recommended oil LAND ROVER DISCOVERY 1999 Workshop Manual

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.

GENERAL INFORMATION
03-6
General Fitting Instructions
Component removal
Whenever possible, clean components and
surrounding area before removal.
lBlank off openings exposed by component
removal.
lImmediately seal fuel, oil or hydraulic lines when
apertures are exposed; use plastic caps or
plugs to prevent loss of fluid and ingress of dirt.
lClose the open ends of oilways exposed by
component removal with tapered hardwood
plugs or conspicuous plastic plugs.
lImmediately a component is removed, place it in
a suitable container; use a separate container
for each component and its associated parts.
lClean bench and provide marking materials,
labels and containers before dismantling a
component.
Dismantling
Observe scrupulous cleanliness when dismantling
components, particularly when brake, fuel or
hydraulic system parts are being worked on. A
particle of dirt or a cloth fragment could cause a
serious malfunction if trapped in these systems.
lBlow out all tapped holes, crevices, oilways and
fluid passages with an air line. Ensure that any
'O' rings used for sealing are correctly replaced
or renewed, if disturbed during the process.
lUse marking ink to identify mating parts and
ensure correct reassembly. Do not use a centre
punch or scriber to mark parts, they could
initiate cracks or distortion in marked
components.
lWire together mating parts where necessary to
prevent accidental interchange (e.g. roller
bearing components).
lWire labels on to all parts which are to be
renewed, and to parts requiring further
inspection before being passed for reassembly;
place these parts in separate containers from
those containing parts for rebuild.
lDo not discard a part due for renewal until after
comparing it with a new part, to ensure that its
correct replacement has been obtained.Cleaning components
Always use the recommended cleaning agent or
equivalent. Ensure that adequate ventilation is
provided when volatile degreasing agents are being
used. Do not use degreasing equipment for
components containing items which could be
damaged by the use of this process.
General inspection
All components should be inspected for wear or
damage before being reassembled.
lNever inspect a component for wear or
dimensional check unless it is absolutely clean;
a slight smear of grease can conceal an
incipient failure.
lWhen a component is to be checked
dimensionally against recommended values,
use the appropriate measuring equipment
(surface plates, micrometers, dial gauges etc.).
Ensure the measuring equipment is calibrated
and in good serviceable condition.
lReject a component if its dimensions are
outside the specified tolerances, or if it appears
to be damaged.
lA part may be refitted if its critical dimension is
exactly to its tolerance limit and it appears to be
in satisfactory condition. Use 'Plastigauge' 12
Type PG-1 for checking bearing surface
clearances.

GENERAL INFORMATION
03-8
Oil Seals
General
Always renew oil seals which have been removed
from their working location (whether as an individual
component or as part of an assembly). NEVER use
a seal which has been improperly stored or handled,
such as hung on a hook or nail.
lCarefully examine seal before fitting to ensure
that it is clean and undamaged.
lEnsure the surface on which the new seal is to
run is free of burrs or scratches. Renew the
component if the original sealing surface cannot
be completely restored.
lProtect the seal from any surface which it has to
pass when being fitted. Use a protective sleeve
or tape to cover the relevant surface.
lLubricate the sealing lips with a recommended
lubricant before use to prevent damage during
initial use. On dual lipped seals, smear the area
between the lips with grease.
lIf a seal spring is provided, ensure that it is fitted
correctly. Place lip of seal towards fluid to be
sealed and slide into position on shaft. Use
fitting sleeve where possible to protect sealing
lip from damage by sharp corners, threads or
splines. If a fitting sleeve is not available, use
plastic tube or tape to prevent damage to the
sealing lip.
lGrease outside diameter of seal, place square
to housing recess and press into position using
great care, and if possible a 'bell piece' to
ensure that seal is not tilted. In some cases it
may be preferable to fit seal to housing before
fitting to shaft. Never let weight of unsupported
shaft rest in seal.lUse the recommended service tool to fit an oil
seal. If the correct service tool is not available,
use a suitable tube approximately 0.4 mm
(0.015 in.) smaller than the outside diameter of
the seal. Use a hammer VERY GENTLY on drift
if a suitable press is not available.
lPress or drift the seal in to the depth of its
housing with the sealing lip facing the lubricant
to be retained if the housing is shouldered, or
flush with the face of the housing where no
shoulder is provided. Ensure that the seal does
not enter the housing in a tilted position.

