1999 LAND ROVER DISCOVERY Workshop Manual

GENERAL DATA
04-10
Cooling system - V8
Type Pressurised, spill return, thermostatically controlled water and
antifreeze mixture. Vertical flow radiator with remote header tank and
pump assisted
Cooling fans 9 blade axial flow on viscous coupling and 11 blade axial flow electric
Electric cooling fan switching points:
For A/C system:
⇒ On When vehicle speed is 50 mph (80 km/h) or less and ambient
temperature is 28 °C (82 °F) or more
⇒ Off When vehicle speed increases to (62.5 mph (100 km/h) or ambient
temperature decreases to 25 °C (77 °F)
For engine cooling during normal running:
⇒ On 100 °C (212 °F)
⇒ Off 94.5 °C (202 °F)
For engine cooling at ignition off (to counteract heat
soak):
⇒ On If, within 10 seconds of ignition off, intake air temperature is 60 °C (140
°F) or more and engine coolant temperature is 110 °C (230 °F) or more
⇒ Off After 10 minutes or if engine coolant temperature decreases to 100 °C
(212 °F)
Coolant pump Centrifugal impeller, belt driven from crankshaft
Coolant pump drive ratio 1.293 : 1
Coolant pump output at 1000 rev/min 10 litres/min (2.64 US galls/min) at 0.7 bar (10 lbf.in
2)
Thermostat Waxstat with pressure relief valve
Thermostat operating temperature:
⇒ Initial opening 82 °C (179 °F)
⇒ Fully open 96 °C (204 °F)
Expansion tank cap relief valve - system operating
pressure1.4 bar (20 lbf.in
2)

GENERAL DATA
04-11
Clutch - Td5
Type Diaphragm spring, hydraulically operated with self-centering,
preloaded release bearing
Drive plate diameter 267 mm (10.5118 in)
Pressure plate diameter 267 mm (10.5118 in)
Clutch plate friction material Verto F202
Diaphragm finger height when clamped on a 8.5 mm
(0.33 in) thick gauge plate42.5 to 48.5 mm (1.673 to 1.904 in)
Diaphragm finger clearance (service limit) 1.00 mm (0.040 in)
Clutch plate thickness under 6500 N (1461 lb) axial
load:
⇒ New 8.2 to 8.8 mm (0.33 to 0.34 in)
⇒ Service limit 7.0 mm (0.27 in)

GENERAL DATA
04-12
Clutch - V8
Type Diaphragm spring, hydraulically operated with self-centering,
preloaded release bearing
Clutch plate friction material APTEC 385
Drive plate diameter 267 mm (10.5118 in)
Pressure plate diameter 268 mm (10.5512 in)
Clutch plate thickness (clamped state)
⇒ New 8.4-8.9 mm (0.33-0.35 in)
⇒ Service limit 7.1 mm (0.28 in)
Rivet depth:
⇒ New 1.73 mm (0.07 in)
⇒ Service limit 0.25 mm (0.01 in)
Clutch plate runout:
⇒ New 0.5 mm (0.02 in)
⇒ Service limit 0.5 mm (0.02 in)

