engine LAND ROVER DISCOVERY 1999 Workshop Manual

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-20 DESCRIPTION AND OPERATION
P1613
(1)* Solenoid valves
power supply relay,
sticking open or short
circuitLimp home mode in low and high ranges. Shift
pressure to maximum, harsh gear shifts/
engagement.On On
P1705
(39)Transmission high/low
range, implausible
inputNo apparent effect On Off
P1810
(12, 13)Sport/Manual warning
lamp circuit faultLamp fails bulb check or is permanently
illuminated. No effect on gearbox operation.On Off
P1841
(16)* CAN bus fault Maintains current gear in low range, limp
home mode in high range. Shift pressure to
maximum, harsh gear shifts/engagement.On On
P1842
(15)* CAN level monitoring Maintains current gear in low range, limp
home mode in range. Shift pressure to
maximum, harsh gear shifts/engagement.On On
P1843
(17)* CAN time-out
monitoringMaintains current gear in low range, limp
home mode in high range. Shift pressure to
maximum, harsh gear shifts/engagement.On On
P1884
(11)* CAN message:
Engine friction invalidNo apparent effect. On Off
P1884
(18)* CAN message:
Throttle position invalidSubstitute throttle angle of 50% adopted. No
kickdown. Operates in economy modes only.On On
P1884
(19)CAN message: Engine
temperature invalidSubstitute engine temperature derived from
other inputs. No apparent effect.On Off
P1884
(20)CAN message: Road
speed invalidNo apparent effect On Off
P1884
(33, 34)* CAN message:
Engine torque invalidSubstitute engine torque of derived from other
inputs. May affect shift quality.On Off
P1884
(35)* CAN message:
Engine speed invalidMaintains current gear in low range, limp
home mode in high range. Shift pressure to
maximum, harsh gear shifts/engagement.On On
P1884
(37)CAN message: Engine
air intake temperature
invalidNo apparent effect. On Off
P1844
(38)Altitude shift control
invalidNo reduced torque compensation, possible
reduction in performance/ driveability at
altitude or high ambient temperatures.On Off
* = Emissions (OBD II) relevant
†On = MIL illuminates immediately (in all other faults, MIL On = illuminates in the 2nd consecutive drive cycle if
fault still present)Fault code,
OBD II
(TestBook)Fault description Effect Warning lamp
illumination
MIL Sport/
Manual

AUTOMATIC GEARBOX - ZF4HP22 - 24
ADJUSTMENTS 44-21
ADJUST ME NTS
Cable - selector
$% 44.30.04
Check
1.Position vehicle on ramp.
2.Select position 'P'.
3.Loosen selector cable trunnion nut.
4.Ensure that gearbox selector lever is in 'P'
position, (fully forward) and tighten trunnion
nut.
5.Lower ramp.
Stall test
$% 44.30.13
Testing
1.Chock the wheels and fully apply the
handbrake.
2.Start the engine and run it until it reaches
normal operating temperature.
3.Apply the footbrake and select 'D'.
4.Fully depress the accelerator pedal and note
the tachometer reading. The figures should be
as given below. Do not carry out stall test for
longer than 10 seconds, and DO NOT repeat
until 30 minutes have elapsed.
lV8: 2200 to 2400 rev/min
lDiesel: 2600 to 2800 rev/min
5.A reading below 1300 rev/min indicates a
torque converter fault, ie stator free-wheel.
6.A reading between 1300 and 2200 rev/min (V8)
or between 1300 and 2600 rev/min (Diesel)
indicates reduced engine power.
7.A reading above 2400 rev/min (V8) or above
2800 rev/min (Diesel) indicates clutch slip.
NOTE: The figures quoted above were
measured at sea level with an ambient
temperature of 20
°C (68°F). At higher altitudes
or higher ambient temperatures, these figures
will be reduced.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-27
Gearbox - convertor and transfer
gearbox - Diesel
$% 44.20.04.99
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Raise vehicle on a ramp.
4.Remove starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
5.Remove 2 upper bolts securing gearbox
housing to engine.
6.Remove bolt securing closing plate to gearbox
housing.
7.Remove exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
8.Remove 3 nuts securing intermediate silencer
to tail pipe.
9.Release and remove silencer from rubber
mountings. 10.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
11.Drain transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
12.Remove front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
13.Remove rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
14.Remove and discard 3 bolts securing torque
converter to drive plate.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-29
24. 03 Model Year onwards - If fitted: Release
and disconnect both differential lock warning
lamp switch multiplugs from main harness.
