engine LAND ROVER DISCOVERY 1999 Workshop Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 1999, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 1999Pages: 1529, PDF Size: 34.8 MB
Page 1093 of 1529
PANEL REPAIRS
77-2-26 REPAIRS
9.Fit headlamp.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
10. Diesel models: Fit gearbox fluid cooler.
11. Models with A/C: Fit condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
12.Fit bumper assembly.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
13.Connect leads/multiplug to alternator.
14.Connect battery leads, negative lead last.
Headlamp mounting panel - LH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
4. Models with A/C: Remove condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
5. Diesel models: Remove gearbox fluid cooler.
6.Remove headlamp.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
7.Remove 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 air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
11.Remove 2 earth leads from LH of front
bulkhead.
12.Release and remove A/C pipes.
13.Remove crush can.
14.Remove bonnet release cable.
15.Remove 2 bolts securing front bulkhead
assembly to chassis.
16.Remove centre brace.
Page 1094 of 1529
PANEL REPAIRS
REPAIRS 77-2-27
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 bonnet release cable.
4.Fit crush can.
5. Models with A/C: Fit A/C pipes.
6.Fit 2 earth leads to LH of front bulkhead.
7.Fit air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
8.Fit battery tray.
9.Fit headlamp wiring and headlamp levelling
motors.
10.Fit repeater lamp.
+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
11.Fit headlamp.
+ 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 washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
15.Connect leads/multiplug to alternator.
16.Connect battery leads, negative lead last.
Page 1095 of 1529
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
Page 1096 of 1529
PANEL REPAIRS
REPAIRS 77-2-29
Refit
1. Models with A/C: Fit A/C pipes and recharge
A/C system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
2.Fit harness to valance.
3.Fit brake pipes to valance.
4.Fit ABS modulator.
+ BRAKES, REPAIRS, Modulator unit
- ABS.
5.Fit PAS/ACE reservoir, refill fluids to correct
levelsand bleed ACE system.
+ FRONT SUSPENSION,
ADJUSTMENTS, ACE hydraulic system
bleeding.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Fluids.
6.Fit air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
7.Fit front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
8.Connect leads/multiplug to alternator.
9.Connect battery leads, negative lead last.
Valance upper assembly - RH
In this procedure, the front wing and the valance
outer reinforcement are replaced in conjunction with
the RH 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 battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
5.Remove battery tray.
6.Remove fuse box.
7.Release expansion tank from fixings and
position aside.
8.Release harness from valance and position
aside.
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 1692A
M77 1750
Page 1097 of 1529
PANEL REPAIRS
77-2-30 REPAIRS
Refit
1.Fit harness to valance.
2.Fit and secure expansion tank to fixings.
3.Fit fuse box.
4.Fit battery tray.
5.Fit battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
6.Fit front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
7.Connect leads/multiplug to alternator.
8.Connect battery leads, negative lead last.
Valance upper assembly (front section) -
LH
In this procedure, the front wing, the valance outer
reinforcement (front section) and the bonnet alarm
switch mounting bracket are replaced in conjunction
with the LH valance upper assembly (front section).
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 -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
5.Remove PAS/ACE reservoir.
6.Remove ABS modulator.
+ BRAKES, REPAIRS, Modulator unit
- ABS.
7.Release harness from valance and position
aside.
8. 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.
Page 1098 of 1529
PANEL REPAIRS
REPAIRS 77-2-31
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. Models with A/C: Fit A/C pipes and recharge
A/C system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
2.Fit harness to valance.
3.Fit ABS modulator.
+ BRAKES, REPAIRS, Modulator unit
- ABS.
4.Fit PAS/ACE reservoir and refill fluids to correct
levels.
+ FRONT SUSPENSION,
ADJUSTMENTS, ACE hydraulic system
bleeding.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Fluids.
5.Fit air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
6.Fit front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
7.Connect leads/multiplug to alternator.
8.Connect battery leads, negative lead last.
M77 1744
M77 1689A
Page 1100 of 1529
PANEL REPAIRS
REPAIRS 77-2-33
Front valance assembly - RH
Remove
1.Disconnect battery eath lead.
2.Remove front bulkhead assembly.
+ PANEL REPAIRS, REPAIRS, Front
bulkhead assembly.
3.Remove engine compartment fusebox and
related wiring.
4.Remove radiator expansion tank from
mountings and position aside.
5. Petrol models: Remove cruise control
actuator mounting bracket.
6. Diesel models: Remove EGR modulator
mounting bracket.
7. RHD models: Remove brake servo.
+ BRAKES, REPAIRS, Servo - brake.
