torque LAND ROVER DISCOVERY 1999 Owner's Guide

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
10-22 PROCEDURES
Anti-roll bar links
Check rear links
Rubber boots
Fixings
1.Check anti-roll bar links for free play.
2.Check rubber boots for splits, damage and
security.Anti-roll bar mountings - front
1.Check condition of mounting rubbers and
security of fixings.

+ TORQUE WRENCH SETTINGS,
Front suspension.
Anti-roll bar mountings - rear
Fixings
Rubber mountings
1.Check condition of mounting rubbers and
security of fixings.

+ TORQUE WRENCH SETTINGS, Rear
suspension.

MAINTENANCE
PROCEDURES 10-25
Engine, gearbox, transfer box and axles
Check
1.Check for oil leaks from engine, gearbox
(manual and automatic), transfer box and front
and rear axles; pay particular attention to areas
around oil seals.
Exhaust system
Check
1.Check for signs of exhaust system leaks,
damage and security.
Steering box and front suspension
Check/tighten steering box fixings
1.Check steering box fixings and tighten to 90
Nm (66 lbf.ft).
Check/tighten front axle suspension fixings
1.Check/tighten front suspension LH radius arm
fixings.

+ TORQUE WRENCH SETTINGS,
Front suspension.

MAINTENANCE
10-26 PROCEDURES
2.Check/tighten front suspension RH radius arm
fixings.
3.Check/tighten front suspension Panhard rod
fixingsCheck rear axle suspension fixings
1.Check and tighten if necessary all rear axle
suspension fixings.

+ TORQUE WRENCH SETTINGS, Rear
suspension.

MAINTENANCE
PROCEDURES 10-27
Steering rod ball joints
Check
1.Check condition of ball joints and dust covers,
and security of fixings.

+ TORQUE WRENCH SETTINGS,
Steering.
2.Attempt to move the ball joints forwards,
backwards, side to side and up and down. No
end float in any direction should be detected. If
end float is present, the ball joint must be
renewed.
Dampers and SLS height sensors
Check – Dampers
Front dampers
Rear dampers
1.Check dampers for security and signs of
leakage.

MAINTENANCE
10-28 PROCEDURES
Check – Height sensors
SLS height sensors
1.Check height sensors for condition and
security.
2.Check electrical harness for chafing and
damage.
Front and rear axle suspension links
Check
Rear suspension
Front suspension
1.Check condition of front and rear axle
suspension link mounting rubbers.
2.Check security of fixings.

+ TORQUE WRENCH SETTINGS,
Front suspension.

+ TORQUE WRENCH SETTINGS, Rear
suspension.

MAINTENANCE
10-30 PROCEDURES
Engine mountings - V8 engine
Check for security and condition
1.Check condition of Transfer box - RH mounting
rubber.
2.Check condition of Transfer box - LH mounting
rubber.
3.Check condition of Engine - LH mounting
rubber.4.Check condition of Engine - RH mounting
rubber
5.Check tightness of all mounting bolts.

+ TORQUE WRENCH SETTINGS,
Engine V8.

ENGINE - V8
REPAIRS 12-2-29
30. Models with automatic gearbox: Remove
access plug and remove 4 bolts securing
torque converter to drive plate.
31.Rotate engine to access bolts.
32.Remove 12 bolts securing engine to gearbox.
DO NOT remove the top 2 bolts at this
stage.
33.Collect support brackets from bell housing
bolts.
34.Attach suitable lifting equipment to engine. 35.Remove 4 nuts securing engine mountings,
raise engine and remove engine mountings.
36.Lower engine, remove top bolts securing
engine to gearbox and collect bracket.
37.Support gearbox on a jack.
38.Release engine from gearbox dowels.
39.With assistance remove engine from engine
bay.

