wheel LAND ROVER DISCOVERY 1999 Owner's Guide

MAINTENANCE
10-6 PROCEDURES
Handbrake
Check
1.With the vehicle stationary, on a level surface,
apply and release handbrake and check for
correct operation.

+ BRAKES, ADJUSTMENTS,
Handbrake.
Alarm handset battery
Replace
1.Insert the blade of a small, flat bladed
screwdriver into the slot at the rear of the
handset and prise the back from the handset.
2.Slide the battery out of the clip taking care not
to touch the circuit board or the battery
contacts.
3.Press and hold one of the buttons for at least 5
seconds.
4.Fit the replacement battery ensuring that
correct polarity is maintained (+) side facing
upwards. Avoid touching the flat surfaces of the
battery.
5.Press the 2 halves of the handset together.
6.Check that handset operates correctly.
Road wheels
Remove
1.Mark the wheel to stud relationship to ensure
that the wheels are refitted in the same
position.
2.Loosen wheel nuts. Raise the vehicle to a
wheel-free condition and remove the wheel
nuts.
Tyres
Check
1.Check tyres for compliance with manufacturer's
specification; visually for cuts, lumps, bulges,
uneven tread wear and depth.
2.Check tyre pressures, condition and tread
depth. Measure the tread depth across the
width of the tyre and around the circumference.
Brake pads, discs and calipers
Check
1. Check front and rear brake pads for wear,
ensure all pads are wearing evenly.
2.Check brake discs for signs of cracking,
excessive scoring or oil contamination.
3.Check calipers for signs of fluid leaks.
4.Clean excessive deposits of brake dust from
pads, calipers and disc shields using brake
cleaner.

MAINTENANCE
PROCEDURES 10-7
Road wheel speed sensors
Inspect
Front wheel
Rear wheel
1.Inspect each sensor harness for damage.
Brake fluid
Replace
1.Replace brake fluid.

+ BRAKES, ADJUSTMENTS, Brake
system bleeding.
Fuel filter - diesel engine
Replace
1.Replace filter element.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Element - fuel filter.
Fuel filter sedimenter
Drain
1.Position suitable container beneath fuel filter.
2.Disconnect multiplug from sedimenter.
3.Rotate sedimenter anti-clockwise until water
flows from drain tube.
4.Allow to drain until diesel fuel flows from drain
tube.
5.Rotate sedimenter fully clockwise.
6.Connect multiplug.

MAINTENANCE
10-8 PROCEDURES
Road wheels
Refit
1.Apply anti-seize compound to wheel hub
centre.
2.Refit road wheels to original hub position.
Tighten wheel nuts to 140 Nm (103 lbf.ft).
Radiator/Intercooler
Check
1.Visually check radiator/intercooler for external
obstructions, remove debris.
2.Visually check fan blades for damage.
Ambient air Temperature and pressure
sensor
Check
1.Check ambient air temperature and pressure
sensor for damage.
Doors, bonnet and fuel filler flap
Check
1.Check operation of each door, door lock,
bonnet catch and fuel filler flap. Ensure doors
close securely.
Lubricate
1.Lubricate door locks, hinges, check straps,
bonnet catch and fuel filler flap.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.

MAINTENANCE
PROCEDURES 10-13
Steering box
Check
1.Check steering box for fluid leaks.
Adjust
1.Check that there is no backlash in steering box
with road wheels in straight ahead position.
Adjust if required.

+ STEERING, ADJUSTMENTS,
Steering box - check and adjust.
Battery
Check
1.Check battery condition by checking colour of
condition indicator.
lGreen = O.K.
lBlack = Battery requires charging.
lClear/white = New battery required.
Clean
1.Clean and grease battery terminals with
petroleum jelly.

MAINTENANCE
10-18 PROCEDURES
Automatic gearbox
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Replace oil filter
1.Replace oil filter.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Filter - oil.
Replace oil
1. Ensure that gearbox is cool. Apply
handbrake and securely chock front and rear
wheels.
2.Place a suitable container beneath gearbox.
3.Clean area around oil filler/level and drain
plugs.
4.Remove oil drain plug, remove and discard
sealing washer.
5.Allow oil to drain.
6.Fit new sealing washer to oil drain plug.
7.Fit automatic gearbox drain plug and tighten to
15 Nm (11 lbf.ft).
8.Remove oil filler/level plug, remove and discard
sealing washer.
9.Fill gearbox with recommended oil to bottom of
oil level/filler plug hole.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
10.Select 'P' (Park).
11.Ensure handbrake is applied.
12.Start engine and allow it to idle.
13.Apply footbrake. 14.Move selector lever through all gear positions,
while continuing to fill the gearbox. Select 'P'
(Park).
15.With engine idling, continue filling gearbox until
a 2 mm bead of oil runs from oil filler/level plug
hole.
16.Fit new sealing washer to automatic gearbox
filler/level plug, fit plug and tighten to 30 Nm (22
l b f . f t ) .
17.Stop engine.
18.Remove all traces of oil from gearbox casing.

