1999 LAND ROVER DISCOVERY Workshop Manual

STEERING
57-36 REPAIRS
17.Remove nut securing drag link to drop arm.
Using LRT-57-036, break taper joint and
release drag link.
18. Models with ACE: Remove nut securing anti-
roll bar link lower ball joint and release joint. 19. Models with ACE: Position ACE control arms
to access steering box bolts.
20.With assistance, remove 4 bolts securing
steering box and remove steering box.
21.Remove centralising bolt from steering box.

STEERING
REPAIRS 57-37
Refit
1.Fit centralising bolt to steering box.
2.With assistance, position steering box to
chassis, fit bolts and tighten to 90 Nm (66 lbf.ft).
3. Models with ACE: Ensure washer is in place
on lower ball joint of anti-roll bar link, then
connect lower ball joint to axle and tighten nut
to 100 Nm (74 lbf.ft).
4.Position drag link, fit nut and tighten to 80 Nm
(59 lbf.ft).
5.Position Panhard rod, fit bolt and nut and
tighten to 230 Nm (170 lbf.ft).
6.Position coolant rail and secure with clips and
bolt.
7.Fit coolant hoses and secure with clips.
8. Models with ACE: Fit and tighten bolt
securing ACE pipes to chassis.
9.Clean PAS pipes ends and 'O' ring recess.
10.Lubricate new 'O' rings for PAS pipes with
clean PAS fluid.
11.Fit 'O' rings to PAS pipes and position pipes in
steering box. Fit PAS pipe bracket and tighten
bolt to 22 Nm 16 lbf.ft).
12.Ensure steering wheel is centralised. Fit
universal joint between steering box and
intermediate shaft and tighten bolts to 25 Nm
(18 lbf.ft).
13.Remove centralising bolt from steering box.
14.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft).
15.Remove stand(s) and lower vehicle.
16.Connect battery earth lead.
17.Fit battery cover.
18.Refill cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
19.Bleed PAS system.

+ STEERING, ADJUSTMENTS,
Hydraulic system - bleed.
20.Centralise steering linkage

+ STEERING, ADJUSTMENTS,
Steering linkage - centralise.
Seal - input shaft - steering box
$% 57.10.16
Remove
1.Remove 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.
2.Secure steering box in vice.
3.Remove circlip and extract oil seal from
steering box. Take care not to damage
surface of the shaft.
Refit
1.Clean oil seal recess and input shaft.
2.Lubricate new seal with clean PAS fluid.
3.Fit seal using LRT-57-503.
4.Fit circlip.
5.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.

STEERING
57-38 REPAIRS
Seal - output shaft - steering box
$% 57.10.17
Remove
1.Remove 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.
2.Secure steering box in vice.
3.Release lock washer from drop arm nut.
4.Loosen but do not remove nut securing drop
arm.
5.Using LRT-57-012, release drop arm.
6.Remove nut and discard lock washer.
7.Remove drop arm. 8.Mark position of rack adjuster.
9.Remove Allen screw securing rack adjuster
and loosen adjuster one turn.
10.Remove 4 bolts securing output shaft assembly
and remove output shaft assembly. Remove
and discard 'O' ring from end cover.
11.Remove seal shield and circlip.
12.Remove seal and spacer.

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.

STEERING
57-42 REPAIRS
Pump - power steering - diesel
$% 57.20.14
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Remove 3 bolts securing PAS pump pulley and
remove pulley.
3.Position tray to catch spillage, release PAS
pump pressure pipe.
4.Remove clip and release PAS pump inlet hose.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove 4 bolts and remove PAS pump.
6.Remove bolt, and remove mounting bracket
from PAS pump.
7.Remove 2 bolts, remove low pressure adaptor
pipe and discard 'O' ring. Refit
1.Clean PAS pump and adaptor pipe.
2.Fit new 'O' ring to adaptor pipe, fit pipe and
tighten bolts to 10 Nm (7 lbf.ft).
3.Position mounting bracket to PAS pump, fit but
do not tighten bolt.
4.Position PAS pump and align pump drive to
coolant pump. Fit and tighten bolts to 25 Nm
(18 lbf.ft).
5.Tighten mounting plate bolt to 25 Nm (18 lbf.ft).
6.Clean PAS pump and pipe union.
7.Fit and tighten PAS pump pressure pipe to 20
Nm (15 lbf.ft).
8.Fit PAS pump inlet hose and secure with clip.
9.Clean PAS pump and pulley mating faces.
10.Position PAS pump pulley, fit and tighten bolts
to 10 Nm (7 lbf.ft).
11.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
12.Bleed power steering system.

+ STEERING, ADJUSTMENTS,
Hydraulic system - bleed.

STEERING
REPAIRS 57-43
Steering column assembly and lock
$% 57.40.01
Remove
1.Remove steering column intermediate shaft.

+ STEERING, REPAIRS, Shaft -
intermediate and universal joint - steering
column.
2.Remove rotary coupler.

+ RESTRAINT SYSTEMS, REPAIRS,
Rotary coupler.
3.Open fascia lower access panel.
4.Remove steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
steering column.
5.Disconnect multiplug and illumination bulb
from passive coil and remove passive coil.
6.Disconnect 2 multiplugs from wiper switch
assembly. 7.Disconnect 2 multiplugs from light switch
assembly.
8.Loosen screw and remove switch assembly.
9.Disconnect ignition switch multiplug.
10.Disconnect multiplug from ignition switch
housing.
11.Release harness from column clip.