air condition LAND ROVER DISCOVERY 1999 Manual Online
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 1999, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 1999Pages: 1529, PDF Size: 34.8 MB
Page 1093 of 1529
PANEL REPAIRS
77-2-26 REPAIRS
9.Fit headlamp.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
10. Diesel models: Fit gearbox fluid cooler.
11. Models with A/C: Fit condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
12.Fit bumper assembly.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
13.Connect leads/multiplug to alternator.
14.Connect battery leads, negative lead last.
Headlamp mounting panel - LH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
4. Models with A/C: Remove condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
5. Diesel models: Remove gearbox fluid cooler.
6.Remove headlamp.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
7.Remove repeater lamp.
+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
8.Release headlamp levelling motor and position
aside.
9.Release headlamp wiring and position aside.
10.Remove air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
11.Remove 2 earth leads from LH of front
bulkhead.
12.Release and remove A/C pipes.
13.Remove crush can.
14.Remove bonnet release cable.
15.Remove 2 bolts securing front bulkhead
assembly to chassis.
16.Remove centre brace.
Page 1094 of 1529
PANEL REPAIRS
REPAIRS 77-2-27
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.Refit
1.Fit centre brace.
2.Fit 2 bolts securing bulkhead to chassis and
tighten bolts to 45 Nm (33 lbf.ft).
3.Fit bonnet release cable.
4.Fit crush can.
5. Models with A/C: Fit A/C pipes.
6.Fit 2 earth leads to LH of front bulkhead.
7.Fit air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
8.Fit battery tray.
9.Fit headlamp wiring and headlamp levelling
motors.
10.Fit repeater lamp.
+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
11.Fit headlamp.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
12. Diesel models: Fit gearbox fluid cooler.
13. Models with A/C: Fit condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
14.Fit washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
15.Connect leads/multiplug to alternator.
16.Connect battery leads, negative lead last.
Page 1095 of 1529
PANEL REPAIRS
77-2-28 REPAIRS
Valance upper assembly - LH
In this procedure, the front wing, the valance outer
reinforcement and the bonnet alarm switch mounting
bracket are replaced in conjunction with the LH
valance upper assembly.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
4.Remove air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
5.Remove PAS/ACE reservoir.
6.Remove ABS modulator.
+ BRAKES, REPAIRS, Modulator unit
- ABS.
7.Remove brake pipes from valance.
8.Release harness from valance and position
aside.
9. Models with A/C: Depressurise A/C system
and remove pipes from valance.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
M77 1743
M77 1690A
Page 1096 of 1529
PANEL REPAIRS
REPAIRS 77-2-29
Refit
1. Models with A/C: Fit A/C pipes and recharge
A/C system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
2.Fit harness to valance.
3.Fit brake pipes to valance.
4.Fit ABS modulator.
+ BRAKES, REPAIRS, Modulator unit
- ABS.
5.Fit PAS/ACE reservoir, refill fluids to correct
levelsand bleed ACE system.
+ FRONT SUSPENSION,
ADJUSTMENTS, ACE hydraulic system
bleeding.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Fluids.
6.Fit air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
7.Fit front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
8.Connect leads/multiplug to alternator.
9.Connect battery leads, negative lead last.
Valance upper assembly - RH
In this procedure, the front wing and the valance
outer reinforcement are replaced in conjunction with
the RH valance upper assembly.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
4.Remove battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
5.Remove battery tray.
6.Remove fuse box.
7.Release expansion tank from fixings and
position aside.
8.Release harness from valance and position
aside.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
M77 1692A
M77 1750
Page 1097 of 1529
PANEL REPAIRS
77-2-30 REPAIRS
Refit
1.Fit harness to valance.
2.Fit and secure expansion tank to fixings.
3.Fit fuse box.
4.Fit battery tray.
5.Fit battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
6.Fit front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
7.Connect leads/multiplug to alternator.
8.Connect battery leads, negative lead last.
