Gear ratio LAND ROVER DISCOVERY 1999 Workshop Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 1999, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 1999Pages: 1529, PDF Size: 34.8 MB
Page 5 of 1529
CONTENTS
2CONTENTS
IDENTIFICATION NUMBERS .................................................................. 05-1
Vehicle Identification Number ......................................................................................................... 05-1
Identification Number Locations ..................................................................................................... 05-3
TORQUE WRENCH SETTINGS .............................................................. 06-1
Maintenance ................................................................................................................................... 06-1
Engine Td5 ..................................................................................................................................... 06-2
Engine V8 ....................................................................................................................................... 06-4
Emission control - Td5 .................................................................................................................... 06-5
Emission control - V8 ...................................................................................................................... 06-5
Engine management system - Td5 ................................................................................................. 06-6
Engine management system - V8................................................................................................... 06-6
Cooling system ............................................................................................................................... 06-7
Manifolds and exhaust systems - Td5 ............................................................................................ 06-8
Manifolds and exhaust systems - V8 .............................................................................................. 06-8
Clutch.............................................................................................................................................. 06-9
Manual gearbox - R380 .................................................................................................................. 06-10
Transfer box - LT230SE ................................................................................................................. 06-11
Automatic gearbox - ZF4HP22 ....................................................................................................... 06-12
Propeller shafts ............................................................................................................................... 06-13
Axles ............................................................................................................................................... 06-13
Steering .......................................................................................................................................... 06-14
Front suspension ............................................................................................................................ 06-15
Rear suspension ............................................................................................................................. 06-16
Brakes............................................................................................................................................. 06-17
Restraint systems ........................................................................................................................... 06-18
Body................................................................................................................................................ 06-19
Heating and air conditioning ........................................................................................................... 06-20
Wipers and washers ....................................................................................................................... 06-20
Electrical ......................................................................................................................................... 06-21
LIFTING AND TOWING ........................................................................... 08-1
LIFTING .......................................................................................................................................... 08-1
TOWING ......................................................................................................................................... 08-2
TRANSPORTING ........................................................................................................................... 08-4
CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS ...................... 09-1
Capacities ....................................................................................................................................... 09-1
Fluids .............................................................................................................................................. 09-2
Anti-Freeze Concentration .............................................................................................................. 09-2
Lubrication ...................................................................................................................................... 09-3
Sealants .......................................................................................................................................... 09-4
Page 8 of 1529
CONTENTS
CONTENTS 5
ENGINE - V8 ............................................................................................. 12-2-1
DESCRIPTION AND OPERATION
V8 Engine ....................................................................................................................................... 12-2-1
Cylinder head components ............................................................................................................. 12-2-2
Cylinder block components ............................................................................................................. 12-2-4
Description ...................................................................................................................................... 12-2-6
ADJUSTMENTS
Engine oil pressure check .............................................................................................................. 12-2-11
REPAIRS
Seal - crankshaft - rear .................................................................................................................. 12-2-13
Gasket - cylinder head - LH ........................................................................................................... 12-2-14
Gasket - cylinder head - RH ............................................................................................................ 12-2-16
Gasket - rocker cover - LH ............................................................................................................ 12-2-19
Gasket - rocker cover - RH ............................................................................................................ 12-2-20
Mounting - front - LH ...................................................................................................................... 12-2-22
Mounting - front - RH ..................................................................................................................... 12-2-23
Mounting - rear - LH ....................................................................................................................... 12-2-24
Mounting - rear - RH ...................................................................................................................... 12-2-25
Engine assembly............................................................................................................................. 12-2-26
Flywheel ........................................................................................................................................ 12-2-31
Plate - drive - automatic ................................................................................................................ 12-2-32
Ring gear - starter ......................................................................................................................... 12-2-34
Filter - oil ....................................................................................................................................... 12-2-35
Strainer - oil pick-up ...................................................................................................................... 12-2-35
Pump - oil ...................................................................................................................................... 12-2-36
Gasket - sump ................................................................................................................................ 12-2-37
Switch - oil pressure ....................................................................................................................... 12-2-39
