1999 LAND ROVER DISCOVERY clutch

CONTENTS
CONTENTS 1
INTRODUCTION ...................................................................................... 01-1
How To Use This Manual................................................................................................................ 01-1
Repairs and Replacements ............................................................................................................. 01-2
Specifications .................................................................................................................................. 01-2
Abbreviations and Symbols ............................................................................................................ 01-3
GENERAL INFORMATION ...................................................................... 03-1
General Precautions ....................................................................................................................... 03-1
Safety Instructions .......................................................................................................................... 03-2
Environmental Precautions ............................................................................................................. 03-3
General Fitting Instructions ............................................................................................................. 03-6
Ball and Roller Bearings ................................................................................................................. 03-7
Oil Seals.......................................................................................................................................... 03-8
Joints and Joint Faces .................................................................................................................... 03-9
Locking Devices .............................................................................................................................. 03-9
Screw Threads ................................................................................................................................ 03-10
Bolt and Nut Identification ............................................................................................................... 03-11
Flexible Pipes and Hoses ............................................................................................................... 03-13
Rolling Road Testing....................................................................................................................... 03-15
Fuel Handling Precautions .............................................................................................................. 03-16
Electrical Precautions ..................................................................................................................... 03-17
Supplementary Restraint System Precautions ............................................................................... 03-18
SRS Component Replacement Policy ............................................................................................ 03-23
Air Conditioning System Precautions .............................................................................................. 03-24
Air Conditioning Compressor Replacement .................................................................................... 03-26
Body Repairs .................................................................................................................................. 03-27
GENERAL DATA ..................................................................................... 04-1
Engine - Td5 ................................................................................................................................... 04-1
Engine - V8 ..................................................................................................................................... 04-4
Fuel system - Td5 ........................................................................................................................... 04-8
Fuel system - V8 ............................................................................................................................. 04-8
Cooling system - Td5 ...................................................................................................................... 04-9
Cooling system - V8 ........................................................................................................................ 04-10
Clutch - Td5 .................................................................................................................................... 04-11
Clutch - V8 ...................................................................................................................................... 04-12
Manual gearbox - R380 .................................................................................................................. 04-13
Transfer box - LT230SE .................................................................................................................. 04-14
Automatic gearbox - ZF4HP22/24 .................................................................................................. 04-15
Rear axle......................................................................................................................................... 04-16
Front axle ........................................................................................................................................ 04-16
Steering........................................................................................................................................... 04-17
Suspension ..................................................................................................................................... 04-18
Brakes ............................................................................................................................................. 04-19
Wheels and tyres ............................................................................................................................ 04-20
Air conditioning ............................................................................................................................... 04-21
Electrical - Td5 ................................................................................................................................ 04-22
Electrical - V8 .................................................................................................................................. 04-22
Dimensions ..................................................................................................................................... 04-23
Weights ........................................................................................................................................... 04-24

CONTENTS
2CONTENTS
IDENTIFICATION NUMBERS .................................................................. 05-1
Vehicle Identification Number ......................................................................................................... 05-1
Identification Number Locations ..................................................................................................... 05-3
TORQUE WRENCH SETTINGS .............................................................. 06-1
Maintenance ................................................................................................................................... 06-1
Engine Td5 ..................................................................................................................................... 06-2
Engine V8 ....................................................................................................................................... 06-4
Emission control - Td5 .................................................................................................................... 06-5
Emission control - V8 ...................................................................................................................... 06-5
Engine management system - Td5 ................................................................................................. 06-6
Engine management system - V8................................................................................................... 06-6
Cooling system ............................................................................................................................... 06-7
Manifolds and exhaust systems - Td5 ............................................................................................ 06-8
Manifolds and exhaust systems - V8 .............................................................................................. 06-8
Clutch.............................................................................................................................................. 06-9
Manual gearbox - R380 .................................................................................................................. 06-10
Transfer box - LT230SE ................................................................................................................. 06-11
Automatic gearbox - ZF4HP22 ....................................................................................................... 06-12
Propeller shafts ............................................................................................................................... 06-13
Axles ............................................................................................................................................... 06-13
Steering .......................................................................................................................................... 06-14
Front suspension ............................................................................................................................ 06-15
Rear suspension ............................................................................................................................. 06-16
Brakes............................................................................................................................................. 06-17
Restraint systems ........................................................................................................................... 06-18
Body................................................................................................................................................ 06-19
Heating and air conditioning ........................................................................................................... 06-20
Wipers and washers ....................................................................................................................... 06-20
Electrical ......................................................................................................................................... 06-21
LIFTING AND TOWING ........................................................................... 08-1
LIFTING .......................................................................................................................................... 08-1
TOWING ......................................................................................................................................... 08-2
TRANSPORTING ........................................................................................................................... 08-4
CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS ...................... 09-1
Capacities ....................................................................................................................................... 09-1
Fluids .............................................................................................................................................. 09-2
Anti-Freeze Concentration .............................................................................................................. 09-2
Lubrication ...................................................................................................................................... 09-3
Sealants .......................................................................................................................................... 09-4

