1999 LAND ROVER DISCOVERY ECU

MANIFOLDS AND EXHAUST SYSTEMS - V8
REPAIRS 30-2-17
20.Remove 6 bolts securing upper inlet manifold
and remove upper inlet manifold.
21.Collect upper inlet manifold gasket. Refit
1.Clean upper and lower inlet manifold mating
faces, dowels and dowel holes.
2.Using a new gasket, position upper inlet
manifold. Fit bolts and, working in a diagonal
sequence, tighten to 22 Nm (16 lbf.ft).
3.Connect hose and multiplug to TP sensor.
4.Connect hose and multiplug to IACV. Secure
hose with clip.
5.Secure ht leads to upper inlet manifold.
6.Position ignition coils, fit bolts and tighten to 8
Nm (6 lbf.ft).
7.Ensure clip under ignition coils is located on
fuel pipe.
8.Secure engine harness in bulkhead clips.
9.Fit coolant rail bolt and tighten to 22 Nm (16
lbf.ft).
10.Connect breather hose to inlet plenum.
11.Connect brake servo vacuum pipe to inlet
plenum.
12.Connect EVAP pipe to inlet plenum.
13.Position coolant hoses to throttle body and
secure hose clips.
14.Fit breather hose to throttle body and secure
clip.
15.Connect multiplug to throttle body.
16.Connect throttle and cruise control cables and
secure in throttle body cams.
17.Adjust throttle and cruise control cables.
l

+ ENGINE MANAGEMENT SYSTEM
- V8, ADJUSTMENTS, Cable - cruise
control.
l

+ ENGINE MANAGEMENT SYSTEM
- V8, ADJUSTMENTS, Cable - throttle.
18.Connect air intake hose and tighten clips.
Secure harness to air intake hose.
19.Top-up cooling system

+ MAINTENANCE, PROCEDURES,
Cooling system..
20.Fit bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.
21.Connect battery earth lead.
22.Fit battery cover and secure with fixings.

MANIFOLDS AND EXHAUST SYSTEMS - V8
30-2-18 REPAIRS
Gasket - inlet manifold - upper - With
Secondary Air Injection
$% 30.15.24
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.
4.Disconnect multiplug from MAF sensor.
5.Release clip on intake hose and release
harness.
Note: Pre 03 MY air intake hose illustrated.
6.Release and disconnect IACV hose.
7.Loosen clip securing air intake hose to throttle
body.
8.Release 2 clips securing MAF sensor.
9.Release and remove air intake hose.10.Disconnect vacuum hose from air valve.
11.Loosen clip securing air valve hose to air valve.
12.Remove 2 nuts securing air manifold support
bracket to upper inlet manifold.
13.Disconnect 2 air manifold unions from adapters
in cylinder head.
CAUTION: Take care that air manifold pipes
are not damaged during removal of union
nuts.
14.Remove LH air manifold.
15.Disconnect purge valve hose from inlet
manifold.
16.Release purge valve from clips and air control
valve from bracket and lay aside.
17.Disconnect multiplug from IACV.
18.Release clip and disconnect breather hose
from throttle housing.
19.Disconnect multiplug from TP sensor.

MANIFOLDS AND EXHAUST SYSTEMS - V8
REPAIRS 30-2-19
20.Position container to collect spillage.
21.Release clips and disconnect 2 coolant hoses
from throttle housing.
22.Loosen outer cable locknuts and release
throttle and cruise control cables from
abutment.
23.Release throttle and cruise control cables from
clips and throttle cams and position aside.
24.Depress plastic collar and disconnect brake
servo hose from inlet manifold.
25.Release clip and disconnect breather hose
from manifold.
26.Disconnect vacuum hose from manifold.
27.Release engine harness from bulkhead clips
and position aside.
28.Release and remove bonnet seal from rear of
engine bay.
29.Remove 2 bolts securing air pipe and coil
bracket to manifold.
30.Loosen 2 lower bolts securing coil bracket
sufficiently to allow bracket to clear manifold.31.Release plug leads from upper manifold clips.
32.Loosen clip and disconnect air hose from air
valve.
33.Remove 2 nuts securing RH air manifold
support bracket to upper inlet manifold.

MANIFOLDS AND EXHAUST SYSTEMS - V8
30-2-20 REPAIRS
34.Release clip and disconnect IACV hose.
35.Remove 6 bolts securing upper manifold and
remove manifold.
36.Collect upper manifold gasket.
Refit
1.Clean upper and lower inlet manifold mating
faces, dowels and dowel holes.
2.Using a new gasket, position upper inlet
manifold. Fit bolts and, working in a diagonal
sequence, tighten to 22 Nm (16 lbf.ft).
3.Connect IACV hose and secure clip.
4.Connect hose to air valve and tighten clip.
5.Secure plug leads to clips.
6.Fit and tighten nuts securing RH air manifold
support bracket.
7.Align air pipe and coil bracket, fit bolts and
tighten to 8 Nm (6 lbf.ft).
8.Tighten 2 lower bolts securing coil bracket to 8
Nm (6 lbf.ft).
9.Fit bonnet seal.
10.Secure engine harness in bulkhead clips.
11.Connect breather hose to manifold and secure
clip.
12.Connect vacuum hose to inlet manifold.
13.Connect brake servo hose to inlet manifold.
14.Connect throttle and cruise control cables.
15.Adjust throttle cable.