GENERAL INFORMATION
03-9
Joints and Joint Faces
General
Fit joints dry unless specified otherwise.
lAlways use the correct gaskets as specified.
lWhen jointing compound is used, apply in a thin
uniform film to metal surfaces; take care to
prevent jointing compound from entering
oilways, pipes or blind tapped holes.
lIf gaskets and/or jointing compound is
recommended for use; remove all traces of old
jointing material prior to reassembly. Do not use
a tool which will damage the joint faces and
smooth out any scratches or burrs using an oil
stone. Do not allow dirt or jointing material to
enter any tapped holes or enclosed parts.
lPrior to reassembly, blow through any pipes,
channels or crevices with compressed air.
Locking Devices
General
Always replace locking devices with one of the same
design.
Tab washers
Always release locking tabs and fit new locking
washers. Do not re-use locking tabs.
Locking nuts
Always use a backing spanner when loosening or
tightening locking nuts, brake and fuel pipe unions.
Roll pins
Always fit new roll pins of an interference fit in the
hole.
Circlips
Always fit new circlips of the correct size for the
groove.
Keys and keyways
Remove burrs from edges of keyways with a fine file
and clean thoroughly before attempting to refit key.
Clean and inspect key closely; keys are suitable for
refitting only if indistinguishable from new, as any
indentation may indicate the onset of wear.

GENERAL INFORMATION
03-10
Split pins
Always fit new split-pins of the correct size for the
hole in the bolt or stud.
Screw Threads
General
Metric threads to ISO standards are used.
Damaged nuts, bolts and screws must always be
discarded. Cleaning damaged threads with a die or
tap impairs the strength and fit of the threads and is
not recommended.
Always ensure that replacement bolts are at least
equal in strength to those replaced. Castellated nuts
must not be loosened to accept a split-pin, except in
recommended cases when this forms part of an
adjustment.
Do not allow oil or grease to enter blind threaded
holes. The hydraulic action on screwing in the bolt or
stud could split the housing.
Always tighten a nut or bolt to the recommended
torque figure. Damaged or corroded threads can
affect the torque reading.
To check or re-tighten a bolt or screw to a specified
torque figure, first loosen a quarter of a turn, then
retighten to the correct torque figure.
Oil thread lightly before tightening to ensure a free
running thread, except in the case of threads treated
with sealant/lubricant, and self-locking nuts.

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
09-2
Fluids
Anti-freeze
Use Havoline Extended Life Coolant (XLC), or any
ethylene glycol based anti-freeze (containing no
methanol) with only Organic Acid Technology (OAT)
corrosion inhibitors, to protect the cooling system
CAUTION: No other anti-freeze should be used
with Havoline Extended Life Coolant.
The cooling system should be drained, flushed and
refilled with the correct amount of anti-freeze solution
at the intervals given on the Service Maintenance
Check Sheet.
After filling with anti-freeze solution, attach a warning
label to a prominent position on the vehicle stating
the type of anti-freeze contained in the cooling
system to ensure that the correct type is used for
topping-up.
Brake/Clutch fluid
Use only DOT 4 brake fluid.
PAS fluid
Use Texaco cold climate power assisted steering
fluid PSF 14315.
ACE fluid
Where ambient temperature falls below -20° C (-4°
F), use only Texaco cold climate power assisted
steering fluid PSF 14315. Where ambient
temperature remains above -20° C (-4° F), use either
Texaco cold climate power assisted steering fluid ,
Dexron 11 or Dexron 111 non-synthetic fluid.
Air conditioning
Use only refrigerant R134a.
Refrigerant oil
Use only Nippon Denso ND-oil 8.
Refrigerant oil absorbs water and must not be stored
for long periods. Do not pour unused oil back into the
container.
NOTE: The total quantity of refrigerant oil in the
system is 180 ml.
CAUTION: Do not use any other type of
refrigerant oil.
Anti-Freeze Concentration
The overall anti-freeze concentration should not fall,
by volume, below 50% to ensure that the anti-
corrosion properties of the coolant are maintained.
Anti-freeze concentrations greater than 60% are not
recommended as cooling efficiency will be impaired.
The following recommended quantities of anti-freeze
will provide frost protection to -48°C (-53°F):
Engine - TD5
Engine - V8
Concentration 50%
Amount of Anti-freeze 4 litres
Concentration 50%
Amount of Anti-freeze 6.5 litres
13.5 pts (US)

