1999 LAND ROVER DISCOVERY height

MAINTENANCE
10-4 PROCEDURES
5. Check security of seat belt upper mountings.
6. Check for correct operation of seat belt height
adjusters.
7.Check security of seat belt buckle mountings.
8.Connect each belt to the correct buckle, check
seat buckle and tongue are secure. Release
seat belt buckle and check for correct
operation.9.Check tightness of accessible seat belt fixings.
10.Check tightness of accessible seat belt
mountings.

MAINTENANCE
PROCEDURES 10-27
Steering rod ball joints
Check
1.Check condition of ball joints and dust covers,
and security of fixings.

+ TORQUE WRENCH SETTINGS,
Steering.
2.Attempt to move the ball joints forwards,
backwards, side to side and up and down. No
end float in any direction should be detected. If
end float is present, the ball joint must be
renewed.
Dampers and SLS height sensors
Check – Dampers
Front dampers
Rear dampers
1.Check dampers for security and signs of
leakage.

MAINTENANCE
10-28 PROCEDURES
Check – Height sensors
SLS height sensors
1.Check height sensors for condition and
security.
2.Check electrical harness for chafing and
damage.
Front and rear axle suspension links
Check
Rear suspension
Front suspension
1.Check condition of front and rear axle
suspension link mounting rubbers.
2.Check security of fixings.

+ TORQUE WRENCH SETTINGS,
Front suspension.

+ TORQUE WRENCH SETTINGS, Rear
suspension.

ENGINE - V8
12-2-62 OVERHAUL
10.Remove cylinder head gasket.
CAUTION: Support both ends of cylinder
head on blocks of wood.
Inspect
1.Clean mating faces of cylinder block and head
using suitable gasket removal spray and a
plastic scraper, ensure that bolt holes in block
are clean and dry.
CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.
2.Check head and block faces for warping and
pitting.
lMaximum cylinder head warp = 0.05 mm
(0.002 in).
Note: Cylinder head can be refaced to 0.50
mm (0.02 in) maximum below head height –
See cylinder head overhaul.
3. Models with SAI: Using a 5/8 in x 20 TPI (
threads per inch) UNF tap having a class 2A
thread, remove deposits from secondary air
injection adapter tappings in cylinder head.
CAUTION: Ensure that tap used has 20 TPI.Reassembly
1.Ensure that cylinder head bolt holes are clean
and dry.
2.Fit cylinder head gasket with the word TOP
uppermost.
CAUTION: Gaskets must be fitted dry.
3.Carefully fit cylinder head and locate on
dowels.
4.Lightly lubricate new cylinder head bolt threads
with clean engine oil.
5.Noting that bolts 1, 3 and 5 are longer than the
remainder, fit bolts and tighten in the sequence
shown to 20 Nm (15 lbf.ft) then turn through 90
°, then a further 90 °. CAUTION: Do not
tighten bolts 180° in one operation.
6. Models with SAI: Fit new air injection adapters
and using a 9 mm hexagonal drive bit, tighten
to 33 Nm (24 lbf.ft).
CAUTION: Do not use an air tool to tighten
adapters.
7.Clean the push rods, Lubricate ends of push
rods with clean engine oil, and fit in their
removed order.
8.Clean bases of rocker pillars and mating faces
on cylinder head.
9.Clean contact surfaces on rockers, valves and
push rods.
10.Lubricate contact surfaces and rocker shaft
with clean engine oil.
11.Fit rocker shaft assembly and engage push
rods.
12.Fit rocker shaft bolts and progressively tighten
to 40 Nm (30 lbf.ft).
13.Connect ht leads to spark plugs in their correct
fitted order.
14. RH cylinder head: Position alternator
mounting bracket, fit bolts and tighten to 40 Nm
(30 lbf.ft).
15. RH cylinder head: Fit auxiliary drive belt
tensioner.
16.Fit inlet manifold gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
inlet manifold.

