oil level 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 29 of 1529
CONTENTS
26 CONTENTS
LIGHTING.................................................................................................. 86-2-1
ADJUSTMENTS
Headlamps beam alignment - up to 03MY ..................................................................................... 86-2-1
Headlamps beam alignment - from 03MY ...................................................................................... 86-2-2
REPAIRS
Lamp - front repeater - up to 03MY ................................................................................................ 86-2-3
Headlamp - up to 03MY .................................................................................................................. 86-2-4
Headlamp - from 03MY .................................................................................................................. 86-2-5
Lamp - tail ..................................................................................................................................... 86-2-6
Lamp - front fog up to 03MY ........................................................................................................... 86-2-6
Lamp - front fog from 03MY ............................................................................................................ 86-2-7
Housing - number plate lamp ......................................................................................................... 86-2-8
Motor - headlamp levelling ............................................................................................................ 86-2-9
Lamp - stop - centre high mounted (CHMSL) .............................................................................. 86-2-10
Lamp - tail/flasher - bumper ............................................................................................................ 86-2-10
Lamp - interior - front .................................................................................................................... 86-2-11
Lamp - interior - rear ..................................................................................................................... 86-2-11
Rheostat - panel lights dimmer ...................................................................................................... 86-2-12
Switch - hazard warning ................................................................................................................ 86-2-13
Switch - indicator and exterior lighting - combined ......................................................................... 86-2-13
Socket - accessory ........................................................................................................................ 86-2-14
Switch - front/rear fog lamps ......................................................................................................... 86-2-14
BODY CONTROL UNIT ............................................................................ 86-3-1
DESCRIPTION AND OPERATION
Description ...................................................................................................................................... 86-3-1
Operation ........................................................................................................................................ 86-3-19
REPAIRS
Body control unit (BCU) .................................................................................................................. 86-3-35
ALARM SYSTEM AND HORN.................................................................. 86-4-1
DESCRIPTION AND OPERATION
Alarm system component layout..................................................................................................... 86-4-2
Alarm system block diagram........................................................................................................... 86-4-4
Description ...................................................................................................................................... 86-4-5
Operation ........................................................................................................................................ 86-4-17
REPAIR
Switch - central door locking ......................................................................................................... 86-4-25
Switches - horn ............................................................................................................................. 86-4-25
Vehicle horn .................................................................................................................................. 86-4-26
Sounder - alarm ............................................................................................................................ 86-4-26
Sounder - battery backed-up (BBUS) ............................................................................................. 86-4-27
Switch - bonnet ............................................................................................................................. 86-4-27
Receiver - alarm system - models with sunroof ............................................................................. 86-4-28
Receiver - alarm system - models without sunroof ......................................................................... 86-4-28
Coil - passive immobilisation ........................................................................................................ 86-4-29
Page 37 of 1529
GENERAL INFORMATION
03-2
Safety Instructions
Whenever possible, use a lift or pit when working
beneath vehicle, in preference to jacking. Chock
wheels as well as applying parking brake.
Jacking
Always use the recommended jacking points.
Always ensure that any lifting apparatus has
sufficient load capacity for the weight to be lifted.
Ensure the vehicle is standing on level ground prior
to lifting or jacking.
Apply the handbrake and chock the wheels.
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the
vehicle on safety stands.
Do not leave tools, lifting equipment, spilt oil, etc.
around or on the work bench area. Always keep a
clean and tidy work area.
Brake shoes and pads
Always fit the correct grade and specification of
brake linings. When renewing brake pads and brake
shoes, always replace as complete axle sets.Brake hydraulics
Observe the following recommendations when
working on the brake system:
lAlways use two spanners when loosening or
tightening brake pipe or hose connections.
lEnsure that hoses run in a natural curve and are
not kinked or twisted.
lFit brake pipes securely in their retaining clips
and ensure that the pipe cannot contact a
potential chafing point.
lContainers used for brake fluid must be kept
absolutely clean.
lDo not store brake fluid in an unsealed
container, it will absorb water and in this
condition would be dangerous to use due to a
lowering of its boiling point.
lDo not allow brake fluid to be contaminated with
mineral oil, or put new brake fluid in a container
which has previously contained mineral oil.
lDo not re-use brake fluid removed from the
system.
lAlways use clean brake fluid or a recommended
alternative to clean hydraulic components.
lAfter disconnection of brake pipes and hoses,
immediately fit suitable blanking caps or plugs to
prevent the ingress of dirt.
lOnly use the correct brake fittings with
compatible threads.
lObserve absolute cleanliness when working
with hydraulic components.