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
09-3
Lubrication
General
The engine and other lubricating systems are filled
with high-performance lubricants giving prolonged
life.
CAUTION: Always use a high quality oil of the
correct viscosity range in the engine. The use of
oil of the incorrect specification can lead to high
oil and fuel consumption and ultimately to
damaged components.
Oil to the correct specification contains additives
which disperse the corrosive acids formed by
combustion and prevent the formation of sludge
which can block the oil ways. Additional oil additives
should not be used.
Always adhere to the recommended servicing
intervals.Engine oil viscosity
The above chart indicates the ambient temperature
ranges which each engine oil viscosity is suitable for.
Engine oil - V8 - Not North America
Use a 5W/30, 5W/40, 5W/50, 10W/30, 10W/40,
10W/50 or 10W/60 oil meeting specifications ACEA
A1 or A2, having a viscosity band suitable for the
temperature range of your locality.
Engine oil - V8 - North America
Use a 5W/30, 5W/40 or 10W/40 oil meeting
specifications API SH or SJ, having a viscosity band
suitable for the temperature range of your locality.
Engine oil - Td5
Use 5W/30, 5W/40, 5W/50, 10W/30, 10W/40, 10W/
50 or 10W/60 oil to specifications ACEA A1/B1,
having a viscosity band suitable for the temperature
range of your locality.
Note: Where oils to these specifications are not
available, oils to specifications ACEA A3/B3 or A2/
B2 may be used but use of these oils may have an
adverse effect on fuel economy.
Note: Where oils to these European specifications
are not available, well known brands of oil meeting
specifications API SH or SJ may be used.

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.

MAINTENANCE
10-14 PROCEDURES
Intercooler - diesel engine
Remove
1.Remove intercooler.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
Flush
1.Flush intercooler element using Flushing
Solvent Part No. STC 9713, following the
manufacturer's instructions.
2.Thoroughly dry intercooler ensuring that no
trace of solvent remains in the element.
3.Refit intercooler on completion.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
Engine oil - 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.Position suitable container beneath sump.
2.Clean area around oil drain plug.
3.Remove oil drain plug, discard sealing washer.
4.Allow oil to drain.
5.Fit new sealing washer to oil drain plug.
6.Fit engine drain plug and tighten to 33 Nm (24
lbf.ft).
7.Fill engine with recommended grade of oil to
correct mark on dipstick.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.

MAINTENANCE
PROCEDURES 10-15
Engine oil - diesel 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.Release fixings, remove underbelly panel.
2.Position suitable container beneath sump.
3.Clean area around drain plug.
4.Remove oil drain plug, discard sealing washer.
5.Allow oil to drain.
6.Fit new sealing washer to oil drain plug.
7.Fit engine drain plug and tighten to 23 Nm (17
lbf.ft).
8.Fill engine with recommended grade of oil to
correct mark on dipstick.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
9.Fit front underbelly panel, secure fixings.
Centrifuge rotor – diesel engine
Replace
1.Replace centrifuge rotor.

+ ENGINE - Td5, REPAIRS, Rotor -
centrifuge.