1999 LAND ROVER DISCOVERY maintenance

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
CONTENTS 3
MAINTENANCE ........................................................................................ 10-1
PROCEDURES
V8 engine underbonnet view .......................................................................................................... 10-1
Diesel underbonnet view ................................................................................................................. 10-2
Seats and seat belts ...................................................................................................................... 10-3
Lamps, horns and warning indicators ............................................................................................. 10-5
Wipers and washers ...................................................................................................................... 10-5
Handbrake .................................................................................................................................. 10-6
Alarm handset battery ..................................................................................................................... 10-6
Road wheels ................................................................................................................................... 10-6
Tyres .............................................................................................................................................. 10-6
Brake pads, discs and calipers ....................................................................................................... 10-6
Road wheel speed sensors ............................................................................................................. 10-7
Brake fluid ....................................................................................................................................... 10-7
Fuel filter - diesel engine ................................................................................................................. 10-7
Fuel filter sedimenter ...................................................................................................................... 10-7
Road wheels ................................................................................................................................... 10-8
Radiator/Intercooler ........................................................................................................................ 10-8
Ambient air Temperature and pressure sensor .............................................................................. 10-8
Doors, bonnet and fuel filler flap ..................................................................................................... 10-8
Air suspension intake filter .............................................................................................................. 10-9
Anti-freeze....................................................................................................................................... 10-9
Cooling system ............................................................................................................................... 10-9
Spark plugs - V8 engine.................................................................................................................. 10-10
Air cleaner - V8 engine ................................................................................................................... 10-10
Air cleaner and dump valve - diesel engine .................................................................................... 10-10
Auxiliary drive belt ........................................................................................................................... 10-11
Auxiliary drive belt - V8 engine ....................................................................................................... 10-11
Auxiliary drive belt - diesel engine .................................................................................................. 10-11
Fluid reservoirs ............................................................................................................................... 10-12
Steering box .................................................................................................................................... 10-13
Battery ............................................................................................................................................. 10-13
Intercooler - diesel engine............................................................................................................... 10-14
Engine oil - V8 engine ..................................................................................................................... 10-14
Engine oil - diesel engine ................................................................................................................ 10-15
Centrifuge rotor – diesel engine ...................................................................................................... 10-15
Engine oil filter - diesel engine ........................................................................................................ 10-16
Engine oil filter – V8 engine ............................................................................................................ 10-16
Manual gearbox .............................................................................................................................. 10-17
Automatic gearbox ......................................................................................................................... 10-18
Transfer box .................................................................................................................................... 10-19
Front and rear axle .......................................................................................................................... 10-20
Propeller shafts ............................................................................................................................... 10-20
Anti-roll bar links ............................................................................................................................. 10-22
ACE actuators ................................................................................................................................. 10-23
ACE filter ......................................................................................................................................... 10-23

INTRODUCTION
01-1
INTRODUCTION
How To Use This Manual
Introduction
This Manual is designed to assist skilled technicians
in the efficient repair and maintenance of Discovery
vehicles.
Individuals who undertake their own repairs should
have some skill and training, and limit repairs to
components which could not affect the safety of the
vehicle or its passengers. Any repairs required to
safety critical items such as steering, brakes,
suspension or supplementary restraint system
should be carried out by a Land Rover Dealer.
Repairs to such items should NEVER be attempted
by untrained individuals.
General
To assist in the use of this Manual, it is divided into
sections and sub-sections. The section title is given
at the top of each page and the relevant sub-section
is given at the bottom.
There is a single contents section at the front of the
Manual, which is divided by section and sub-section.
Each section is numbered from page 1.
The individual items comprising repair operations are
to be followed in the sequence in which they appear.
Items numbers in the illustration are referred to in the
text.
Adjustment and Repair operations include reference
to Service tool numbers and the associated
illustration depicts the tool in use. Adjustment and
repair operations also include reference to wear
limits, relevant data, torque figures, and specialist
information and useful assembly details. Each
adjustment or repair operation is given its Service
Repair Operation number.
WARNINGS, CAUTIONS and NOTES have the
following meanings:
WARNING: Procedures which must be followed
precisely to avoid the possibility of injury.
CAUTION: Calls attention to procedures which
must be followed to avoid damage to
components.
NOTE: Gives helpful information.References
References to the LH or RH side given in this Manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
crankshaft pulley end of the engine is referred to as
the front.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and tested after
completion and if necessary a road test of the vehicle
is carried out particularly where safety related items
are concerned.
Dimensions
The dimensions quoted are to design engineering
specification with Service limits where applicable.

