brake LAND ROVER DISCOVERY 1999 Repair Manual

MANIFOLDS AND EXHAUST SYSTEMS - V8
REPAIRS 30-2-19
20.Position container to collect spillage.
21.Release clips and disconnect 2 coolant hoses
from throttle housing.
22.Loosen outer cable locknuts and release
throttle and cruise control cables from
abutment.
23.Release throttle and cruise control cables from
clips and throttle cams and position aside.
24.Depress plastic collar and disconnect brake
servo hose from inlet manifold.
25.Release clip and disconnect breather hose
from manifold.
26.Disconnect vacuum hose from manifold.
27.Release engine harness from bulkhead clips
and position aside.
28.Release and remove bonnet seal from rear of
engine bay.
29.Remove 2 bolts securing air pipe and coil
bracket to manifold.
30.Loosen 2 lower bolts securing coil bracket
sufficiently to allow bracket to clear manifold.31.Release plug leads from upper manifold clips.
32.Loosen clip and disconnect air hose from air
valve.
33.Remove 2 nuts securing RH air manifold
support bracket to upper inlet manifold.

MANIFOLDS AND EXHAUST SYSTEMS - V8
30-2-20 REPAIRS
34.Release clip and disconnect IACV hose.
35.Remove 6 bolts securing upper manifold and
remove manifold.
36.Collect upper manifold gasket.
Refit
1.Clean upper and lower inlet manifold mating
faces, dowels and dowel holes.
2.Using a new gasket, position upper inlet
manifold. Fit bolts and, working in a diagonal
sequence, tighten to 22 Nm (16 lbf.ft).
3.Connect IACV hose and secure clip.
4.Connect hose to air valve and tighten clip.
5.Secure plug leads to clips.
6.Fit and tighten nuts securing RH air manifold
support bracket.
7.Align air pipe and coil bracket, fit bolts and
tighten to 8 Nm (6 lbf.ft).
8.Tighten 2 lower bolts securing coil bracket to 8
Nm (6 lbf.ft).
9.Fit bonnet seal.
10.Secure engine harness in bulkhead clips.
11.Connect breather hose to manifold and secure
clip.
12.Connect vacuum hose to inlet manifold.
13.Connect brake servo hose to inlet manifold.
14.Connect throttle and cruise control cables.
15.Adjust throttle cable.

+ ENGINE MANAGEMENT SYSTEM -
V8, ADJUSTMENTS, Cable - throttle.16.Adjust cruise control cable.

+ ENGINE MANAGEMENT SYSTEM -
V8, ADJUSTMENTS, Cable - cruise control.
17.Connect coolant hoses to throttle housing and
secure clips.
18.Connect multiplug to TP sensor.
19.Connect breather hose to throttle housing and
secure with clip.
20.Connect multiplug to IACV.
21.Secure purge valve and air control valve to clips
and bracket.
22.Connect purge hose to manifold.
23.Clean air manifold unions.
24.Apply a small amount of engine oil to top of air
manifold union nuts and around air manifold
pipes.
25.Position air manifold and finger tighten both air
manifold union nuts.
CAUTION: Finger tighten union nuts as far
as possible, damage to air manifold pipes or
adaptors may result if this is not done.
26.Tighten both air manifold union nuts to 25 Nm
(18 lbf.ft).
CAUTION: Ensure that air manifold pipes
are not distorted during tightening
operation.
27.Fit nuts securing air manifold support bracket
and tighten to 25 Nm (18 lbf.ft).
28.Connect hose to air valve and tighten clip.
29.Connect vacuum hose to air valve.
30.Fit air intake hose.
31.Connect multiplug to MAF sensor.
32.Secure harness to clip.
33.Connect battery earth lead.
34.Fit battery cover and secure with fixings.
35.Top up cooling system.

+ MAINTENANCE, PROCEDURES,
Cooling system.
36.Fit bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.

CLUTCH - V8
DESCRIPTION AND OPERATION 33-2-3
1Brake/clutch reservoir
2Connecting hose
3Bolt 2 off
4Master cylinder
5Clutch pedal
6Gearbox housing
7Primary driveshaft
8Bolt 2 off
9Slave cylinder
10Bleed nipple
11Pressure plate
12Drive plate13Flywheel
14Metal hydraulic pipes
15Ball spigot
16Clutch release bearing sleeve
17Bolt 2 off
18Pivot washer
19Release lever
20Release bearing
21Retaining clip
22Pipe
23Pipe

CLUTCH - V8
DESCRIPTION AND OPERATION 33-2-5
1Brake/clutch reservoir
2Fluid supply pipe
3Hydraulic feed pipe
4Master cylinder
5Piston
6Clutch pedal
7Primary driveshaft
8Engine crankshaft
9Drive plate
10Flywheel
11Ring gear12Cover - Pressure plate
13Leaf spring
14Retractor clip
15Diaphragm
16Release bearing
17Ball spigot
18Release bearing sleeve
19Release lever
20Slave cylinder
21Piston
22Bleed nipple

