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Discovery Series II - Workshop Manual - 1999MY ON - 6th Edition - NAS

Discovery Series II - Workshop Manual - 1999MY ON - 6th Edition - NAS
Discovery Series II - Workshop Manual - 1999MY ON - 6th Edition - NAS|Page 3
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INTRODUCTION
- How To Use This Manual
- Repairs and Replacements
- INTRODUCTION|Specifications
- Abbreviations and Symbols
- Abbreviations and Symbols|Page 37
GENERAL INFORMATION
- General Precautions
- Safety Instructions
- Environmental Precautions
- Environmental Precautions|Page 42
- Environmental Precautions|Page 43
- General Fitting Instructions
- Ball and Roller Bearings
- Oil Seals
- Joints and Joint Faces
- Locking Devices
- Screw Threads
- Bolt and Nut Identification
- Bolt and Nut Identification|Page 51
- Flexible Pipes and Hoses
- Flexible Pipes and Hoses|Page 53
- Rolling Road Testing
- Fuel Handling Precautions
- Electrical Precautions
- Supplementary Restraint System Precautions
- Supplementary Restraint System Precautions|Page 58
- Supplementary Restraint System Precautions|Page 59
- Supplementary Restraint System Precautions|Page 60
- Supplementary Restraint System Precautions|Page 61
- SRS Component Replacement Policy
- Air Conditioning System Precautions
- Air Conditioning System Precautions|Page 64
- Air Conditioning Compressor Replacement
- Body Repairs
- Body Repairs|Page 67
GENERAL DATA
- Engine - Td5
- Engine - Td5|Page 70
- Engine - Td5|Page 71
- Engine - V8
- Engine - V8|Page 73
- Engine - V8|Page 74
- Engine - V8|Page 75
- Fuel system - Td5
- Fuel system - V8
- Cooling system - Td5
- Cooling system - V8
- Clutch - Td5
- Clutch - V8
- Manual gearbox - R380
- Transfer box - LT230SE
- Automatic gearbox - ZF4HP22/24
- Rear axle
- Front axle
- Steering
- Suspension
- GENERAL DATA|Brakes
- Wheels and tyres
- Air conditioning
- Electrical - Td5
- Electrical - V8
- Dimensions
- GENERAL DATA|Weights
IDENTIFICATION NUMBERS
- Vehicle Identification Number
- Vehicle Identification Number|Page 98
- Identification Number Locations
- Identification Number Locations|Page 100
TORQUE WRENCH SETTINGS
- TORQUE WRENCH SETTINGS|Maintenance
- Engine Td5
- Engine Td5|Page 104
- Engine V8
- Emission control - Td5
- Emission control - V8
- Engine management system - Td5
- Engine management system - V8
- Cooling system
- Manifolds and exhaust systems - Td5
- Manifolds and exhaust systems - V8
- TORQUE WRENCH SETTINGS|Clutch
- Manual gearbox - R380
- Transfer box - LT230SE
- Automatic gearbox - ZF4HP22
- Propeller shafts
- TORQUE WRENCH SETTINGS|Axles
- Steering
- Front suspension
- Rear suspension
- TORQUE WRENCH SETTINGS|Brakes
- Restraint systems
- TORQUE WRENCH SETTINGS|Body
- Heating and air conditioning
- Wipers and washers
- Electrical
- Electrical|Page 128
LIFTING AND TOWING
- LIFTING AND TOWING|LIFTING
- LIFTING AND TOWING|TOWING
- LIFTING AND TOWING|TOWING|Page 132
- TRANSPORTING
CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
- Capacities
- Fluids
- Anti-Freeze Concentration
- Lubrication
- Sealants
- Sealants|Page 140
- Sealants|Page 141
MAINTENANCE
- PROCEDURES
  - V8 engine underbonnet view
  - Diesel underbonnet view
  - Seats and seat belts
  - Seats and seat belts|Page 147
  - Lamps, horns and warning indicators