Cooler - engine oil .......................................................................................................................... 12-2-39
Gasket - timing gear cover ............................................................................................................ 12-2-41
Seal - cover - timing gears ............................................................................................................ 12-2-43
OVERHAUL
Gasket - inlet manifold ................................................................................................................... 12-2-45
Gasket - exhaust manifold ............................................................................................................. 12-2-48
Seal - crankshaft - rear - automatic models .................................................................................... 12-2-49
Seal - crankshaft - rear - manual models ........................................................................................ 12-2-50
Bearing - spigot - crankshaft .......................................................................................................... 12-2-52
Gasket - engine sump .................................................................................................................... 12-2-53
Strainer - oil pick-up ....................................................................................................................... 12-2-54
Seal - timing gear cover ................................................................................................................. 12-2-55
Gasket - timing gear cover ............................................................................................................. 12-2-56
Timing chain and gears .................................................................................................................. 12-2-58
Rocker shaft - overhaul ................................................................................................................. 12-2-59
Gasket - cylinder head .................................................................................................................... 12-2-61
Cylinder head - overhaul ................................................................................................................ 12-2-63
Piston assemblies ........................................................................................................................... 12-2-67
Bearings - connecting rods ............................................................................................................ 12-2-72
Crankshaft and main bearings ........................................................................................................ 12-2-73
Camshaft ....................................................................................................................................... 12-2-77
Page 13 of 1529
CONTENTS
10 CONTENTS
MANUAL GEARBOX - R380 .................................................................... 37-1
DESCRIPTION AND OPERATION
R380 gearbox ................................................................................................................................. 37-1
Gearbox casings, gear change and oil pump ................................................................................ 37-2
Selector shaft and forks, synchromesh assemblies and gear train ............................................... 37-4
R380 gearbox cross section ........................................................................................................... 37-6
Description ...................................................................................................................................... 37-7
Operation ........................................................................................................................................ 37-8
ADJUSTMENTS
Spring - gear lever bias .................................................................................................................. 37-9
REPAIRS
Housing - gear selector .................................................................................................................. 37-11
Gearbox - V8 .................................................................................................................................. 37-12
Gearbox - Diesel ............................................................................................................................. 37-16
Seal - gearbox mainshaft ............................................................................................................... 37-20
Seal - input shaft ............................................................................................................................ 37-21
Cooler - oil - gearbox - Diesel ......................................................................................................... 37-23
Cooler - oil - gearbox - V8............................................................................................................... 37-24
Switch - Reverse light ................................................................................................................... 37-25
OVERHAUL
Shaft - output ................................................................................................................................. 37-27
Synchroniser - gearbox - set ......................................................................................................... 37-32
Fork - set - selector shaft .............................................................................................................. 37-34
Shaft - gearbox - input .................................................................................................................. 37-35
Extension - gearbox rear ............................................................................................................... 37-38
Pump - gearbox oil ......................................................................................................................... 37-41
Filter - gearbox oil ......................................................................................................................... 37-41
Gear - 5th gear set ........................................................................................................................ 37-42
Synchronizer assembly - 5th/reverse ........................................................................................... 37-43
5th gear - layshaft ......................................................................................................................... 37-44
Bearing - layshaft rear support ..................................................................................................... 37-46
Bearing - output shaft rear support ............................................................................................... 37-47
Shaft - reverse idler ...................................................................................................................... 37-48
Housing - gear selector mechanism ............................................................................................. 37-50
Lever - gear change ...................................................................................................................... 37-51
Housing - clutch ............................................................................................................................ 37-52
Cover - front ................................................................................................................................... 37-53
Page 14 of 1529
CONTENTS
CONTENTS 11
TRANSFER BOX - LT230SE .................................................................... 41-1
DESCRIPTION AND OPERATION
LT230SE transfer box ..................................................................................................................... 41-1
Transfer box cross section .............................................................................................................. 41-2
Main casing components – Vehicles up to 03 model year .............................................................. 41-4
Main casing components – Vehicles from 03 model year ............................................................... 41-5
Differential components – Vehicles up to 03 model year ................................................................ 41-6
Differential components – Vehicles from 03 model year ................................................................. 41-7
Front output housing components – Vehicles up to 03 model year ................................................ 41-8
Front output housing components – Vehicles from 03 model year ................................................. 41-10
Rear output housing components ................................................................................................... 41-12
Description ...................................................................................................................................... 41-13
Operation ........................................................................................................................................ 41-18
ADJUSTMENTS