Valance upper assembly (front section) -
LH
In this procedure, the front wing, the valance outer
reinforcement (front section) and the bonnet alarm
switch mounting bracket are replaced in conjunction
with the LH valance upper assembly (front section).
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
4.Remove air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
5.Remove PAS/ACE reservoir.
6.Remove ABS modulator.
+ BRAKES, REPAIRS, Modulator unit
- ABS.
7.Release harness from valance and position
aside.
8. Models with A/C: Depressurise A/C system
and remove pipes from valance.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
Page 1098 of 1529
PANEL REPAIRS
REPAIRS 77-2-31
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.Refit
1. Models with A/C: Fit A/C pipes and recharge
A/C system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
2.Fit harness to valance.
3.Fit ABS modulator.
+ BRAKES, REPAIRS, Modulator unit
- ABS.
4.Fit PAS/ACE reservoir and refill fluids to correct
levels.
+ FRONT SUSPENSION,
ADJUSTMENTS, ACE hydraulic system
bleeding.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Fluids.
5.Fit air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
6.Fit front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
7.Connect leads/multiplug to alternator.
8.Connect battery leads, negative lead last.
M77 1744
M77 1689A
Page 1105 of 1529
PANEL REPAIRS
77-2-38 REPAIRS
Sill outer assembly
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove RH or LH front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
4.Remove RH or LH front door.
+ DOORS, REPAIRS, Door - front.
5.Remove RH or LH rear door.
+ DOORS, REPAIRS, Door - rear.
6.Remove RH or LH sill finisher.
7.Remove RH or LH 'A' post inner lower
finishers.
8.Remove RH or LH front seat.
+ SEATS, REPAIRS, Seat - front.
9. LH side: Remove power amplifier and EAT
ECU.
+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
10. RH side: Remove CD autochanger.
+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
11.Remove rear seats.
+ SEATS, REPAIRS, Seat - rear.
12.Remove RH or LH front seat belt.
+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
13.Remove tread plates from front and rear door
apertures.
14.Release carpet and position aside.
15.Remove front and rear door aperture seals.
16.Release relevant wiring from 'A' post, 'B/C' post
and sill areas, and position aside.
17.Remove loadspace lower trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
18. RH side: Remove lower ACE accelerometer.
+ FRONT SUSPENSION, REPAIRS,
Accelerometer - ACE - lower.
19. LH side: Remove SLS air compressor unit.
+ REAR SUSPENSION, REPAIRS,
Compressor unit - air - SLS.
20. Models with rear A/C: Recover refrigerant
from A/C system and remove A/C pipes from
LH sill.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
21.Remove 2 bolts securing body to chassis.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit 2 bolts securing body to chassis and tighten
to 45 Nm (33 lbf.ft).
2. Models with rear A/C: Fit A/C pipes to sill and
recharge A/C system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
3. LH side: Fit SLS air compressor unit.
+ REAR SUSPENSION, REPAIRS,
Compressor unit - air - SLS.
4. RH side: Fit lower ACE accelerometer.
+ FRONT SUSPENSION, REPAIRS,
Accelerometer - ACE - lower.
5.Fit loadspace lower trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
6.Fit relevant wiring to 'A' post, 'B/C' post and sill
areas.
7.Fit front and rear door door aperture seals.
8.Fit carpet and secure into position.
9.Fit tread plates to front and rear door apertures.
10.Fit front seat belt.
+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
11.Fit rear seats.
+ SEATS, REPAIRS, Seat - rear.
12. LH side: Fit CD autochanger.
+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
13. RH side: Fit power amplifier and EAT ECU.
+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
14.Fit front seat.
+ SEATS, REPAIRS, Seat - front.
15.Fit 'A' post inner lower finishers.
