check transmission fluid LAND ROVER DISCOVERY 1999 Workshop Manual

GENERAL INFORMATION
03-27
Body Repairs
General
Body shells are of welded construction and bolted to
a chassis frame. Front and rear sections of the shell
are designed as 'energy absorbing' zones. This
means they are designed to deform progressively
when subjected to impact in order to minimise the
likelihood of injury to vehicle occupants.
It is essential that design dimensions and strength
are restored in accident rectification. It is important
that neither structural weakness nor excessive local
stiffness are introduced into the vehicle during body
repair.
Repairs usually involve a combination of operations
ranging from straightening procedures to renewal of
individual panels or panel assemblies. The repairer
will determine the repair method and this decision will
take into account a balance of economics between
labour and material costs and the availability of repair
facilities in both equipment and skills. It may also
involve considerations of the vehicles' downtime,
replacement vehicle availability and repair turn-
around time.
It is expected that a repairer will select the best and
most economic repair method possible, making use
of the facilities available. The instructions given are
intended to assist a skilled body repairer by
expanding approved procedures for panel
replacement. The objective is to restore the vehicle
to a safe running condition by carrying out a repair
which is as close as is feasible to original standard.
The results should not advertise to the experienced
eye that the vehicle has been damaged, although the
repair might not be identical in all respects to the
original factory build. Commercial bodyshop repair
facilities cannot always duplicate methods of
construction used during production.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and suspension
geometry checked after completion. Where
necessary a road test of the vehicle should be carried
out, particularly where safety-related items are
concerned.
Where major units have been disconnected or
removed it is necessary to ensure that fluid levels are
checked and topped up where necessary. It is also
necessary to ensure that the repaired vehicle is in a
roadworthy condition in respect of tyre pressures,
lights, washer fluid etc. Body repairs often involve the removal of mechanical
and electrical units and associated wiring. Where
necessary, refer to the relevant section of the
Workshop Manual for removal and refitting
instructions.
Taking into consideration the differences in body
styles, suspension systems and engine and
transmission layouts, the location of the following
components as applicable to a particular vehicle is
critical:
lFront suspension upper damper mountings on
RH and LH chassis longitudinals.
lFront suspension or sub frame mountings.
lEngine mountings on RH and LH chassis
longitudinals.
lRear suspension upper damper mountings on
RH and LH chassis longitudinals.
lRear suspension mountings or lower pivots.
Additional points which can be used to check
alignment and assembly are:
lInner holes in cross member - side - main floor.
lHoles in front bulkhead.
lHoles in rear longitudinals.
lHoles in rear lower panels.
Apertures for windscreen, rear screen, bonnet and
doors can be measured and checked using the
dimensional information provided and also by
offering up an undamaged component as a gauge.
Straightening
Whenever possible, structural members should be
cold straightened under tension. Do not attempt to
straighten with a single pull but rework the damaged
area using a series of pulls, releasing tension
between each stage and using the opportunity to
check alignment.
Body jig
Unless damage is limited to cosmetic panels, all
repair work to body members must be carried out on
a body jig, to ensure that impact damage has not
spread into more remote parts of the structure.
Mounting on a jig will also ensure that the
straightening and panel replacement procedures do
not cause further distortion.
If original dimensions cannot be satisfactorily
restored by these methods, damaged structural
members should be replaced. Damaged areas
should be cut away using a high speed saw, NOT an
oxy-acetylene torch.
As a rule, body dimensions are symmetrical about
the centre line. A good initial check for distortion is
therefore to measure diagonally and to investigate
apparent differences in dimensions.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-42 REPAIRS
Refit
1.Clean intermediate plate and mating faces with
a lint free cloth.
2.Position intermediate plate to converter
housing, fit bolts and tighten evenly to 46 Nm
(34 lbf.ft)
3.Fit new sealing washers to M14 Allen plugs, fit
plugs and tighten to 40 Nm (30 lbf.ft).
4.Fit new sealing washers to M20 plugs, fit plugs
and tighten to 50 Nm (37 lbf.ft).
5.Fit oil cooler adaptors and tighten to 42 Nm (30
lbf.ft)
6.Clean pump housing and mating face on
intermediate plate with lint free cloth.
7.Lubricate new 'O' ring with transmission fluid
and fit to pump housing.
8.Position pump locating dowel into intermediate
plate.
9.Align pump to dowel and position in
intermediate plate.
10.Fit bolts and tighten in a diagonal sequence to
10 Nm (7 lbf.ft)
11.Position LRT-44-003/1 into pump and check
that the pump rotors turn freely.
12.Fit intermediate plate gasket.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gasket - intermediate plate.
M44 1342
LRT-44-003/1

