1999 LAND ROVER DISCOVERY Workshop Manual

ENGINE - V8
12-2-30 REPAIRS
Refit
1.Clean mating faces of engine and gearbox,
dowel and dowel holes.
2.Lubricate splines and bearing surface on first
motion shaft with grease.
3.With assistance position engine in engine bay,
align to gearbox and locate on dowels.
4.Position support brackets, fit bell housing bolts
and tighten to 50 Nm (37 lbf.ft).
5.Position engine mountings, fit nuts and tighten
to 85 Nm (63 lbf.ft).
6.Lower lifting equipment and remove from
engine.
7. Models with automatic gearbox: Align torque
converter to drive plate, fit bolts and tighten to
50 Nm (37 lbf.ft). Fit access plug.
8.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
9.Position oil cooling pipe saddle clamps and
tighten bolts.
10.Position engine harness into foot well.
11.Connect 5 multiplugs to ECM.
12.Fit toe board and secure with trim fixings.
13.Connect engine harness earth to body and
secure with nut.
14.Connect engine harness to main harness
multiplug.
15.Connect multiplug to EVAP purge valve.
16.Connect engine harness multiplugs to fuse
box.
17.Connect starter lead to fuse box and secure
with nut.
18.Connect engine harness positive lead to
battery and tighten nut.
19.Fit fuse box cover.
20.Position engine earth lead and secure with
bolt.
21.Position coolant rail and secure with bolt.
22.Connect harness clips to coolant rail.
23.Connect hose to coolant rail and coolant pump
and secure with clips.
24.Connect PAS pump high and low pressure
pipes and secure with clips.
25.Position oil cooling pipe saddle clamp to PAS
pump housing and secure with bolt.
26.Clean A/C compressor and housing mating
faces, dowels and dowel holes.
27.Position A/C compressor, fit bolts and tighten
to 22 Nm (16 lbf.ft).
28.Connect multiplug to A/C compressor.
29.Clean ACE pump and housing mating faces,
dowels and dowel holes.
30.Position ACE pump, fit bolts and tighten to 22
Nm (16 lbf.ft). 31.Clean all pulley 'V's, fit auxiliary drive belt,
using a 15mm spanner, release belt tensioner
secure belt and re-tension drive belt .
32.Ensure auxiliary drive belt is correctly located
on all pulleys.
33.Fit radiator.

+ COOLING SYSTEM - V8, REPAIRS,
Radiator.
34.Fit top hose and secure with clips.
35.Connect fuel pipe to fuel rail.
36.Position ignition coils and connect ht leads.
37.Fit upper inlet manifold.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
38.Fit new oil filter and refill engine with oil.

+ ENGINE - V8, REPAIRS, Filter - oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - V8 engine.
39.Top up gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.

ENGINE - V8
REPAIRS 12-2-31
Flywheel
$% 12.53.07
Remove
1.Remove gearbox

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
2.Restrain flywheel.
3.Working in sequence, progressively slacken 6
bolts securing clutch cover to flywheel.
Remove bolts.
4.Remove clutch cover.
5.Remove clutch plate.
6.Release crankshaft sensor multiplug from
bracket.
7.Remove 2 bolts securing crankshaft sensor
cover. 8.Remove crankshaft sensor cover.
9.Remove 2 nuts securing crankshaft sensor.
10.Remove crankshaft sensor.
11.Remove 6 bolts securing flywheel.
12.Remove flywheel.
On early engines, balance weights are on
engine side of flywheel; replacement flywheels
will have balance weights on clutch side of
flywheel.
Refit
1.Clean mating faces of flywheel and crankshaft,
dowel and dowel hole. Ensure bolt holes in
crankshaft are clean and dry.
2.Fit flywheel to crankshaft and tighten bolts to
78 Nm (58 lbf.ft).
3.Clean crankshaft sensor and mating face.
4.Fit crankshaft sensor and tighten nuts to 6 Nm
(4.4 lbf.ft).
5.Fit crankshaft sensor cover and tighten bolts to
6 Nm (5 lbf.ft).
6.Fit crankshaft sensor multiplug to bracket.
7.Clean clutch cover, drive plate and spigot bush
in end of crankshaft. Renew worn components
as necessary.
8.If refitting existing drive plate, apply 'Molycote
FB 180' to splines.

ENGINE - V8
12-2-32 REPAIRS
9.Fit alignment tool LRT-12-001 to spigot
bearing in crankshaft.
10.Fit drive plate onto tool LRT-12-001 ensure
side marked 'flywheel side' is towards flywheel.
11.Fit clutch cover and locate on dowels.
12.Fit clutch cover bolts and tighten in diagonal
sequence to 40 Nm (30 lbf.ft).
13.Fit gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
Plate - drive - automatic
$% 12.53.13
Remove
Note: Later engines are fitted with a modified
starter ring gear which incorporates the reluctor
plate, spacer and hub. The modified ring gear
may be fitted as a replacement to early
engines.
1.Remove automatic gearbox.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gearbox - convertor and
transfer gearbox - V8.
2.Remove 2 bolts securing CKP sensor cover.
3.Remove CKP sensor cover.
4.Remove 2 nuts securing CKP sensor.
5.Remove CKP sensor.