Cable - selector - differential lock - adjust ...................................................................................... 41-21
Cable - high/low selector ................................................................................................................. 41-21
REPAIRS
Bottom cover - transfer box .......................................................................................................... 41-23
Cable - selector - differential lock .................................................................................................... 41-24
Transfer box - Diesel....................................................................................................................... 41-25
Transfer box - V8 ............................................................................................................................ 41-29
Gasket - rear cover plate ................................................................................................................ 41-33
Switch - differential lock - Up to 03 MY ........................................................................................... 41-34
Cable - high/low selector ................................................................................................................. 41-35
Oil seal - input shaft ...................................................................................................................... 41-36
Seal - front output shaft................................................................................................................... 41-36
Seal - rear output shaft ................................................................................................................... 41-38
Gasket - rear output shaft housing.................................................................................................. 41-39
Solenoid - interlock - Up to 03 MY .................................................................................................. 41-40
Solenoid - interlock - from 03 MY .................................................................................................... 41-40
Sensor - neutral ........................................................................................................................... 41-41
Sensor - oil temperature - If fitted ................................................................................................... 41-41
Switch - high low - warning ........................................................................................................... 41-42
Switch(es) - differential lock warning From 03 MY .......................................................................... 41-42
OVERHAUL
Intermediate gear assembly .......................................................................................................... 41-43
Differential assembly .................................................................................................................... 41-46
Dog clutch - differential lock .......................................................................................................... 41-64
Input gear/bearing .......................................................................................................................... 41-68
Low gear - differential ................................................................................................................... 41-70
Page 15 of 1529
CONTENTS
12 CONTENTS
AUTOMATIC GEARBOX - ZF4HP22 - 24 ................................................ 44-1
DESCRIPTION AND OPERATION
Automatic gearbox component layout ............................................................................................ 44-1
Control schematic ........................................................................................................................... 44-2
Description ...................................................................................................................................... 44-4
Operation ........................................................................................................................................ 44-17
ADJUSTMENTS
Cable - selector ............................................................................................................................. 44-21
Stall test .......................................................................................................................................... 44-21
REPAIRS
Cable and lever assembly - selector .............................................................................................. 44-23
Selector indicator .......................................................................................................................... 44-24
Switch - starter inhibitor ................................................................................................................. 44-25
Seal - selector shaft ........................................................................................................................ 44-26
Gearbox - convertor and transfer gearbox - Diesel ....................................................................... 44-27
Gearbox - convertor and transfer gearbox - V8 ............................................................................ 44-32
Torque converter and oil seal ......................................................................................................... 44-37
Housing - torque converter ............................................................................................................ 44-38
Gasket - intermediate plate ............................................................................................................ 44-39
Intermediate plate .......................................................................................................................... 44-41
Pump - fluid .................................................................................................................................... 44-43
Seal - rear extension housing ......................................................................................................... 44-44
Gasket - rear extension housing. .................................................................................................. 44-45
Parking pawl assembly. ................................................................................................................ 44-46
Gasket - oil sump ........................................................................................................................... 44-47
Filter - oil ........................................................................................................................................ 44-48
Cooler - fluid - Td5 .......................................................................................................................... 44-49
Cooler - fluid - V8 ........................................................................................................................... 44-50
Valve body assembly ..................................................................................................................... 44-51
Seal - valve body ........................................................................................................................... 44-53
Pressure regulator ......................................................................................................................... 44-54
Lock-up solenoid valve (MV 3) ...................................................................................................... 44-55
Solenoids - shift control valves
(MV 1 & 2) 44-56
Harness - solenoid valves .............................................................................................................. 44-57
Electronic control unit - automatic transmission ............................................................................. 44-58
PROPELLER SHAFTS ............................................................................. 47-1
DESCRIPTION AND OPERATION
Propeller shaft component layout ................................................................................................... 47-1
Description ...................................................................................................................................... 47-2
REPAIRS
Propeller shaft - front ..................................................................................................................... 47-5
Propeller shaft - rear ...................................................................................................................... 47-5
Bush - spigot - rear propeller shaft ................................................................................................ 47-6
Flexible coupling ............................................................................................................................ 47-7
OVERHAUL
Propeller shaft................................................................................................................................. 47-9
Page 32 of 1529
INTRODUCTION
01-1
INTRODUCTION
How To Use This Manual
Introduction
This Manual is designed to assist skilled technicians
in the efficient repair and maintenance of Discovery
vehicles.