  - Wipers and washers
  - Handbrake
  - Alarm handset battery
  - Road wheels
  - Tyres
  - Brake pads, discs and calipers
  - Road wheel speed sensors
  - Brake fluid
  - Fuel filter - diesel engine
  - Fuel filter sedimenter
  - Road wheels
  - Radiator/Intercooler
  - Ambient air Temperature and pressure sensor
  - Doors, bonnet and fuel filler flap
  - Air suspension intake filter
  - Anti-freeze
  - Cooling system
  - Spark plugs - V8 engine
  - Air cleaner - V8 engine
  - Air cleaner and dump valve - diesel engine
  - Auxiliary drive belt
  - Auxiliary drive belt - V8 engine
  - Auxiliary drive belt - diesel engine
  - Fluid reservoirs
  - Steering box
  - PROCEDURES|Battery
  - Intercooler - diesel engine
  - Engine oil - V8 engine
  - Engine oil - diesel engine
  - Centrifuge rotor – diesel engine
  - Engine oil filter - diesel engine
  - Engine oil filter – V8 engine
  - Manual gearbox
  - Automatic gearbox
  - Transfer box
  - Front and rear axle
  - Propeller shafts
  - Propeller shafts|Page 186
  - Anti-roll bar links
  - ACE actuators
  - ACE filter
  - Brake hose, brake, fuel, ACE, clutch pipes and unions/electrical harnesses
  - Engine, gearbox, transfer box and axles
  - Exhaust system
  - Steering box and front suspension
  - Steering box and front suspension|Page 194
  - Steering rod ball joints
  - Dampers and SLS height sensors
  - Front and rear axle suspension links
  - Towing bracket
  - Engine mountings - V8 engine
  - Road/roller test
  - Road/roller test|Page 201
ENGINE - V8
- DESCRIPTION AND OPERATION
- ADJUSTMENTS
  - Engine oil pressure check
  - Engine oil pressure check|Page 216
- REPAIRS
- OVERHAUL
EMISSION CONTROL - V8
- DESCRIPTION AND OPERATION
- REPAIRS
  - Canister - EVAP
  - Canister - EVAP - Models with Fuel Leak Detection Pump - up to 03MY
  - Canister - EVAP - Models with Fuel Leak Detection Pump - from 03MY
  - Valve - purge control
  - Solenoid - evap canister vent solenoid (CVS) valve
  - Sensor - heated oxygen (HO
  - Sensor - heated oxygen (HO
  - Control Valve - Secondary Air Injection (SAI)
  - Reservoir - Vacuum - Secondary Air Injection (SAI) - up to 03MY
  - Reservoir - vacuum - Secondary Air Injection (SAI) - from 03MY
  - Pump - Air - Secondary Air Injection (SAI)
  - Air Manifold - LH - Secondary Air Injection (SAI)
  - Air Manifold - RH - Secondary Air Injection (SAI)
  - Solenoid - Vacuum - Secondary Air Injection (SAI)
  - Pipe - Secondary Air Injection (SAI)
  - Pipe - Secondary Air Injection (SAI)|Page 355
  - Pump - Fuel Leak Detection - up to 03MY
  - Pump - fuel leak detection - from 03MY
  - Filter - fuel leak detection pump - up to 03MY
  - Filter - fuel leak detection pump - from 03MY
  - Filter - fuel leak detection pump - from 03MY|Page 360
ENGINE MANAGEMENT SYSTEM - V8
- DESCRIPTION AND OPERATION
- DESCRIPTION AND OPERATION
- ADJUSTMENTS
  - Cable - throttle
  - Cable - cruise control
  - Cable - cruise control|Page 443
- REPAIRS
  - Spark plugs
  - Coil - ignition
  - Engine control module (ECM)
  - Sensor - engine coolant temperature (ECT)
  - Sensor - crankshaft position (CKP)
  - Sensor - radiator temperature
  - Sensor - camshaft position (CMP)
  - Knock sensor (KS)
  - Air cleaner assembly
  - Element - air filter
  - Cable - throttle
  - Sensor - Mass Air Flow (MAF)
  - Throttle Body
