1999 LAND ROVER DISCOVERY fuel
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CONTENTS
CONTENTS 1
INTRODUCTION ...................................................................................... 01-1
How To Use This Manual................................................................................................................ 01-1
Repairs and Replacements ............................................................................................................. 01-2
Specifications .................................................................................................................................. 01-2
Abbreviations and Symbols ............................................................................................................ 01-3
GENERAL INFORMATION ...................................................................... 03-1
General Precautions ....................................................................................................................... 03-1
Safety Instructions .......................................................................................................................... 03-2
Environmental Precautions ............................................................................................................. 03-3
General Fitting Instructions ............................................................................................................. 03-6
Ball and Roller Bearings ................................................................................................................. 03-7
Oil Seals.......................................................................................................................................... 03-8
Joints and Joint Faces .................................................................................................................... 03-9
Locking Devices .............................................................................................................................. 03-9
Screw Threads ................................................................................................................................ 03-10
Bolt and Nut Identification ............................................................................................................... 03-11
Flexible Pipes and Hoses ............................................................................................................... 03-13
Rolling Road Testing....................................................................................................................... 03-15
Fuel Handling Precautions .............................................................................................................. 03-16
Electrical Precautions ..................................................................................................................... 03-17
Supplementary Restraint System Precautions ............................................................................... 03-18
SRS Component Replacement Policy ............................................................................................ 03-23
Air Conditioning System Precautions .............................................................................................. 03-24
Air Conditioning Compressor Replacement .................................................................................... 03-26
Body Repairs .................................................................................................................................. 03-27
GENERAL DATA ..................................................................................... 04-1
Engine - Td5 ................................................................................................................................... 04-1
Engine - V8 ..................................................................................................................................... 04-4
Fuel system - Td5 ........................................................................................................................... 04-8
Fuel system - V8 ............................................................................................................................. 04-8
Cooling system - Td5 ...................................................................................................................... 04-9
Cooling system - V8 ........................................................................................................................ 04-10
Clutch - Td5 .................................................................................................................................... 04-11
Clutch - V8 ...................................................................................................................................... 04-12
Manual gearbox - R380 .................................................................................................................. 04-13
Transfer box - LT230SE .................................................................................................................. 04-14
Automatic gearbox - ZF4HP22/24 .................................................................................................. 04-15
Rear axle......................................................................................................................................... 04-16
Front axle ........................................................................................................................................ 04-16
Steering........................................................................................................................................... 04-17
Suspension ..................................................................................................................................... 04-18
Brakes ............................................................................................................................................. 04-19
Wheels and tyres ............................................................................................................................ 04-20
Air conditioning ............................................................................................................................... 04-21
Electrical - Td5 ................................................................................................................................ 04-22
Electrical - V8 .................................................................................................................................. 04-22
Dimensions ..................................................................................................................................... 04-23
Weights ........................................................................................................................................... 04-24
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CONTENTS
