AUX LAND ROVER DISCOVERY 1999 Workshop Manual

CONTENTS
CONTENTS 3
MAINTENANCE ........................................................................................ 10-1
PROCEDURES
V8 engine underbonnet view .......................................................................................................... 10-1
Diesel underbonnet view ................................................................................................................. 10-2
Seats and seat belts ...................................................................................................................... 10-3
Lamps, horns and warning indicators ............................................................................................. 10-5
Wipers and washers ...................................................................................................................... 10-5
Handbrake .................................................................................................................................. 10-6
Alarm handset battery ..................................................................................................................... 10-6
Road wheels ................................................................................................................................... 10-6
Tyres .............................................................................................................................................. 10-6
Brake pads, discs and calipers ....................................................................................................... 10-6
Road wheel speed sensors ............................................................................................................. 10-7
Brake fluid ....................................................................................................................................... 10-7
Fuel filter - diesel engine ................................................................................................................. 10-7
Fuel filter sedimenter ...................................................................................................................... 10-7
Road wheels ................................................................................................................................... 10-8
Radiator/Intercooler ........................................................................................................................ 10-8
Ambient air Temperature and pressure sensor .............................................................................. 10-8
Doors, bonnet and fuel filler flap ..................................................................................................... 10-8
Air suspension intake filter .............................................................................................................. 10-9
Anti-freeze....................................................................................................................................... 10-9
Cooling system ............................................................................................................................... 10-9
Spark plugs - V8 engine.................................................................................................................. 10-10
Air cleaner - V8 engine ................................................................................................................... 10-10
Air cleaner and dump valve - diesel engine .................................................................................... 10-10
Auxiliary drive belt ........................................................................................................................... 10-11
Auxiliary drive belt - V8 engine ....................................................................................................... 10-11
Auxiliary drive belt - diesel engine .................................................................................................. 10-11
Fluid reservoirs ............................................................................................................................... 10-12
Steering box .................................................................................................................................... 10-13
Battery ............................................................................................................................................. 10-13
Intercooler - diesel engine............................................................................................................... 10-14
Engine oil - V8 engine ..................................................................................................................... 10-14
Engine oil - diesel engine ................................................................................................................ 10-15
Centrifuge rotor – diesel engine ...................................................................................................... 10-15
Engine oil filter - diesel engine ........................................................................................................ 10-16
Engine oil filter – V8 engine ............................................................................................................ 10-16
Manual gearbox .............................................................................................................................. 10-17
Automatic gearbox ......................................................................................................................... 10-18
Transfer box .................................................................................................................................... 10-19
Front and rear axle .......................................................................................................................... 10-20
Propeller shafts ............................................................................................................................... 10-20
Anti-roll bar links ............................................................................................................................. 10-22
ACE actuators ................................................................................................................................. 10-23
ACE filter ......................................................................................................................................... 10-23