  - Plenum chamber
  - Sensor - throttle position (TP)
  - Valve - idle air control (IACV)
  - Injectors
  - Injectors|Page 462
  - Actuator - cruise control
  - Vacuum control unit - up to 03MY
  - Vacuum control unit - from 03MY
  - Cable - cruise control
  - Switch - cruise control (on/off)
  - Switch - cruise control (set/resume)
  - Switch - clutch pedal - cruise control
  - ECU - Cruise control
FUEL DELIVERY SYSTEM - V8
- DESCRIPTION AND OPERATION
- ADJUSTMENTS
  - Fuel tank - drain
  - Fuel tank - drain|Page 485
- REPAIRS
  - Switch - inertia - fuel cut-off
  - Pump - fuel
  - Pump - fuel|Page 489
  - Tank - fuel
  - Filler tube - fuel
  - Solenoid - fuel filler flap release
  - Switch - fuel filler flap release - up to 03MY
  - Switch - fuel filler flap release - from 03MY
  - Switch - fuel filler flap release - from 03MY|Page 495
COOLING SYSTEM - V8
- DESCRIPTION AND OPERATION
- ADJUSTMENTS
  - Drain and refill
  - Drain and refill|Page 511
- REPAIRS
  - Fan - viscous
  - Radiator
  - Radiator|Page 515
  - Radiator|Page 516
  - Thermostat
  - Gasket - coolant pump
  - Gasket - coolant pump|Page 519
MANIFOLDS AND EXHAUST SYSTEMS - V8
- DESCRIPTION AND OPERATION
- REPAIRS
CLUTCH - V8
- DESCRIPTION AND OPERATION
- ADJUSTMENTS
  - Clutch hydraulic system - bleed
  - Clutch hydraulic system - bleed|Page 559
- REPAIRS
  - Clutch assembly
  - Master cylinder
  - Bearing and lever - clutch release
  - Slave cylinder
  - Slave cylinder|Page 565
MANUAL GEARBOX - R380
- DESCRIPTION AND OPERATION
- ADJUSTMENTS
  - Spring - gear lever bias
  - Spring - gear lever bias|Page 578
- REPAIRS
- OVERHAUL
TRANSFER BOX - LT230SE
- DESCRIPTION AND OPERATION
- ADJUSTMENTS
  - Cable - selector - differential lock - adjust
  - Cable - high/low selector
  - Cable - high/low selector|Page 651
- REPAIRS
  - Bottom cover - transfer box
  - Cable - selector - differential lock
  - Transfer box - Diesel
  - Transfer box - Diesel|Page 656
  - Transfer box - Diesel|Page 657
  - Transfer box - Diesel|Page 658
  - Transfer box - V8
  - Transfer box - V8|Page 660
  - Transfer box - V8|Page 661
  - Transfer box - V8|Page 662
  - Gasket - rear cover plate
  - Switch - differential lock - Up to 03 MY
  - Cable - high/low selector
  - Oil seal - input shaft
  - Seal - front output shaft
  - Seal - front output shaft|Page 668
  - Seal - rear output shaft
  - Gasket - rear output shaft housing
  - Solenoid - interlock - Up to 03 MY
  - Solenoid - interlock - from 03 MY
  - Sensor - neutral
  - Sensor - oil temperature - If fitted
  - Switch - high low - warning
  - Switch(es) - differential lock warning From 03 MY
- OVERHAUL
AUTOMATIC GEARBOX - ZF4HP22 - 24
- DESCRIPTION AND OPERATION
- ADJUSTMENTS
  - Cable - selector
  - Stall test
  - Stall test|Page 733
- REPAIRS
PROPELLER SHAFTS
- DESCRIPTION AND OPERATION
- REPAIRS
  - Propeller shaft - front
  - Propeller shaft - rear
  - Bush - spigot - rear propeller shaft
  - Flexible coupling
  - Flexible coupling|Page 782
- OVERHAUL
  - Propeller shaft
  - Propeller shaft|Page 785
REAR AXLE
- DESCRIPTION AND OPERATION
- REPAIRS
- OVERHAUL
FRONT AXLE
- DESCRIPTION AND OPERATION
- REPAIRS
STEERING
- DESCRIPTION AND OPERATION
- ADJUSTMENTS
- REPAIRS
FRONT SUSPENSION
- DESCRIPTION AND OPERATION
- DESCRIPTION AND OPERATION
- ADJUSTMENTS