CONTENTS 3
MAINTENANCE ........................................................................................ 10-1
PROCEDURES
V8 engine underbonnet view .......................................................................................................... 10-1
Diesel underbonnet view ................................................................................................................. 10-2
Seats and seat belts ...................................................................................................................... 10-3
Lamps, horns and warning indicators ............................................................................................. 10-5
Wipers and washers ...................................................................................................................... 10-5
Handbrake .................................................................................................................................. 10-6
Alarm handset battery ..................................................................................................................... 10-6
Road wheels ................................................................................................................................... 10-6
Tyres .............................................................................................................................................. 10-6
Brake pads, discs and calipers ....................................................................................................... 10-6
Road wheel speed sensors ............................................................................................................. 10-7
Brake fluid ....................................................................................................................................... 10-7
Fuel filter - diesel engine ................................................................................................................. 10-7
Fuel filter sedimenter ...................................................................................................................... 10-7
Road wheels ................................................................................................................................... 10-8
Radiator/Intercooler ........................................................................................................................ 10-8
Ambient air Temperature and pressure sensor .............................................................................. 10-8
Doors, bonnet and fuel filler flap ..................................................................................................... 10-8
Air suspension intake filter .............................................................................................................. 10-9
Anti-freeze....................................................................................................................................... 10-9
Cooling system ............................................................................................................................... 10-9
Spark plugs - V8 engine.................................................................................................................. 10-10
Air cleaner - V8 engine ................................................................................................................... 10-10
Air cleaner and dump valve - diesel engine .................................................................................... 10-10
Auxiliary drive belt ........................................................................................................................... 10-11
Auxiliary drive belt - V8 engine ....................................................................................................... 10-11
Auxiliary drive belt - diesel engine .................................................................................................. 10-11
Fluid reservoirs ............................................................................................................................... 10-12
Steering box .................................................................................................................................... 10-13
Battery ............................................................................................................................................. 10-13
Intercooler - diesel engine............................................................................................................... 10-14
Engine oil - V8 engine ..................................................................................................................... 10-14
Engine oil - diesel engine ................................................................................................................ 10-15
Centrifuge rotor – diesel engine ...................................................................................................... 10-15
Engine oil filter - diesel engine ........................................................................................................ 10-16
Engine oil filter – V8 engine ............................................................................................................ 10-16
Manual gearbox .............................................................................................................................. 10-17
Automatic gearbox ......................................................................................................................... 10-18
Transfer box .................................................................................................................................... 10-19
Front and rear axle .......................................................................................................................... 10-20
Propeller shafts ............................................................................................................................... 10-20
Anti-roll bar links ............................................................................................................................. 10-22
ACE actuators ................................................................................................................................. 10-23
ACE filter ......................................................................................................................................... 10-23
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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
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CONTENTS
6CONTENTS
EMISSION CONTROL - V8 ....................................................................... 17-2-1
DESCRIPTION AND OPERATION
Crankcase emission control system ............................................................................................... 17-2-1
