1999 LAND ROVER DISCOVERY Workshop Manual

CONTENTS
14 CONTENTS
STEERING ................................................................................................ 57-1
DESCRIPTION AND OPERATION
Steering system component layout................................................................................................. 57-1
Steering column assembly and intermediate shaft ......................................................................... 57-2
Steering box.................................................................................................................................... 57-4
Description ...................................................................................................................................... 57-5
Operation ........................................................................................................................................ 57-16
ADJUSTMENTS
Steering box - check and adjust ..................................................................................................... 57-17
Hydraulic system - bleed ................................................................................................................ 57-18
Steering linkage - centralise ......................................................................................................... 57-18
Wheel alignment - front ................................................................................................................. 57-19
Power steering pressure check - diesel models ............................................................................. 57-20
Power steering pressure check - V8 LHD models .......................................................................... 57-22
Power steering pressure check - V8 RHD models ......................................................................... 57-24
REPAIRS
Power steering box - V8 ................................................................................................................. 57-27
Power steering box - LHD - diesel .................................................................................................. 57-30
Steering box - RHD - diesel ............................................................................................................ 57-34
Seal - input shaft - steering box ..................................................................................................... 57-37
Seal - output shaft - steering box ................................................................................................... 57-38
Pump - power steering - V8 ............................................................................................................ 57-39
Pump - power steering - diesel ....................................................................................................... 57-42
Steering column assembly and lock ............................................................................................... 57-43
Shaft - intermediate and universal joint - steering column ............................................................ 57-45
Nacelle - steering column ............................................................................................................... 57-47
Drop arm - steering box ................................................................................................................ 57-47
Ball joint - track rod ....................................................................................................................... 57-48
Ball joint - drag link ....................................................................................................................... 57-49
Drag link ........................................................................................................................................ 57-50
Damper - steering ......................................................................................................................... 57-51
Steering wheel ............................................................................................................................... 57-52

CONTENTS
CONTENTS 15
FRONT SUSPENSION.............................................................................. 60-1
DESCRIPTION AND OPERATION
Front suspension component layout (ACE torsion bar shown) ....................................................... 60-1
Front suspension components (ACE torsion bar shown) ................................................................ 60-2
Description ...................................................................................................................................... 60-4
DESCRIPTION AND OPERATION
ACE system component layout ....................................................................................................... 60-7
ACE system control diagram .......................................................................................................... 60-8
Description - ACE ........................................................................................................................... 60-9
Operation ........................................................................................................................................ 60-22
ADJUSTMENTS
ACE hydraulic system bleeding ..................................................................................................... 60-25
Fluid level check - ACE system ...................................................................................................... 60-25
REPAIRS
Bushes - Panhard rod ................................................................................................................... 60-27
Ball joint - upper - steering knuckle ............................................................................................... 60-28
Ball joint - lower - steering knuckle ................................................................................................. 60-29
Steering knuckle ........................................................................................................................... 60-30
Road spring - front ........................................................................................................................ 60-32
Wheel hub ....................................................................................................................................... 60-33
Damper - front ............................................................................................................................... 60-35
Bushes - radius arm ...................................................................................................................... 60-37
ECU - ACE ..................................................................................................................................... 60-39
Accelerometer - ACE - upper ........................................................................................................ 60-40
Accelerometer - ACE - lower ........................................................................................................ 60-40
Pump - ACE - V8 ............................................................................................................................ 60-41
Pump - ACE - diesel ....................................................................................................................... 60-42
Valve block - ACE ......................................................................................................................... 60-44
Filter - high pressure - ACE .......................................................................................................... 60-47
Pressure transducer - ACE ........................................................................................................... 60-48
Solenoid - pressure control valve - ACE ....................................................................................... 60-49
Solenoid - directional control valve - ACE ..................................................................................... 60-49
Pipe assembly - valve block to front actuator - ACE ...................................................................... 60-50
Pipe assembly - pump or reservoir to valve block - ACE - V8 ....................................................... 60-52
Pipe assembly - pump or reservoir to valve block - ACE - diesel .................................................. 60-55
Pipe assembly - valve block to rear actuator - ACE ........................................................................ 60-59
Actuator - front - ACE .................................................................................................................... 60-61
Bushes - front long arm - ACE ........................................................................................................ 60-63

