1999 LAND ROVER DISCOVERY warning

STEERING
57-30 REPAIRS
Power steering box - LHD - diesel
$% 57.10.01
Remove
1.Remove battery cover.
2.Disconnect battery earth lead.
3.Drain cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
4.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
5.Remove LH front road wheel.
6.Ensure steering wheel is centralised, remove
key from steering lock and engage column lock.
7.Fit centralising bolt to steering box.
8.Loosen 2 clips securing intercooler to turbo
hose. Remove hose.9.Remove 3 bolts securing intermediate shaft
and universal joint.
10.Push intermediate shaft upwards, release and
remove universal joint.
CAUTION: Do not turn the steering wheel
with the intermediate shaft or universal joint
disconnected as damage to the rotary
coupler and the steering wheel switches
may occur.
11.Position container below PAS pipes to catch
fluid spillage.

STEERING
57-34 REPAIRS
Steering box - RHD - diesel
$% 57.10.01
Remove
1.Remove battery cover.
2.Disconnect battery earth lead.
3.Drain cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
4.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
5.Remove RH front road wheel.
6.Ensure steering wheel is centralised, remove
key from steering lock and engage column lock.
7.Fit centralising bolt to steering box.
8.Remove 3 bolts securing intermediate shaft
and universal joint.
9.Push intermediate shaft upwards, release and
remove universal joint.
CAUTION: Do not turn the steering wheel
with the intermediate shaft or universal joint
disconnected as damage to the rotary
coupler and the steering wheel switches
may occur.
10.Position container below PAS pipes to catch
fluid spillage.

STEERING
57-48 REPAIRS
Ball joint - track rod
$% 57.55.07
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove LH front road wheel.
3.Loosen adjuster clamp bolts.
4.Remove nut securing track rod ball joint to
steering knuckle.
5.Using tool LRT-57-036 break taper joint and
release track rod.
CAUTION: Before disconnecting any part of
the steering linkage, ensure the road wheels
are positioned straight ahead and the
steering wheel is prevented from turning.
Unrestricted turning of the steering wheel
will damage the SRS rotary coupler.
6.Unscrew ball joint and adjuster.
7.Remove clamps from adjuster and track rod. Refit
1.Clean adjuster, clamps and track rod.
2.Fit clamps to track rod and adjuster. Screw in
adjuster and ball joint.
3.Clean ball joint taper and taper seat.
4.Adjust length of track rod so that ball joint taper
is centralised in steering knuckle.
5.Fit track rod to steering knuckle and tighten nut
to 80 Nm (59 lbf.in).
6.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
7.Remove stand(s) and lower vehicle.
8.Check and, if necessary, adjust wheel
alignment.

+ STEERING, ADJUSTMENTS, Wheel
alignment - front.
9.After check/adjustment of wheel alignment,
ensure track rod adjuster clamp bolts are
tightened. Tighten M8 bolts to 22 Nm (16 lbf.ft)
and M10 bolts to 33 Nm (24 lbf.ft).

STEERING
REPAIRS 57-49
Ball joint - drag link
$% 57.55.15
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2. RHD models: Remove LH front road wheel.
3. LHD models: Remove RH front road wheel.
4.Remove nut securing drag link to steering
knuckle.
5.Using LRT-57-036, break taper joint and
release drag link.
CAUTION: Before disconnecting any part of
the steering linkage, ensure the road wheels
are positioned straight ahead and the
steering wheel is prevented from turning.
Unrestricted turning of the steering wheel
will damage the SRS rotary coupler.
6.Loosen adjuster clamp bolts and unscrew ball
joint and adjuster.
7.Remove clamps from adjuster and drag link. Refit
1.Clean adjuster, clamps and drag link.
2.Fit clamps to drag link and adjuster. Screw in
adjuster and ball joint.
3.Clean ball joint taper and taper seat.
4.Adjust length of drag link so that ball joint taper
is centralised in steering knuckle.
5.Fit drag link to steering knuckle and tighten nut
to 80 Nm (59 lbf.ft).
6.Tighten drag link adjuster clamp bolts. Tighten
M8 bolts to 22 Nm (16 lbf.ft) and M10 bolts to
33 Nm (24 lbf.ft).
7.Check steering linkage is centralised.

+ STEERING, ADJUSTMENTS,
Steering linkage - centralise.
8.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
9.Remove stand(s) and lower vehicle.