Exhaust emission control ................................................................................................................ 17-2-2
Evaporative emission system component layout ............................................................................ 17-2-3
Evaporative emission system (with positive pressure leak detection) component layout (NAS only) 17-2-4
Evaporative emission system control diagram ............................................................................... 17-2-5
Secondary air injection system component layout.......................................................................... 17-2-6
Secondary air injection system control diagram ............................................................................. 17-2-8
Emission Control Systems .............................................................................................................. 17-2-9
Crankcase Emission Control System ............................................................................................. 17-2-10
Exhaust Emission Control System.................................................................................................. 17-2-11
Evaporative Emission Control System............................................................................................ 17-2-15
Secondary Air Injection System ...................................................................................................... 17-2-26
Crankcase Emission Control Operation.......................................................................................... 17-2-34
Exhaust Emission Control Operation .............................................................................................. 17-2-35
Evaporative Emission Control Operation ........................................................................................ 17-2-39
Secondary Air Injection System Operation ..................................................................................... 17-2-43
SAI System Fault Finding and Check Malfunctions ........................................................................ 17-2-44
REPAIRS
Canister - EVAP ............................................................................................................................ 17-2-51
Canister - EVAP - Models with Fuel Leak Detection Pump - up to 03MY ...................................... 17-2-52
Canister - EVAP - Models with Fuel Leak Detection Pump - from 03MY ....................................... 17-2-53
Valve - purge control ..................................................................................................................... 17-2-54
Solenoid - evap canister vent solenoid (CVS) valve ..................................................................... 17-2-55
Sensor - heated oxygen (HO2S) - pre-catalytic converter .............................................................. 17-2-56
Sensor - heated oxygen (HO2S) - post-catalytic converter ............................................................ 17-2-57
Control Valve - Secondary Air Injection (SAI) ............................................................................... 17-2-58
Reservoir - Vacuum - Secondary Air Injection (SAI) - up to 03MY ................................................. 17-2-58
Reservoir - vacuum - Secondary Air Injection (SAI) - from 03MY .................................................. 17-2-59
Pump - Air - Secondary Air Injection (SAI) ..................................................................................... 17-2-59
Air Manifold - LH - Secondary Air Injection (SAI) ........................................................................... 17-2-60
Air Manifold - RH - Secondary Air Injection (SAI) .......................................................................... 17-2-61
Solenoid - Vacuum - Secondary Air Injection (SAI) ...................................................................... 17-2-62
Pipe - Secondary Air Injection (SAI) .............................................................................................. 17-2-62
Pump - Fuel Leak Detection - up to 03MY...................................................................................... 17-2-64
Pump - fuel leak detection - from 03MY ......................................................................................... 17-2-64
Filter - fuel leak detection pump - up to 03MY ................................................................................ 17-2-65
Filter - fuel leak detection pump - from 03MY ................................................................................. 17-2-65
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CONTENTS
8CONTENTS
FUEL DELIVERY SYSTEM - V8 ............................................................... 19-2-1
DESCRIPTION AND OPERATION
Fuel delivery system ....................................................................................................................... 19-2-1
Fuel tank and breather components (all except NAS) .................................................................... 19-2-2
Fuel tank and breather components (NAS) .................................................................................... 19-2-3
Description ...................................................................................................................................... 19-2-4
Operation ........................................................................................................................................ 19-2-10
ADJUSTMENTS
Fuel tank - drain .............................................................................................................................. 19-2-11
REPAIRS
Switch - inertia - fuel cut-off ............................................................................................................ 19-2-13
Pump - fuel .................................................................................................................................... 19-2-13
Tank - fuel ...................................................................................................................................... 19-2-15
Filler tube - fuel ............................................................................................................................. 19-2-16
Solenoid - fuel filler flap release...................................................................................................... 19-2-17
Switch - fuel filler flap release - up to 03MY ................................................................................... 19-2-17
Switch - fuel filler flap release - from 03MY .................................................................................... 19-2-18
COOLING SYSTEM - V8........................................................................... 26-2-1
DESCRIPTION AND OPERATION
Cooling system component layout .................................................................................................. 26-2-2