+ ENGINE MANAGEMENT SYSTEM -
V8, ADJUSTMENTS, Cable - throttle.16.Adjust cruise control cable.

+ ENGINE MANAGEMENT SYSTEM -
V8, ADJUSTMENTS, Cable - cruise control.
17.Connect coolant hoses to throttle housing and
secure clips.
18.Connect multiplug to TP sensor.
19.Connect breather hose to throttle housing and
secure with clip.
20.Connect multiplug to IACV.
21.Secure purge valve and air control valve to clips
and bracket.
22.Connect purge hose to manifold.
23.Clean air manifold unions.
24.Apply a small amount of engine oil to top of air
manifold union nuts and around air manifold
pipes.
25.Position air manifold and finger tighten both air
manifold union nuts.
CAUTION: Finger tighten union nuts as far
as possible, damage to air manifold pipes or
adaptors may result if this is not done.
26.Tighten both air manifold union nuts to 25 Nm
(18 lbf.ft).
CAUTION: Ensure that air manifold pipes
are not distorted during tightening
operation.
27.Fit nuts securing air manifold support bracket
and tighten to 25 Nm (18 lbf.ft).
28.Connect hose to air valve and tighten clip.
29.Connect vacuum hose to air valve.
30.Fit air intake hose.
31.Connect multiplug to MAF sensor.
32.Secure harness to clip.
33.Connect battery earth lead.
34.Fit battery cover and secure with fixings.
35.Top up cooling system.

+ MAINTENANCE, PROCEDURES,
Cooling system.
36.Fit bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.

CLUTCH - V8
33-2-6 DESCRIPTION AND OPERATION
Description
General
The clutch system is a conventional diaphragm type clutch operated by a hydraulic cylinder. The clutch requires no
adjustment to compensate for wear.
Hydraulic clutch
The hydraulic clutch comprises a master cylinder, slave cylinder and a hydraulic reservoir, which is also shared with
the braking system. The master and slave cylinders are connected to each other hydraulically by plastic and metal
pipes. The plastic section of the pipe allows ease of pipe routing and also absorbs engine movements and vibrations.
The master cylinder comprises a body with a central bore. Two ports in the body connect the bore to the hydraulic
feed pipe to the slave cylinder and the brake/clutch fluid reservoir. A piston is fitted in the bore and has an external
rod which is attached to the clutch pedal with a pin. Two coiled springs on the clutch pedal reduce the effort required
to depress the pedal.
The master cylinder is mounted on the bulkhead in the engine compartment and secured with two bolts. The cylinder
is connected to the shared brake/clutch reservoir on the brake servo by a braided connecting hose.
The slave cylinder is located on the left hand side of the gearbox housing and secured with two bolts. A heat shield
protects the underside of the cylinder from heat generated from the exhaust system. The slave cylinder comprises a
cylinder with a piston and a rod. A port in the cylinder body provides the attachment for the hydraulic feed pipe from
the master cylinder. A second port is fitted with a bleed nipple for removing air from the hydraulic system after
servicing. The piston rod locates on a clutch release lever located in the gearbox housing. The rod is positively
retained on the release lever with a clip.
Clutch mechanism
The clutch mechanism comprises a flywheel, drive plate, pressure plate, release lever and a release bearing. The
clutch mechanism is fully enclosed at the rear of the engine by the gearbox housing.
A clutch release bearing sleeve is attached in the gearbox housing with two bolts and located on two dowels. A spigot
with a ball end is formed on the release bearing sleeve and provides a mounting and pivot point for the clutch release
lever. A dished pivot washer is located on the ball of the spigot. When the release lever is located on the ball, the pivot
washer seats against the rear face of the release lever. A spring clip is located on the lever and the pivot washer and
secures the lever on the spigot. A small bolt retains the spring clip in position.
The release lever is forked at its inner end and locates on the clutch release bearing carrier. The outer end of the
release lever has a nylon seat which locates the slave cylinder piston rod. A second nylon seat, positioned centrally
on the release lever, locates on the ball spigot of the release bearing sleeve and allows the release lever to pivot freely
around the ball.
The clutch release bearing locates on the clutch release lever and the release bearing sleeve. The bearing is retained
on a carrier which has two flats to prevent the carrier rotating on the release lever. A clip retains the release lever on
the carrier. The bearing and carrier are not serviceable individually.
Flywheel
The flywheel is bolted to a flange on the rear of the crankshaft with six bolts. A dowel on the crankshaft flange ensures
that the flywheel is correctly located. A ring gear is fitted on the outside diameter of the flywheel and seats against a
flange. The ring gear is an interference fit on the flywheel and is installed by heating the ring and cooling the flywheel.
The ring gear is a serviceable item and can be replaced if damaged or worn.
The operating face of the flywheel is machined to provide a smooth surface for the drive plate to engage on. Three
dowels and six threaded holes provide for the location and attachment of the pressure plate. The flywheel is balanced
to ensure that it does not produce vibration when rotating. A machined slot, with a series of holes within the slot, is
located on the engine side of the flywheel. The slot accommodates the tip of the crankshaft position sensor which is
used by the Engine Control Module (ECM) for engine management.