CONTENTS
4CONTENTS
Brake hose, brake, fuel, ACE, clutch pipes and unions/electrical harnesses ................................ 10-24
Engine, gearbox, transfer box and axles ........................................................................................ 10-25
Exhaust system .............................................................................................................................. 10-25
Steering box and front suspension ................................................................................................. 10-25
Steering rod ball joints ................................................................................................................... 10-27
Dampers and SLS height sensors .................................................................................................. 10-27
Front and rear axle suspension links .............................................................................................. 10-28
Towing bracket ............................................................................................................................... 10-29
Engine mountings - V8 engine........................................................................................................ 10-30
Road/roller test ............................................................................................................................... 10-31

CONTENTS
CONTENTS 7
ENGINE MANAGEMENT SYSTEM - V8 .................................................. 18-2-1
DESCRIPTION AND OPERATION
Engine management component location - Passenger compartment ............................................ 18-2-1
Engine management component location - Engine compartment .................................................. 18-2-2
Engine management block diagram ............................................................................................... 18-2-4
Description - engine management .................................................................................................. 18-2-6
Operation - engine management .................................................................................................... 18-2-49
DESCRIPTION AND OPERATION
Cruise control component layout .................................................................................................... 18-2-61
Cruise control block diagram .......................................................................................................... 18-2-62
Description - cruise control ............................................................................................................. 18-2-63
Operation - cruise control................................................................................................................ 18-2-74
ADJUSTMENTS
Cable - throttle ............................................................................................................................. 18-2-77
Cable - cruise control .................................................................................................................... 18-2-77
REPAIRS
Spark plugs .................................................................................................................................. 18-2-79
Coil - ignition ................................................................................................................................. 18-2-80
Engine control module (ECM) ......................................................................................................... 18-2-81
Sensor - engine coolant temperature (ECT) ................................................................................ 18-2-82
Sensor - crankshaft position (CKP) ............................................................................................... 18-2-83
Sensor - radiator temperature ....................................................................................................... 18-2-84
Sensor - camshaft position (CMP) ................................................................................................. 18-2-84
Knock sensor (KS) .......................................................................................................................... 18-2-85
Air cleaner assembly ..................................................................................................................... 18-2-86
Element - air filter .......................................................................................................................... 18-2-87
Cable - throttle ................................................................................................................................ 18-2-88
Sensor - Mass Air Flow (MAF) ...................................................................................................... 18-2-89
Throttle Body................................................................................................................................... 18-2-90
Plenum chamber ............................................................................................................................. 18-2-91
Sensor - throttle position (TP) ....................................................................................................... 18-2-91
Valve - idle air control (IACV) ........................................................................................................ 18-2-92
Injectors ......................................................................................................................................... 18-2-92
Actuator - cruise control ................................................................................................................ 18-2-94
Vacuum control unit - up to 03MY................................................................................................... 18-2-94
Vacuum control unit - from 03MY ................................................................................................... 18-2-95
Cable - cruise control ..................................................................................................................... 18-2-96
Switch - cruise control (on/off) ........................................................................................................ 18-2-96
Switch - cruise control (set/resume) ............................................................................................... 18-2-97
Switch - clutch pedal - cruise control ............................................................................................ 18-2-97
ECU - Cruise control ..................................................................................................................... 18-2-98