Individuals who undertake their own repairs should
have some skill and training, and limit repairs to
components which could not affect the safety of the
vehicle or its passengers. Any repairs required to
safety critical items such as steering, brakes,
suspension or supplementary restraint system
should be carried out by a Land Rover Dealer.
Repairs to such items should NEVER be attempted
by untrained individuals.
General
To assist in the use of this Manual, it is divided into
sections and sub-sections. The section title is given
at the top of each page and the relevant sub-section
is given at the bottom.
There is a single contents section at the front of the
Manual, which is divided by section and sub-section.
Each section is numbered from page 1.
The individual items comprising repair operations are
to be followed in the sequence in which they appear.
Items numbers in the illustration are referred to in the
text.
Adjustment and Repair operations include reference
to Service tool numbers and the associated
illustration depicts the tool in use. Adjustment and
repair operations also include reference to wear
limits, relevant data, torque figures, and specialist
information and useful assembly details. Each
adjustment or repair operation is given its Service
Repair Operation number.
WARNINGS, CAUTIONS and NOTES have the
following meanings:
WARNING: Procedures which must be followed
precisely to avoid the possibility of injury.
CAUTION: Calls attention to procedures which
must be followed to avoid damage to
components.
NOTE: Gives helpful information.References
References to the LH or RH side given in this Manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
crankshaft pulley end of the engine is referred to as
the front.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and tested after
completion and if necessary a road test of the vehicle
is carried out particularly where safety related items
are concerned.
Dimensions
The dimensions quoted are to design engineering
specification with Service limits where applicable.
Page 64 of 1529
GENERAL DATA
04-1
GENERAL DATA
Engine - Td5
General
Type 2.5 litre in-line direct injection diesel, turbocharged and intercooled
Cylinder arrangement 5 in-line, No. 1 cylinder at front of engine
Bore 84.450 mm (3.3248 in)
Stroke 88.950 mm (3.5020 in)
Capacity 2498 cm
3 (152.5 in3)
Firing order 1 - 2 - 4 - 5 - 3
Compression ratio 19.5 : 1
Direction of rotation Clockwise viewed from the front of the engine
Dimensions:
⇒ Length 766 mm (30.1 in)
⇒ Width 708 mm (27.8 in)
⇒ Height 788 mm (31.0 in)
Injection timing Controlled by ECM
Injectors:
⇒ Make/Type Lucas EV1/Dual stage
⇒ Injector operating pressures:
Pre EU3 models:
⇒ Initial opening pressure 270 bar (3915 lbf.in
2)
⇒ Fully opened pressure 440 bar (6380 lbf.in
2)
