ECU LAND ROVER DISCOVERY 1999 Workshop Manual

WIPERS AND WASHERS
REPAIRS 84-29
Motor - wiper - rear screen
$% 84.35.12
Remove
1.Remove spare wheel from taildoor.
2.Remove tail door trim casing.

+ DOORS, REPAIRS, Trim casing - tail
door.
3.Remove tail door water shedder.
4.Disconnect washer tube
5.Raise nut cover, remove nut and release wiper
arm.
6.Remove spindle nut and flat washer and
discard rubber seal.
7.Disconnect taildoor harness multiplug from
wiper motor.
8.Remove 2 bolts securing wiper motor to tail
door.
9.Remove wiper motor. Refit
1.Position wiper motor to door and secure with
bolts.
2.Connect tail door harness multiplug to wiper
motor.
3.Fit rubber seal, flat washer and spindle nut.
Tighten spindle nut to 3 Nm (2.2 lbf.ft).
4.Position wiper arm to tail door and connect
washer tube.
5.Tighten wiper arm nut to 20 Nm (15 lbf.ft) and
fit nut cover.
6.Fit tail door water shedder.
7.Fit tail door trim casing.

+ DOORS, REPAIRS, Trim casing - tail
door.
8.Fit spare wheel to tail door.

WIPERS AND WASHERS
84-30 REPAIRS
Switch - wiper - rear - up to 03MY
$% 84.35.33
Remove
1.Carefully remove switch from instrument cowl.
2.Disconnect multiplug and remove switch.
Refit
1.Position new switch and connect multiplug.
2.Carefully push switch into instrument cowl.
Switch - wiper - rear - from 03MY
$% 843533
Remove
1.Remove 2 screws securing instrument cowl to
fascia and release the cowl from the retaining
clips.
2.Disconnect multiplug from the rear wiper
switch.
3.Remove the rear wiper switch from the
instrument cowl.
Refit
1.Fit and secure the rear wiper switch to the
instrument cowl and connect the multiplug.
2.Fit the instrument cowl to the fascia and secure
with screws.

CHARGING AND STARTING
REPAIRS 86-1-1
CHARGING AND STARTING REPAIRS
Alternator - diesel
$% 86.10.02
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.

CHARGING AND STARTING
86-1-2 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.

CHARGING AND STARTING
REPAIRS 86-1-3
Alternator - V8
$% 86.10.02
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Remove 2 bolts securing alternator to
mounting bracket.
3.Release alternator from mounting bracket
4.Remove nuts securing alternator cables, and
release cables. 5.Remove alternator from mounting bracket.
6.Remove pulley from alternator.
Refit
1.Fit alternator pulley and tighten nut to 80 Nm
(59 lbf.ft).
2.Position alternator to mounting bracket.
3.Connect alternator cables and tighten B+ nut to
18 Nm (13 lbf.ft), and D+ nut to 5 Nm (3.7 lbf.ft).
4.Locate alternator in mounting bracket.
5.Fit alternator mounting bolts and tighten to 45
Nm (33 lbf.ft).
6.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.

CHARGING AND STARTING
86-1-4 REPAIRS
Belt - auxiliary drive
$% 86.10.03
Remove
1.Remove viscous fan:
l

+ COOLING SYSTEM - V8,
REPAIRS, Fan - viscous.
l

+ COOLING SYSTEM - Td5,
REPAIRS, Fan - viscous.
2.Turn drive belt tensioner using a 15 mm ring
spanner and release belt from pulleys.
Refit
1.Clean drive belt pulley grooves and ensure
grooves are not damaged.
2.Fit new drive belt around pulleys, ensure belt is
correctly aligned in pulley grooves.
3.With assistance, hold tensioner fully clockwise
and fit drive belt around remaining pulley.
Release tensioner.
4.Fit viscous fan:
l

+ COOLING SYSTEM - Td5,
REPAIRS, Fan - viscous.
l

+ COOLING SYSTEM - V8,
REPAIRS, Fan - viscous.
Battery
$% 86.15.01
Remove
1.Release fixings and remove battery cover.
2.Disconnect both battery leads, negative lead
first.
3.Remove lock nuts and retaining nuts securing
battery clamp.
4.Remove battery clamp.
5.Remove battery.
Refit
1.Clean battery terminals and coat with
petroleum jelly.
2.Fit battery.
3.Fit battery clamp and tighten retaining nuts and
lock nuts.
4.Fit both battery leads, negative lead last.
5.Fit battery cover and secure fixings.