25.Remove cable tie and multiplug from bracket
on transfer box.
26.Release transfer and automatic gearbox
breather pipes from clip at rear of cylinder
block.
27.Position gearbox support jack and secure tool
LRT-99-008A to support plate on jack. 28.Position a second support jack under engine
using a block between engine sump and jack
to prevent damage to sump.
29.Remove 4 bolts and nut, remove engine LH
rear mounting.
30.Remove 4 bolts and nut, remove engine RH
rear mounting.
31.Remove 2 bolts securing gearbox oil cooler
pipe clips to engine sump and alternator
mounting bracket.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-30 REPAIRS
32.Remove bolt and 2 nuts securing clamps to oil
cooler pipes and remove clamps.
33.Loosen gearbox oil cooler pipe unions, release
pipes from gearbox and discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.34.Remove 'C' clip securing selector cable to
gearbox bracket.
35.Remove nut securing selector lever to inhibitor
switch and release lever.
36.Disconnect multiplug from inhibitor switch.
37.Loosen gearbox multi plug locking ring and
disconnect plug.
38.Remove 6 remaining gearbox housing bolts.
39.With assistance remove automatic gearbox
from engine.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-31
40.Fit suitable strap to retain torque converter.
Refit
1.Clean gearbox to engine mating faces.
2.Remove torque converter retaining strap.
3.With assistance position gearbox to engine.
4.Fit but do not tighten six bolts securing gearbox
housing to engine.
5.Connect multiplug to gearbox and tighten
locking ring.
6.Connect multiplug to inhibitor switch.
7. If fitted: Connect and adjust differential lock
selector cable.

+ TRANSFER BOX - LT230SE,
ADJUSTMENTS, Cable - selector -
differential lock - adjust.
8.Position selector lever to inhibitor switch and
tighten nut to 25 Nm (18 lbf.ft).
9.Position selector cable to gearbox and secure
with 'C' clip.
10.Clean oil pipe unions and fit new 'O' rings.
11.Position and tighten pipe unions to gearbox.
12.Position and tighten oil cooler pipe clamps.
13.Position and tighten oil cooler pipe clips to
engine sump and alternator bracket.
14.Position engine RH and LH rear mountings
and tighten bolts to 85 Nm (63 lbf.ft) and nuts to
85 Nm (63 lbf.ft).
15.Secure gearbox breather pipes to bulkhead
clip.
16. Up to 03 Model Year - If fitted: Connect 2
Lucars to differential lock warning lamp switch
and multiplugs to high/low ratio switch and
neutral sensor.
17. 03 Model Year onwards - If fitted: Connect
differential lock warning lamp switch multiplugs
to main harness.
18.Position cable tie and multiplug to transfer box
bracket.
19.Connect high/low ratio selector cable to
selector lever and secure with clevis pin. 20.Position high/low ratio selector cable to
abutment bracket and secure with 'C' clip.
21. Models fitted with high/low shift interlock
solenoid: Position interlock solenoid harness
to high/low shift cable, fit sleeve around cable
and harness.
22. Models fitted with high/low shift interlock
solenoid: Connect solenoid multiplug to main
harness and secure multiplug to bracket.
23.Position handbrake backplate and tighten bolts
to 75 Nm (55 lbf.ft).
24.Fit hand brake drum and tighten screw.
25.Remove bolts securing tool LRT-99-008A to
gearbox.
26.Rotate engine to align torque converter, fit new
bolts and tighten to 50 Nm (37 lbf.ft).
27.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
28.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
29.Fill transfer gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
30.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
31.Position intermediate silencer and secure to
mounting rubbers.
32.Clean silencer and tail pipe mating faces.
33.Position new gasket to tail pipe and tighten
nuts to 25 Nm (18 lbf.ft).
34.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
35.Fit bolt securing closing plate to gearbox
housing and tighten to 7 Nm (5.2 lbf.ft).
36.Fit upper bolts securing gearbox housing to
engine and tighten to 50 Nm (37 lbf.ft).
37.Fit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
38.Tighten remaining gearbox housing to engine
bolts to 50 Nm (37 lbf.ft).
39.Connect battery earth lead.
40.Fit battery cover and secure with fixings.
41.Check and adjust selector cable.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, ADJUSTMENTS, Cable - selector.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-34 REPAIRS
25.Position gearbox support jack and secure tool
LRT-99-008A to support plate on jack.
26.Position a second support jack under engine
using a block between engine sump and jack to
prevent damage to sump.
27.Remove 4 bolts and nut, remove engine LH
rear mounting.