MAINTENANCE
PROCEDURES 10-31
Road/roller test
WARNING: Roller test must be restricted to 3
mph (5 km/h). If 2 wheel rolling road is to be used,
disconnect propeller shaft from the transfer box
output shaft driving the axle which is NOT on the
rolling road.
Testing
1. 2 wheel rolling road: Engage differential lock
using a 10 mm open ended spanner on flats
machined on differential lock selector
shaft.Switch on ignition and check that the
differential lock, electronic brake
distribution and hill descent warning lamps
are illuminated.
2.Check for correct operation of starter switch,
ensure engine starts correctly; leave the engine
running.
3.Check for correct operation of starter switch,
ensure engine starts correctly; leave the engine
running.
4.With vehicle stationary, turn steering from lock
to lock. Check for smooth operation and ensure
there is no undue noise from power steering
pump or drive belt.
5.Depress clutch and select all gears in turn,
check for smooth, notch free engagement.6. Check all vehicle systems for correct
operation.
7.Check for unusual engine, gearbox and
suspension noises.
8.Check braking system operation.
9.Check for smooth gear engagement.
10.Check engine performance.
11.Check operation of all instruments and warning
devices where practicable.
12.Where possible, check for correct operation of
hill descent control (HDC) mechanism. This
should not be carried out if excessive journey
time is required.
13.After road/roller test, carry out a final inspection
of vehicle, with vehicle on a ramp.
14.Check all fluid levels and top-up if necessary.
15. 2 wheel rolling road: Ensure differential lock is
disengaged and propeller shaft is connected on
completion of test. Switch on ignition and
check that differential lock, electronic brake
distribution and hill descent warning lamps
are extinguished.

ENGINE - V8
DESCRIPTION AND OPERATION 12-2-5
1Core plugs
2Cylinder block
3Camshaft
4Dipstick tube, clamp and bolt
5Woodruff key
6Timing chain
7Camshaft timing gear
8Washer
9Bolt - camshaft timing gear
10Thrust plate - camshaft end-float
11Bolt - camshaft thrust plate
12Gasket - timing cover
13Timing cover
14Oil pressure switch
15Bolt
16Crankshaft front oil seal
17Oil filter element
18Crankshaft front pulley
19Washer
20Bolt - crankshaft front pulley
21Upper main bearing shell
22Upper centre main bearing shell and thrust
washer
23Crankshaft
24Woodruff key
25Crankshaft timing gear
26Lower main bearing shells
27Numbers 1, 2 and 3 main bearing caps
28Bolt - main bearing caps
29Oil pick-up pipe and strainer30'O' ring
31Bolt - oil pick-up pipe
32Gasket - sump
33Sump
34Bolt - sump
35Sump oil drain plug
36Sealing washer
37Spacer, washers and nut - oil pick-up pipe
38Number 4 main bearing cap
39Bolt - connecting rod big-end bearing cap
40Connecting rod big-end bearing shell - lower
41Connecting rod big-end bearing cap
42Number 5 - rear main bearing cap
43Cruciform seal - rear main bearing cap
44Number 5 - rear main bearing shell
45Crankshaft rear oil seal
46Crankshaft knock sensor
47Side bolt - main bearing cap
48Side Allen bolt - main bearing cap
49Dowty washers
50Connecting rod big-end bearing shell - upper
51Connecting rod
52Piston
53Gudgeon pin
54Oil control ring
55Top compression ring
562nd compression ring
57Flywheel/drive plate and starter ring gear
58Bolt - flywheel/drive plate

