washer fluid LAND ROVER DISCOVERY 1999 Owner's Manual

STEERING
57-8 DESCRIPTION AND OPERATION
Steering box
The steering box is located behind the first cross member of the chassis and is secured to the chassis rail with four
bolts. The steering box is of the worm and roller type and has a rotary control valve. The steering box is connected to
the steering knuckles of the front road wheels by the drop arm, drag link and track rod. The steering box is lubricated
by the hydraulic fluid in the housing. The input shaft is attached to the steering wheel via the intermediate shaft and
steering column. The drop arm is secured to the output shaft with a nut and tab washer. A ball joint allows movement
between drop arm and drag link, the ball joint is secured with a locknut. The steering box requries approximately 3.5
turns from lock to lock.
As a maintenance aid, an alignment bolt can be used to lock the drop arm at the steering box centre position. The bolt
fits in a groove in the rear face of the drop arm and screws in to a threaded hole on the bottom of the steering box
housing.
Cross section through steering box
1Relief valve stop 2 off
2Relief valve 2 off
3Piston
4Rack
5Housing
6Output shaft
7Roller
8Valve rotor9Torsion bar
10Input shaft
11Pin
12Valve sleeve
13Course spline
14Worm gear
15Spline (worm gear to torsion bar)

STEERING
REPAIRS 57-29
12. RH drive models with ACE: Position ACE
control arms to access steering box bolts.
13.With assistance remove 4 securing bolts and
remove steering box.
14.Remove centralising bolt from steering box. Refit
1.Fit centralising bolt to steering box.
2. With assistance, position steering box, fit bolts
and tighten to 90 Nm (66 lbf.ft).
3. RH drive models with ACE: Ensure washer is
in place on lower ball joint of anti-roll bar link,
then connect lower ball joint to axle. Tighten nut
to 100 Nm (74 lbf.ft).
4.Position drag link, fit nut and tighten to 80 Nm
(59 lbf.ft).
5.Position Panhard rod, fit bolt and nut and
tighten to 230 Nm (170 lbf.ft).
6.Clean PAS pipe ends and 'O' ring recess.
7.Lubricate new 'O' rings for PAS pipes with clean
PAS fluid.
8.Fit 'O' rings to PAS pipes and position pipes in
steering box. Fit PAS pipe bracket and tighten
bolt to 22 Nm (16 lbf.ft).
9. RHD models: Fit oil filter and housing:
lClean oil filter housing and engine mating
faces.
lLubricate new 'O' ring with clean engine oil
and fit to housing.
lPosition oil filter housing and tighten bolts to
9 Nm (7 lbf.ft).
10.Ensure steering wheel is centralised. Fit
universal joint between steering box and
intermediate shaft and tighten bolts to 25 Nm
(18 lbf.ft).
11.Remove centralising bolt from steering box.
12.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft)..
13.Remove stand(s) and lower vehicle.
14.Check and top up engine oil.
15.Bleed PAS system.

+ STEERING, ADJUSTMENTS,
Hydraulic system - bleed.
16.Centralise steering linkage

+ STEERING, ADJUSTMENTS,
Steering linkage - centralise.

STEERING
REPAIRS 57-33
21.With assistance remove 2 nuts and bolts
securing RH engine mounting to chassis.
22.Support the engine weight on a jack.
CAUTION: To prevent damage to
components, cushion the jack pad with a
block of wood or hard rubber.
23.Raise the engine sufficiently to allow the
steering box to clear the sump.
24. Models with ACE: Position ACE control arms
to access steering box bolts. 25.With assistance remove 4 bolts securing
steering box and remove steering box.
26.Remove centralising bolt from steering box.
Refit
1.Fit centralising bolt to steering box.
2.With assistance, position steering box, fit bolts
and tighten to 90 Nm (66 lbf.ft).
3.Lower the engine onto its mountings. Fit engine
mounting bolts and tighten to 85 Nm (63 lbf.ft).
4. Models with ACE: Ensure washer is in place
on lower ball joint of anti-roll bar link, then
connect lower ball joint to axle. Tighten nut to
100 Nm (74 lbf.ft).
5.Position drag link, fit nut and tighten to 80 Nm
(59 lbf.ft).
6.Position Panhard rod, fit bolt and nut and
tighten to 230 Nm (170 lbf.ft).
7.Position coolant rail and secure with clips and
bolt.
8.Fit coolant hoses and secure with clips.
9. Models with ACE: Fit and tighten bolt
securing ACE pipes to chassis.
10.Clean PAS pipe ends and 'O' ring recess.
11.Lubricate new 'O' rings for PAS pipes with clean
PAS fluid.
12.Fit 'O' rings to PAS pipes and position pipes in
steering box. Fit PAS pipe bracket and tighten
bolt to 22 Nm (16 lbf.ft).
13.Ensure steering wheel is centralised. Fit
universal joint between steering box and
intermediate shaft and tighten bolts to 25 Nm
(18 lbf.ft).
14.Remove centralising bolt from steering box.
15.Fit intercooler to turbo hose and secure with
clips.
16.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft).
17.Remove stand(s) and lower vehicle.
18.Connect battery earth lead.
19.Fit battery cover.
20.Refill cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
21.Bleed PAS system.

+ STEERING, ADJUSTMENTS,
Hydraulic system - bleed.
22.Centralise steering linkage

+ STEERING, ADJUSTMENTS,
Steering linkage - centralise.

