AUX LAND ROVER DISCOVERY 1999 Owner's Guide

STEERING
57-40 REPAIRS
5. Models with A/C: Disconnect A/C compressor
multiplug. Remove 4 bolts securing A/C
compressor, release compressor and position
aside.
6.Remove 3 bolts securing PAS pump pulley and
remove pulley.
7.Position tray to catch spillage, release PAS
pump pressure pipe.
8.Remove clip and release PAS pump inlet hose.
CAUTION: Always fit plugs to open
connections to prevent contamination.9.Remove jockey pulley.
10.Remove bolt securing oil cooling pipe bracket
and release bracket from housing.
11.Remove two bolts securing PAS pump.
12.Remove 4 bolts and one nut securing auxiliary
housing. Pull housing forward and release
PAS pump. Remove PAS pump.

STEERING
REPAIRS 57-41
Refit
1.Position PAS pump to auxiliary housing and
locate housing to engine. Fit and tighten
auxiliary housing bolts to 40 Nm (30 lbf.ft).
2.Tighten auxiliary housing nut to 10 Nm (7 lbf.ft).
3.Fit bolts securing PAS pump and tighten to 22
Nm (16 lbf.ft).
4.Position PAS pump pipe bracket, fit and tighten
bolt to 22 Nm (16 lbf.ft).
5.Fit and tighten PAS pump pressure pipe.
6.Fit PAS pump inlet hose and secure with clip.
7.Position jockey pulley and tighten bolt to 50 Nm
(37 lbf.ft).
8.Clean PAS pump pulley mating faces.
9.Position PAS pump pulley, fit bolts and tighten
to 22 Nm (16 lbf.ft).
10. Models with ACE: Clean ACE pump dowels
and dowel holes. Position ACE pump, fit bolts
and tighten to 25 Nm (18 lbf.ft).
11. Models with A/C: Clean A/C compressor
dowels and dowel holes. Position A/C
compressor, fit bolts and tighten to 22 Nm (16
lbf.ft).
12.Position air intake hose and secure with clips.
13.Secure harness to air intake hose with new
cable tie.
14.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive..
15.Bleed PAS system.

+ STEERING, ADJUSTMENTS,
Hydraulic system - bleed.

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
60-12 DESCRIPTION AND OPERATION
Hydraulic pump
1Outlet port
2Cap
3Piston spring
4Piston
5Inlet port
6Cylinder housing
7Shaft8Cam
9Inlet housing
10Spring
11Discharge valve
12Housing
13Pulley attachment flange
The hydraulic pump is attached to a bracket on the left hand side of the engine and is driven at crankshaft speed by
the auxiliary drive belt. The pump is of the radial piston type which delivers fluid at high pressure.
The radial piston pump has six pistons located in bores in a cylinder housing. A central shaft, which is driven by a
pulley and the auxiliary drive belt, has a cam which operates the pistons as it rotates.
As the cam lobe reaches each piston, the piston is pushed outward, moving the fluid above the piston. The pressure
created by the fluid flow from the bore opens a spring loaded discharge valve and allows the fluid to flow to the pump
outlet port. When the piston reaches its full stroke, the flow reduces and the discharge valve closes under spring
pressure.
As the cam lobe moves away from the piston, a spring pushes the piston down the bore creating a vacuum above the
piston. As the piston moves down the bore, ports in the piston are exposed and connect with the fluid inlet. The
vacuum draws fluid into the piston filling the piston and the chamber above it. As the piston is again pushed upwards,
the ports are closed off by the bore and the fluid opens the discharge valve and flows to the outlet port.

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
70-10 DESCRIPTION AND OPERATION
Vacuum pump (diesel models only)
1Alternator
2Vacuum pump
3Brake servo assembly vacuum connection4Oil feed pipe
5Oil drain pipe
As the diesel engine air inlet system does not produce sufficient depression to operate the brake servo assembly, an
engine driven vacuum pump is installed.
The vacuum pump is integrated with the engine alternator and driven by the auxiliary drive belt. The pump is a rotary
vane type, lubricated and cooled by engine oil supplied through a pipe connected to the engine block and returned
through a pipe connected to the engine oil sump. Air extracted from the brake servo assembly is vented into the oil
sump with returning lubricating oil.

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.