Cooling system coolant flow ........................................................................................................... 26-2-4
Description ...................................................................................................................................... 26-2-6
Operation ........................................................................................................................................ 26-2-10
ADJUSTMENTS
Drain and refill................................................................................................................................. 26-2-13
REPAIRS
Fan - viscous .................................................................................................................................. 26-2-15
Radiator ......................................................................................................................................... 26-2-15
Thermostat...................................................................................................................................... 26-2-18
Gasket - coolant pump .................................................................................................................. 26-2-19
MANIFOLDS AND EXHAUST SYSTEMS - V8......................................... 30-2-1
DESCRIPTION AND OPERATION
Exhaust manifold component layout ............................................................................................... 30-2-1
Inlet manifold component layout ..................................................................................................... 30-2-2
Exhaust system component layout ................................................................................................. 30-2-4
Description ...................................................................................................................................... 30-2-5
REPAIRS
Front pipe........................................................................................................................................ 30-2-7
Intermediate pipe/silencer .............................................................................................................. 30-2-8
Tail pipe .......................................................................................................................................... 30-2-9
Heat shield - brake servo - Without Secondary Air Injection .......................................................... 30-2-9
Heat shield - brake servo - With Secondary Air Injection .............................................................. 30-2-10
Gasket - inlet manifold - lower ........................................................................................................ 30-2-10
Gasket - exhaust manifold ........................................................................................................... 30-2-14
Gasket - inlet manifold - upper - Without Secondary Air Injection .................................................. 30-2-15
Gasket - inlet manifold - upper - With Secondary Air Injection ..................................................... 30-2-18
Page 26 of 1529
CONTENTS
CONTENTS 23
BODY SEALING MATERIALS ................................................................. 77-3-1
MATERIALS AND APPLICATIONS
Materials applications ..................................................................................................................... 77-3-1
Approved materials ......................................................................................................................... 77-3-2
Application equipment..................................................................................................................... 77-3-4
CORROSION PREVENTION AND SEALING .......................................... 77-4-1
CORROSION PREVENTION
Cavity wax treatment areas and injection holes - 'A' post and sill ................................................... 77-4-1
Cavity wax treatment area and injection hole - fuel filler neck ........................................................ 77-4-2
Cavity wax treatment areas and injection holes - rear cross member ............................................ 77-4-3
Cavity wax treatment areas and injection holes - front door, rear door and tail door ...................... 77-4-4
Corrosion prevention....................................................................................................................... 77-4-6
SEALING
Body Sealing ................................................................................................................................... 77-4-9
Water leaks ..................................................................................................................................... 77-4-22
PAINTING ................................................................................................ 77-5-1
PROCEDURES
Panel preparation............................................................................................................................ 77-5-1
Paint preparation............................................................................................................................. 77-5-2
HEATING AND VENTILATION................................................................. 80-1
DESCRIPTION AND OPERATION
Heating and ventilation component layout ...................................................................................... 80-1
Fuel burning heater component layout ........................................................................................... 80-2
Description ...................................................................................................................................... 80-3
Operation ........................................................................................................................................ 80-13
REPAIRS
Heater control and fan switch ....................................................................................................... 80-15
Cables - heater control .................................................................................................................. 80-15
Servo - recirculation flap ............................................................................................................... 80-17
Switch - recirculation control ......................................................................................................... 80-18
Servo - air distribution control ........................................................................................................ 80-19
Servo - air temperature control ....................................................................................................... 80-20
Plenum Air Intake ........................................................................................................................... 80-21
Heater assembly - models without air conditioning ......................................................................... 80-22