CONTENTS
CONTENTS 19
EXTERIOR FITTINGS ............................................................................... 76-2-1
REPAIRS
Wing - front - up to 03MY ................................................................................................................ 76-2-1
Wing - front - from 03MY ................................................................................................................. 76-2-2
Rear folding step ............................................................................................................................ 76-2-4
Liner - wheel arch - front ................................................................................................................. 76-2-5
Liner - wheel arch - rear ................................................................................................................. 76-2-6
Panel - underbelly .......................................................................................................................... 76-2-7
Mirror - exterior - electric ................................................................................................................ 76-2-7
Roof bars ....................................................................................................................................... 76-2-8
Bonnet ........................................................................................................................................... 76-2-9
Cable - bonnet release - up to 03MY .............................................................................................. 76-2-9
Cable - bonnet release - from 03MY ............................................................................................... 76-2-11
Bumper assembly - front ............................................................................................................... 76-2-12
Bumper assembly - rear - from 03MY ............................................................................................. 76-2-13
Trim finisher - bumper - front - from 03MY ...................................................................................... 76-2-14
Bumper assembly - rear - up to 03MY ............................................................................................ 76-2-15
Side finisher - windscreen .............................................................................................................. 76-2-16
Grille - front - up to 03MY................................................................................................................ 76-2-16
Grille - front - from 03MY ................................................................................................................ 76-2-17
INTERIOR TRIM COMPONENTS ............................................................. 76-3-1
REPAIRS
Trim casing - tail door speaker ...................................................................................................... 76-3-1
Trim casing - side - loadspace ....................................................................................................... 76-3-2
Trim casing - upper - 'B' post ......................................................................................................... 76-3-3
Trim casing - lower - 'B' post ......................................................................................................... 76-3-3
Trim casing - 'D' post ...................................................................................................................... 76-3-4
Console - centre - automatic models .............................................................................................. 76-3-5
Console - centre - manual models .................................................................................................. 76-3-7
Fascia ............................................................................................................................................. 76-3-10
Panel - auxiliary switch ................................................................................................................... 76-3-14
Panel - fascia access - driver's side .............................................................................................. 76-3-15
Drink tray assembly - centre fascia ................................................................................................. 76-3-15
Louvre panel assembly - centre fascia ........................................................................................... 76-3-16
Carpet - front ................................................................................................................................... 76-3-18
Carpet - rear .................................................................................................................................. 76-3-19
Carpet - loadspace ......................................................................................................................... 76-3-20
Headlining ...................................................................................................................................... 76-3-20
Stowage pocket - front .................................................................................................................. 76-3-24

CONTENTS
CONTENTS 25
WIPERS AND WASHERS ........................................................................ 84-1
DESCRIPTION AND OPERATION
Wipers and washers component layout .......................................................................................... 84-1
Front wiper components ................................................................................................................. 84-2
Rear wiper components .................................................................................................................. 84-3
Washer components ....................................................................................................................... 84-4
Wipers and washers block diagram ................................................................................................ 84-6
Description ...................................................................................................................................... 84-8
Operation ........................................................................................................................................ 84-17
REPAIRS
Reservoir - washer - up to 03MY .................................................................................................... 84-21
Reservoir - washer - from 03MY ..................................................................................................... 84-22
Jet - washer - windscreen ............................................................................................................... 84-23
Pump - washer - screen and headlamp ....................................................................................... 84-24
Motor and linkage - wiper - windscreen .......................................................................................... 84-25
Switch - wiper and washer - windscreen ......................................................................................... 84-26
Jet - washer - headlamp ................................................................................................................ 84-27
Jet - washer - rear screen ............................................................................................................ 84-27
Switch - rear wash .......................................................................................................................... 84-28
Motor - wiper - rear screen ............................................................................................................. 84-29
Switch - wiper - rear - up to 03MY .................................................................................................. 84-30
Switch - wiper - rear - from 03MY ................................................................................................... 84-30
CHARGING AND STARTING ................................................................... 86-1-1
REPAIRS
Alternator - diesel .......................................................................................................................... 86-1-1
Alternator - V8 ................................................................................................................................. 86-1-3
Belt - auxiliary drive ......................................................................................................................... 86-1-4
Battery ............................................................................................................................................ 86-1-4
Battery carrier ................................................................................................................................ 86-1-5
Starter motor - diesel ...................................................................................................................... 86-1-6
Starter motor - V8 ........................................................................................................................... 86-1-7