ENGINE - V8
OVERHAUL 12-2-63
Cylinder head - overhaul
$% 12.29.19.01
Disassembly
1.Remove cylinder head gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
cylinder head.
2.Loosen screw on tool LRT-12-034.
3.Fit tool LRT-12-034 to valve and tighten screw
to compress valve spring sufficiently to release
collets from valve spring cap.
4.Remove 2 collets and release valve spring
compressor.
5.Remove valve spring cap and valve spring.
6.Remove valve from cylinder head.
7.Remove and discard valve stem oil seal.
8.Repeat above operations for remaining valves.
9.Keep valves, springs, caps and collets in their
fitted order. Inspect
1.Clean mating faces of cylinder block and head
using suitable gasket removal spray and a
plastic scraper, ensure that bolt holes in block
are clean and dry.
CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.
2.Clean cylinder head, valve springs, valves and
inlet valve guide bores. Ensure all loose
particles of carbon are removed on completion.
3. Models with SAI: Using a 5/8 in x 20 TPI (
threads per inch) UNF tap having a class 2A
thread, remove deposits from secondary air
injection adapter tappings in cylinder head.
CAUTION: Ensure that tap used has 20 TPI.
4.Check head and block faces for warping and
pitting. Maximum warp = 0.05 mm (0.002 in).
5.Check cylinder head height at each end of
head. Renew a head which is outside limits.
a22.94 mm (0.903 in) - New
b62.56 mm (2.463 in) - New

ENGINE - V8
12-2-64 OVERHAUL
6.Cylinder head can be refaced to 0.50 mm (0.02
in) max. below head height.
7.Remove carbon deposits from exhaust valve
guide using a 8.70 mm (0.34 in) diameter
reamer inserted from combustion face side of
cylinder head.
NOTE: Modified inlet valves, exhaust valves
and valve guides were fitted to 4.0 litre engines
from the following engine numbers: 55D
05678A; 56D 50788A and 97D 05505A and are
fitted to all 4.6 litre engines.
8.Modified inlet valves may be identified by
measuring the distance 'A' from the valve head
face to the top of the undercut on the valve
stem:
lEarly valves = 29.5 to 30.5 mm (1.16 to 1.20
in)
lLater valves = 32.5 to 33.5 mm (1.28 to 1.32
in)9.Modified exhaust valves may be identified as
follows:
lEarly valves 'A' – Chrome finish
lLater valves 'B' – Black nitrided finish
10.Modified valve guides are 5 mm (0.211 in)
shorter than the early type, the overall length is
now 57 mm (2.24 in); the reduction in length
being the distance the guide protrudes into the
combustion chamber side of the cylinder head.
NOTE: The modified valves and guides may be
fitted to 4.0 litre engines prior to the above
numbers in cylinder sets. Early type valves will
continue to be supplied for early 4.0 litre
engines but if valve guides are found to be
worn, the later valves and guides must be fitted.