ENGINE - V8
12-2-6 DESCRIPTION AND OPERATION
Description
General
The V8 petrol engine is an eight cylinder, water cooled unit having two banks of four cylinders positioned at 90 degrees
to each other. The engine comprises five main castings - two cylinder heads, cylinder block, timing cover and the oil
sump, all of which are manufactured from aluminium alloy.
NAS market vehicles from 03 model year receive a 4.6 litre version of the V8 engine to replace the previous 4.0 litre
version.
Cylinder heads
The cylinder heads are fitted with replaceable valve guides and valve seat inserts with the combustion chambers
formed in the head. Each cylinder head is sealed to the cylinder block with a gasket. The exhaust manifolds are bolted
to the outside of each cylinder head whilst the inlet manifolds are located in the centre of the 'Vee' and are bolted to
the inside face of each head. Inlet and exhaust manifolds are sealed to the cylinder heads by means of gaskets.
Each cylinder has a single inlet and exhaust valve. The exhaust valves are of the 'carbon break' type, a recess on the
valve stem prevents a build-up of carbon in the valve guide by dislodging particles of carbon as the valve stem moves
up and down the guide. Inlet and exhaust valve stem oil seals are fitted at the top of each valve guide. Valve operation
is by means of rocker arms, push rods and hydraulic tappets. Each of the rocker arms is located on a rocker shaft
which is supported by means of pedestals bolted to the cylinder heads. A spring, positioned on either side of each
rocker arm, maintains the correct relative position of the arm to its valve stem. The rocker arms are operated directly
by the push rods which pass through drillings in the cylinder heads and cylinder block. The bottom end of each push
rod locates in a hydraulic tappet operated by the single, chain driven camshaft.
The rocker covers are bolted to the cylinder heads and are sealed to the heads by a rubber gasket. Stub pipes for
crankcase ventilation hose connections are fitted to each rocker cover, the pipe in the right hand cover incorporates
an oil separator. The engine oil filler cap is situated in the right hand cover.
Cylinder block and camshaft
The cylinder block is fitted with cast iron cylinder liners which are shrink fitted and locate on stops in the block. The
camshaft is positioned in the centre of the cylinder block and runs in one piece bearing shells which are line bored
after fitting. Camshaft end-float is controlled by a thrust plate bolted to the front of the cylinder block. A timing gear,
chain driven by the crankshaft timing gear is bolted to the front of the camshaft.
Crankshaft and main bearings
The crankshaft is carried in five main bearings. The upper main bearing shell locations are an integral part of the
cylinder block casting. The lower main bearing caps are bolted to the cylinder block on either side of the upper bearing
shell locations with an additional bolt being inserted into each cap from either side of the cylinder block. The rear
main bearing cap carries the crankshaft rear oil seal and is sealed to the cylinder block by means of cruciform shaped
seals in each side of the cap. Number four main bearing cap carries the stud fixing for the oil pick-up pipe. Lower
main bearing shells are plain whilst the upper shells have an oil feed hole and are grooved. Crankshaft end-float is
controlled by the thrust faces of the upper centre shell. The crankshaft timing gear is located on the front of the
crankshaft by means of a Woodruff key which is also used to drive the gear type oil pump. The flywheel/drive plate
carries the crankshaft position sensor reluctor ring and is dowel located and bolted to the flywheel.
Timing cover
The timing cover is bolted to the front of the cylinder block and is sealed to the block with a gasket. The disposable,
full flow oil filter canister is screwed on to the timing cover which also carries the oil pressure switch, oil pressure relief
valve and crankshaft front oil seal. The gear type oil pump is integral with the cover which also has an internal oilway
to direct oil from the oil cooler to the filter.
NOTE: Oil coolers are only fitted to vehicles up to VIN 756821.

ENGINE - V8
REPAIRS 12-2-13
REPAIRS
Seal - crankshaft - rear
$% 12.21.20
Remove
1. Automatic gearbox models:Remove
converter drive plate.

+ ENGINE - V8, REPAIRS, Plate - drive
- automatic.
2. Manual gearbox models:Remove flywheel.

+ ENGINE - V8, REPAIRS, Flywheel.
3.Carefully remove oil seal from cylinder block to
avoid damage to seal location or running
surface on crankshaft. Discard seal.Refit
1.Ensure both seal location and running surface
on crankshaft are clean.
2.Lubricate replacement oil seal with engine oil.
3.Lubricate seal guide LRT-12-095 with engine
oil, fit seal guide to crankshaft.
4.Fit oil seal squarely onto crankshaft and
remove seal guide LRT-12-095.
5.Fit seal into location using tools LRT-12-091
and LRT-99-003.
6. Automatic gearbox models:Fit converter
drive plate.

+ ENGINE - V8, REPAIRS, Plate - drive
- automatic.
7. Manual gearbox models:Fit flywheel.

+ ENGINE - V8, REPAIRS, Flywheel.

ENGINE - V8
REPAIRS 12-2-31
Flywheel
$% 12.53.07
Remove
1.Remove gearbox

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
2.Restrain flywheel.
3.Working in sequence, progressively slacken 6
bolts securing clutch cover to flywheel.
Remove bolts.
4.Remove clutch cover.
5.Remove clutch plate.
6.Release crankshaft sensor multiplug from
bracket.
7.Remove 2 bolts securing crankshaft sensor
cover. 8.Remove crankshaft sensor cover.
9.Remove 2 nuts securing crankshaft sensor.
10.Remove crankshaft sensor.
11.Remove 6 bolts securing flywheel.
12.Remove flywheel.
On early engines, balance weights are on
engine side of flywheel; replacement flywheels
will have balance weights on clutch side of
flywheel.
Refit
1.Clean mating faces of flywheel and crankshaft,
dowel and dowel hole. Ensure bolt holes in
crankshaft are clean and dry.
2.Fit flywheel to crankshaft and tighten bolts to
78 Nm (58 lbf.ft).
3.Clean crankshaft sensor and mating face.
4.Fit crankshaft sensor and tighten nuts to 6 Nm
(4.4 lbf.ft).
5.Fit crankshaft sensor cover and tighten bolts to
6 Nm (5 lbf.ft).
6.Fit crankshaft sensor multiplug to bracket.
7.Clean clutch cover, drive plate and spigot bush
in end of crankshaft. Renew worn components
as necessary.
8.If refitting existing drive plate, apply 'Molycote
FB 180' to splines.