M77 1716A
Page 1139 of 1529
CORROSION PREVENTION AND SEALING
77-4-6 CORROSION PREVENTION
Corrosion prevention
Factory treatments
During production, vehicle bodies are treated with the following anti-corrosion materials:
lA PVC-based underbody sealer which is sprayed onto the underside of the main floor, rear floor, front and rear
wheelarches and the front valance assembly;
lAn application of cavity wax which is sprayed into the sill panels, 'A' post, 'B-C' post, fuel filler aperture, body rear
panel and the lower areas of the door panels;
lA coating of underbody wax which is applied to the entire underbody inboard of the sill vertical flanges, and
covers all moving and flexible components EXCEPT for wheels, tyres, brakes and exhaust;
lA coat of protective wax applied to the engine bay area.
Whenever body repairs are carried out, ensure the anti-corrosion materials in the affected area are repaired or
renewed as necessary using the approved materials.
+ BODY SEALING MATERIALS, MATERIALS AND APPLICATIONS, Approved materials.
Precautions during body repairs and handling
Take care when handling the vehicle in the workshop. Underbody sealers, seam sealers, underbody wax and body
panels may be damaged if the vehicle is carelessly lifted.
+ LIFTING AND TOWING, LIFTING.
Proprietary anti-corrosion treatments
The application of proprietary anti-corrosion treatments, in addition to the factory-applied treatment, could invalidate
the Corrosion Warranty and should be discouraged. This does not apply to Rover approved, compatible, preservative
waxes which may be applied on top of existing coatings.
Fitting approved accessories
When fitting accessories ensure that the vehicle's corrosion protection is not affected, either by breaking the protective
coating or by introducing a moisture trap.
Do not screw self-tapping screws directly into body panels. Fit suitable plastic inserts to the panel beforehand. Always
ensure that the edges of holes drilled into panels, chassis members and other body parts are protected with a suitable
zinc rich or acid etch primer, and follow with a protective wax coating brushed onto the surrounding area.
Do not attach painted metal surfaces of any accessory directly to the vehicle's bodywork unless suitably protected.
Where metal faces are bolted together always interpose a suitable interface material such as weldable zinc rich
primer, extruded strip, or zinc tape.
Steam cleaning and dewaxing
Due to the high temperatures generated by steam cleaning equipment, there is a risk that certain trim components
could be damaged and some adhesives and corrosion prevention materials softened or liquified.
Adjust the equipment so that the nozzle temperature does not exceed 90° C (194° F). Take care not to allow the steam
jet to dwell on one area, and keep the nozzle at least 300 mm (11.811 in) from panel surfaces.
DO NOT remove wax or lacquer from underbody or underbonnet areas during repairs. Should it be necessary to
steam clean these areas, apply a new coating of wax or underbody protection as soon as possible.
Inspections during maintenance servicing
It is a requirement of the Corrosion Warranty that the vehicle body is checked for corrosion by an authorised Land
Rover Dealer at least once a year, to ensure that the factory-applied protection remains effective.
Service Job Sheets include the following operations to check bodywork for corrosion:
lWith the vehicle on a lift, carry out visual check of underbody sealer for damage;
lWith the vehicle lowered, inspect exterior paintwork for damage and body panels for corrosion.
It will be necessary for the vehicle to be washed by the Dealer prior to inspection of bodywork if the customer has
offered the vehicle in a dirty condition.
Page 1140 of 1529
CORROSION PREVENTION AND SEALING
CORROSION PREVENTION 77-4-7
The checks described above are intended to be visual only. It is not intended that the operator should remove trim
panels, finishers, rubbing strips or sound-deadening materials when checking the vehicle for corrosion and paint
damage.
With the vehicle on a lift, and using an inspection or spot lamp, visually check for the following:
lCorrosion damage and damaged paintwork, condition of underbody sealer on front and rear lower panels, sills
and wheel arches;
lDamage to underbody sealer. Corrosion in areas adjacent to suspension mountings and fuel tank fixings.
NOTE: The presence of small blisters in the underbody sealer is acceptable, providing they do not expose bare metal.
Pay special attention to signs of damage caused to panels or corrosion protection material by incorrect jack
positioning.