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-43
Pump - fluid
$% 44.32.01
Remove
1.Remove intermediate plate gasket.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gasket - intermediate plate.
2.Remove 8 bolts securing fluid pump to
intermediate plate and carefully remove pump
from intermediate plate.
3.Note position and remove pump locating dowel.
4.Remove and discard 'O' ring from pump
housing.Refit
1.Clean pump housing and mating face on
intermediate plate with lint free cloth.
2.Lubricate new 'O' ring with transmission fluid
and fit to pump housing.
3.Position pump locating dowel into intermediate
plate.
4.Align fluid pump to dowel and position in
intermediate plate.
5.Fit bolts and tighten in a diagonal sequence to
10 Nm (7 lbf.ft)
6.Position LRT-44-003/1 into pump and check
that the pump rotors turn freely.
7.Fit intermediate plate gasket.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gasket - intermediate plate.
M44 1336
M44 1341
M44 1342
LRT-44-003/1

INSTRUMENTS
88-6 DESCRIPTION AND OPERATION
The third warning lamp pack is located in the top right-hand side of the instrument pack and contains the following
warning lamps:
lSRS warning lamp.
lSLS off road mode warning lamp.
lTrailer warning lamp.
lGlow plug warning lamp.
lWater in fuel filter warning lamp.
lSeat belt warning lamp.
lTransmission high temperature warning lamp.
The fourth warning lamp pack is located underneath the tachometer of the instrument pack contains the following
warning lamps:
lOil pressure warning lamp.
lAlternator charge warning lamp.
lHDC fault warning lamp.
lSelf Levelling Suspension (SLS) warning lamp.
lActive Cornering Enhancement (ACE) warning lamp.
lGearbox manual/sport mode warning lamps.
The serial communication link is used to allow information to travel to and from the instrument pack, and it provides
the ability to configure the instrument pack to a specific market. It also allows the instrument pack to be controlled by
TestBook for diagnostics.
There are five market specific variants of the instrument pack:
lUnited Kingdom (UK).
lNorth American Specification (NAS).
lCanada.
lAustralia.
lRest Of the World (ROW), Gulf and Japan.
The main difference between the five markets is that the speedometer will indicate road speed in mph as major figures
and km/h as minor figures, km/h as major figures and mph as minor figures or km/h only.
When TestBook is used to diagnose the instrument pack it demands each of the dials and warning lamps to operate
in-turn so a visual check of their operation can be made.
CAUTION: The instrument pack must not be stored on its face side at any time. This is because the dials have
damping fluid within them to ensure smooth operation of the dials' indicator needles. This fluid will leak out.
Speedometer
The speedometer informs the driver of the current vehicle road speed. It has a Liquid Crystal Display (LCD) to show
odometer, trip meter and, on automatic gearbox models, the selected gear. The speedometer will not show speeds
of less than 1.5 mph (2.5 km/h).
There are three different market configurations:
lNAS and UK = mph as major figures km/h as minor figures.
lCanada = km/h as major figures mph as minor figures.
lROW and Australia = km/h only.
The Self Levelling and Anti-Lock Brake System (SLABS) ECU provides the signal input for the road speed. The signal
is at 8000 pulses per mile (1.6 kilometres).