1999 LAND ROVER DISCOVERY AUX

MANIFOLDS AND EXHAUST SYSTEMS - V8
30-2-10 REPAIRS
Heat shield - brake servo - With
Secondary Air Injection
$% 30.10.48
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove nut securing heat shield bracket to
valance.
4.Remove 2 bolts securing heat shield and
remove heat shield.
Refit
1.Fit heat shield, tightening bolts to 25 Nm (18
lbf.ft) and nut to 10 Nm (7 lbf.ft).
2.Connect battery earth lead.
3.Fit battery cover and secure with fixings.
Gasket - inlet manifold - lower
$% 30.15.08
Remove
1.Remove both rocker covers.
l

+ ENGINE - V8, REPAIRS, Gasket
- rocker cover - LH.
l

+ ENGINE - V8, REPAIRS, Gasket
- rocker cover - RH.
2.Release and disconnect LH injector harness
and multiplugs.
3.Release 3 clips securing top hose and remove
top hose.
4.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.

MANIFOLDS AND EXHAUST SYSTEMS - V8
REPAIRS 30-2-11
5.Remove 3 bolts securing ACE pump, release
pump and position aside.
6.Remove 2 bolts securing alternator and
remove alternator. 7.Remove 3 bolts securing PAS pump pulley and
remove pulley.
8.Remove jockey pulley.
9.Position tray to catch spillage, release PAS
pump high pressure pipe.
CAUTION: Always fit plugs to open
connections to prevent contamination.
10.Remove bolt securing oil cooling pipe and
release bracket from auxiliary housing.
11.Remove two bolts securing PAS pump.
12.Remove 5 bolts and one nut securing auxiliary
housing. Pull housing forward, release PAS
pump and remove housing.

MANIFOLDS AND EXHAUST SYSTEMS - V8
REPAIRS 30-2-13
20.Remove inlet manifold gasket.
21.Remove gasket seals.
Refit
1.Clean all traces of sealant from cylinder head
and cylinder block notches.
2.Clean mating faces of cylinder block, cylinder
head and inlet manifold.
3.Apply sealant, Part No. STC 50550 to cylinder
head and cylinder block notches.
4.Fit new gasket seals, ensuring ends engage
correctly in notches.
5.Fit new inlet manifold gasket.
6.Position gasket clamps and fit bolts, but do not
tighten at this stage.
7.Position inlet manifold to engine. Fit manifold
bolts and, working in the sequence shown,
tighten bolts initially to 10 Nm (7 lbf.ft) then to
51 Nm (38 lbf.ft).
8.Tighten gasket clamp bolts to 18 Nm (13 lbf.ft).
9.Connect fuel pipe.
10.Clean top hose outlet pipe mating faces.
11.Fit new 'O' ring to outlet pipe.
12.Position outlet pipe, fit bolts and tighten to 22
Nm (16 lbf.ft).
13.Position alternator, fit bolts and tighten to 45
Nm (33 lbf.ft).
14.Position PAS pump to auxiliary housing and
locate housing on engine. Fit bolts and tighten
to 40 Nm (30 lbf.ft).15.Fit and tighten auxiliary housing nut to 10 Nm (7
lbf.ft).
16.Fit bolts securing PAS pump and tighten to 22
Nm (16 lbf.ft).
17.Position oil cooling pipe bracket fit bolt and
tighten to 22 Nm (16 lbf.ft).
18.Fit and tighten PAS pump high pressure pipe.
19.Position jockey pulley and tighten bolt to 50 Nm
(37 lbf.ft).
20.Clean PAS pump pulley mating faces.
21.Position PAS pump pulley, fit bolts and tighten
to 22 Nm (16 lbf.ft).
22.Clean ACE pump dowels and dowel holes.
23.Position ACE pump, fit bolts and tighten to 22
Nm (16 lbf.ft).
24.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
25.Secure injector harness and connect injector
multiplugs.
26.Position top hose and secure clips.
27.Fit rocker covers.
l

+ ENGINE - V8, REPAIRS, Gasket
- rocker cover - LH.
l

+ ENGINE - V8, REPAIRS, Gasket
- rocker cover - RH.
28.Check and top up PAS fluid

STEERING
57-12 DESCRIPTION AND OPERATION
PAS pump - V8
1Bolt 2 off
2Nut
3Stud
4Auxiliary housing
5PAS pump6Outlet
7Inlet
8Bolt 3 off
9Drive pulley
The PAS pump is located on the auxiliary housing and is attached by two bolts, the bolts go through flanged bushes
in the auxiliary housing. A stud passes through the PAS pump and through a flanged bush in the auxiliary housing,
the auxiliary housing and PAS pump are secured by a nut. As the two bolts and nut are tightened the bushes move
slightly and the flange of each bush clamps the PAS pump. A drive pulley is attached to the pump drive shaft with
three bolts, and is belt driven at a ratio of 1.4 crankshaft revolutions to 1 of the drive pulley. Fluid is drawn into the
PAS pump inlet from the reservoir through a flexible hose at low (suction) pressure. Fluid at high pressure from the
PAS pump outlet is supplied to the rotary control valve on the steering box.
The PAS pump is a roller vane type and has an internal pressure regulator and flow control valve. The roller vanes
can move in slots in the pumps rotor and are moved outwards by centrifugal force as the pump rotates. The pump
rotor rotates in the pump housing, the internal shape of the housing forms a 'cam' shape. Due to the 'cam' shape the
volume of the housing decreases between the inlet and outlet ports.
As the pump rotor rotates towards the pump inlet the volume between the roller vanes and the pump housing
increases, this action causes a depression in the chamber between the pump roller vanes and the housing. As the
rotation continues the chamber is opened to the pump inlet, and the depression in the chamber causes fluid to be
drawn in. The roller vanes continue past the inlet port, closing off the inlet port and trapping the fluid in the chamber
between the rollers and the pump housing.