8.Remove brake pipes from valance assembly.
9.Remove RH road wheel.
10.Remove RH front mud flap.
11.Remove insulation pad from engine bulkhead.
12.Remove windscreen side finisher.
+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
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 windscreen side finisher.
+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
2.Fit insulation pad to engine bulkhead.
3.Fit front mud flap.
4.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
5.Fit brake pipes to valance assembly.
6. RHD models: Fit brake servo.
7. Diesel models: Fit EGR modulator mounting
bracket.
8. Petrol models: Fit cruise control actuator
mounting bracket.
9.Fit radiator expansion tank.
10.Fit fusebox and secure wiring.
11.Fit front bulkhead assembly.
+ PANEL REPAIRS, REPAIRS, Front
bulkhead assembly.
12.Connect battery leads, negative lead last.
M77 1694A
Page 1101 of 1529
PANEL REPAIRS
77-2-34 REPAIRS
Front valance assembly - LH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front bulkhead assembly.
+ PANEL REPAIRS, REPAIRS, Front
bulkhead assembly.
4.Remove ABS modulator unit.
+ BRAKES, REPAIRS, Modulator unit
- ABS.
5. LHD models: Remove brake servo.
+ BRAKES, REPAIRS, Servo - brake.
6.Remove brake pipes from valance assembly.
7.Remove PAS/ACE reservoir.
8. Models with A/C: Remove A/C pipes from
valance assembly.
9.Remove wiring harness from valance
assembly.
10.Remove LH front road wheel.
11.Remove LH front mud flap.
12.Remove insulation pad from engine bulkhead.
13.Remove windscreen side finisher.
+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
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 windscreen side finisher.
+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
2.Fit insulation pad to engine bulkhead.
3.Fit front mud flap.
4.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
5.Fit wiring harness to valance assembly.
6. Models with A/C: Fit A/C pipes to valance
assembly.
7.Fit PAS/ACE reservoir.
8.Fit brake pipes to valance assembly.
9. LHD models: Fit brake servo.
+ BRAKES, REPAIRS, Servo - brake.
10.Fit ABS modulator unit.
+ BRAKES, REPAIRS, Modulator unit
- ABS.
11.Fit front bulkhead assembly.
+ PANEL REPAIRS, REPAIRS, Front
bulkhead assembly.
12.Connect leads/multiplug to alternator.
13.Connect battery leads, negative lead last.
M77 1742
Page 1102 of 1529
PANEL REPAIRS
REPAIRS 77-2-35
'A' post assembly
In this procedure, the front wing and the valance
outer reinforcement (rear section) are replaced in
conjunction with the 'A' post assembly. The dash side
assembly can also be replaced in this procedure if
required.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove bonnet.
4.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
5.Remove RH or LH front door.
+ DOORS, REPAIRS, Door - front.
6.Remove RH or LH sill finisher.
7.Remove windscreen.
+ SCREENS, REPAIRS, Windscreen.
8. Diesel models: Remove ECM.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Engine control module
(ECM).
9.Remove RH or LH 'A' post inner finishers and
disconnect speaker multiplug (if fitted).
10.Release sunroof drain tube and position aside.
11.Remove RH or LH front seat.
+ SEATS, REPAIRS, Seat - front.
12. RH side: Remove CD autochanger.
+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
13.Remove fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia.
14. Driver's side: Remove steering column
support bracket.
15.Remove relevant wiring from 'A' post.
16.Remove tread plate from front door aperture.
17.Release front carpet and position aside.
18.Remove front door aperture seal.
19.Remove engine bulkhead insulation.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 1751
Page 1103 of 1529
PANEL REPAIRS
77-2-36 REPAIRS
Refit
1.Fit insulation pad to engine bulkhead.
2.Fit front door aperture seal.
3.Position front carpet and fit tread plate to front
door aperture.
4.Fit wiring to 'A' post.
5. Driver's side: Fit steering column support
bracket.
6.Fit fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia.
7. RH side: Fit CD autochanger.
+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
8.Fit RH or LH front seat.
+ SEATS, REPAIRS, Seat - front.
9.Fit sunroof drain tube.
10.Connect multiplug to speaker (if fitted) and fit
finisher to 'A' post.
11. Diesel models: Fit ECM.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Engine control module
(ECM).
12.Fit windscreen.
+ SCREENS, REPAIRS, Windscreen.
13.Fit sill finisher.
14.Fit front door.
+ DOORS, REPAIRS, Door - front.
15.Fit front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
16.Fit bonnet.
17.Connect leads/multiplug to alternator.
18.Connect battery leads, negative lead last.