ENGINE - V8
REPAIRS 12-2-33
6. Early engines: Remove 4 bolts securing drive
plate clamp ring and remove ring.
7. Early engines: Remove drive plate from hub.
8. Early engines: Remove 6 Allen bolts securing
hub and starter ring gear, remove hub, starter
ring gear and collect spacer.
On early engines, balance weights are on
engine side of drive plate; replacement drive
plates will have balance weights on torque
converter side of drive plate.9. Later engines: Remove 4 bolts securing drive
plate clamp ring and remove ring.
10. Later engines: Remove drive plate.
11. Later engines: Remove 6 Allen bolts securing
starter ring gear to crankshaft; remove starter
ring gear.
Refit
1. All engines: Ensure bolt holes in crankshaft
are clean and dry.
2. All engines: Clean all components
3. All engines: Check that drive plate is free from
cracks and distortion.
4. Early engines: Fit hub, starter ring gear and
spacer to crankshaft, fit Allen bolts and tighten
to 78 Nm (58 lbf.ft).
5. Early engines: Fit drive plate and clamp ring,
fit bolts and tighten to 45 Nm (33 lbf.ft).
6. Later engines: Fit starter ring gear, fit Allen
bolts and tighten to 85 Nm (63 lbf.ft).
7. Later engines: Fit drive plate and clamp ring,
fit bolts and tighten to 45 Nm (33 lbf.ft).
8.Clean CKP sensor and mating face.
9.Fit crankshaft sensor and tighten nuts to 6 Nm
(5 lbf.ft).
10.Fit CKP sensor cover and tighten bolts to 6 Nm
(5 lbf.ft).
11.Fit CKP sensor multiplug to bracket.
12.Fit automatic gearbox.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gearbox - convertor and
transfer gearbox - V8.

ENGINE - V8
12-2-34 REPAIRS
Ring gear - starter
$% 12.53.19
Remove
1.Remove flywheel.

+ ENGINE - V8, REPAIRS, Flywheel.
2.Drill a 3 mm (0.12 in) diameter hole at root of 2
teeth.
3.Apply a cold chisel in root of one of ring gear
teeth, strike chisel with hammer to break ring
gear.
WARNING: SUITABLE EYE PROTECTION
MUST BE WORN.
4.Remove starter ring gear. Refit
1.Clean flywheel and starter ring gear.
2.Heat new starter ring gear evenly to 350°C
(660°F), indicated when the ring is a light blue
colour.
3.Locate ring gear on flywheel and press ring
gear hard against flange on flywheel.
4.Ensure ring gear is correctly seated around the
complete circumference of flywheel and allow
to cool.
5.Fit flywheel.

+ ENGINE - V8, REPAIRS, Flywheel.

ENGINE - V8
REPAIRS 12-2-35
Filter - oil
$% 12.60.04
Remove
1.Clean area around filter head and place a
container beneath engine.
2.Using a strap wrench, unscrew and discard
filter.
Refit
1.Clean mating face of filter head.
2.Lubricate sealing ring of new filter with clean
engine oil.
3.Fit filter and tighten by hand until it seats then
tighten a further half turn.
4.Start and run engine to check for leaks.
5.Stop engine, wait a few minutes, then check oil
level.
6.Top up engine oil.
Strainer - oil pick-up
$% 12.60.20
Remove
1.Remove sump gasket.

+ ENGINE - V8, REPAIRS, Gasket -
sump.
2.Remove 2 bolts and one nut securing oil pick-
up strainer.
3.Remove oil pick-up strainer.
4.Collect spacer from stud.
5.Remove and discard 'O'ring.
Refit
1.Clean oil pick up strainer and 'O' ring recess.
2.Lubricate and fit new 'O' ring.
3.Locate spacer on stud.
4.Position oil pick-up strainer, fit bolts and tighten
to 10 Nm (8 lbf.ft). Fit nut and tighten to 22 Nm
(16 lbf.ft).
5.Fit new sump gasket.

+ ENGINE - V8, REPAIRS, Gasket -
sump.

ENGINE - V8
12-2-36 REPAIRS
Pump - oil
$% 12.60.26
Remove
1.Remove timing gear cover gasket.

+ ENGINE - V8, REPAIRS, Gasket -
timing gear cover.
2.Remove bolt securing CMP sensor, remove
clamp and sensor.
3.Remove 6 bolts securing coolant pump,
remove pump and discard gasket.
4.Remove oil pressure switch and discard
sealing washer.
5.Remove 4 bolts securing oil filter head, remove
filter head and discard 2 'O' rings.
6.Remove filter head adaptor. Refit
1.Ensure filter head adaptor is clean.
2.Fit filter head adaptor and tighten bolts to 13
Nm (9 lbf.ft).
3.Clean filter head and mating face.
4.Fit new 'O' rings to filter head and filter head
adaptor.
5.Fit filter head and tighten bolts to 8 Nm (6 lbf.ft).
6.Ensure oil pressure switch and mating face is
clean.
7.Fit new sealing washer and tighten switch to 15
Nm (11 lbf.ft).
8.Clean coolant pump and mating face.
9.Use a new gasket and fit coolant pump.
Tighten bolts securing coolant pump to 25 Nm
(19 lbf.ft).
10.Ensure CMP sensor is clean and fit sensor to
cover.
11.Fit clamp to CMP sensor and tighten bolt to 8
Nm (6 lbf.ft).
12.Fit timing gear cover gasket.

+ ENGINE - V8, REPAIRS, Gasket -
timing gear cover.

ENGINE - V8
REPAIRS 12-2-37
Gasket - sump
$% 12.60.38
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove dipstick.
4.Raise the vehicle on a ramp.
5.Drain engine oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - V8 engine.
6.Remove 8 bolts securing cross member and
remove cross member.
7.Raise front of vehicle under body to increase
clearance between engine and front axle.
8.Disconnect and release gearbox oil cooler pipe
and discard 'O' ring. 9.Remove 2 clips securing oil cooler pipes at
front of sump.
10.Remove clip securing oil cooler pipes to side of
sump.
11.Remove clip bracket.
12.Remove 2 forward facing bolts securing sump
to bell housing.
13.Remove 4 rear facing bolts securing sump to
bell housing.
14.Remove 2 bolts in sump recess.
15.Remove 3 nuts securing front of sump.