CONTENTS
16 CONTENTS
REAR SUSPENSION ................................................................................ 64-1
DESCRIPTION AND OPERATION
Rear suspension component layout (vehicles with SLS) ............................................................... 64-2
Rear suspension component layout (vehicles without SLS) .......................................................... 64-3
Rear suspension components ........................................................................................................ 64-4
Description ...................................................................................................................................... 64-6
DESCRIPTION AND OPERATION
SLS component layout.................................................................................................................... 64-9
SLS system control diagram ........................................................................................................... 64-10
Description - SLS ............................................................................................................................ 64-12
Operation ........................................................................................................................................ 64-21
ADJUSTMENTS
SLS calibration blocks .................................................................................................................... 64-25
REPAIRS
Wheel hub....................................................................................................................................... 64-27
Road spring - rear ........................................................................................................................... 64-29
Air spring - SLS............................................................................................................................... 64-30
Damper - rear ............................................................................................................................... 64-31
Bushes - radius arm ....................................................................................................................... 64-31
Bushes - Watts linkage ................................................................................................................. 64-34
Sensor - height - SLS ..................................................................................................................... 64-35
Compressor unit - air - SLS ............................................................................................................ 64-35
Filter - intake - SLS ......................................................................................................................... 64-37
Switch - ride height ......................................................................................................................... 64-37
Air valve - SLS ................................................................................................................................ 64-38
Actuator - rear - ACE ...................................................................................................................... 64-39
Bushes - rear long arm - ACE......................................................................................................... 64-41

CONTENTS
CONTENTS 17
BRAKES ................................................................................................... 70-1
DESCRIPTION AND OPERATION
Brake system control component layout ......................................................................................... 70-1
Brake system control diagram ........................................................................................................ 70-2
Brake system hydraulic component layout ..................................................................................... 70-4
Description ...................................................................................................................................... 70-5
Operation ........................................................................................................................................ 70-20
DESCRIPTION AND OPERATION
Handbrake component layout ......................................................................................................... 70-25
Description ...................................................................................................................................... 70-26
ADJUSTMENTS
Handbrake .................................................................................................................................... 70-29
Brake system bleeding ................................................................................................................... 70-30
REPAIRS
Brake disc - front .......................................................................................................................... 70-33
Brake disc - rear ............................................................................................................................ 70-34
Master cylinder - brake ................................................................................................................. 70-35
Cable - handbrake ........................................................................................................................ 70-36
Switch - brake light ........................................................................................................................ 70-37
Brake pads - front ......................................................................................................................... 70-38
Brake pads - rear .......................................................................................................................... 70-39
Brake shoes - handbrake ................................................................................................................ 70-40
Servo - brake .................................................................................................................................. 70-42
Vacuum pump - servo ..................................................................................................................... 70-43
Housing - caliper - front ................................................................................................................. 70-45
Housing - caliper - rear ................................................................................................................. 70-46
ECU - Self levelling and anti locking brakes (SLABS) ................................................................. 70-47
Sensor – ABS – front ..................................................................................................................... 70-48
Sensor – ABS – rear ....................................................................................................................... 70-48
Modulator unit - ABS ...................................................................................................................... 70-49
Switch - Hill descent control ............................................................................................................ 70-50
Switch - handbrake ....................................................................................................................... 70-50