Cooling system caps and plugs
Extreme care is necessary when removing
expansion tank caps and coolant drain or bleed
screws when the engine is hot, especially if it is
overheated. To avoid the possibility of scalding,
allow the engine to cool before attempting removal.
Air suspension system
Whilst working on the air suspension system, eye
protection must be worn at all times.
Page 38 of 1529
GENERAL INFORMATION
03-3
Environmental Precautions
General
This section provides general information which can
help to reduce the environmental impacts from the
activities carried out in workshops.
Emissions to air
Many of the activities that are carried out in
workshops emit gases and fumes which contribute to
global warming, depletion of the ozone layer and/or
the formation of photochemical smog at ground
level. By considering how the workshop activities are
carried out, these gases and fumes can be
minimised, thus reducing the impact on the
environment.
Exhaust fumes
Running car engines is an essential part of workshop
activities and exhaust fumes need to be ventilated to
atmosphere. However, the amount of time engines
are running and the position of the vehicle should be
carefully considered at all times, to reduce the
release of poisonous gases and minimise the
inconvenience to people living nearby.
Solvents
Some of the cleaning agents used are solvent based
and will evaporate to atmosphere if used carelessly,
or if cans are left unsealed. All solvent containers
should be firmly closed when not needed and
solvent should be used sparingly. Suitable
alternative materials may be available to replace
some of the commonly used solvents. Similarly,
many paints are solvent based and the spray should
be minimised to reduce solvent emissions.
Refrigerant
It is illegal to release any refrigerants into the
atmosphere. Discharge and replacement of these
materials from air conditioning units should only be
carried out using the correct equipment.
Checklist
Always adhere to the following.
Engines:
ldon't leave engines running unnecessarily;
lminimise testing times and check where the
exhaust fumes are being blown.
Materials:
lkeep lids on containers of solvents;
lonly use the minimum quantity;
lconsider alternative materials;
lminimise over-spray when painting. Gases:
luse the correct equipment for collecting
refrigerants;
ldon't burn rubbish on site.
Discharges to water
Most sites will have two systems for discharging
water: storm drains and foul drains. Storm drains
should only receive clean water, foul drains will take
dirty water.
The foul drain will accept many of the normal waste
waters such as washing water, detergents and
domestic type wastes, but oil, petrol, solvent, acids,
hydraulic oil, antifreeze and other such substances
should never be poured down the drain. If in any
doubt speak to the Water Company first.
Every precaution must be taken to prevent spillage of
oil, fuel, solvents etc. reaching the drains. All
handling of such materials must take place well away
from the drains and preferably in an area with a kerb
or wall around it, to prevent discharge into the drain.
If a spillage occurs it should be soaked up
immediately. Having a spill kit available will make
this easier.
Additional precautions
Check whether the surface water drains are
connected to an oil water separator, this could
reduce the pollution if an incident was to occur. Oil
water separators do need regular maintenance to
ensure effectiveness.
Checklist
Always adhere to the following.
Disposal:
lnever pour anything down a drain without first
checking that it is environmentally safe to do so,
and that it does not contravene any local
regulations or bye-laws;
l have oil traps emptied regularly.
Spillage prevention:
lstore liquids in a walled area;
lmake sure that taps on liquid containers are
secure and cannot be accidentally turned on;
lprotect bulk storage tanks from vandalism by
locking the valves;
ltransfer liquids from one container to another in
an area away from open drains;
lensure lids are replaced securely on containers;
lhave spill kits available near to points of storage
and handling of liquids.
Page 61 of 1529
GENERAL INFORMATION
03-26
Precautions for refrigerant recovery, recycling
and recharging
When the air conditioning system is recharged, any
existing refrigerant is first recovered from the system
and recycled. The system is then charged with the
required weight of refrigerant and volume of
refrigerant oil.
WARNING: Refrigerant must always be recycled
before re-use to ensure that the purity of the
refrigerant is high enough for safe use in the air
conditioning system.
