1999 LAND ROVER DISCOVERY ad blue

GENERAL DATA
04-18
Suspension
* Measurement taken with vehicle at unladen weight.
Type - Front Beam axle with coil springs, longitudinal radius arms, Panhard rod,
twin tube dampers and either anti-roll bar or active cornering
enhancement (ACE)
Nominal height from hub centre to wheel arch (not
liner)*500 ± 15 mm (19.7 ± 0.6 in)
Front road spring colour codes:
⇒ V8 LHS Pink/orange
⇒ V8 RHS - LHD Pink/orange
⇒ V8 RHS - RHD White/purple
⇒ Td5 LHS White/purple
⇒ Td5 RHS - LHD White/purple
⇒ Td5 RHS - RHD White/purple
Rear road spring colour codes:
5 seat, LHS Purple
5 seat, RHS - LHD Purple
5 seat, RHS - RHD Purple/purple
7 seat, LHS - LHD Grey/blue
7 seat, LHS - RHD Grey/green
7 seat, RHS - LHD Grey/blue
7 seat, RHS - RHD Grey/white
Bump stop height (top of bump stop to axle bracket) 44.5 mm (1.75 in)
Anti-roll bar diameter - front
⇒ With ACE fitted 35 mm (1.38 in)
⇒ Without ACE 30 mm (1.18 in)
Type - Rear Beam axle with coil or air springs, longitudinal radius arms, Watts
linkage, twin tube dampers and either anti-roll bar or active cornering
enhancement (ACE)
Nominal height from hub centre to wheel arch (not
liner):*
⇒ Coil spring 483 ± 15 mm (19.0 ± 0.6 in)
⇒ Air spring 473 ± 15 mm (18.6 ± 0.6 in)
Road spring colour code Purple (all models)
Bump stop height (top of bump stop to axle bracket):
⇒ Coil spring 71.5 mm (2.8 in)
⇒ Air spring 61.5 mm (2.4 in)
Anti-roll bar diameter - rear
⇒ With ACE fitted 35 mm (1.38 in)
⇒ Without ACE - SLS fitted 29 mm (1.14 in)
⇒ Without ACE - SLS not fitted 5 seats = 19 mm (0.75 in)
7 seats = 16 mm (0.63 in)

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
12-2-66 OVERHAUL
26.Remove worn valve seat.
CAUTION: Take care not to damage the
counterbore in the cylinder head when
removing valve seats.
27.Heat cylinder head evenly to approximately
120° C (250°F).
WARNING: Handle the hot cylinder head
with care.
28.Using a suitable mandrel, press new insert fully
into counterbore.
29.Allow cylinder head to air cool.
CAUTION: Renew worn valve guides and/or
valve seats before lapping the valves.
30.Recut valve seat in head and lap in valves
using fine paste.
31.Coat valve with a small quantity of engineer's
blue, insert valve and press into position
several times without rotating. Seating position
should be in centre of valve face. 32.Check valve installed height if valve seats have
been refaced or renewed.
lValve installed height, end of valve to base
of spring seat, 'A' = 44.16 to 45.29 mm (1.74
to 1.80 in).
33.Reface valves as necessary. If a valve has to
be ground to a knife-edge to obtain a true seat,
renew valve.
34.Cut valve seats using suitable cutters:
lValve seat angle 'A' = 45°.
lValve seat insert diameter 'B' Inlet = 36.83
mm (1.45 in).
lValve seat insert diameter 'B' Exhaust =
31.50 mm (1.24 in).
lSeating width 'C' - Inlet = 0.89 to 1.4 mm
(0.035 to 0.055 in).
lSeating width 'C' - Exhaust = 1.32 to 1.83
mm (0.052 to 0.072 in).
lAngle 'D' = 70° .
lAngle 'E' = 46° to 46° 25'.
lAngle 'F' = 20° .

REAR AXLE
51-14 OVERHAUL
42.Fit adjusting nuts, tighten crown wheel side nut
to 22 Nm (16 lbf.ft). Ensure opposing nut is
loose.
43.Position DTI to check crown wheel backlash.
Adjust opposing nut to obtain correct crown
wheel backlash.
44.Rotate pinion in both directions to settle
bearings.
45.Measure in 3 places to obtain correct crown
wheel backlash.
NOTE: Crown wheel backlash should be within
0.076 mm - 0.177 mm (0.003' - 0.007').
46.Align adjusting nuts to next roll pin slot, do not
loosen nuts to align slots.
47.Tighten bearing cap bolts to 90 Nm (66.5 lbf.ft).
48.Secure adjusting nuts with new roll pins.
49.Apply Prussian Blue to crown wheel teeth to
check tooth contact.50.Rotate pinion several times to obtain full tooth
contact.
51.A = Normal pattern, the drive pattern should be
centred on the gear teeth. The coast pattern
should be centred on the gear teeth but may be
towards the toe. There should be some
clearance between the pattern and the top of
the gear teeth.
52.B = Backlash correct, thinner pinion shim
required.
53.C = Backlash correct, thicker pinion shim
required.
54.D = Pinion shim correct, decrease backlash.
55.E = Pinion shim correct, increase backlash.
56.Note assembly Torque to Turn when checking
tooth contact. Total Torque to Turn should not
exceed 10.85 Nm (8 lbf.ft).
Reassembly
1.Fit differential assembly.