Heater assembly - models with air conditioning .............................................................................. 80-24
Blower assembly ............................................................................................................................ 80-26
Motor - blower ............................................................................................................................. 80-27
Resistor pack - power resistor A/C ............................................................................................... 80-28
Heater matrix ................................................................................................................................ 80-29
Pipe - Heater - Feed ...................................................................................................................... 80-29
Pipe - Heater - Return .................................................................................................................... 80-30
Fuel burning heater - (FBH) - Td5................................................................................................... 80-31
Page 34 of 1529
INTRODUCTION
01-3
Abbreviations and Symbols
A Amperes
AAP Ambient Air Pressure
ABDC After Bottom Dead Centre
ABS Anti-Lock Brake System
ac Alternating current
A/C Air Conditioning
ACE Active Cornering Enhancement
ACEA Association of Constructors of
European Automobiles
AFR Air Fuel Ratio
AP Ambient Pressure
ASC Anti-shunt Control
ATC Air Temperature Control
ATDC After Top Dead Centre
BBDC Before Bottom Dead Centre
BBUS Battery Backed Up Sounder
BCU Body Control Unit
BDC Bottom Dead Centre
bhp Brake Horse Power
BP Boost Pressure
BPP Brake Pedal Position
BS British Standard
BTDC Before Top Dead Centre
C Celsius
CAN Controller Area Network
CD Compact Disc
CDC Centre Differential Control
CDL Central Door Locking
CD - ROM Compact Disc - Read Only
Memory
CFC Chlorofluorocarbon
CHMSL Centre High Mounted Stop Lamp
CKP Crankshaft Position
CLV Calculated Load Value
cm Centimetre
cm
2Square centimetre
cm3Cubic centimetre
CMP Camshaft Position
CPP Clutch Pedal Position
CO Carbon Monoxide
CO
2Carbon Dioxide
CR Common Rail
CVS Canister Vent Solenoid
deg. Degree, angle or temperature
dia. Diameter
DIN Deutsche Industrie Normen
(German Industrial Standards)
dc Direct current
DCV Directional Control Valve
DOHC Double Overhead Camshaft
DTI Dial Test Indicator
DFM Dual Mass Flywheel
DVD Digital Versatile Disc
EACV Electronic Air Control Valve EAT Electronic Automatic
Transmission
EBD Electronic Brake pressure
Distribution
ECD European Community Directive
ECM Engine Control Module
ECT Engine Coolant Temperature
ECU Electronic Control Unit
EDC Electronic Diesel Control
EEPROM Electronic Erasable
Programmable Read Only
Memory
EGR Exhaust Gas Recirculation
EKA Emergency Key Access
EN European Norm
EOBD European On Board Diagnostics
ETC Electronic Traction Control
EUI Electronic Unit Injector
EVAP Evaporative Emission
EVR Electronic Vacuum Regulator
F Fahrenheit
FBH Fuel Burning Heater
FIP Fuel Injection Pump
FTC Fast Throttle Control
g Gramme or Gravity
hHour
hc High compression
HC Hydro Carbons
HDC Hill Descent Control
HDPE High Density Polyethylene
HFS Heated Front Screen
Hg Mercury
HO2S Heated Oxygen Sensor
HMW High Molecular Weight
HRW Heated Rear Window
ht/HT High tension
IACV Idle Air Control Valve
IAT Intake Air Temperature
ICE In-Car Entertainment
i.dia. Internal diameter
IDM Intelligent Driver Module
in3Cubic inch
ILT Inlet Throttle
ISO International Organisation for
Standardisation
k Thousand
kg Kilogramme
km Kilometre
km/h Kilometres per hour
kPa KiloPascal
KS Knock Sensor
lLitre
lbf.in Pounds force inches
lbf/in
2Pounds per square inch
lbf.ft Pounds force feet
Page 36 of 1529
GENERAL INFORMATION
03-1
GENERAL INFORMATION
General Precautions
Dangerous substances
Modern vehicles contain many materials and liquids
which if not handled with care can be hazardous to
both personal health and the environment.
WARNING: Many liquids and other substances
used in motor vehicles are poisonous and should
under no circumstances be consumed and
should, as far as possible, be kept from contact
with the skin. These liquids and substances
include acid, anti-freeze, asbestos, brake fluid,
fuel, windscreen washer additives, lubricants,
refrigerants and various adhesives.
Always read carefully the instructions printed on
labels or stamped on components and obey them
implicitly. Such instructions are included for
reasons of your health and personal safety.
Never disregard them.
Synthetic rubber
Many 'O' rings, seals, hoses, flexible pipes and other
similar items which appear to be natural rubber, are
in fact, made of synthetic materials called
Fluoroelastomers. Under normal operating
conditions this material is safe and does not present
a health hazard. However, if the material is damaged
by fire or excessive heating, it can break down and
produce highly corrosive Hydrofluoric acid.
Contact with Hydrofluoric acid can cause serious
burns on contact with skin. If skin contact does occur:
lRemove any contaminated clothing
immediately.
lIrrigate effected area of skin with a copious
amount of cold water or limewater for 15 to 60
minutes.
lObtain medical assistance immediately.
Should any material be in a burnt or overheated
condition, handle with extreme caution and wear
protective clothing (seamless industrial gloves,
protective apron etc.).
Decontaminate and dispose of gloves immediately
after use.Lubricating oils
Avoid excessive skin contact with used lubricating
oils and always adhere to the health protection
precautions.
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.
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Health protection precautions
The following precautions should be observed at all
times.
lWear protective clothing, including impervious
gloves where practicable.
lAvoid prolonged and repeated contact with oils,
particularly used engine oils.
lDo not put oily rags in pockets.
lAvoid contaminating clothes (particularly those
next to the skin) with oil.
lOveralls must be cleaned regularly. Discard
heavily soiled clothing and oil impregnated
footwear.
lFirst aid treatment should be obtained
immediately for open cuts and wounds.
lApply barrier creams before each work period to
help prevent lubricating oil from contaminating
the skin.
lWash with soap and water to ensure all oil is
removed (proprietary skin cleansers and nail
brushes will help).
lUse moisturisers after cleaning; preparations
containing lanolin help replace the skin's natural
oils which have been removed.
lDo not use petrol/gasoline, kerosene, diesel
fuel, oil, thinners or solvents for cleaning skin.
lWhere practicable, degrease components prior
to handling.
lIf skin disorders develop, obtain medical advice
without delay.
lWear eye protection (e.g. goggles or face
shield) if there is a risk of eye contamination.
Eye wash facilities should be provided in close
vicinity of the work area.