CONTENTS
18 CONTENTS
RESTRAINT SYSTEMS ............................................................................ 75-1
DESCRIPTION AND OPERATION
SRS component layout ................................................................................................................... 75-1
SRS block diagram ......................................................................................................................... 75-2
Description - SRS ........................................................................................................................... 75-3
Operation - SRS ............................................................................................................................. 75-9
DESCRIPTION AND OPERATION
Description - seat belts ................................................................................................................... 75-11
REPAIRS
Seat belt - front .............................................................................................................................. 75-13
Seat belt - rear - centre ................................................................................................................. 75-13
Seat belt - rear - side .................................................................................................................... 75-15
Mounting - seat belt - 'B' post ...................................................................................................... 75-16
Seat belts - third row ....................................................................................................................... 75-17
Pre-tensioner - front seat belt ....................................................................................................... 75-18
Pre-tensioner - seat belt - front - deployment - in vehicle ............................................................... 75-19
Pre-tensioner - seat belt - front - deployment - off vehicle .............................................................. 75-20
Airbag module - drivers .................................................................................................................. 75-22
Airbag module - passenger ........................................................................................................... 75-23
DCU ................................................................................................................................................ 75-24
Air bag - steering wheel - deployment - off vehicle ......................................................................... 75-25
Air bag - fascia - passenger - deployment - in vehicle ................................................................... 75-26
Air bag - fascia - passenger - deployment - off vehicle .................................................................. 75-27
Rotary coupler ................................................................................................................................ 75-29
DOORS...................................................................................................... 76-1-1
REPAIRS
Door - front .................................................................................................................................... 76-1-1
Door - rear .................................................................................................................................... 76-1-2
Door - tail ........................................................................................................................................ 76-1-3
Glass - front or rear door .............................................................................................................. 76-1-5
Quarter light ................................................................................................................................... 76-1-6
Regulator and motor - front and rear door glass .......................................................................... 76-1-7
Trim casing - front door .................................................................................................................. 76-1-8
Trim casing - rear door .................................................................................................................. 76-1-9
Trim casing - tail door .................................................................................................................... 76-1-10
Latch and motor - front door .......................................................................................................... 76-1-11
Latch and motor - rear door ........................................................................................................... 76-1-12
Latch and motor - tail door ............................................................................................................ 76-1-13
Handle - exterior - rear door ......................................................................................................... 76-1-13
Handle - exterior - tail door ........................................................................................................... 76-1-14
Handle - exterior - front door .......................................................................................................... 76-1-14

CONTENTS
CONTENTS 19
EXTERIOR FITTINGS ............................................................................... 76-2-1
REPAIRS
Wing - front - up to 03MY ................................................................................................................ 76-2-1
Wing - front - from 03MY ................................................................................................................. 76-2-2
Rear folding step ............................................................................................................................ 76-2-4
Liner - wheel arch - front ................................................................................................................. 76-2-5
Liner - wheel arch - rear ................................................................................................................. 76-2-6
Panel - underbelly .......................................................................................................................... 76-2-7
Mirror - exterior - electric ................................................................................................................ 76-2-7
Roof bars ....................................................................................................................................... 76-2-8
Bonnet ........................................................................................................................................... 76-2-9
Cable - bonnet release - up to 03MY .............................................................................................. 76-2-9
Cable - bonnet release - from 03MY ............................................................................................... 76-2-11
Bumper assembly - front ............................................................................................................... 76-2-12
Bumper assembly - rear - from 03MY ............................................................................................. 76-2-13
Trim finisher - bumper - front - from 03MY ...................................................................................... 76-2-14
Bumper assembly - rear - up to 03MY ............................................................................................ 76-2-15
Side finisher - windscreen .............................................................................................................. 76-2-16
Grille - front - up to 03MY................................................................................................................ 76-2-16
Grille - front - from 03MY ................................................................................................................ 76-2-17
INTERIOR TRIM COMPONENTS ............................................................. 76-3-1
REPAIRS
Trim casing - tail door speaker ...................................................................................................... 76-3-1
Trim casing - side - loadspace ....................................................................................................... 76-3-2
Trim casing - upper - 'B' post ......................................................................................................... 76-3-3
Trim casing - lower - 'B' post ......................................................................................................... 76-3-3
Trim casing - 'D' post ...................................................................................................................... 76-3-4
Console - centre - automatic models .............................................................................................. 76-3-5
Console - centre - manual models .................................................................................................. 76-3-7
Fascia ............................................................................................................................................. 76-3-10
Panel - auxiliary switch ................................................................................................................... 76-3-14
Panel - fascia access - driver's side .............................................................................................. 76-3-15
Drink tray assembly - centre fascia ................................................................................................. 76-3-15
Louvre panel assembly - centre fascia ........................................................................................... 76-3-16
Carpet - front ................................................................................................................................... 76-3-18
Carpet - rear .................................................................................................................................. 76-3-19
Carpet - loadspace ......................................................................................................................... 76-3-20
Headlining ...................................................................................................................................... 76-3-20
Stowage pocket - front .................................................................................................................. 76-3-24