FRONT SUSPENSION
DESCRIPTION AND OPERATION 60-5
Coil springs
Coil springs are fitted to the front axle of the vehicle. The front springs differ between petrol and Diesel variants. Each
spring is retained at its base by the lower spring seat. The top of each spring is located in the upper spring seat
isolator. The upper spring seat is manufactured from natural rubber , with a bonded metal plate and four bonded studs
which provide for the attachment of the damper turret. The rubber isolator reduces noise transmitted to the chassis
and body from the suspension.
The coil springs must be installed correctly. The bottom coil of the spring locates in a recess in the lower spring seat.
The top coil of the spring is ground flat to locate the upper spring seat isolator.
Coil Spring Specifications – Models up to 03 Model Year
The front springs on petrol variants are manufactured from carbon chrome 13.9 mm (0.55 in) diameter bar. The spring
has 7.6 coils and a free length of 377 mm (14.8 in). The petrol front spring is identified by a pink and orange stripe
painted on a number of coils.
The front springs on Diesel variants are manufactured from carbon chrome 13.9 mm (0.55 in) diameter bar. The spring
has 7.6 coils and a free length of 383 mm (15.0 in). The Diesel front spring is identified by a white and purple stripe
painted on a number of coils.
Coil Spring Specifications – Models from 03 Model Year
The introduction of the 03MY vehicle introduced a range of additional spring fitments. These were introduced to cover
the introduction of the 4.6l V8 engine, the fitment of a front mounted winch and to optimise the vehicle trim heights.
The coil springs are manufactured from silicon manganese 13.8 mm or 13.9 mm (0.54 in or 0.55 in) diameter bar. The
following spring data table shows the colour codes, number of coils and spring free length.
Spring Data
The following table shows spring fitment applicablity.
Spring Fitment Applicability
The following table shows standard springs and uprated springs required when a front winch is fitted.
Winch Fitment Spring Applicability
Colour Code Total No. of Coils Free Length
Red/Purple 7.4 371 mm (14.6 in)
Yellow/Purple 7.4 378.4 mm (14.9 in)
Blue/Purple 7.4 365 mm (14.4 in)
Grey/Purple 7.4 387 mm (15.2 in)
Purple/Purple 7.4 373.8 mm (14.7 in)
Yellow/Orange 7.4 394.6 mm (15.5 in)
Green/Orange 7.4 382.6 mm (15 in)
Pink/Brown 7.6 405.6 mm (15.9 in)
Left Hand Drive Right Hand Drive
RH side LH side RH side LH side
Red/Purple Red/Purple Yellow/Purple Blue/Purple
Yellow/Purple Yellow/Purple Grey/Purple Purple/Purple
Grey/Purple Grey/Purple Yellow/Orange Green/Orange
Standard Spring Winch Fitted Spring
RH Side LH Side Both Sides
Red/Purple Red/Purple Grey/Purple
Yellow/Purple Blue/Purple Yellow/Orange
Yellow/Purple Yellow/Purple Yellow/Orange
Grey/Purple Purple/Purple Green/Orange
Grey/Purple Grey/Purple Green/Orange
Yellow/Orange Green/Orange Pink/Brown