Recycling should always be carried out with
equipment which is design certified by
Underwriter Laboratory Inc. for compliance with
SAE J1991. Other equipment may not recycle
refrigerant to the required level of purity.
A R134a Refrigerant Recovery Recycling
Recharging Station must not be used with any
other type of refrigerant.
Refrigerant R134a from domestic and
commercial sources must not be used in motor
vehicle air conditioning systems.
CAUTION: The system must be evacuated
immediately before recharging commences.
Delay between evacuation and recharging is not
permitted.
Air Conditioning Compressor
Replacement
A new compressor is supplied filled with a full charge
(X cm3) of refrigerant oil.
+ CAPACITIES, FLUIDS, LUBRICANTS
AND SEALANTS, Capacities.A calculated quantity
of oil must be drained from the new compressor
before fitting. To calculate the quantity of oil to be
drained:
1Remove the drain plug from the old
compressor.
2Invert the compressor and gravity drain the oil
into a calibrated measuring cylinder. Rotate the
compressor clutch to ensure the compressor is
completely drained.
3Note the quantity of oil drained (Y cm
3).
4Calculate the quantity of oil to be drained from
the new compressor using the following
formula:
X cm
3 — (Y cm3 + 20 cm3) = Q cm3
5Remove the drain plug from the new
compressor and drain Q cm3 of oil. Fit and
tighten the compressor drain plug.
Page 87 of 1529
GENERAL DATA
04-24
Weights
NOTE: The rear axle load for vehicles with self levelling suspension can be increased to a maximum of 1928 kg (4249
lb) when towing, provided road speed is limited to 60 mph (100 km/h).
NOTE: Axle weights are non additive. The individual maximum weights and gross vehicle weight must not be
exceeded.
kgs lbs
Unladen weight:
⇒ V8 models 2095 - 2235 4619 - 4928
⇒ Td5 model 2150 - 2280 4740 - 5027
Max.GVW:
⇒ All 5 seat vehicles (coil springs) 2750 6063
⇒ All 7 seat Diesel engine vehicles (coil springs) 2880 6347
⇒ All 7 seat Petrol engine vehicles (coil springs) 2825 6215
⇒ V8 models with self levelling suspension 2825 6228
⇒ Td5 models with self levelling suspension 2880 6349
Max. front axle load 1200 2646
Max. rear axle load:
⇒ With coil springs 1720 3792
⇒ With self levelling suspension 1800 3968
Page 92 of 1529
TORQUE WRENCH SETTINGS
06-1
TORQUE WRE NCH SETTINGS
Maintenance
TORQUE DESCRIPTION METRIC IMPERIAL
Wheel nuts 140 Nm (103 lbf.ft)
V8 oil drain plug 33 Nm (24 lbf.ft)
Td5 oil drain plug 23 Nm (17 lbf.ft)
Oil filter element, tighten two thirds of a turn by hand or to - 17 Nm (13 lbf.ft)
Manual gearbox oil drain plug 50 Nm (37 lbf.ft)
Manual gearbox oil filler/level plug 30 Nm (22 lbf.ft)
Automatic gearbox oil drain plug 15 Nm (11 lbf.ft)
Automatic gearbox oil drain plug 30 Nm (22 lbf.ft)
Transfer gearbox oil drain plug 30 Nm (22 lbf.ft)
Transfer gearbox oil filler/level plug 25 Nm (18 lbf.ft)
Axle oil drain plug 64 Nm (47 lbf.ft)
Axle oil filler/level plug 10 Nm (7 lbf.ft)
Page 129 of 1529
MAINTENANCE
10-6 PROCEDURES
Handbrake
Check
1.With the vehicle stationary, on a level surface,
apply and release handbrake and check for
correct operation.
+ BRAKES, ADJUSTMENTS,
Handbrake.
Alarm handset battery
Replace
1.Insert the blade of a small, flat bladed
screwdriver into the slot at the rear of the
handset and prise the back from the handset.
2.Slide the battery out of the clip taking care not
to touch the circuit board or the battery
contacts.
3.Press and hold one of the buttons for at least 5
seconds.
4.Fit the replacement battery ensuring that
correct polarity is maintained (+) side facing
upwards. Avoid touching the flat surfaces of the
battery.
5.Press the 2 halves of the handset together.