+ ENGINE MANAGEMENT SYSTEM - V8, DESCRIPTION AND OPERATION, Description - engine
management.

CLUTCH - V8
DESCRIPTION AND OPERATION 33-2-7
Pressure plate
1Leaf spring
2Fulcrum ring
3Fulcrum ring
4Drive plate
5Pressure plate6Diaphragm
7Cover
8Rivet
9Retractor clip
The pressure plate assembly comprises a pressure plate, cover and diaphragm and is mounted on and rotates with
the flywheel.
The pressure plate is forged from cast iron and machined to provide a smooth surface for the drive plate to engage
on. Three lugs on the outer diameter of the pressure plate connect it via three leaf springs to the cover. The leaf
springs have two tempered steel leaves which assist in pulling the pressure plate away from the drive plate when the
clutch pedal is depressed.
The cover is made from pressed steel and houses and locates all pressure plate components. Shouldered rivets
support the diaphragm and fulcrum rings inside the cover. The cover also provides attachment for balance weights
when the pressure plate assembly is balanced. Three holes in the cover locate on the dowels on the flywheel and six
further holes provide for the attachment of the cover to the flywheel with six bolts and spring washers. Larger holes
in the cover provide ventilation for the drive plate and pressure plate and flywheel contact surfaces.
The diaphragm comprises a cast ring with eighteen fingers. The diaphragm is attached to the cover with nine
shouldered rivets. Two circular steel fulcrum rings are also secured by the shouldered rivets on each side of the
diaphragm. The fulcrum rings allow the diaphragm to pivot between them when the clutch is depressed or released.
When pressure is applied to the diaphragm fingers by the release bearing, the diaphragm pivots between the fulcrum
rings and moves away from the pressure plate. Retractor clips are secured to the pressure plate and are located on
the outer diameter of the diaphragm. The retractor clips ensure that the diaphragm remains in contact with the
pressure plate.

CLUTCH - V8
33-2-8 DESCRIPTION AND OPERATION
Drive plate
1Friction material
2Hub
3Damper spring4Retainer plate
5Disc adaptor
6Stop pin
The drive plate is of the spring centred type and is sandwiched between the pressure plate and the flywheel. The drive
plate has a splined hub which engages with the splines on the primary drive shaft from the gearbox. The hub is located
in an inner plate which contains six compression damper springs. A spring retainer plate and a disc adaptor are
secured together with stop pins which limit the angular deflection of the disc adaptor. Engine power is transmitted from
the disc adaptor to the damper springs. The damper springs then transfer the power to the retainer plate and the hub.
Friction washers are located between the hub, retainer plate and disc adaptor and provide further damping.
A spring steel plate is riveted to the disc adaptor and provides the attachment surface for the drive plate friction
material. The friction material comprises discs which are secured with rivets to each side of the plate. The rivets are
installed through recessed holes in the disc and emerge in recessed holes in the opposite disc. The drive plate is 267
mm (10.5 in) diameter and has a friction material manufactured from APTEC T385.

CLUTCH - V8
REPAIRS 33-2-13
REPAIRS
Clutch assembly
$% 33.10.01
Remove
1.Remove gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
2.Restrain flywheel.
3.Working in diagonal sequence, progressively
loosen 6 bolts securing clutch cover to flywheel.
Remove bolts.
4.Remove clutch cover.
5.Remove clutch plate.
6.Renew all worn or damaged components.Refit
1.Clean clutch cover and flywheel mating faces
and spigot bush in end of crankshaft.
2.Fit LRT-12-001 to spigot bearing in crankshaft.
3.Fit clutch plate onto LRT-12-001, ensure side
marked 'flywheel side' is against flywheel.
4.Fit clutch cover and locate on dowels.
5.Fit clutch cover bolts and progressively tighten,
in diagonal sequence shown, to 40 Nm. (30
lbf.ft).
6.Fit gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.