⇒ Maximum pressure 1560 bar (22620 lbf.in
2)
EU3 models:
⇒ Initial opening pressure 270 bar (3915 lbf.in
2)
⇒ Fully opened pressure 440 bar (6380 lbf.in
2)
⇒ Maximum pressure 1750 bar (25375 lbf.in
2)
Maximum governed speed 4850 rev/min
Maximum overrun speed 5460 rev/min
Idle speed:
⇒ Manual gearbox 740 ± 50 rev/min
⇒ Automatic gearbox 760 ± 50 rev/min
Glow plugs Beru 12 V. Four plugs in cylinders 1, 2, 3 and 4
Turbocharger Garrett GT 20
Emissions standard:
⇒ Pre EU3 models ECD 2
⇒ EU3 models ECD 3
Valve timing
Inlet valves:
⇒ Opens 14° BTDC
⇒ Closes 33° ABDC
Exhaust valves:
⇒ Opens 57° BBDC
⇒ Closes 14° ATDC
Page 76 of 1529
GENERAL DATA
04-13
Manual gearbox - R380
Type Single helical constant mesh
Gears 5 forward, 1 reverse, all synchromesh
Gear ratios: Td5 Diesel
⇒ First 3.692 : 1
⇒ Second 2.132 : 1
⇒ Third 1.397 : 1
⇒ Fourth 1.0 : 1
⇒ Fifth 0.770 : 1
⇒ Reverse 3.536 : 1
Gear ratios: V8 Petrol
⇒ First 3.321:1
⇒ Second 2.132:1
⇒ Third 1.397:1
⇒ Fourth 1.0:1
⇒ Fifth 0.732:1
⇒ Reverse 3.536:1
Baulk ring clearance:
⇒ New 0.500 mm (0.0197 in)
⇒ Service limit 0.500 mm (0.0197 in)
⇒ Selector fork pad widths - minimum 6.5 mm (0.255 in)
First gear end float:
⇒ New 0.050 - 0.200 mm (0.0020 - 0.0079 in)
⇒ Service limit 0.327 mm (0.0129 in)
Second gear end float:
⇒ New 0.040 - 0.210 mm (0.0016 - 0.0083 in)
⇒ Service limit 0.337 mm (0.0133 in)
Third gear end float:
⇒ New 0.110 - 0.210 mm (0.0043 - 0.0083 in)
⇒ Service limit 0.337 mm (0.0133 in)
Adjust fifth / reverse hub - shim to
⇒ New 0.005 - 0.055 mm (0.0002 - 0.0022 in)
⇒ Service limit 0.055 mm (0.0022 in)
Reverse gear idler shaft clearance
⇒ New 0.040 - 0.380 mm (0.0016 - 0.0150 in)
⇒ Service limit 0.380 mm (0.0150 in)
Mainshaft end float:
⇒ New 0.000 - 0.050 mm (0.0000 - 0.0020 in)
⇒ Service limit 0.000 - 0.050 mm (0.0000 - 0.0020 in)
Layshaft end float:
⇒ New 0.000 - 0.050 mm (0.0000 - 0.0020 in)
⇒ Service limit 0.000 - 0.050 mm (0.0000 - 0.0020 in)
Page 77 of 1529
GENERAL DATA
04-14
Transfer box - LT230SE
Type LT230SE, two speed reduction with front and rear drives
Reduction ratios:
⇒ High range 1.211 : 1
⇒ Low range 3.32 : 1
Low range gear to high/low range hub clearance 0.05 to 0.15 mm (0.002 to 0.006 in)
High range gear to high/low range hub clearance 0.05 to 0.15 mm (0.002 to 0.006 in)
Mainshaft input gear bearing pre-load 0.05 mm (0.002 in)
Intermediate gear bearing pre-load Torque intermediate shaft nut to 88 Nm (65 lbf.ft)
Page 78 of 1529
GENERAL DATA
04-15
Automatic gearbox - ZF4HP22/24
Type ZF4HP22, electro-hydraulic shift control with fluid torque converter
Gears 4 forward, 1 reverse
Gear ratios:
⇒ First 2.480:1
⇒ Second 1.480:1
⇒ Third 1.000:1
⇒ Fourth 0.728:1
⇒ Reverse 2.086:1
Torque converter lock-up Engaged in third and fourth gears above 72 km/h (45 mph)
Input shaft axial end-float 0.2 to 0.4 mm (0.008 to 0.016 in)