6.Check that handset operates correctly.
Road wheels
Remove
1.Mark the wheel to stud relationship to ensure
that the wheels are refitted in the same
position.
2.Loosen wheel nuts. Raise the vehicle to a
wheel-free condition and remove the wheel
nuts.
Tyres
Check
1.Check tyres for compliance with manufacturer's
specification; visually for cuts, lumps, bulges,
uneven tread wear and depth.
2.Check tyre pressures, condition and tread
depth. Measure the tread depth across the
width of the tyre and around the circumference.
Brake pads, discs and calipers
Check
1. Check front and rear brake pads for wear,
ensure all pads are wearing evenly.
2.Check brake discs for signs of cracking,
excessive scoring or oil contamination.
3.Check calipers for signs of fluid leaks.
4.Clean excessive deposits of brake dust from
pads, calipers and disc shields using brake
cleaner.
Page 132 of 1529
MAINTENANCE
PROCEDURES 10-9
Air suspension intake filter
Check
1.Check condition of filter and that filter is clean,
replace if necessary.
+ REAR SUSPENSION, REPAIRS,
Filter - intake - SLS.
Anti-freeze
Replace
1.Replace anti-freeze.
+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
Cooling system
Check
1.Check cooling, intercooler and heating systems
for leaks; hoses and oil pipes for security and
condition.
2.Check accessible hose clips for tightness.
3.Check coolant level, top-up if necessary.
Top-up
1.With engine cold, remove expansion tank filler
cap.
2.Top-up with recommended mixture of coolant
until level reaches mark on expansion tank.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Anti-Freeze
Concentration.
3.Fit expansion tank filler cap.
Page 139 of 1529
MAINTENANCE
10-16 PROCEDURES
Engine oil filter - diesel engine
Replace
1.Replace oil filter.
+ ENGINE - Td5, REPAIRS, Filter - oil.
Engine oil filter – V8 engine
WARNING: Avoid excessive skin contact with
used engine oil. Used engine oil contains
potentially harmful contaminants which may
cause skin cancer or other serious skin
disorders.
Replace
1.Disconnect battery.
2.Position suitable container beneath oil filter.
3.Using a strap type filter wrench, remove filter
element, discard element.
4.Smear sealing ring of replacement filter
element with engine oil.
5.Fit filter element, tighten two thirds of a turn by
hand or to 17 Nm (13 lbf.ft).
6.Top-up engine with recommended grade of oil
to correct mark on dipstick.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
7.Connect battery.
8.Run engine and check for oil leaks from filter.
9.Stop engine, wait for oil to return to sump.
10.Re-check oil level and top-up if necessary.
Page 140 of 1529
MAINTENANCE
PROCEDURES 10-17
Manual gearbox
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Check/top-up oil level
1.Release fixings, remove rear underbelly panel.
2.Clean area around oil filler/level plug.
3.Remove oil filler/level plug.
4.Check that oil level is to bottom of oil filler/level
plug hole.
5.Top-up level (if required) with recommended oil
to bottom of filler/level plug hole.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
6.Remove all traces of sealant from threads of oil
filler/level plug.
7.Apply Loctite 290 to threads of oil filler/level
plug.
8. Fit manual gearbox filler/level plug and tighten
to 30 Nm (22 lbf.ft).
9.Remove all traces of oil from gearcase.
10.Fit rear underbelly panel, secure fixings.Replace oil
1.Release fixings, remove rear underbelly panel.
2.Place a suitable container beneath gearbox
drain plug.
3.Clean area around oil filler/level and drain
plugs.
4.Remove oil filler/level plug.
5.Remove oil drain plug, remove and discard
sealing washer.
6.Allow oil to drain.
7.Clean magnet in oil drain plug.
8.Fit new sealing washer to oil drain plug.
9.Fit manual gearbox drain plug and tighten to 50
Nm (37 lbf.ft).
10.Fill gearbox with recommended oil to bottom of
filler/level plug hole.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
11.Remove all traces of sealant from threads of oil
filler/level plug.
12.Apply Loctite 290 to threads of oil filler/level
plug.
13. Fit manual gearbox filler/level plug and tighten
to 30 Nm (22 lbf.ft).
14.Remove all traces of oil from gearcase.
15.Fit rear underbelly panel, secure fixings.