CONTENTS
20 CONTENTS
SCREENS ................................................................................................. 76-4-1
REPAIRS
Glass/sealing rubber - tail door ..................................................................................................... 76-4-1
Windscreen ................................................................................................................................... 76-4-2
Glass - body side - rear ................................................................................................................ 76-4-4
Glass - alpine light ........................................................................................................................ 76-4-6
SEATS ....................................................................................................... 76-5-1
DESCRIPTION AND OPERATION
Electric seat component location .................................................................................................... 76-5-1
Electric seat block diagram ............................................................................................................. 76-5-2
Description - electric seats.............................................................................................................. 76-5-4
Operation - electric seats ................................................................................................................ 76-5-8
DESCRIPTION AND OPERATION
Heated seat component location .................................................................................................... 76-5-9
Heated seat block diagram (electric seats).................................................................................... 76-5-10
Description - heated seats .............................................................................................................. 76-5-11
Operation - heated seats ................................................................................................................ 76-5-13
REPAIRS
Seat - front ..................................................................................................................................... 76-5-15
Seat - third row ............................................................................................................................... 76-5-16
Seat - rear ....................................................................................................................................... 76-5-18
Bolster assembly - rear armrest ..................................................................................................... 76-5-19
Cover - cushion - front seat .......................................................................................................... 76-5-20
Heating element - cushion - front seat .......................................................................................... 76-5-21
Cover - cushion - rear seat ........................................................................................................... 76-5-22
Bladder - lumbar support .............................................................................................................. 76-5-23
Motor - fore and aft - front seat ..................................................................................................... 76-5-23
Motor - rise and fall - front seat ..................................................................................................... 76-5-24
Motor - tilt - front seat .................................................................................................................... 76-5-24
Motor - recline ................................................................................................................................. 76-5-25
Switch - electric seats .................................................................................................................... 76-5-25
Cable - rear squab latch ............................................................................................................... 76-5-26
Latch - rear seat ........................................................................................................................... 76-5-26
Cover - squab - front seat ............................................................................................................. 76-5-28
Cover - squab - RH rear seat ........................................................................................................ 76-5-31
Heating element - squab - front seat ............................................................................................ 76-5-33
Head restraint - third row seat ....................................................................................................... 76-5-33

CONTENTS
CONTENTS 21
SUNROOF................................................................................................. 76-6-1
DESCRIPTION AND OPERATION
Electric sunroof component location ............................................................................................... 76-6-1
Sunroof components ....................................................................................................................... 76-6-2
System block diagram..................................................................................................................... 76-6-4
Description ...................................................................................................................................... 76-6-5
Operation ........................................................................................................................................ 76-6-13
REPAIRS
Sunroof - front ................................................................................................................................. 76-6-15
Sunroof - rear ................................................................................................................................ 76-6-16
Glass panel - sunroof ...................................................................................................................... 76-6-17
Motor - sunroof ............................................................................................................................... 76-6-18
Drive cable assembly ..................................................................................................................... 76-6-19
Switch pack - sunroof ..................................................................................................................... 76-6-20
ECU - sunroof ................................................................................................................................ 76-6-20
CHASSIS AND BODY DIMENSIONS....................................................... 77-1-1
CHASSIS DIMENSIONS
Chassis body mounting points - front end....................................................................................... 77-1-1
Chassis body mounting points - rear end ....................................................................................... 77-1-2
Chassis dimensions - front end ....................................................................................................... 77-1-3
Chassis dimensions - rear end ....................................................................................................... 77-1-4
BODY DIMENSIONS
Body Dimensions ............................................................................................................................ 77-1-5
Gaps and profiles ............................................................................................................................ 77-1-13