ENGINE - V8
12-2-30 REPAIRS
Refit
1.Clean mating faces of engine and gearbox,
dowel and dowel holes.
2.Lubricate splines and bearing surface on first
motion shaft with grease.
3.With assistance position engine in engine bay,
align to gearbox and locate on dowels.
4.Position support brackets, fit bell housing bolts
and tighten to 50 Nm (37 lbf.ft).
5.Position engine mountings, fit nuts and tighten
to 85 Nm (63 lbf.ft).
6.Lower lifting equipment and remove from
engine.
7. Models with automatic gearbox: Align torque
converter to drive plate, fit bolts and tighten to
50 Nm (37 lbf.ft). Fit access plug.
8.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
9.Position oil cooling pipe saddle clamps and
tighten bolts.
10.Position engine harness into foot well.
11.Connect 5 multiplugs to ECM.
12.Fit toe board and secure with trim fixings.
13.Connect engine harness earth to body and
secure with nut.
14.Connect engine harness to main harness
multiplug.
15.Connect multiplug to EVAP purge valve.
16.Connect engine harness multiplugs to fuse
box.
17.Connect starter lead to fuse box and secure
with nut.
18.Connect engine harness positive lead to
battery and tighten nut.
19.Fit fuse box cover.
20.Position engine earth lead and secure with
bolt.
21.Position coolant rail and secure with bolt.
22.Connect harness clips to coolant rail.
23.Connect hose to coolant rail and coolant pump
and secure with clips.
24.Connect PAS pump high and low pressure
pipes and secure with clips.
25.Position oil cooling pipe saddle clamp to PAS
pump housing and secure with bolt.
26.Clean A/C compressor and housing mating
faces, dowels and dowel holes.
27.Position A/C compressor, fit bolts and tighten
to 22 Nm (16 lbf.ft).
28.Connect multiplug to A/C compressor.
29.Clean ACE pump and housing mating faces,
dowels and dowel holes.
30.Position ACE pump, fit bolts and tighten to 22
Nm (16 lbf.ft). 31.Clean all pulley 'V's, fit auxiliary drive belt,
using a 15mm spanner, release belt tensioner
secure belt and re-tension drive belt .
32.Ensure auxiliary drive belt is correctly located
on all pulleys.
33.Fit radiator.

+ COOLING SYSTEM - V8, REPAIRS,
Radiator.
34.Fit top hose and secure with clips.
35.Connect fuel pipe to fuel rail.
36.Position ignition coils and connect ht leads.
37.Fit upper inlet manifold.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
38.Fit new oil filter and refill engine with oil.

+ ENGINE - V8, REPAIRS, Filter - oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - V8 engine.
39.Top up gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.

ENGINE - V8
REPAIRS 12-2-33
6. Early engines: Remove 4 bolts securing drive
plate clamp ring and remove ring.
7. Early engines: Remove drive plate from hub.
8. Early engines: Remove 6 Allen bolts securing
hub and starter ring gear, remove hub, starter
ring gear and collect spacer.
On early engines, balance weights are on
engine side of drive plate; replacement drive
plates will have balance weights on torque
converter side of drive plate.9. Later engines: Remove 4 bolts securing drive
plate clamp ring and remove ring.
10. Later engines: Remove drive plate.
11. Later engines: Remove 6 Allen bolts securing
starter ring gear to crankshaft; remove starter
ring gear.
Refit
1. All engines: Ensure bolt holes in crankshaft
are clean and dry.
2. All engines: Clean all components
3. All engines: Check that drive plate is free from
cracks and distortion.
4. Early engines: Fit hub, starter ring gear and
spacer to crankshaft, fit Allen bolts and tighten
to 78 Nm (58 lbf.ft).
5. Early engines: Fit drive plate and clamp ring,
fit bolts and tighten to 45 Nm (33 lbf.ft).
6. Later engines: Fit starter ring gear, fit Allen
bolts and tighten to 85 Nm (63 lbf.ft).
7. Later engines: Fit drive plate and clamp ring,
fit bolts and tighten to 45 Nm (33 lbf.ft).
8.Clean CKP sensor and mating face.
9.Fit crankshaft sensor and tighten nuts to 6 Nm
(5 lbf.ft).
10.Fit CKP sensor cover and tighten bolts to 6 Nm
(5 lbf.ft).
11.Fit CKP sensor multiplug to bracket.
12.Fit automatic gearbox.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gearbox - convertor and
transfer gearbox - V8.