GENERAL DATA
04-13
Manual gearbox - R380
Type Single helical constant mesh
Gears 5 forward, 1 reverse, all synchromesh
Gear ratios: Td5 Diesel
⇒ First 3.692 : 1
⇒ Second 2.132 : 1
⇒ Third 1.397 : 1
⇒ Fourth 1.0 : 1
⇒ Fifth 0.770 : 1
⇒ Reverse 3.536 : 1
Gear ratios: V8 Petrol
⇒ First 3.321:1
⇒ Second 2.132:1
⇒ Third 1.397:1
⇒ Fourth 1.0:1
⇒ Fifth 0.732:1
⇒ Reverse 3.536:1
Baulk ring clearance:
⇒ New 0.500 mm (0.0197 in)
⇒ Service limit 0.500 mm (0.0197 in)
⇒ Selector fork pad widths - minimum 6.5 mm (0.255 in)
First gear end float:
⇒ New 0.050 - 0.200 mm (0.0020 - 0.0079 in)
⇒ Service limit 0.327 mm (0.0129 in)
Second gear end float:
⇒ New 0.040 - 0.210 mm (0.0016 - 0.0083 in)
⇒ Service limit 0.337 mm (0.0133 in)
Third gear end float:
⇒ New 0.110 - 0.210 mm (0.0043 - 0.0083 in)
⇒ Service limit 0.337 mm (0.0133 in)
Adjust fifth / reverse hub - shim to
⇒ New 0.005 - 0.055 mm (0.0002 - 0.0022 in)
⇒ Service limit 0.055 mm (0.0022 in)
Reverse gear idler shaft clearance
⇒ New 0.040 - 0.380 mm (0.0016 - 0.0150 in)
⇒ Service limit 0.380 mm (0.0150 in)
Mainshaft end float:
⇒ New 0.000 - 0.050 mm (0.0000 - 0.0020 in)
⇒ Service limit 0.000 - 0.050 mm (0.0000 - 0.0020 in)
Layshaft end float:
⇒ New 0.000 - 0.050 mm (0.0000 - 0.0020 in)
⇒ Service limit 0.000 - 0.050 mm (0.0000 - 0.0020 in)

GENERAL DATA
04-14
Transfer box - LT230SE
Type LT230SE, two speed reduction with front and rear drives
Reduction ratios:
⇒ High range 1.211 : 1
⇒ Low range 3.32 : 1
Low range gear to high/low range hub clearance 0.05 to 0.15 mm (0.002 to 0.006 in)
High range gear to high/low range hub clearance 0.05 to 0.15 mm (0.002 to 0.006 in)
Mainshaft input gear bearing pre-load 0.05 mm (0.002 in)
Intermediate gear bearing pre-load Torque intermediate shaft nut to 88 Nm (65 lbf.ft)

GENERAL DATA
04-15
Automatic gearbox - ZF4HP22/24
Type ZF4HP22, electro-hydraulic shift control with fluid torque converter
Gears 4 forward, 1 reverse
Gear ratios:
⇒ First 2.480:1
⇒ Second 1.480:1
⇒ Third 1.000:1
⇒ Fourth 0.728:1
⇒ Reverse 2.086:1
Torque converter lock-up Engaged in third and fourth gears above 72 km/h (45 mph)
Input shaft axial end-float 0.2 to 0.4 mm (0.008 to 0.016 in)

GENERAL DATA
04-16
Rear axle
Front axle
Type Solid axle casing incorporating a spiral bevel differential and drive
shafts
Reduction ratio 3.538:1
Type Solid axle casing incorporating spiral bevel differential and drive shafts
with constant velocity joints.
Reduction ratio 3.538:1

GENERAL DATA
04-17
Steering
Note: Measurements taken at EEC kerb weight.
Type Hydraulically assisted worm and roller
Steering wheel turns lock to lock 3.5
Steering wheel diameter 400 mm (15.7 in)
Turning circle, kerb to kerb 11.9 metres (39.1 feet)
PAS pump Hobourn Automotive Ltd. Series 500, belt driven
PAS pump pressure - engine at idle with steering at full lock 21 to 62 bar (305 to 900 lbf/in
2
Delivery pressure (nominal) 100 bar (1450 lbf.in2) 8.5 litres/min (15.1 pints/min)
(18.1 US pints/min)
Steering geometry:
⇒ Camber angle - Front, up to VIN 2A 754807 - unladen condition
⇒ Camber angle - Front, from VIN 2A 754808 - unladen condition
⇒ Camber angle - Rear - unladen condition–10' ± 30'
+20' ± 30'
–10' ± 30'
⇒ Cross camber - Front and rear 45' (Maximum)
⇒ Castor angle - unladen condition 3° 45' ± 45'
⇒ Cross castor 1° (Maximum)
⇒ Toe out - Front
⇒ Toe in - Rear– 0° 10' ± 0° 10' (total)
+ 0° 5' ± 0° 15' (total)
⇒ Thrust angle 0° ± 20'
⇒ Swivel pin inclination 13° 11'