CHARGING AND STARTING
REPAIRS 86-1-5
Battery carrier
$% 86.15.11
Remove
1.Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
2.Release strap and remove jack.
3.Release coolant hose from clip.
4. Diesel models: Remove screw securing ECM,
release ECM and position aside.
5.Remove 7 bolts securing battery carrier.
6.Remove battery carrier.
NOTE: Do not carry out further dismantling if
component is removed for access only.
7.Remove jack retaining strap, speed nut and
clip.Refit
1.Fit jack retaining strap, speed nut and clip.
2.Fit battery carrier, fit bolts and tighten to 28 Nm
(21 lbf.ft).
3. Diesel models: Fit ECM and secure with
screw.
4.Secure coolant hose.
5.Fit and secure jack.
6.Fit battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.

CHARGING AND STARTING
86-1-6 REPAIRS
Starter motor - diesel
$% 86.60.01
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.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.
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Disconnect Lucar connector from starter
solenoid.
6.Remove nut and disconnect battery lead from
starter solenoid.
7.Remove nut and 2 bolts securing starter motor
and remove starter motor from engine.Refit
1.Clean starter motor and mating face on engine.
2.Fit starter motor and tighten nut and 2 bolts to
27 Nm (20 lbf.ft).
3.Connect lead to starter solenoid and tighten nut
to 10 Nm (7 lbf.ft).
4.Connect Lucar connector to starter solenoid.
5.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Remove stand(s) and lower vehicle.
7.Connect battery earth lead.
8.Fit battery cover and secure the fixings.

CHARGING AND STARTING
REPAIRS 86-1-7
Starter motor - V8
$% 86.60.01
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.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.
4.Remove 3 nuts securing exhaust flange to
front pipe, release front pipe and collect
gasket.
5.Remove bolt securing heat shield to engine
mounting bracket, release heat shield from
starter motor and remove from vehicle.
6.Remove nut securing battery lead to starter
solenoid and release lead.
7.Disconnect Lucar connector from starter
solenoid.
8.Remove 2 Allen bolts securing starter motor
and remove starter motor from engine. Refit
1.Clean starter motor and mating face on engine.
2.Fit starter motor and tighten Allen bolts to 44
Nm (32 lbf.ft).
3.Connect Lucar connector to starter solenoid.
4.Fit battery lead to solenoid and tighten nut.
5.Position heat shield to starter motor, locate tag
in engine mounting bracket, fit bolt and tighten
to 10 Nm (7 lbf.ft).
6.Clean exhaust manifold and front pipe mating
faces.
7.Using a new gasket, position front pipe, fit nuts
and tighten to 30 Nm (22 lbf.ft).
8.Remove stand(s) and lower vehicle.
9.Connect battery earth lead.
10.Fit battery cover and secure fixings.

LIGHTING
ADJUSTMENTS 86-2-1
LIGHTING ADJUST ME NTS
Headlamps beam alignment - up to 03MY
$% 86.40.17
Check
1.Ensure vehicle is unladen and tyres are at
correct pressures.
2. Models with SLS: Ensure vehicle is at
standard ride height.
3. Models with headlamp levelling: Ensure
headlamp levelling switch is set to '0'.
4.Align suitable beam setting equipment to
headlamp.
5.Switch headlamps on and measure main beam
settings. Beam must be 1.4% below the
horizontal and parallel to the vehicle centre line.
If necessary, adjust headlamp to get correct
beam settings.
6.Align beam setting equipment to 2nd headlamp
and repeat check.
7.Switch off headlamps and remove beam setting
equipment.Adjust
1. For RH headlamps: Release fixings and
remove battery cover
2.Remove headlamp access cover.
3.Turn vertical adjuster as necessary to get
correct beam setting. Use a 7 mm Allen key for
models with headlamp levelling, or a 10 mm
spanner for models without headlamp levelling.
4.Turn horizontal adjuster as necessary to get
correct beam setting. Use a 10 mm spanner.
5.Fit headlamp access cover.
6. For RH headlamp adjustment: Fit battery
cover and secure fixings.