Workshop Manual
Discovery Series II
Discovery Series II
WORKSHOP MANUAL - 1999MY ON
Publication Part No. VDR 100330 NAS (6)
© Land Rover 2003
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form,
electronic, mechanical, recording or other means without prior written permission from Land Rover.
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
2 CONTENTS
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
CONTENTS
4 CONTENTS
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 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
CONTENTS
6 CONTENTS
EMISSION CONTROL - V8 ....................................................................... 17-2-1
DESCRIPTION AND OPERATION
Crankcase emission control system ............................................................................................... 17-2-1
Exhaust emission control ................................................................................................................ 17-2-2
Evaporative emission system component layout ............................................................................ 17-2-3
Evaporative emission system (with positive pressure leak detection) component layout (NAS only) 17-2-4
Evaporative emission system control diagram ............................................................................... 17-2-5
Secondary air injection system component layout.......................................................................... 17-2-6
Secondary air injection system control diagram ............................................................................. 17-2-8
Emission Control Systems .............................................................................................................. 17-2-9
Crankcase Emission Control System ............................................................................................. 17-2-10
Exhaust Emission Control System.................................................................................................. 17-2-11
Evaporative Emission Control System............................................................................................ 17-2-15
Secondary Air Injection System...................................................................................................... 17-2-26
Crankcase Emission Control Operation.......................................................................................... 17-2-34
Exhaust Emission Control Operation .............................................................................................. 17-2-35
Evaporative Emission Control Operation ........................................................................................ 17-2-39
Secondary Air Injection System Operation ..................................................................................... 17-2-43
SAI System Fault Finding and Check Malfunctions ........................................................................ 17-2-44
REPAIRS
Canister - EVAP ............................................................................................................................ 17-2-51
Canister - EVAP - Models with Fuel Leak Detection Pump - up to 03MY ...................................... 17-2-52
Canister - EVAP - Models with Fuel Leak Detection Pump - from 03MY ....................................... 17-2-53
Valve - purge control ..................................................................................................................... 17-2-54
Solenoid - evap canister vent solenoid (CVS) valve ..................................................................... 17-2-55
Sensor - heated oxygen (HO2S) - pre-catalytic converter .............................................................. 17-2-56
Sensor - heated oxygen (HO2S) - post-catalytic converter ............................................................ 17-2-57
Control Valve - Secondary Air Injection (SAI) ............................................................................... 17-2-58
Reservoir - Vacuum - Secondary Air Injection (SAI) - up to 03MY ................................................. 17-2-58
Reservoir - vacuum - Secondary Air Injection (SAI) - from 03MY .................................................. 17-2-59
Pump - Air - Secondary Air Injection (SAI) ..................................................................................... 17-2-59
Air Manifold - LH - Secondary Air Injection (SAI) ........................................................................... 17-2-60
Air Manifold - RH - Secondary Air Injection (SAI) .......................................................................... 17-2-61
Solenoid - Vacuum - Secondary Air Injection (SAI) ...................................................................... 17-2-62
Pipe - Secondary Air Injection (SAI) .............................................................................................. 17-2-62
Pump - Fuel Leak Detection - up to 03MY...................................................................................... 17-2-64
Pump - fuel leak detection - from 03MY ......................................................................................... 17-2-64
Filter - fuel leak detection pump - up to 03MY ................................................................................ 17-2-65
Filter - fuel leak detection pump - from 03MY ................................................................................. 17-2-65
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
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