GENERAL INFORMATION
03-3
Environmental Precautions
General
This section provides general information which can
help to reduce the environmental impacts from the
activities carried out in workshops.
Emissions to air
Many of the activities that are carried out in
workshops emit gases and fumes which contribute to
global warming, depletion of the ozone layer and/or
the formation of photochemical smog at ground
level. By considering how the workshop activities are
carried out, these gases and fumes can be
minimised, thus reducing the impact on the
environment.
Exhaust fumes
Running car engines is an essential part of workshop
activities and exhaust fumes need to be ventilated to
atmosphere. However, the amount of time engines
are running and the position of the vehicle should be
carefully considered at all times, to reduce the
release of poisonous gases and minimise the
inconvenience to people living nearby.
Solvents
Some of the cleaning agents used are solvent based
and will evaporate to atmosphere if used carelessly,
or if cans are left unsealed. All solvent containers
should be firmly closed when not needed and
solvent should be used sparingly. Suitable
alternative materials may be available to replace
some of the commonly used solvents. Similarly,
many paints are solvent based and the spray should
be minimised to reduce solvent emissions.
Refrigerant
It is illegal to release any refrigerants into the
atmosphere. Discharge and replacement of these
materials from air conditioning units should only be
carried out using the correct equipment.
Checklist
Always adhere to the following.
Engines:
ldon't leave engines running unnecessarily;
lminimise testing times and check where the
exhaust fumes are being blown.
Materials:
lkeep lids on containers of solvents;
lonly use the minimum quantity;
lconsider alternative materials;
lminimise over-spray when painting. Gases:
luse the correct equipment for collecting
refrigerants;
ldon't burn rubbish on site.
Discharges to water
Most sites will have two systems for discharging
water: storm drains and foul drains. Storm drains
should only receive clean water, foul drains will take
dirty water.
The foul drain will accept many of the normal waste
waters such as washing water, detergents and
domestic type wastes, but oil, petrol, solvent, acids,
hydraulic oil, antifreeze and other such substances
should never be poured down the drain. If in any
doubt speak to the Water Company first.
Every precaution must be taken to prevent spillage of
oil, fuel, solvents etc. reaching the drains. All
handling of such materials must take place well away
from the drains and preferably in an area with a kerb
or wall around it, to prevent discharge into the drain.
If a spillage occurs it should be soaked up
immediately. Having a spill kit available will make
this easier.
Additional precautions
Check whether the surface water drains are
connected to an oil water separator, this could
reduce the pollution if an incident was to occur. Oil
water separators do need regular maintenance to
ensure effectiveness.
Checklist
Always adhere to the following.
Disposal:
lnever pour anything down a drain without first
checking that it is environmentally safe to do so,
and that it does not contravene any local
regulations or bye-laws;
l have oil traps emptied regularly.
Spillage prevention:
lstore liquids in a walled area;
lmake sure that taps on liquid containers are
secure and cannot be accidentally turned on;
lprotect bulk storage tanks from vandalism by
locking the valves;
ltransfer liquids from one container to another in
an area away from open drains;
lensure lids are replaced securely on containers;
lhave spill kits available near to points of storage
and handling of liquids.

TORQUE WRENCH SETTINGS
06-1
TORQUE WRE NCH SETTINGS
Maintenance
TORQUE DESCRIPTION METRIC IMPERIAL
Wheel nuts 140 Nm (103 lbf.ft)
V8 oil drain plug 33 Nm (24 lbf.ft)
Td5 oil drain plug 23 Nm (17 lbf.ft)
Oil filter element, tighten two thirds of a turn by hand or to - 17 Nm (13 lbf.ft)
Manual gearbox oil drain plug 50 Nm (37 lbf.ft)
Manual gearbox oil filler/level plug 30 Nm (22 lbf.ft)
Automatic gearbox oil drain plug 15 Nm (11 lbf.ft)
Automatic gearbox oil drain plug 30 Nm (22 lbf.ft)
Transfer gearbox oil drain plug 30 Nm (22 lbf.ft)
Transfer gearbox oil filler/level plug 25 Nm (18 lbf.ft)
Axle oil drain plug 64 Nm (47 lbf.ft)
Axle oil filler/level plug 10 Nm (7 lbf.ft)

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
09-2
Fluids
Anti-freeze
Use Havoline Extended Life Coolant (XLC), or any
ethylene glycol based anti-freeze (containing no
methanol) with only Organic Acid Technology (OAT)
corrosion inhibitors, to protect the cooling system
CAUTION: No other anti-freeze should be used
with Havoline Extended Life Coolant.
The cooling system should be drained, flushed and
refilled with the correct amount of anti-freeze solution
at the intervals given on the Service Maintenance
Check Sheet.
After filling with anti-freeze solution, attach a warning
label to a prominent position on the vehicle stating
the type of anti-freeze contained in the cooling
system to ensure that the correct type is used for
topping-up.
Brake/Clutch fluid
Use only DOT 4 brake fluid.
PAS fluid
Use Texaco cold climate power assisted steering
fluid PSF 14315.
ACE fluid
Where ambient temperature falls below -20° C (-4°
F), use only Texaco cold climate power assisted
steering fluid PSF 14315. Where ambient
temperature remains above -20° C (-4° F), use either
Texaco cold climate power assisted steering fluid ,
Dexron 11 or Dexron 111 non-synthetic fluid.
Air conditioning
Use only refrigerant R134a.
Refrigerant oil
Use only Nippon Denso ND-oil 8.
Refrigerant oil absorbs water and must not be stored
for long periods. Do not pour unused oil back into the
container.
NOTE: The total quantity of refrigerant oil in the
system is 180 ml.
CAUTION: Do not use any other type of
refrigerant oil.
Anti-Freeze Concentration
The overall anti-freeze concentration should not fall,
by volume, below 50% to ensure that the anti-
corrosion properties of the coolant are maintained.
Anti-freeze concentrations greater than 60% are not
recommended as cooling efficiency will be impaired.
The following recommended quantities of anti-freeze
will provide frost protection to -48°C (-53°F):
Engine - TD5
Engine - V8
Concentration 50%
Amount of Anti-freeze 4 litres
Concentration 50%
Amount of Anti-freeze 6.5 litres
13.5 pts (US)

MAINTENANCE
PROCEDURES 10-1
MAINTENANCE PROCEDURES
V8 engine underbonnet view
1Brake/clutch fluid reservoir filler caps
2Engine oil filler cap
3Spark plug
4Engine oil dipstick
5Coolant header tank6Battery
7Auxiliary drive belt
8ACE/PAS fluid reservoirs
9Windscreen washer reservoir

MAINTENANCE
10-2 PROCEDURES
Diesel underbonnet view
1Coolant header tank
2Brake/clutch fluid reservoir filler caps
3Engine oil dipstick
4Engine oil filler cap
5ACE/PAS fluid reservoirs6Battery
7Auxiliary drive belt
8Air cleaner
9Windscreen washer reservoir