REAR SUSPENSION
DESCRIPTION AND OPERATION 64-7
Coil Spring Specifications – Models up to 03 Model Year
The rear coil springs are of the variable rate type and are manufactured from silicon manganese 16.5 mm (0.65 in.)
diameter bar. Each spring has 9 coils and a free length of 385 mm (15.1 in.). The variable rate of the spring is achieved
by the active coils at one end being closer together. The rear coil spring is identified by a purple stripe painted on a
number of coils.
Coil Spring Specifications – Models From 03 Model Year
The introduction of the 03MY vehicle introduced a range of additional rear coil spring fitments. These were introduced
as a package to optimise vehicle trim heights.
The coil springs are manufactured from silicon manganese 16.35 mm (0.64 in.) diameter bar for springs on five seater
models and 16.57 mm (0.65 in.) diameter bar on seven seater models. The following spring data table shows the
colour codes, number of coils and spring free length.
Spring Data
The following table shows spring fitment applicability.
Spring Fitment Applicability
Watts linkage
A Watts linkage is used to ensure that the rear axle remains centrally located. The Watts linkage comprises two
transverse links and a pivot housing. The transverse links and pivot housing allow the rear axle to move vertically
without any transverse movement.
The transverse links are made from fabricated and welded steel. Each transverse link has a bush press fitted into a
housing at one end. The opposite end has a forked bracket with two cross holes.
The pivot housing is made from cast iron. Three bushes are press fitted in the housing, one in the centre and one at
each end.
The pivot housing is located in a fabricated bracket centrally located on the rear of the axle. The central bush of the
pivot housing is secured in the bracket with a bolt and locknut. Fabricated brackets on each chassis longitudinal
provide for the attachment of each transverse link. Each link is secured through its bush with a bolt and locknut. The
forked end of each link locates over the bushes at each end of the pivot housing and is secured with a bolt and locknut.
The attachment bolts for each link are coated with a clear, dry wax which reduces friction on the bolt and allows the
correct torque to be applied to the clamping of the bushes. The bolts can be re-used, but if bolt replacement is
necessary the correct bolt with the wax coating must be used.
Colour Code Total No. of Coils Free Length Model
Brown/Orange 8.73 384.7 mm (15.14 in) 5 Seat
Grey/Orange 8.73 392 mm (15.43 in) 5 Seat
Yellow/Grey 8.73 376.6 mm (14.82 in) 5 Seat
Pink/Grey 8.73 400.3 mm (15.75 in) 5 Seat
Blue/Grey 9.10 387.8 mm (15.26 in) 7 Seat
Green/Grey 9.10 395.2 mm (15.55 in) 7 Seat
White/Grey 9.10 380.6 mm (14.98 in) 7 Seat
Left Hand Drive Right Hand Drive
Both Sides RH Side LH Side
Brown/Orange Grey/Orange Yellow/Grey
Grey Orange Pink/Grey Brown/Orange
Blue/Grey Green/Grey White/Grey

REAR SUSPENSION
DESCRIPTION AND OPERATION 64-13
Air supply unit
1Compressor electrical connector
2Electric motor
3Air intake hose
4Compressor
5Air dryer
6Pressure limiting valve
7Exhaust hose
8Exhaust valve electrical connector
(black harness connector)
9Exhaust valve10LH air valve electrical connector
(blue harness connector)
11LH air valve
12LH air spring supply pipe
13Air supply/exhaust pipe
14RH air spring supply pipe
15RH air valve
16RH air valve electrical connector
(natural harness connector)
17Housing
The air supply unit is located in a central position on the outside of the left hand chassis longitudinal. The unit is
contained in a plastic housing attached to the chassis. The housing has a removable lid which is secured with Dzus
fasteners for access to the unit.
The air supply unit comprises a 12 V electric motor, a compressor and air dryer unit, a pressure limiting valve, an
exhaust valve and two air supply control valves. The exhaust and control valves are solenoid operated responding to
signals from the SLABS ECU. The electric motor, compressor, air dryer and pressure limiting and exhaust valve are
mounted on flexible rubber mountings to reduce operating noise.
The electric motor drives a crank with an eccentric pin to which a connecting rod is attached. The connecting rod has
a piston which fits in the bore of the compressor. Operation of the motor rotates the crank, moving the piston in the
bore of the compressor.

INTERIOR TRIM COMPONENTS
76-3-12 REPAIRS
20.Separate blue section from ICE multiplug.
21.Release coaxial cables from fascia panel.
22.Disconnect multiplug from passenger air bag.
23.Disconnect multiplug from blower motor.
24.Working through glove box aperture remove 2
bolts, or 4 bolts if passenger airbag module is
fitted, securing fascia to body.25.Remove 4 bolts securing lower edge of fascia
to mounting brackets on transmission tunnel.
26.Remove 4 bolts securing lower edge of fascia
to brackets on 'A' post.
27.With assistance carefully remove fascia from
vehicle.
28.If renewing fascia, transfer components to new
fascia as necessary.
Refit
1.With assistance carefully fit fascia and tighten
bolts securing lower edge of fascia to 26 Nm
(19 lbf.ft).
2.Tighten bolts securing fascia to body to 26 Nm
(19 lbf.ft).
3.Fit nuts securingfascia to steering column
bracket to 11 Nm (8 lbf.ft).
4.Secure coaxial cables to fascia and secure blue
multiplug to main ICE multiplug.
5. Models with A/C: Connect heater control
multiplug.
6. Models without A/C: Connect temperature
and air distribution inner cables to heater
control levers. Set temperature control knobs to
fully hot, distribution knob to demist position
and, with flap levers fully closed, secure outer
cables to clips on heater casing.
7.Connect multiplugs to blower motor and
passenger air bag (where fitted).
8.Fit glove box and secure with bolts.
9.Connect fascia harness multiplugs to main
harness and fuse box.
10.Position instrument pack and connect
multiplugs.