WARNING: It is essential to follow the correct jacking and lifting procedures.
With the vehicle lowered, visually check for evidence of damage and corrosion on all visible painted areas, in
particular the following:
lFront edge of bonnet;
lVisible flanges in engine compartment;
lLower body and door panels.
Rectify any bodywork damage or evidence of corrosion found during inspection as soon as is practicable, both to
minimise the extent of the damage and to ensure the long term effectiveness of the factory-applied corrosion
prevention treatment. Where the cost of rectification work is the owner's responsibility, the Dealer must advise the
owner and endorse the relevant documentation accordingly.
Where corrosion has become evident and is emanating from beneath a removable component (e.g. trim panel,
window glass, seat etc.), remove the component as required to permit effective rectification.
Underbody protection repairs
Whenever body repairs are carried out, ensure that full sealing and corrosion protection treatments are reinstated.
This applies both to the damaged areas and also to areas where protection has been indirectly impaired, as a result
either of accident damage or repair operations.
Remove corrosion protection from the damaged area before straightening or panel beating. This applies in particular
to panels coated with wax, PVC underbody sealer, sound deadening pads etc.
WARNING: DO NOT use oxy-acetylene gas equipment to remove corrosion prevention materials. Large
volumes of fumes and gases are liberated by these materials when they burn.
NOTE: Equipment for the removal of tough anti-corrosion sealers offers varying degrees of speed and effectiveness.
The compressed air-operated scraper (NOT an air chisel) offers a relatively quiet mechanical method using an
extremely rapid reciprocating action. Move the operating end of the tool along the work surface to remove the material.
The most common method of removal is by means of a hot air blower with integral scraper.
Another tool, and one of the most efficient methods, is the rapid-cutting 'hot knife'. This tool uses a wide blade and is
quick and versatile, able to be used easily in profiled sections where access is otherwise difficult.
Use the following procedure when repairing underbody coatings:
1Remove existing underbody coatings
2After panel repair, clean the affected area with a solvent wipe, and treat bare metal with an etch phosphate
material
3Re-prime the affected area
CAUTION: DO NOT, under any circumstances, apply underbody sealer directly to bare metal surfaces.
4Replace all heat-fusible plugs which have been disturbed. Where such plugs are not available use rubber
grommets of equivalent size, ensuring that they are embedded in sealer
5Mask off all mounting faces from which mechanical components, hoses and pipe clips, have been removed.
Underbody sealer must be applied before such components are refitted
6Brush sealer into all exposed seams
7Spray the affected area with an approved service underbody sealer
8Remove masking from component mounting faces, and touch-in where necessary. Allow adequate drying time
before applying underbody wax
Page 1176 of 1529
HEATING AND VENTILATION
REPAIRS 80-19
Servo - air distribution control
$% 80.10.30
Remove
1.Disconnect battery earth lead.
2. RHD models: Remove heater assembly.
+ HEATING AND VENTILATION,
REPAIRS, Heater assembly - models with
air conditioning.
3. LHD models: Remove heater motor assembly.
+ HEATING AND VENTILATION,
REPAIRS, Blower assembly.
4.Release clip securing operating lever and
release the lever from linkage.
5.Remove 3 screws securing servo support
bracket to casing and release servo.
6.Disconnect multiplug from servo and remove
servo. 7.Release clip securing operating lever to servo
and remove lever.
8.Remove 2 screws securing support bracket
and remove support bracket.
Refit
1.Position support bracket to servo and secure
with screws.
2.Position servo lever to servo and secure clip.
3.Connect multiplug to servo.
4.Position servo to casing and secure with
screws.
5.Connect operating lever to servo and secure
with clip.
6. RHD models: Fit heater assembly.
+ HEATING AND VENTILATION,
REPAIRS, Heater assembly - models with
air conditioning.
7. LHD models: Fit heater motor assembly.
+ HEATING AND VENTILATION,
REPAIRS, Blower assembly.
8.Connect battery earth lead.