STEERING
57-14 DESCRIPTION AND OPERATION
PAS pump - diesel
1Drive pulley
2Mounting bracket
3Bolt 2 off
4Bolt
5PAS pump
6Coupling7Auxiliary housing
8Outlet
9Inlet adaptor pipe and seal
10Bolt 2 off
11Bolt 2 off
12Bolt 3 off
The PAS pump is located on the auxiliary housing, two bolts go through the PAS pump, mounting bracket and into
the auxiliary housing. One bolt also attaches the mounting bracket to the PAS pump, two bolts secure the mounting
bracket to the auxiliary housing. An inlet adaptor pipe with a seal is secured to the bottom of the pump with two bolts.
A drive pulley is attached to the pump drive shaft with three bolts, and is belt driven at a ratio of 1.35 crankshaft
revolutions to 1 of the drive pulley. A coupling on the rear of the PAS pump rotates the water pump impeller located
in the auxiliary housing. Fluid is supplied to the PAS pump inlet from the reservoir through a flexible hose at low
(suction) pressure. Fluid at high pressure from the PAS pump outlet is supplied to the rotary control valve on the
steering box.
The PAS pump is a roller vane type and has an internal pressure regulator and flow control valve. The roller vanes
can move in slots in the pumps rotor and are moved outwards by centrifugal force as the pump rotates. The pump
rotor rotates in the pump housing, the internal shape of the housing forms a 'cam' shape. Due to the 'cam' shape the
volume of the housing decreases between the inlet and outlet ports.

STEERING
REPAIRS 57-39
Refit
1.Clean seal recess, output shaft, end cover and
mating face.
2.Lubricate new end cover 'O' ring with clean
PAS fluid. Fit 'O' ring to end cover.
3.Position output shaft, fit bolts and tighten to 88
Nm (65 lbf.ft).
4.Tighten rack adjuster one turn, align marks and
secure with Allen screw.
5.Lubricate new output shaft seal with clean PAS
fluid.
6.Fit seal using LRT-57-504.
7.Fit spacer, circlip and seal shield.
8.Clean drop arm and steering box splines.
9.Ensure steering box is in the central position.
Align and fit drop arm to output shaft and
secure with new lock washer and nut. Tighten
nut to 240 Nm (177 lbf.ft).
10.Secure lock washer to drop arm nut.
11.Fit steering box.
lFor V8 models:

+ STEERING, REPAIRS, Power
steering box - V8.
lFor LHD diesel models:

+ STEERING, REPAIRS, Power
steering box - LHD - diesel.
lFor RHD diesel models:

+ STEERING, REPAIRS, Steering
box - RHD - diesel.
Pump - power steering - V8
$% 57.20.14
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Remove cable tie securing harness to air intake
hose.
3.Loosen 3 clips securing air intake hose, release
and remove hose.
Note: Pre 03 MY air intake hose illustrated.
4. Models with ACE: Remove 3 bolts securing
ACE pump, release pump and position aside.

STEERING
57-40 REPAIRS
5. Models with A/C: Disconnect A/C compressor
multiplug. Remove 4 bolts securing A/C
compressor, release compressor and position
aside.
6.Remove 3 bolts securing PAS pump pulley and
remove pulley.
7.Position tray to catch spillage, release PAS
pump pressure pipe.
8.Remove clip and release PAS pump inlet hose.
CAUTION: Always fit plugs to open
connections to prevent contamination.9.Remove jockey pulley.
10.Remove bolt securing oil cooling pipe bracket
and release bracket from housing.
11.Remove two bolts securing PAS pump.
12.Remove 4 bolts and one nut securing auxiliary
housing. Pull housing forward and release
PAS pump. Remove PAS pump.

STEERING
REPAIRS 57-41
Refit
1.Position PAS pump to auxiliary housing and
locate housing to engine. Fit and tighten
auxiliary housing bolts to 40 Nm (30 lbf.ft).
2.Tighten auxiliary housing nut to 10 Nm (7 lbf.ft).
3.Fit bolts securing PAS pump and tighten to 22
Nm (16 lbf.ft).
4.Position PAS pump pipe bracket, fit and tighten
bolt to 22 Nm (16 lbf.ft).
5.Fit and tighten PAS pump pressure pipe.
6.Fit PAS pump inlet hose and secure with clip.
7.Position jockey pulley and tighten bolt to 50 Nm
(37 lbf.ft).
8.Clean PAS pump pulley mating faces.
9.Position PAS pump pulley, fit bolts and tighten
to 22 Nm (16 lbf.ft).
10. Models with ACE: Clean ACE pump dowels
and dowel holes. Position ACE pump, fit bolts
and tighten to 25 Nm (18 lbf.ft).
11. Models with A/C: Clean A/C compressor
dowels and dowel holes. Position A/C
compressor, fit bolts and tighten to 22 Nm (16
lbf.ft).
12.Position air intake hose and secure with clips.
13.Secure harness to air intake hose with new
cable tie.
14.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive..
15.Bleed PAS system.

+ STEERING, ADJUSTMENTS,
Hydraulic system - bleed.