28.Remove 4 bolts and nut, remove engine RH
rear mounting. 29.Remove bolt securing gearbox oil cooler pipe
clips to engine.
30.Remove bolt and 2 nuts securing clamps to oil
cooler pipes and remove clamps.
31.Loosen gearbox oil cooler pipe unions, release
pipes from gearbox and discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-35
32.Remove 'C' clip securing selector cable to
gearbox bracket.
33.Remove nut securing selector lever to inhibitor
switch and release lever.
34.Disconnect multiplug from inhibitor switch.
35.Loosen gearbox multiplug locking ring and
disconnect plug.
36.Lower gearbox sufficiently to access bell
housing bolts, take care not to trap any pipes or
cables when lowering gearbox.
37.Remove 14 bolts securing gearbox to engine.
38.With assistance remove gearbox from engine.39.Fit suitable strap to retain torque converter.
Refit
1.Clean gearbox to engine mating faces.
2.Remove torque converter retaining strap.
3.With assistance position gearbox to engine.
4.Fit gearbox bell housing bolts and tighten to 46
Nm (34 lbf.ft)..
5.Connect multiplug to gearbox and tighten
locking ring.
6.Connect inhibitor switch multiplug.
7. If fitted: Connect and adjust differential lock
selector cable.

+ TRANSFER BOX - LT230SE,
ADJUSTMENTS, Cable - selector -
differential lock - adjust.
8.Position selector lever to inhibitor switch and
tighten nut to 25 Nm (18 lbf.ft).
9.Position selector cable to gearbox and secure
with 'C' clip.
10.Clean oil pipe unions and fit new 'O' rings.
11.Position and tighten pipe unions to gearbox.
12.Position and tighten oil cooler pipe clamps.
13.Position and tighten oil cooler pipe clip to
engine sump.
14.Position engine RH and LH rear mountings
and tighten bolts to 85 Nm (63 lbf.ft) and nuts to
85 Nm (63 lbf.ft).
15.Secure gearbox breather pipes to bulkhead
clip.
16. Up to 03 Model Year - If fitted: Connect 2
Lucars to differential lock warning lamp switch
and multiplugs to high/low ratio switch and
neutral sensor.
17. 03 Model Year onwards - If fitted: Connect
differential lock warning lamp switch multiplugs
to main harness.
18.Position cable tie and multiplug to transfer
gearbox bracket.
19.Connect high/low ratio selector cable to
selector lever and secure with clevis pin.
20.Position high/low ratio selector cable to
abutment bracket and secure with 'C' clip.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-36 REPAIRS
21. Models fitted with high/low shift interlock
solenoid: Position interlock solenoid harness
to high/low shift cable, fit sleeve around cable
and harness, secure sleeve.
22. Models fitted with high/low shift interlock
solenoid: Connect solenoid multiplug to main
harness and secure multiplug to bracket.
23.Position hand brake back plate and tighten
bolts to 75 Nm (55 lbf.ft).
24.Fit hand brake drum and tighten screw.
25.Remove bolts securing tool LRT-99-008A to
gearbox.
26.Rotate engine to align torque converter, fit new
bolts and tighten to 50 Nm (37 lbf.ft).
27.Fit access plug to torque converter housing.
28.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
29.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
30.Fill transfer gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
31.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
32.Position intermediate silencer and secure to
mounting rubbers.
33.Clean silencer and tail pipe mating faces.
34.Position new gasket to tail pipe and tighten nuts
to 40 Nm (30 lbf.ft).
35.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
36.Position centre cross member, fit bolts and
tighten to 26 Nm (19 lbf.ft).
37.Connect battery earth lead.
38.Fit battery cover and secure fixings.
39.Check and adjust selector cable.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, ADJUSTMENTS, Cable - selector.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-49
Cooler - fluid - Td5
$% 44.24.10
Remove
1.Remove intercooler.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
2.Disconnect fluid temperature sensor multiplug.
3.Position absorbent cloth under each gearbox
cooler hose connection to collect spillage.
4.Push against coupling release ring and
disconnect both fluid hoses from cooler.
5.Remove screw and release cooler from
radiator.
6.Carefully remove cooler.7.Remove temperature sensor and discard
sealing washer.
Refit
1.Use new sealing washer and tighten
temperature sensor to 14 Nm (10 lbf.ft).
2.Fit cooler, engage with radiator and secure with
screw.
3.Connect temperature sensor multiplug.
4.Ensure connections are clean and fit hoses to
cooler.
5.Fit intercooler.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
6.Check and if necessary top up gearbox fluid.