  - ACE hydraulic system bleeding
  - Fluid level check - ACE system
  - Fluid level check - ACE system|Page 909
- REPAIRS
REAR SUSPENSION
- DESCRIPTION AND OPERATION
- DESCRIPTION AND OPERATION
- ADJUSTMENTS
  - SLS calibration blocks
  - SLS calibration blocks|Page 980
- REPAIRS
BRAKES
- DESCRIPTION AND OPERATION
- DESCRIPTION AND OPERATION
- ADJUSTMENTS
- REPAIRS
RESTRAINT SYSTEMS
- DESCRIPTION AND OPERATION
- DESCRIPTION AND OPERATION
  - Description - seat belts
  - Description - seat belts|Page 1074
- REPAIRS
DOORS
- REPAIRS
  - Door - front
  - Door - rear
  - Door - tail
  - Door - tail|Page 1100
  - Glass - front or rear door
  - Quarter light
  - Regulator and motor - front and rear door glass
  - Trim casing - front door
  - Trim casing - rear door
  - Trim casing - tail door
  - Latch and motor - front door
  - Latch and motor - rear door
  - Latch and motor - tail door
  - Handle - exterior - rear door
  - Handle - exterior - tail door
  - Handle - exterior - front door
EXTERIOR FITTINGS
- REPAIRS
INTERIOR TRIM COMPONENTS
- REPAIRS
SCREENS
- REPAIRS
SEATS
- DESCRIPTION AND OPERATION
- DESCRIPTION AND OPERATION
- REPAIRS
  - Seat - front
  - Seat - third row
  - Seat - third row|Page 1195
  - Seat - rear
  - Bolster assembly - rear armrest
  - Cover - cushion - front seat
  - Heating element - cushion - front seat
  - Cover - cushion - rear seat
  - Bladder - lumbar support
  - Motor - fore and aft - front seat
  - Motor - rise and fall - front seat
  - Motor - tilt - front seat
  - Motor - recline
  - Switch - electric seats
  - Cable - rear squab latch
  - Latch - rear seat
  - Latch - rear seat|Page 1209
  - Cover - squab - front seat
  - Cover - squab - front seat|Page 1211
  - Cover - squab - front seat|Page 1212
  - Cover - squab - RH rear seat
  - Cover - squab - RH rear seat|Page 1214
  - Heating element - squab - front seat
  - Head restraint - third row seat
  - Head restraint - third row seat|Page 1217
SUNROOF
- DESCRIPTION AND OPERATION
- REPAIRS
  - Sunroof - front
  - Sunroof - rear
  - Glass panel - sunroof
  - Motor - sunroof
  - Drive cable assembly
  - Switch pack - sunroof
  - ECU - sunroof
CHASSIS AND BODY DIMENSIONS
- CHASSIS DIMENSIONS
- BODY DIMENSIONS
PANEL REPAIRS
- REPLACEMENT PANELS
  - Replacement panels
  - Front end inner panels
  - Valance panels
  - Body side panels
  - Body side assembly
  - 'D'-post assembly
  - Rear floor assembly.
  - Rear end panels
  - Front and rear doors
  - Taildoor
  - Roof panels
  - Replacement panels
- PROCEDURES
  - General welding precautions
  - Electronic control units
- PROCEDURES
- PROCEDURES|Page 1279
- PROCEDURES|Page 1280
- PROCEDURES|Page 1281
- PROCEDURES|Page 1282
- PROCEDURES|Page 1283
- PANEL REPAIRS|REPAIRS
- PANEL REPAIRS|REPAIRS|Page 1285
- PANEL REPAIRS|REPAIRS|Page 1286
- PANEL REPAIRS|REPAIRS|Page 1287
- PANEL REPAIRS|REPAIRS|Page 1288
- PANEL REPAIRS|REPAIRS|Page 1289
- PANEL REPAIRS|REPAIRS|Page 1290
- PANEL REPAIRS|REPAIRS|Page 1291
- PANEL REPAIRS|REPAIRS|Page 1292
- PANEL REPAIRS|REPAIRS|Page 1293
- PANEL REPAIRS|REPAIRS|Page 1294
- PANEL REPAIRS|REPAIRS|Page 1295
- PANEL REPAIRS|REPAIRS|Page 1296
- PANEL REPAIRS|REPAIRS|Page 1297
- PANEL REPAIRS|REPAIRS|Page 1298
- PANEL REPAIRS|REPAIRS|Page 1299
- PANEL REPAIRS|REPAIRS|Page 1300
- PANEL REPAIRS|REPAIRS|Page 1301