CLUTCH - V8
33-2-6 DESCRIPTION AND OPERATION
Description
General
The clutch system is a conventional diaphragm type clutch operated by a hydraulic cylinder. The clutch requires no
adjustment to compensate for wear.
Hydraulic clutch
The hydraulic clutch comprises a master cylinder, slave cylinder and a hydraulic reservoir, which is also shared with
the braking system. The master and slave cylinders are connected to each other hydraulically by plastic and metal
pipes. The plastic section of the pipe allows ease of pipe routing and also absorbs engine movements and vibrations.
The master cylinder comprises a body with a central bore. Two ports in the body connect the bore to the hydraulic
feed pipe to the slave cylinder and the brake/clutch fluid reservoir. A piston is fitted in the bore and has an external
rod which is attached to the clutch pedal with a pin. Two coiled springs on the clutch pedal reduce the effort required
to depress the pedal.
The master cylinder is mounted on the bulkhead in the engine compartment and secured with two bolts. The cylinder
is connected to the shared brake/clutch reservoir on the brake servo by a braided connecting hose.
The slave cylinder is located on the left hand side of the gearbox housing and secured with two bolts. A heat shield
protects the underside of the cylinder from heat generated from the exhaust system. The slave cylinder comprises a
cylinder with a piston and a rod. A port in the cylinder body provides the attachment for the hydraulic feed pipe from
the master cylinder. A second port is fitted with a bleed nipple for removing air from the hydraulic system after
servicing. The piston rod locates on a clutch release lever located in the gearbox housing. The rod is positively
retained on the release lever with a clip.
Clutch mechanism
The clutch mechanism comprises a flywheel, drive plate, pressure plate, release lever and a release bearing. The
clutch mechanism is fully enclosed at the rear of the engine by the gearbox housing.
A clutch release bearing sleeve is attached in the gearbox housing with two bolts and located on two dowels. A spigot
with a ball end is formed on the release bearing sleeve and provides a mounting and pivot point for the clutch release
lever. A dished pivot washer is located on the ball of the spigot. When the release lever is located on the ball, the pivot
washer seats against the rear face of the release lever. A spring clip is located on the lever and the pivot washer and
secures the lever on the spigot. A small bolt retains the spring clip in position.
The release lever is forked at its inner end and locates on the clutch release bearing carrier. The outer end of the
release lever has a nylon seat which locates the slave cylinder piston rod. A second nylon seat, positioned centrally
on the release lever, locates on the ball spigot of the release bearing sleeve and allows the release lever to pivot freely
around the ball.
The clutch release bearing locates on the clutch release lever and the release bearing sleeve. The bearing is retained
on a carrier which has two flats to prevent the carrier rotating on the release lever. A clip retains the release lever on
the carrier. The bearing and carrier are not serviceable individually.
Flywheel
The flywheel is bolted to a flange on the rear of the crankshaft with six bolts. A dowel on the crankshaft flange ensures
that the flywheel is correctly located. A ring gear is fitted on the outside diameter of the flywheel and seats against a
flange. The ring gear is an interference fit on the flywheel and is installed by heating the ring and cooling the flywheel.
The ring gear is a serviceable item and can be replaced if damaged or worn.
The operating face of the flywheel is machined to provide a smooth surface for the drive plate to engage on. Three
dowels and six threaded holes provide for the location and attachment of the pressure plate. The flywheel is balanced
to ensure that it does not produce vibration when rotating. A machined slot, with a series of holes within the slot, is
located on the engine side of the flywheel. The slot accommodates the tip of the crankshaft position sensor which is
used by the Engine Control Module (ECM) for engine management.

+ ENGINE MANAGEMENT SYSTEM - V8, DESCRIPTION AND OPERATION, Description - engine
management.

CLUTCH - V8
ADJUSTMENTS 33-2-11
ADJUST ME NTS
Clutch hydraulic system - bleed
$% 33.15.01
CAUTION: Ensure the fluid in the reservoir is
maintained between the minimum and maximum
levels throughout the bleed procedure using new
brake fluid.
CAUTION: Brake fluid will damage paint finished
surfaces. If spilled, immediately remove fluid and
clean area with water.
Bleeding
1.Top up reservoir.
2.Raise the front of the vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
3.Connect tube to bleed screw on clutch slave
cylinder and submerge free end in a clear
container containing brake fluid.
4.Loosen bleed screw, then apply steady
pressure to the clutch pedal, depressing it
through its full stroke. Allow the pedal to return
unassisted.
5.Repeat the procedure until a flow of clean, air-
free fluid is purged into the container.
6.Hold the pedal to the floor and tighten the
clutch bleed screw to 9 Nm (7 lbf.ft).
7.Check and top up reservoir.
CAUTION: Never re-use fluid that has been
bled from the system.
8.Remove stands and lower the vehicle.