TORQUE WRENCH SETTINGS
06-4
Engine V8
* New bolts must be fitted
+ Apply sealant, Part Number STC 50552 to threads
TORQUE DESCRIPTION METRIC IMPERIAL
Engine mounting bolts (rear, LH & RH) to gearbox bolts 85 Nm (63 lbf.ft)
Engine mounting (rear, LH & RH) nuts 45 Nm (33 lbf.ft)
Cylinder head bolts tighten, then 90°, then a further 90° * 20 Nm (15 lbf.ft)
Rocker shaft bolts 40 Nm (30 lbf.ft)
Alternator mounting bracket 40 Nm (30 lbf.ft)
Auxiliary drive belt tensioner 45 Nm (33 lbf.ft)
Engine earth lead 22 Nm (16 lbf.ft)
Rocker cover screws/bolts * 8 Nm (6 lbf.ft)
Torque converter to drive plate 50 Nm (37 lbf.ft)
A/C compressor 22 Nm (16 lbf.ft)
ACE pump 22 Nm (16 lbf.ft)
Flywheel to crankshaft 78 Nm (58 lbf.ft)
Crankshaft sensor 6 Nm (5 lbf.ft)
Crankshaft sensor cover 6 Nm (5 lbf.ft)
Spacer and hub to crankshaft - Early engines 85 Nm (63 lbf.ft)
Drive plate and clamp ring - Early engines 45 Nm (33 lbf.ft)
Drive plate to crankshaft Allen bolts - Later engines 85 Nm 63 lbf.ft)
Oil pick up strainer 10 Nm (7 lbf.ft)
Filter head adaptor 13 Nm (10 lbf.ft)
Filter head 8 Nm (6 lbf.ft)
Sump bolts 22 Nm (16 lbf.ft)
Oil pressure switch 15 Nm (11 lbf.ft)
Timing gear cover to cylinder block + 22 Nm (16 lbf.ft)
Oil cooler pipe to timing gear cover 15 Nm (11 lbf.ft)
Crankshaft pulley bolt 270 Nm (200 lbf.ft)
Coolant outlet elbow 22 Nm (16 lbf.ft)
Auxiliary housing 40 Nm (30 lbf.ft)
Jockey pulley 50 Nm (37 lbf.ft)
Camshaft gear 50 Nm (37 lbf.ft)
Rocker shaft bolts 40 Nm (30 lbf.ft)
Connecting rod bolts
Final torque - turn through 80°°20 Nm
80°(15 lbf.ft)
80°
Initial torque - all main bearing cap bolts and side bolts 13.5 Nm (10 lbf.ft)
Final torque - main bearing cap side bolts 11 to 15 45 Nm (33 lbf.ft)
Final torque - main bearing cap bolts 1 to 8 72 Nm (53 lbf.ft)
Final torque - main bearing cap bolts 9 and 10 92 Nm (68 lbf.ft)
Final torque - main bearing cap side bolts 16 to 20 45 Nm (33 lbf.ft)
Viscous fan nut 45 Nm (33 lbf.ft)
Camshaft thrust plate bolts 22 Nm (16 lbf.ft)
Secondary Air Injection adapters 33 Nm (24 lbf.ft)

TORQUE WRENCH SETTINGS
06-14
Steering
TORQUE DESCRIPTION METRIC IMPERIAL
Drag link to drop arm 80 Nm (59 lbf.ft)
Track rod to steering knuckle 125 Nm (92 lbf.ft)
Tension collet to steering knuckle 5 Nm (3.7 lbf.ft)
Steering damper125 Nm (92 lbf.ft)
Steering knuckle to axle yoke upper ball joint 110 Nm (81 lbf.ft)
High pressure pipe union 20 Nm (15 lbf.ft)
Drag link/track rod M8 bolts 22 Nm (16 lbf.ft)
Drag link/track rod M10 bolts 33 Nm (24 lbf.ft)
Steering box90 Nm (66 lbf.ft)
Universal joint to intermediate shaft 25 Nm (18 lbf.ft)
Panhard rod230 Nm (170 lbf.ft)
Steering box output shaft 88 Nm (65 lbf.ft)
Drop arm240 Nm (177 lbf.ft)
Auxiliary housing bolts 40 Nm (30 lbf.ft)
Auxiliary housing nut 10 Nm (7 lbf.ft)
PAS pump - V822 Nm (16 lbf.ft)
PAS pump pipe bracket bolt 22 Nm (16 lbf.ft)
Jockey pulley bolt 50 Nm (37 lbf.ft)
PAS pump adaptor pipe 10 Nm (7 lbf.ft)
PAS pump to coolant pump bolts - Td5 25 Nm (18 lbf.ft)
Steering column to fascia 25 Nm (18 lbf.ft)
Universal joint to steering box 25 Nm (18 lbf.ft)
Ball joint to swivel hub 77 Nm (57 lbf.ft)
PAS pump pulley22 Nm (16 lbf.ft)
Steering wheel nut 43 Nm (32 lbf.ft)