CONTENTS
CONTENTS 9
CLUTCH - V8 ............................................................................................ 33-2-1
DESCRIPTION AND OPERATION
Clutch components ......................................................................................................................... 33-2-2
Hydraulic operation ......................................................................................................................... 33-2-4
Description ...................................................................................................................................... 33-2-6
Operation ........................................................................................................................................ 33-2-9
ADJUSTMENTS
Clutch hydraulic system - bleed ...................................................................................................... 33-2-11
REPAIRS
Clutch assembly ............................................................................................................................. 33-2-13
Master cylinder ................................................................................................................................ 33-2-14
Bearing and lever - clutch release ................................................................................................ 33-2-15
Slave cylinder.................................................................................................................................. 33-2-15

CONTENTS
10 CONTENTS
MANUAL GEARBOX - R380 .................................................................... 37-1
DESCRIPTION AND OPERATION
R380 gearbox ................................................................................................................................. 37-1
Gearbox casings, gear change and oil pump ................................................................................ 37-2
Selector shaft and forks, synchromesh assemblies and gear train ............................................... 37-4
R380 gearbox cross section ........................................................................................................... 37-6
Description ...................................................................................................................................... 37-7
Operation ........................................................................................................................................ 37-8
ADJUSTMENTS
Spring - gear lever bias .................................................................................................................. 37-9
REPAIRS
Housing - gear selector .................................................................................................................. 37-11
Gearbox - V8 .................................................................................................................................. 37-12
Gearbox - Diesel ............................................................................................................................. 37-16
Seal - gearbox mainshaft ............................................................................................................... 37-20
Seal - input shaft ............................................................................................................................ 37-21
Cooler - oil - gearbox - Diesel ......................................................................................................... 37-23
Cooler - oil - gearbox - V8............................................................................................................... 37-24
Switch - Reverse light ................................................................................................................... 37-25
OVERHAUL
Shaft - output ................................................................................................................................. 37-27
Synchroniser - gearbox - set ......................................................................................................... 37-32
Fork - set - selector shaft .............................................................................................................. 37-34
Shaft - gearbox - input .................................................................................................................. 37-35
Extension - gearbox rear ............................................................................................................... 37-38
Pump - gearbox oil ......................................................................................................................... 37-41
Filter - gearbox oil ......................................................................................................................... 37-41
Gear - 5th gear set ........................................................................................................................ 37-42
Synchronizer assembly - 5th/reverse ........................................................................................... 37-43
5th gear - layshaft ......................................................................................................................... 37-44
Bearing - layshaft rear support ..................................................................................................... 37-46
Bearing - output shaft rear support ............................................................................................... 37-47
Shaft - reverse idler ...................................................................................................................... 37-48
Housing - gear selector mechanism ............................................................................................. 37-50
Lever - gear change ...................................................................................................................... 37-51
Housing - clutch ............................................................................................................................ 37-52
Cover - front ................................................................................................................................... 37-53

CONTENTS
CONTENTS 11
TRANSFER BOX - LT230SE .................................................................... 41-1
DESCRIPTION AND OPERATION
LT230SE transfer box ..................................................................................................................... 41-1
Transfer box cross section .............................................................................................................. 41-2
Main casing components – Vehicles up to 03 model year .............................................................. 41-4
Main casing components – Vehicles from 03 model year ............................................................... 41-5
Differential components – Vehicles up to 03 model year ................................................................ 41-6
Differential components – Vehicles from 03 model year ................................................................. 41-7
Front output housing components – Vehicles up to 03 model year ................................................ 41-8
Front output housing components – Vehicles from 03 model year ................................................. 41-10
Rear output housing components ................................................................................................... 41-12
Description ...................................................................................................................................... 41-13
Operation ........................................................................................................................................ 41-18
ADJUSTMENTS
Cable - selector - differential lock - adjust ...................................................................................... 41-21
Cable - high/low selector ................................................................................................................. 41-21
REPAIRS
Bottom cover - transfer box .......................................................................................................... 41-23
Cable - selector - differential lock .................................................................................................... 41-24
Transfer box - Diesel....................................................................................................................... 41-25
Transfer box - V8 ............................................................................................................................ 41-29
Gasket - rear cover plate ................................................................................................................ 41-33
Switch - differential lock - Up to 03 MY ........................................................................................... 41-34
Cable - high/low selector ................................................................................................................. 41-35
Oil seal - input shaft ...................................................................................................................... 41-36
Seal - front output shaft................................................................................................................... 41-36
Seal - rear output shaft ................................................................................................................... 41-38
Gasket - rear output shaft housing.................................................................................................. 41-39
Solenoid - interlock - Up to 03 MY .................................................................................................. 41-40
Solenoid - interlock - from 03 MY .................................................................................................... 41-40
Sensor - neutral ........................................................................................................................... 41-41
Sensor - oil temperature - If fitted ................................................................................................... 41-41
Switch - high low - warning ........................................................................................................... 41-42
Switch(es) - differential lock warning From 03 MY .......................................................................... 41-42
OVERHAUL
Intermediate gear assembly .......................................................................................................... 41-43
Differential assembly .................................................................................................................... 41-46
Dog clutch - differential lock .......................................................................................................... 41-64
Input gear/bearing .......................................................................................................................... 41-68
Low gear - differential ................................................................................................................... 41-70