CLUTCH - V8
33-2-14 REPAIRS
Master cylinder
$% 33.20.01
CAUTION: Brake fluid will damage paint finished
surfaces. If spilled, immediately remove fluid and
clean area with water.
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Release spring clip securing clutch pedal
clevis pin and remove pin from push rod and
clutch pedal.
3.Position container to catch spillage. Disconnect
hydraulic pipe from clutch master cylinder.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Release clip and remove connecting hose from
clutch master cylinder.
5.Remove 2 bolts securing clutch master
cylinder to pedal box and remove clutch master
cylinder. Refit
1.Clean master cylinder and pedal box mating
faces.
2.Position clutch master cylinder to pedal box, fit
bolts and tighten to 25 Nm (18 lbf.ft).
3.Position clevis pin to push-rod and clutch pedal
and secure with spring clip.
4.Fit connecting hose to brake master cylinder
and tighten clip.
5.Position hydraulic pipe and tighten union to 18
Nm (13 lbf.ft).
6.Bleed clutch.

+ CLUTCH - V8, ADJUSTMENTS,
Clutch hydraulic system - bleed.
7.Remove stand(s) and lower vehicle.

MANUAL GEARBOX - R380
REPAIRS 37-13
12.Remove 8 nuts securing front propeller shaft to
transfer gearbox and differential.
13.Remove propeller shaft.
14.Repeat above operation for rear propeller
shaft.
15.Remove handbrake drum retaining screw and
remove handbrake drum.
16.Remove 4 bolts from handbrake back plate,
release back plate and tie aside. 17.Remove 2 bolts securing clutch slave cylinder,
collect heat shield, release slave cylinder and
position aside.
18.Fit support plate LRT-99-007 to gearbox jack.
19.Position gearbox jack and support plate to
gearbox and secure with 3 bolts.
20.Support the weight of gearbox, remove nuts
securing gearbox mountings to body.
21.Remove 8 bolts securing mountings to
gearbox, raise gearbox and remove both
mountings.

MANUAL GEARBOX - R380
REPAIRS 37-15
32.Remove 3 bolts securing oil cooling pipe
housing to gearbox, release housing and
discard 'O' rings.
33.Using a second jack support the weight of the
engine.
34.Remove 14 bolts securing gearbox to engine.
35.With assistance, remove gearbox from engine.
Refit
1.Clean gearbox to engine mating faces, dowels
and dowel holes.
2.Raise gear gearbox on jack and align to clutch
and engine.
3.Fit bolts securing gearbox to engine and
tighten to 45 Nm (33 lbf.ft).
4.Lubricate and fit new 'O' rings to oil cooling
pipe housing. 5.Position coolant pipe housing, fit bolts and
tighten to 25 Nm (18 lbf.ft).
6. If fitted: Secure harness in retaining clips,
connect Lucars to differential lock warning
switch and multiplug to neutral sensor.
7.Position breather pipes and secure 'P' clip with
bolt.
8.Using new sealing washers fit breather pipe
banjo bolts and tighten to 15 Nm (11 lbf.ft).
9.Connect oil temperature sensor Lucars and
reverse lamp switch multiplug.
10.Position low ratio selector cable to housing and
secure with 'C' washer and clevis pin.
11.Secure cable to fuel pipes with new cable ties.
12.Raise gearbox, ensuring gear change lever is
located in grommet.
13.Fit gearbox mountings and tighten bolts to 85
Nm (63 lbf.ft).
14.Fit nuts to mountings and tighten to 48 Nm (37
lbf.ft).
15.Remove 3 bolts securing support plate to
gearbox.
16.Position clutch slave cylinder and heat shield,
fit bolts and tighten to 25 Nm (18 lbf.ft).
17.Clean handbrake back plate and mating face.
18.Position handbrake back plate, fit bolts and
tighten to 75 Nm (46 lbf.ft).
19.Clean handbrake drum.
20.Fit handbrake drum and tighten retaining
screw.
21.Clean propeller shafts and mating faces.
22.Position propeller shafts, align to marks and
tighten bolts to 47 Nm (35 lbf.ft).
23.Clean exhaust silencer and tail pipe mating
faces.
24.Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).
25.Position rear cross member, fit bolts and
tighten to 25 Nm (18 lbf.ft).
26.Refill gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.
27.Refill transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
28.Fit front exhaust pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
29.Fit gear lever extension, fit clamp bolt and
tighten to 25 Nm (18 lbf.ft).
30.Fit gear lever trim and gear change knob.
31.Connect battery earth lead.
32. Fit battery cover and cooling fan cover and
secure fixings.

MANUAL GEARBOX - R380
REPAIRS 37-17
14.Remove handbrake drum retaining screw and
remove handbrake drum.
15.Remove 4 bolts from handbrake back plate,
release back plate and tie aside.
16.Remove 2 bolts securing clutch slave cylinder,
collect heat shield, release slave cylinder and
position aside. 17.Fit support plate LRT-99-007 to gearbox jack.
18.Position gearbox jack and support plate to
gearbox and secure with 3 bolts.
19.Support the weight of gearbox, remove nuts
securing gearbox mountings to body.
20.Remove 4 bolts securing both mountings to
gearbox, raise gearbox and remove both
mountings.
21.Lower gearbox sufficiently to access top of
gearbox.