1999 LAND ROVER DISCOVERY lock
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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
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CONTENTS
CONTENTS 5
ENGINE - V8 ............................................................................................. 12-2-1
DESCRIPTION AND OPERATION
V8 Engine ....................................................................................................................................... 12-2-1
Cylinder head components ............................................................................................................. 12-2-2
Cylinder block components ............................................................................................................. 12-2-4
Description ...................................................................................................................................... 12-2-6
ADJUSTMENTS
Engine oil pressure check .............................................................................................................. 12-2-11
REPAIRS
Seal - crankshaft - rear .................................................................................................................. 12-2-13
Gasket - cylinder head - LH ........................................................................................................... 12-2-14
Gasket - cylinder head - RH ............................................................................................................ 12-2-16
Gasket - rocker cover - LH ............................................................................................................ 12-2-19
Gasket - rocker cover - RH ............................................................................................................ 12-2-20
Mounting - front - LH ...................................................................................................................... 12-2-22
Mounting - front - RH ..................................................................................................................... 12-2-23
Mounting - rear - LH ....................................................................................................................... 12-2-24
Mounting - rear - RH ...................................................................................................................... 12-2-25
Engine assembly............................................................................................................................. 12-2-26
Flywheel ........................................................................................................................................ 12-2-31
Plate - drive - automatic ................................................................................................................ 12-2-32
Ring gear - starter ......................................................................................................................... 12-2-34
Filter - oil ....................................................................................................................................... 12-2-35
Strainer - oil pick-up ...................................................................................................................... 12-2-35
Pump - oil ...................................................................................................................................... 12-2-36
Gasket - sump ................................................................................................................................ 12-2-37
Switch - oil pressure ....................................................................................................................... 12-2-39
Cooler - engine oil .......................................................................................................................... 12-2-39
Gasket - timing gear cover ............................................................................................................ 12-2-41
Seal - cover - timing gears ............................................................................................................ 12-2-43
OVERHAUL
Gasket - inlet manifold ................................................................................................................... 12-2-45
Gasket - exhaust manifold ............................................................................................................. 12-2-48
Seal - crankshaft - rear - automatic models .................................................................................... 12-2-49
Seal - crankshaft - rear - manual models ........................................................................................ 12-2-50
Bearing - spigot - crankshaft .......................................................................................................... 12-2-52
Gasket - engine sump .................................................................................................................... 12-2-53
Strainer - oil pick-up ....................................................................................................................... 12-2-54
Seal - timing gear cover ................................................................................................................. 12-2-55
Gasket - timing gear cover ............................................................................................................. 12-2-56
Timing chain and gears .................................................................................................................. 12-2-58
Rocker shaft - overhaul ................................................................................................................. 12-2-59
Gasket - cylinder head .................................................................................................................... 12-2-61
Cylinder head - overhaul ................................................................................................................ 12-2-63
Piston assemblies ........................................................................................................................... 12-2-67
Bearings - connecting rods ............................................................................................................ 12-2-72
Crankshaft and main bearings ........................................................................................................ 12-2-73
Camshaft ....................................................................................................................................... 12-2-77
Page 10 of 1529
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
Page 14 of 1529
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
Page 15 of 1529
CONTENTS
12 CONTENTS
AUTOMATIC GEARBOX - ZF4HP22 - 24 ................................................ 44-1
DESCRIPTION AND OPERATION
Automatic gearbox component layout ............................................................................................ 44-1
Control schematic ........................................................................................................................... 44-2
Description ...................................................................................................................................... 44-4
Operation ........................................................................................................................................ 44-17
ADJUSTMENTS
Cable - selector ............................................................................................................................. 44-21
Stall test .......................................................................................................................................... 44-21
REPAIRS
Cable and lever assembly - selector .............................................................................................. 44-23
Selector indicator .......................................................................................................................... 44-24
Switch - starter inhibitor ................................................................................................................. 44-25
Seal - selector shaft ........................................................................................................................ 44-26
Gearbox - convertor and transfer gearbox - Diesel ....................................................................... 44-27
Gearbox - convertor and transfer gearbox - V8 ............................................................................ 44-32
Torque converter and oil seal ......................................................................................................... 44-37
Housing - torque converter ............................................................................................................ 44-38
Gasket - intermediate plate ............................................................................................................ 44-39
Intermediate plate .......................................................................................................................... 44-41
Pump - fluid .................................................................................................................................... 44-43
Seal - rear extension housing ......................................................................................................... 44-44
Gasket - rear extension housing. .................................................................................................. 44-45
Parking pawl assembly. ................................................................................................................ 44-46
Gasket - oil sump ........................................................................................................................... 44-47
Filter - oil ........................................................................................................................................ 44-48
Cooler - fluid - Td5 .......................................................................................................................... 44-49
Cooler - fluid - V8 ........................................................................................................................... 44-50
Valve body assembly ..................................................................................................................... 44-51
Seal - valve body ........................................................................................................................... 44-53
Pressure regulator ......................................................................................................................... 44-54
Lock-up solenoid valve (MV 3) ...................................................................................................... 44-55
Solenoids - shift control valves
(MV 1 & 2) 44-56
Harness - solenoid valves .............................................................................................................. 44-57
Electronic control unit - automatic transmission ............................................................................. 44-58
PROPELLER SHAFTS ............................................................................. 47-1
DESCRIPTION AND OPERATION
Propeller shaft component layout ................................................................................................... 47-1
Description ...................................................................................................................................... 47-2
REPAIRS
Propeller shaft - front ..................................................................................................................... 47-5
Propeller shaft - rear ...................................................................................................................... 47-5
Bush - spigot - rear propeller shaft ................................................................................................ 47-6
Flexible coupling ............................................................................................................................ 47-7
OVERHAUL
Propeller shaft................................................................................................................................. 47-9
Page 17 of 1529
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
Page 18 of 1529
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
Page 19 of 1529
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