ENGINE - V8
OVERHAUL 12-2-65
11.Check the following valve dimensions. Renew
valves as necessary.
lValve head diameter 'A': Inlet = 39.75 to
40.00 mm (1.56 to 1.57 in).
lValve head diameter 'A': Exhaust = 34.23 to
34.48 mm (1.35 to 1.36 in).
lValve stem diameter 'B': Inlet = 8.664 to
8.679 mm (0.341 to 0.342 in).
lValve stem diameter 'B': Exhaust – 4.0 litre
engines up to engine nos. 55D 05677A; 56D
50787A and 97D 05504A = 8.651 to 8.666
mm (0.340 to 0.341 in).
lValve stem diameter 'B': Exhaust – 4.0 litre
engines from engine nos. 55D 05678A; 56D
50788A and 97D 05505A and all 4.6 litre
engines = 8.641 to 8.656 mm (0.340 to
0.341 in)
12.Check installed height of valve.
lValve installed height, end of valve to base
of spring seat, 'C' = 44.163 to 45.288 mm
(1.741 to 1.802 in).
13.Check condition of valve springs. Valve
springs must be replaced as a complete
set.
lValve spring free length = 48.30 mm (1.90
in).
lValve spring fitted length = 40.40 mm (1.59
in).
l Spring load - valve closed = 339 ± 10 N (76
± 2.25 lbf).
lSpring load - valve open = 736 ± 10 N (166
± 2.25 lbf).
14.Check valve stem to guide clearance using the
following procedures:
15.Insert each valve into its respective guide.
16.Extend valve head approximately 13 mm (0.6
in) out of valve seat and position a DTI gauge
to rear of valve head.
17.Move valve towards front of cylinder head and
zero DTI gauge ensuring that stylus of gauge
remains in contact with valve head.
18.Move valve towards rear of cylinder head and
record gauge reading to give valve stem to
guide clearance.
l Valve stem to guide clearance 'D': Inlet =
0.025 to 0.066 mm (0.001 to 0.002 in).
l Valve stem to guide clearance 'D': Exhaust
– 4.0 litre engines up to engine nos. 55D
05677A; 56D 50787A; 97D 05504A = 0.038
to 0.078 mm (0.0015 to 0.003 in).
lValve stem to guide clearance 'D': Exhaust
– 4.0 litre engines from engine nos. 55D
05678A; 56D 50788A; 97D 05505A and all
4.6 litre engines = 0.048 to 0.088 mm
(0.0019 to 0.0035 in).
19.Renew valve guides as necessary. 20.Using valve guide remover tool LRT-12-037
press valve guide into combustion face side of
cylinder head.
21.Lubricate new valve guide with engine oil and
with tapered portion of guide leading, insert
guide from valve spring side of head.
Note: Service valve guides are 0.025 mm
(0.001 in) oversize on outside diameter to
ensure an interference fit.
22.Fully fit guide using tool LRT-12-039A and
distance piece tool LRT-12-208
lValve guide installed height 'A' = 15.00 mm
(0.590 in).
23.Ream valve guide to 8.70 mm (0.342 in).
Note: Service valve guides are supplied with an
internal diameter of 8.1 mm 0.025 mm (0.319 in).
24.Position cylinder head stands and mount
cylinder head on stands.
25.Check valve seat insert for pitting, burning,
cracks and wear. Replace as necessary.
Service valve seat inserts are available 0.025
mm (0.001 in) oversize on outside diameter to
ensure interference fit.

ENGINE - V8
12-2-66 OVERHAUL
26.Remove worn valve seat.
CAUTION: Take care not to damage the
counterbore in the cylinder head when
removing valve seats.
27.Heat cylinder head evenly to approximately
120° C (250°F).
WARNING: Handle the hot cylinder head
with care.
28.Using a suitable mandrel, press new insert fully
into counterbore.
29.Allow cylinder head to air cool.
CAUTION: Renew worn valve guides and/or
valve seats before lapping the valves.
30.Recut valve seat in head and lap in valves
using fine paste.
31.Coat valve with a small quantity of engineer's
blue, insert valve and press into position
several times without rotating. Seating position
should be in centre of valve face. 32.Check valve installed height if valve seats have
been refaced or renewed.
lValve installed height, end of valve to base
of spring seat, 'A' = 44.16 to 45.29 mm (1.74
to 1.80 in).
33.Reface valves as necessary. If a valve has to
be ground to a knife-edge to obtain a true seat,
renew valve.
34.Cut valve seats using suitable cutters:
lValve seat angle 'A' = 45°.
lValve seat insert diameter 'B' Inlet = 36.83
mm (1.45 in).
lValve seat insert diameter 'B' Exhaust =
31.50 mm (1.24 in).
lSeating width 'C' - Inlet = 0.89 to 1.4 mm
(0.035 to 0.055 in).
lSeating width 'C' - Exhaust = 1.32 to 1.83
mm (0.052 to 0.072 in).
lAngle 'D' = 70° .
lAngle 'E' = 46° to 46° 25'.
lAngle 'F' = 20° .