1999 LAND ROVER DISCOVERY suspension

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

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
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

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

CONTENTS
CONTENTS 15
FRONT SUSPENSION.............................................................................. 60-1
DESCRIPTION AND OPERATION
Front suspension component layout (ACE torsion bar shown) ....................................................... 60-1
Front suspension components (ACE torsion bar shown) ................................................................ 60-2
Description ...................................................................................................................................... 60-4
DESCRIPTION AND OPERATION
ACE system component layout ....................................................................................................... 60-7
ACE system control diagram .......................................................................................................... 60-8
Description - ACE ........................................................................................................................... 60-9
Operation ........................................................................................................................................ 60-22
ADJUSTMENTS
ACE hydraulic system bleeding ..................................................................................................... 60-25
Fluid level check - ACE system ...................................................................................................... 60-25
REPAIRS
Bushes - Panhard rod ................................................................................................................... 60-27
Ball joint - upper - steering knuckle ............................................................................................... 60-28
Ball joint - lower - steering knuckle ................................................................................................. 60-29
Steering knuckle ........................................................................................................................... 60-30
Road spring - front ........................................................................................................................ 60-32
Wheel hub ....................................................................................................................................... 60-33
Damper - front ............................................................................................................................... 60-35
Bushes - radius arm ...................................................................................................................... 60-37
ECU - ACE ..................................................................................................................................... 60-39
Accelerometer - ACE - upper ........................................................................................................ 60-40
Accelerometer - ACE - lower ........................................................................................................ 60-40
Pump - ACE - V8 ............................................................................................................................ 60-41
Pump - ACE - diesel ....................................................................................................................... 60-42
Valve block - ACE ......................................................................................................................... 60-44
Filter - high pressure - ACE .......................................................................................................... 60-47
Pressure transducer - ACE ........................................................................................................... 60-48
Solenoid - pressure control valve - ACE ....................................................................................... 60-49
Solenoid - directional control valve - ACE ..................................................................................... 60-49
Pipe assembly - valve block to front actuator - ACE ...................................................................... 60-50
Pipe assembly - pump or reservoir to valve block - ACE - V8 ....................................................... 60-52
Pipe assembly - pump or reservoir to valve block - ACE - diesel .................................................. 60-55
Pipe assembly - valve block to rear actuator - ACE ........................................................................ 60-59
Actuator - front - ACE .................................................................................................................... 60-61
Bushes - front long arm - ACE ........................................................................................................ 60-63

CONTENTS
16 CONTENTS
REAR SUSPENSION ................................................................................ 64-1
DESCRIPTION AND OPERATION
Rear suspension component layout (vehicles with SLS) ............................................................... 64-2
Rear suspension component layout (vehicles without SLS) .......................................................... 64-3
Rear suspension components ........................................................................................................ 64-4
Description ...................................................................................................................................... 64-6
DESCRIPTION AND OPERATION
SLS component layout.................................................................................................................... 64-9
SLS system control diagram ........................................................................................................... 64-10
Description - SLS ............................................................................................................................ 64-12
Operation ........................................................................................................................................ 64-21
ADJUSTMENTS
SLS calibration blocks .................................................................................................................... 64-25
REPAIRS
Wheel hub....................................................................................................................................... 64-27
Road spring - rear ........................................................................................................................... 64-29
Air spring - SLS............................................................................................................................... 64-30
Damper - rear ............................................................................................................................... 64-31
Bushes - radius arm ....................................................................................................................... 64-31
Bushes - Watts linkage ................................................................................................................. 64-34
Sensor - height - SLS ..................................................................................................................... 64-35
Compressor unit - air - SLS ............................................................................................................ 64-35
Filter - intake - SLS ......................................................................................................................... 64-37
Switch - ride height ......................................................................................................................... 64-37
Air valve - SLS ................................................................................................................................ 64-38
Actuator - rear - ACE ...................................................................................................................... 64-39
Bushes - rear long arm - ACE......................................................................................................... 64-41