STEERING
57-50 REPAIRS
Drag link
$% 57.55.17
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2. RHD vehicles: Remove the LH front road
wheel.
3. LHD vehicles: Remove the RH front road
wheel.
4.Remove nut and bolt securing damper to drag
link and release damper.
5.Remove 2 nuts securing drag link to drop arm
and steering knuckle.
6.Using LRT-57-036 break taper joints and
remove drag link.
CAUTION: Before disconnecting any part of
the steering linkage, ensure the road wheels
are positioned straight ahead and the
steering wheel is prevented from turning.
Unrestricted turning of the steering wheel
will damage the SRS rotary coupler.7.Loosen adjuster clamp bolts and remove ball
joint and adjuster.
8.Remove clamps from adjuster and drag link.
Refit
1.Clean adjuster, clamps and ball joint.
2.Fit clamps to drag link and adjuster. Screw in
adjuster and ball joint.
3.Clean ball joint tapers and taper seats.
4.Fit drag link to drop arm and tighten nut to 80
Nm (59 lbf.ft).
5.Adjust length of drag link so that ball joint taper
is centralised in steering knuckle.
6.Fit drag link to steering knuckle and tighten nut
to 80 Nm (59 lbf.ft).
7.Tighten drag link adjuster clamp bolts. Tighten
M8 bolts to 22 Nm (16 lbf.ft) and M10 bolts to
33 Nm (24 lbf.ft)
8.Align damper to drag link, fit nut and bolt and
tighten to 125 Nm (92 lbf.ft).
9.Check steering linkage is centralised.

+ STEERING, ADJUSTMENTS,
Steering linkage - centralise.
10.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
11.Remove stand(s) and lower vehicle.

STEERING
REPAIRS 57-51
Damper - steering
$% 57.55.21
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove 2 nuts and bolts securing steering
damper to drag link and chassis.
3.Compress damper and remove from vehicle.
Refit
1.Position damper to chassis and drag link. Fit
nuts and bolts and tighten to 125 Nm (92 lbf.ft).
2.Remove stand(s) and lower vehicle.

FRONT SUSPENSION
60-8 DESCRIPTION AND OPERATION
ACE system control diagram
1Upper accelerometer
2Lower accelerometer
3Pressure transducer
4Directional control valve
5Directional control valve
6Pressure control valve
7Instrument pack warning lamp
8Diagnostic socket9Reverse lamp switch
10SLABS ECU
11Engine Control Module (ECM)
12Ignition feed
13ACE relay
14Battery supply
15ACE ECU
M60 0589B
12
5
4
3
6
7
8
9
10
11
12
13
14
15

FRONT SUSPENSION
DESCRIPTION AND OPERATION 60-11
The ACE system uses a semi-synthetic hydraulic fluid which is the same as the fluid used for the PAS system. The
total capacity of the ACE system is 1.62 litres (0.42 US Gallons).
CAUTION: The ACE hydraulic system is extremely sensitive to the ingress of dirt or debris. The smallest
amount could render the system unserviceable. It is imperative that the following precautions are taken.
lACE components are thoroughly cleaned externally before work commences;
lall opened pipe and module ports are capped immediately;
lall fluid is stored in and administered through clean containers.
In the event of an ECU or hydraulic failure the system will fail safe to a 'locked bars' condition. The 'locked bars'
condition will allow the torsion bars to operate in a similar manner as conventional 'passive' anti-roll bars. Prolonged
cornering forces will allow a progressive increase in roll angle due to hydraulic leakage through the actuators and
valve block. Failures will be relayed to the driver by the illumination of the ACE warning lamp in the instrument pack.
Faults are recorded by the ECU and can be retrieved using TestBook.
When the ignition switch is moved to position II, the warning lamp will illuminate for two seconds to check functionality.
The warning lamp functionality can also be checked using TestBook.
TestBook must also be used to perform a bleeding procedure after maintenance operations have been performed to
ensure that complete system bleeding is performed. Trapped air in the system can seriously reduce the system
performance.
Fluid reservoir
The moulded plastic fluid reservoir is mounted on the left hand side of the engine compartment on a bracket which is
attached to the inner wing. The reservoir is dual purpose, being divided into two separate chambers; one for the ACE
system and one for the PAS system. Each chamber has its own filler neck and cap and is identified by moulded
lettering on the reservoir adjacent to each filler.
A non-serviceable filter assembly is fitted in the base of each chamber. The filter is made from fine stainless steel
mesh which is moulded into the body of the reservoir. The filter removes particulate matter from the fluid before it is
drawn into the hydraulic pump.
Upper and lower fluid level marks are moulded onto the reservoir body. The capacity of the ACE reservoir chamber
to the upper level mark is 0.5 litre (0.13 US Gallon).