INTRODUCTION
01-3
Abbreviations and Symbols
A Amperes
AAP Ambient Air Pressure
ABDC After Bottom Dead Centre
ABS Anti-Lock Brake System
ac Alternating current
A/C Air Conditioning
ACE Active Cornering Enhancement
ACEA Association of Constructors of
European Automobiles
AFR Air Fuel Ratio
AP Ambient Pressure
ASC Anti-shunt Control
ATC Air Temperature Control
ATDC After Top Dead Centre
BBDC Before Bottom Dead Centre
BBUS Battery Backed Up Sounder
BCU Body Control Unit
BDC Bottom Dead Centre
bhp Brake Horse Power
BP Boost Pressure
BPP Brake Pedal Position
BS British Standard
BTDC Before Top Dead Centre
C Celsius
CAN Controller Area Network
CD Compact Disc
CDC Centre Differential Control
CDL Central Door Locking
CD - ROM Compact Disc - Read Only
Memory
CFC Chlorofluorocarbon
CHMSL Centre High Mounted Stop Lamp
CKP Crankshaft Position
CLV Calculated Load Value
cm Centimetre
cm
2Square centimetre
cm3Cubic centimetre
CMP Camshaft Position
CPP Clutch Pedal Position
CO Carbon Monoxide
CO
2Carbon Dioxide
CR Common Rail
CVS Canister Vent Solenoid
deg. Degree, angle or temperature
dia. Diameter
DIN Deutsche Industrie Normen
(German Industrial Standards)
dc Direct current
DCV Directional Control Valve
DOHC Double Overhead Camshaft
DTI Dial Test Indicator
DFM Dual Mass Flywheel
DVD Digital Versatile Disc
EACV Electronic Air Control Valve EAT Electronic Automatic
Transmission
EBD Electronic Brake pressure
Distribution
ECD European Community Directive
ECM Engine Control Module
ECT Engine Coolant Temperature
ECU Electronic Control Unit
EDC Electronic Diesel Control
EEPROM Electronic Erasable
Programmable Read Only
Memory
EGR Exhaust Gas Recirculation
EKA Emergency Key Access
EN European Norm
EOBD European On Board Diagnostics
ETC Electronic Traction Control
EUI Electronic Unit Injector
EVAP Evaporative Emission
EVR Electronic Vacuum Regulator
F Fahrenheit
FBH Fuel Burning Heater
FIP Fuel Injection Pump
FTC Fast Throttle Control
g Gramme or Gravity
hHour
hc High compression
HC Hydro Carbons
HDC Hill Descent Control
HDPE High Density Polyethylene
HFS Heated Front Screen
Hg Mercury
HO2S Heated Oxygen Sensor
HMW High Molecular Weight
HRW Heated Rear Window
ht/HT High tension
IACV Idle Air Control Valve
IAT Intake Air Temperature
ICE In-Car Entertainment
i.dia. Internal diameter
IDM Intelligent Driver Module
in3Cubic inch
ILT Inlet Throttle
ISO International Organisation for
Standardisation
k Thousand
kg Kilogramme
km Kilometre
km/h Kilometres per hour
kPa KiloPascal
KS Knock Sensor
lLitre
lbf.in Pounds force inches
lbf/in
2Pounds per square inch
lbf.ft Pounds force feet