INTRODUCTION
01-1
INTRODUCTION
How To Use This Manual
Introduction
This Manual is designed to assist skilled technicians
in the efficient repair and maintenance of Discovery
vehicles.
Individuals who undertake their own repairs should
have some skill and training, and limit repairs to
components which could not affect the safety of the
vehicle or its passengers. Any repairs required to
safety critical items such as steering, brakes,
suspension or supplementary restraint system
should be carried out by a Land Rover Dealer.
Repairs to such items should NEVER be attempted
by untrained individuals.
General
To assist in the use of this Manual, it is divided into
sections and sub-sections. The section title is given
at the top of each page and the relevant sub-section
is given at the bottom.
There is a single contents section at the front of the
Manual, which is divided by section and sub-section.
Each section is numbered from page 1.
The individual items comprising repair operations are
to be followed in the sequence in which they appear.
Items numbers in the illustration are referred to in the
text.
Adjustment and Repair operations include reference
to Service tool numbers and the associated
illustration depicts the tool in use. Adjustment and
repair operations also include reference to wear
limits, relevant data, torque figures, and specialist
information and useful assembly details. Each
adjustment or repair operation is given its Service
Repair Operation number.
WARNINGS, CAUTIONS and NOTES have the
following meanings:
WARNING: Procedures which must be followed
precisely to avoid the possibility of injury.
CAUTION: Calls attention to procedures which
must be followed to avoid damage to
components.
NOTE: Gives helpful information.References
References to the LH or RH side given in this Manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
crankshaft pulley end of the engine is referred to as
the front.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and tested after
completion and if necessary a road test of the vehicle
is carried out particularly where safety related items
are concerned.
Dimensions
The dimensions quoted are to design engineering
specification with Service limits where applicable.

INTRODUCTION
01-4
λLambda
lc Low compression
LCD Liquid Crystal Display
LED Light Emitting Diode
LH Left-Hand
LHD Left-Hand Drive
LVS Liquid Vapour Separator
mMetre
µMicro
MAF Mass Air Flow
MAP Manifold Absolute Pressure
MFU Multi-Function Unit
MFL Multi-Function Logic
max. Maximum
MEMS Modular Engine Management
System
MIL Malfunction Indicator Lamp
min. Minimum
MPa MegaPascal
- Minus (tolerance)
' Minute (angle)
mm Millimetre
mph Miles per hour
MPi Multi-Point injection
MY Model Year
NAS North American Specification
(-) Negative (electrical)
Nm Newton metre
No. Number
NO
2Nitrogen Dioxide
NO
xOxides of Nitrogen
NTC Negative Temperature
Coefficient
OBD On Board Diagnostics
o.dia. Outside diameter
ORM Off-road Mode
ΩOhm
PAS Power Assisted Steering
PCV Positive Crankcase Ventilation
PDC Parking Distance Control
% Percentage
+ Plus (tolerance) or Positive
(electrical)
±Plus or minus (tolerance)
PTC Positive Temperature Coefficient
PTFE Polytetrafluorethylene
PWM Pulse Width Modulation
rRadius
:Ratio
ref Reference
RES Rover Engineering Standards
rev/min Revolutions per minute
RF Radio Frequency
RH Right-Hand
RHD Right-Hand Drive
ROM Read Only Memory
RON Research Octane Number
ROV Roll Over ValveROW Rest Of World
SAE Society of Automotive Engineers
" Second (angle)
SLABS Self Levelling and Anti-Lock
Brake System
SLS Self Levelling Suspension
SOHC Single Overhead Camshaft
sp.gr Specific gravity
SRS Supplementary Restraint System
std. Standard
synchro Synchronizer or synchromesh
TDC Top Dead Centre
TMAP Temperature, Manifold Absolute
Pressure
TP Throttle Position
TPS Throttle Position Sensor
TV Torsional Vibration
TXV Thermostatic Expansion Valve
UK United Kingdom
US United States
V Volt
Var. Variable
VIN Vehicle Identification Number
VIS Variable Intake System
VRS Variable Reluctance Sensor
VSS Vehicle Speed Signal
WWatt