STEERING
REPAIRS 57-37
Refit
1.Fit centralising bolt to steering box.
2.With assistance, position steering box to
chassis, fit bolts and tighten to 90 Nm (66 lbf.ft).
3. Models with ACE: Ensure washer is in place
on lower ball joint of anti-roll bar link, then
connect lower ball joint to axle and tighten nut
to 100 Nm (74 lbf.ft).
4.Position drag link, fit nut and tighten to 80 Nm
(59 lbf.ft).
5.Position Panhard rod, fit bolt and nut and
tighten to 230 Nm (170 lbf.ft).
6.Position coolant rail and secure with clips and
bolt.
7.Fit coolant hoses and secure with clips.
8. Models with ACE: Fit and tighten bolt
securing ACE pipes to chassis.
9.Clean PAS pipes ends and 'O' ring recess.
10.Lubricate new 'O' rings for PAS pipes with
clean PAS fluid.
11.Fit 'O' rings to PAS pipes and position pipes in
steering box. Fit PAS pipe bracket and tighten
bolt to 22 Nm 16 lbf.ft).
12.Ensure steering wheel is centralised. Fit
universal joint between steering box and
intermediate shaft and tighten bolts to 25 Nm
(18 lbf.ft).
13.Remove centralising bolt from steering box.
14.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft).
15.Remove stand(s) and lower vehicle.
16.Connect battery earth lead.
17.Fit battery cover.
18.Refill cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
19.Bleed PAS system.

+ STEERING, ADJUSTMENTS,
Hydraulic system - bleed.
20.Centralise steering linkage

+ STEERING, ADJUSTMENTS,
Steering linkage - centralise.
Seal - input shaft - steering box
$% 57.10.16
Remove
1.Remove steering box:
lFor V8 models:

+ STEERING, REPAIRS, Power
steering box - V8.
lFor LHD diesel models:

+ STEERING, REPAIRS, Power
steering box - LHD - diesel.
lFor RHD diesel models:

+ STEERING, REPAIRS, Steering
box - RHD - diesel.
2.Secure steering box in vice.
3.Remove circlip and extract oil seal from
steering box. Take care not to damage
surface of the shaft.
Refit
1.Clean oil seal recess and input shaft.
2.Lubricate new seal with clean PAS fluid.
3.Fit seal using LRT-57-503.
4.Fit circlip.
5.Fit steering box.
lFor V8 models:

+ STEERING, REPAIRS, Power
steering box - V8.
lFor LHD diesel models:

+ STEERING, REPAIRS, Power
steering box - LHD - diesel.
lFor RHD diesel models:

+ STEERING, REPAIRS, Steering
box - RHD - diesel.

STEERING
REPAIRS 57-39
Refit
1.Clean seal recess, output shaft, end cover and
mating face.
2.Lubricate new end cover 'O' ring with clean
PAS fluid. Fit 'O' ring to end cover.
3.Position output shaft, fit bolts and tighten to 88
Nm (65 lbf.ft).
4.Tighten rack adjuster one turn, align marks and
secure with Allen screw.
5.Lubricate new output shaft seal with clean PAS
fluid.
6.Fit seal using LRT-57-504.
7.Fit spacer, circlip and seal shield.
8.Clean drop arm and steering box splines.
9.Ensure steering box is in the central position.
Align and fit drop arm to output shaft and
secure with new lock washer and nut. Tighten
nut to 240 Nm (177 lbf.ft).
10.Secure lock washer to drop arm nut.
11.Fit steering box.
lFor V8 models:

+ STEERING, REPAIRS, Power
steering box - V8.
lFor LHD diesel models:

+ STEERING, REPAIRS, Power
steering box - LHD - diesel.
lFor RHD diesel models:

+ STEERING, REPAIRS, Steering
box - RHD - diesel.
Pump - power steering - V8
$% 57.20.14
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Remove cable tie securing harness to air intake
hose.
3.Loosen 3 clips securing air intake hose, release
and remove hose.
Note: Pre 03 MY air intake hose illustrated.
4. Models with ACE: Remove 3 bolts securing
ACE pump, release pump and position aside.

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.

FRONT SUSPENSION
REPAIRS 60-53
10.Loosen clip and disconnect air hose from
throttle body.
Note: Pre 03 MY air intake hose illustrated.
11.Position container to collect fluid loss.
12. Pump to valve block pipe:Remove banjo bolt
securing fluid hose to ACE pump and discard
sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.13. Valve block to reservoir pipe: Release clip,
disconnect hose from ACE fluid reservoir and
remove clip from hose.
CAUTION: Always fit plugs to open
connections to prevent contamination.
14.Remove bolts securing 2 pipe clamps to front
cross member and remove clamps.
15. Valve block to reservoir pipe: Release pipe
from clip on LH chassis member.

FRONT SUSPENSION
60-56 REPAIRS
11.Loosen clip, disconnect air hose from
turbocharger and move hose aside.
12.Release clip and disconnect pressure sensing
hose from turbocharger outlet pipe.
13.Loosen clips securing turbocharger outlet pipe
hoses.
14.Remove turbocharger outlet pipe and hoses as
an assembly. 15.Release clips and disconnect 2 thermostat
housing hoses from coolant pipe.
16.Release clip and disconnect bottom hose from
radiator.
17.Remove thermostat housing with hoses.
18.Position container to collect ACE fluid loss.
19. Pump to valve block pipe: Remove banjo
bolt securing fluid hose to ACE pump and
discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.