TORQUE WRENCH SETTINGS
06-21
Electrical
TORQUE DESCRIPTION METRIC IMPERIAL
Alternator support stay 25 Nm (18 lbf.ft)
Alternator lead - Td5 6 Nm (4.4 lbf.ft)
Auxiliary drive belt tensioner bolt 50 Nm (37 lbf.ft)
Alternator pulley80 Nm (59 lbf.ft)
Alternator B+ nut - V8 18 Nm (13 lbf.ft)
Alternator B+ nut - V8 5 Nm (3.7 lbf.ft)
Starter motor - Td5 27 Nm (20 lbf.ft)
Starter motor solenoid 10 Nm (7 lbf.ft)
Starter motor - V8 44 Nm (32 lbf.ft)
Alternator45 Nm (33 lbf.ft)
Starter motor heat shield - V8 10 Nm (7 lbf.ft)
Horn13 Nm (10 lbf.ft)
Battery carrier bolts 28 Nm (21 lbf.ft)

MAINTENANCE
PROCEDURES 10-1
MAINTENANCE PROCEDURES
V8 engine underbonnet view
1Brake/clutch fluid reservoir filler caps
2Engine oil filler cap
3Spark plug
4Engine oil dipstick
5Coolant header tank6Battery
7Auxiliary drive belt
8ACE/PAS fluid reservoirs
9Windscreen washer reservoir

MAINTENANCE
10-2 PROCEDURES
Diesel underbonnet view
1Coolant header tank
2Brake/clutch fluid reservoir filler caps
3Engine oil dipstick
4Engine oil filler cap
5ACE/PAS fluid reservoirs6Battery
7Auxiliary drive belt
8Air cleaner
9Windscreen washer reservoir

MAINTENANCE
PROCEDURES 10-11
Auxiliary drive belt
Check
TD5 auxiliary belt
V8 auxiliary belt
1Tensioner pulley
2Alternator
3A/C compressor
4ACE pump
5Idler pulley - V8 only
6PAS pump
7Viscous fan pulley
8Crankshaft pulley
9Idler pulley - V8 only
1.Check auxiliary drive belt for signs of splits,
fraying, oil contamination and wear.
Auxiliary drive belt - V8 engine
1.Replace auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
Auxiliary drive belt - diesel engine
Replace
1.Replace auxiliary drive belt.

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

ENGINE - V8
12-2-16 REPAIRS
17.Using new gaskets, position exhaust manifold
to cylinder head, fit bolts and using sequence
shown, tighten initially to 15 Nm (11 lbf.ft), then
finally to 36 Nm (28 lbf.ft).
18. LH drive models: Fit brake servo heat shield.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Heat shield -
brake servo - Without Secondary Air
Injection.
19.Fit engine harness bolt and tighten to 22 Nm
(16 lbf.ft).
20.Connect ht leads to spark plugs in their correct
fitted order.
21.Fit inlet manifold gasket.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - lower.
Gasket - cylinder head - RH
$% 12.29.03
Remove
1.Remove inlet manifold gasket.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - lower.
2.Remove bolt securing auxiliary drive belt
tensioner and remove tensioner.
3.Remove 4 bolts securing alternator mounting
bracket and remove bracket.
4.Noting their fitted order, disconnect ht leads
from spark plugs.
5.Remove bolt securing engine earth lead.