towing LAND ROVER DISCOVERY 1999 Workshop Manual

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

CONTENTS
4CONTENTS
Brake hose, brake, fuel, ACE, clutch pipes and unions/electrical harnesses ................................ 10-24
Engine, gearbox, transfer box and axles ........................................................................................ 10-25
Exhaust system .............................................................................................................................. 10-25
Steering box and front suspension ................................................................................................. 10-25
Steering rod ball joints ................................................................................................................... 10-27
Dampers and SLS height sensors .................................................................................................. 10-27
Front and rear axle suspension links .............................................................................................. 10-28
Towing bracket ............................................................................................................................... 10-29
Engine mountings - V8 engine........................................................................................................ 10-30
Road/roller test ............................................................................................................................... 10-31

GENERAL DATA
04-20
Wheels and tyres
CAUTION: When towing, the additional load imposed may cause the tyre maximum load rating to be
exceeded. This is permissible provided the load rating is not exceeded by more than 15% and that road
speeds are limited to 62 mph (100 km/h) and tyres pressures are increased by at least 3 lbf/in
2 (0.2 bar).
NOTE: The tyre size is displayed on the outer wall of each tyre.
Normal operating conditions: carrying up to 4 passengers and luggage.
Wheel size:
⇒ Steel 7J x 16
⇒ Alloy 7J x 16
8J x 16
8J x 18
Tyre size
⇒ With 7J x 16 wheels 235/70 R16 Wrangler HP 105H
235/70 R16 Michelin XPC * 105H
⇒ With 8J x 16 wheels 255/65 R16 Wrangler HP 109H
255/65 R16 Michelin XPC * 109H
⇒ With 8J x 18 wheels 255/55 R18 Wrangler HP 109H
Tyre Pressures
All tyres - normal operating conditions Front Up to 03MY - 1.9 Bar (28 lbf.in
2)
From 03MY - 2.1 Bar (30 lbf.in2)
Rear 2.6 Bar (38 lbf.in
2)
All tyres - vehicle at GVW Front Up to 03MY - 1.9 Bar (28 lbf.in
2)
From 03MY - 2.1 Bar (30 lbf.in2)
Rear 3.2 Bar (46 lbf.in
2)

GENERAL DATA
04-23
Dimensions
* Measurement taken with vehicle at unladen weight.
Overall length - including towing hitch 4715 mm (185.6 in)
Overall length - including spare wheel 4705 mm (185.24 in)
Overall width (excluding mirrors) 1885 mm (74.2 in)
Overall height - Open sunroof * 2015 mm (79.3 in)
Overall height (without roof bars) * 1940 mm (76.40 in)
Minimum ground clearance * 253.5 mm (10.0 in)
Wheelbase 2540 mm (100.00 in)
Turning circle (kerb to kerb) 11.9 metres (39.1 feet)
Track - front 1540 mm (60.63 in)
Track - rear 1560 mm (61.42 in)

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

LIFTING AND TOWING
08-1
LIFTING AND TOWING
LIFTING
The following instructions must be carried out before
raising the vehicle off the ground.
lUse a solid level ground surface.
lApply hand brake.
lSelect 'P' (Automatic gearbox) or 1st gear
(Manual gearbox) in main gearbox.
lSelect Low range in transfer gearbox.
To avoid damage occurring to the under body
components of the vehicle the following jacking
procedures must be adhered to.
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS:
lBody structure
lBumpers
lFuel lines
lBrake lines
lFront radius arms
lPanhard rod
lSteering linkage
lRear trailing arms
lFuel tank
lEngine sump
lGearbox bell housing
Vehicle jack
The jack provided with the vehicle is only intended for
use in an emergency, for changing a tyre. DO NOT
use the jack for any other purpose. Refer to Owner's
Handbook for vehicle jack location points and
procedure. Never work under a vehicle supported
solely by the vehicle jack.
Hydraulic jack
A hydraulic jack with a minimum 1500 kg, 3,300 lbs
load capacity must be used. Do not commence
work on the underside of the vehicle until
suitable axle stands have been positioned under
the axle.
WARNING: Always chock the wheels when
jacking. The hand brake acts on the
transmission, not the rear wheels, and may be
ineffective when the wheels are off the ground.Raising and supporting the vehicle
Position cup of hydraulic arm under differential
casing (1).The differential casing is not central to
the axle. Care should be taken when raising the
front road wheels off the ground as the rear axle
has less sway stiffness.
Raise vehicle to enable an axle stand to be installed
under left hand axle tube (2).
Position an axle stand under right hand axle tube (4).
Carefully lower jack until vehicle sits securely on both
axle stands, remove jack.
Alternatively, the axle stands can be positioned
under the chassis longitudinals at the front and/or
rear of the vehicle.

LIFTING AND TOWING
08-2
Before commencing work on underside of vehicle re-
check security of vehicle on stands.
WARNING: Always chock the wheels when
jacking. The hand brake acts on the the
transmission, not the rear wheels, and may be
ineffective when the wheels are off the ground.
Reverse procedure when removing vehicle from
stands.
Hydraulic ramps
Use only a 'drive on' type ramp which supports a
vehicle by it's own road wheels. If a 'wheel free'
condition is required, use a 'drive on' ramp
incorporating a 'wheel free' system that supports
under axle casings. Alternatively, place vehicle on a
firm, flat floor and support on axle stands.
TOWING
Towing
The vehicle has permanent four wheel drive. The
following towing instructions must be adhered
to:
Towing on 4 wheels with driver
Turn ignition key to position '1' to release steering
lock.
Select neutral in main gearbox and transfer gearbox.
Secure tow rope, chain or cable to towing eye.
Release the handbrake.
The brake servo and power assisted steering
system will not be functional without the engine
running. Greater pedal pressure will be required
to apply the brakes, the steering system will
require greater effort to turn the front road
wheels. The vehicle tow connection should be
used only in normal road conditions, 'snatch'
recovery should be avoided.
Suspended tow
To prevent vehicle damage, front or rear
propeller shaft MUST BE removed, dependent
upon which axle is being trailed.
Mark propeller shaft drive flanges at transfer box and
axles with identification lines to enable the propeller
shaft to be refitted in its original position.

LIFTING AND TOWING
08-3
Remove the propeller shaft fixings, remove the shaft
from the vehicle.
If the front axle is to be trailed turn ignition key to
position '1' to release steering lock.
The steering wheel and/or linkage must be
secured in a straight ahead position. DO NOT use
the steering lock mechanism for this purpose.
Towing eyes
The towing eyes at the front and rear of the vehicle
are designed for vehicle recovery purposes only and
must NOT be used to tow a trailer or caravan.
Front:A single towing eye, set behind a removable
panel in the front spoiler. DO NOT use the front
lashing rings for towing.Rear: A pair of towing eyes at the rear of the vehicle
can be used as lashing rings and for towing another
light vehicle.

LIFTING AND TOWING
08-4
TRANSPORTING
Transporting by trailer
Front lashing eyes
Rear lashing eyesLashing eyes are provided on the chassis
longitudinals, at the front (behind the front wheels)
and at the rear (behind the rear wheels).
DO NOT secure lashing hooks or trailer fixings to
any other part of the vehicle.
Position the vehicle on the trailer and apply the
handbrake. Select neutral in the manual gearbox ('N'
on automatic gearbox). Selecting 'N' will prevent
damage to the parking pawl in the automatic
gearbox.

MAINTENANCE
PROCEDURES 10-29
Towing bracket
Check
1.Check security of towing bracket.