filter.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Filter - oil.
Replace oil
1. Ensure that gearbox is cool. Apply
handbrake and securely chock front and rear
wheels.
2.Place a suitable container beneath gearbox.
3.Clean area around oil filler/level and drain
plugs.
4.Remove oil drain plug, remove and discard
sealing washer.
5.Allow oil to drain.
6.Fit new sealing washer to oil drain plug.
7.Fit automatic gearbox drain plug and tighten to
15 Nm (11 lbf.ft).
8.Remove oil filler/level plug, remove and discard
sealing washer.
9.Fill gearbox with recommended oil to bottom of
oil level/filler plug hole.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
10.Select 'P' (Park).
11.Ensure handbrake is applied.
12.Start engine and allow it to idle.
13.Apply footbrake. 14.Move selector lever through all gear positions,
while continuing to fill the gearbox. Select 'P'
(Park).
15.With engine idling, continue filling gearbox until
a 2 mm bead of oil runs from oil filler/level plug
hole.
16.Fit new sealing washer to automatic gearbox
filler/level plug, fit plug and tighten to 30 Nm (22
l b f . f t ) .
17.Stop engine.
18.Remove all traces of oil from gearbox casing.

MAINTENANCE
PROCEDURES 10-19
Transfer box
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Check/top-up oil level
1.Release fixings, remove rear underbelly panel.
2.Clean area around oil filler/level plug.
3.Remove oil filler/level plug.
4.Check that oil level is to bottom of filler/level
plug hole.
5.Top-up level (if required) with recommended oil
to bottom of oil filler/level plug hole.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
6. Fit transfer box filler/level plug and tighten to 25
Nm (18 lbf.ft).
7.Remove all traces of oil from main casing.
8.Fit rear underbelly panel (if fitted), secure
fixings.Replace oil
1. Release fixings, remove rear underbelly panel.
2.Place a suitable container beneath transfer box
drain plug.
3.Clean area around oil filler/level and drain
plugs.
4.Remove oil filler/level plug.
5.Remove oil drain plug.
6.Allow oil to drain.
7. Fit transfer box drain plug and tighten to 30
Nm (22 lbf.ft).
8.Fill transfer box with recommended oil to
bottom of oil filler/level plug hole.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
9. Fit transfer box filler/level plug and tighten to 25
Nm (18 lbf.ft).
10. Remove all traces of oil from transfer box.
11.Fit rear underbelly panel (if fitted), secure
fixings.

MAINTENANCE
10-20 PROCEDURES
Front and rear axle
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Replace oil
1.Place a suitable container beneath differential
housing of axle to be drained.
2.Clean area around oil filler/level and drain
plugs.
3.Remove oil filler/level plug.
4.Remove and discard 'O' ring from oil filler/level
plug.
5.Remove oil drain plug, allow oil to drain.
6. Fit axle drain plug and tighten to 64 Nm (47
lbf.ft).
7.Fill differential housing with recommended oil to
bottom of oil filler/level plug hole.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
8.Lubricate a new 'O' ring with recommended oil
and fit to oil filler/level plug.
9.Fit axle filler/level plug and tighten to 10 Nm (7
lbf.ft).
10.Remove all traces of oil from differential
housing.
Propeller shafts
Lubricate
Rear shaft
1.Clean area around front universal joint grease
nipple.
2.Apply recommended grease to the grease
nipple.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
Front shaft
3.Remove blanking plug adjacent to sliding joint
from propeller shaft.
4.Screw a 1/4in UNF grease nipple into blanking
plug hole.

MAINTENANCE
PROCEDURES 10-31
Road/roller test
WARNING: Roller test must be restricted to 3
mph (5 km/h). If 2 wheel rolling road is to be used,
disconnect propeller shaft from the transfer box
output shaft driving the axle which is NOT on the
rolling road.
Testing
1. 2 wheel rolling road: Engage differential lock
using a 10 mm open ended spanner on flats
machined on differential lock selector
shaft.Switch on ignition and check that the
differential lock, electronic brake
distribution and hill descent warning lamps
are illuminated.
2.Check for correct operation of starter switch,
ensure engine starts correctly; leave the engine
running.
3.Check for correct operation of starter switch,
ensure engine starts correctly; leave the engine
running.
4.With vehicle stationary, turn steering from lock
to lock. Check for smooth operation and ensure
there is no undue noise from power steering
pump or drive belt.
5.Depress clutch and select all gears in turn,
check for smooth, notch free engagement.6. Check all vehicle systems for correct
operation.
7.Check for unusual engine, gearbox and
suspension noises.
8.Check braking system operation.
9.Check for smooth gear engagement.
10.Check engine performance.
11.Check operation of all instruments and warning
devices where practicable.
12.Where possible, check for correct operation of
hill descent control (HDC) mechanism. This
should not be carried out if excessive journey
time is required.
13.After road/roller test, carry out a final inspection
of vehicle, with vehicle on a ramp.
14.Check all fluid levels and top-up if necessary.
15. 2 wheel rolling road: Ensure differential lock is
disengaged and propeller shaft is connected on
completion of test. Switch on ignition and
check that differential lock, electronic brake
distribution and hill descent warning lamps
are extinguished.