- PANEL REPAIRS|REPAIRS|Page 1302
- PANEL REPAIRS|REPAIRS|Page 1303
- PANEL REPAIRS|REPAIRS|Page 1304
- PANEL REPAIRS|REPAIRS|Page 1305
- PANEL REPAIRS|REPAIRS|Page 1306
- PANEL REPAIRS|REPAIRS|Page 1307
- PANEL REPAIRS|REPAIRS|Page 1308
- PANEL REPAIRS|REPAIRS|Page 1309
- PANEL REPAIRS|REPAIRS|Page 1310
- PANEL REPAIRS|REPAIRS|Page 1311
- PANEL REPAIRS|REPAIRS|Page 1312
- PANEL REPAIRS|REPAIRS|Page 1313
- PANEL REPAIRS|REPAIRS|Page 1314
- PANEL REPAIRS|REPAIRS|Page 1315
- PANEL REPAIRS|REPAIRS|Page 1316
- PANEL REPAIRS|REPAIRS|Page 1317
- TIMES
  - TIME SCHEDULES
  - TIME SCHEDULES|Page 1320
  - TIME SCHEDULES|Page 1321
  - TIME SCHEDULES|Page 1322
BODY SEALING MATERIALS
- MATERIALS AND APPLICATIONS
CORROSION PREVENTION AND SEALING
- CORROSION PREVENTION
- SEALING
PAINTING
- PROCEDURES
  - Panel preparation
  - Paint preparation
HEATING AND VENTILATION
- DESCRIPTION AND OPERATION
- REPAIRS
AIR CONDITIONING
- DESCRIPTION AND OPERATION
- DESCRIPTION AND OPERATION
- REFRIGERANT RECOVERY, RECYCLING AND RECHARGING
  - Refrigerant recovery, recycling and recharging
  - Refrigerant recovery, recycling and recharging|Page 1430
- REPAIRS
WIPERS AND WASHERS
- DESCRIPTION AND OPERATION
- REPAIRS
  - Reservoir - washer - up to 03MY
  - Reservoir - washer - from 03MY
  - Jet - washer - windscreen
  - Pump - washer - screen and headlamp
  - Motor and linkage - wiper - windscreen
  - Switch - wiper and washer - windscreen
  - Jet - washer - headlamp
  - Jet - washer - rear screen
  - Switch - rear wash
  - Motor - wiper - rear screen
  - Switch - wiper - rear - up to 03MY
  - Switch - wiper - rear - from 03MY
CHARGING AND STARTING
- REPAIRS
LIGHTING
- ADJUSTMENTS
  - Headlamps beam alignment - up to 03MY
  - Headlamps beam alignment - from 03MY
- REPAIRS
  - Lamp - front repeater - up to 03MY
  - Headlamp - up to 03MY
  - Headlamp - from 03MY
  - Lamp - tail
  - Lamp - front fog up to 03MY
  - Lamp - front fog from 03MY
  - Housing - number plate lamp
  - Motor - headlamp levelling
  - Lamp - stop - centre high mounted (CHMSL)
  - Lamp - tail/flasher - bumper
  - Lamp - interior - front
  - Lamp - interior - rear
  - Rheostat - panel lights dimmer
  - Switch - hazard warning
  - Switch - indicator and exterior lighting - combined
  - Socket - accessory
  - Switch - front/rear fog lamps
BODY CONTROL UNIT
- DESCRIPTION AND OPERATION
- REPAIRS
ALARM SYSTEM AND HORN
- DESCRIPTION AND OPERATION
- REPAIR
  - Switch - central door locking
  - Switches - horn
  - Vehicle horn
  - Sounder - alarm
  - Sounder - battery backed-up (BBUS)
  - Switch - bonnet
  - Receiver - alarm system - models with sunroof
  - Receiver - alarm system - models without sunroof
  - Coil - passive immobilisation
  - Coil - passive immobilisation|Page 1596
WINDOWS
- DESCRIPTION AND OPERATION
- REPAIRS
  - Switch - rear door
  - Switch - console
  - Switch - heated rear screen
IN CAR ENTERTAINMENT
- DESCRIPTION AND OPERATION
- DESCRIPTION AND OPERATION
- REPAIRS
  - IN CAR ENTERTAINMENT|Radio
  - Speaker - low/full range - front door
  - Speaker - low range - rear door
  - Switches - remote control - ICE
  - Amplifier - aerial
  - Speaker - mid range - front door
  - Speaker - high range - rear door
  - Amplifier - power
  - Speaker - tail door
  - CD autochanger
  - DVD screen/player unit
  - Switch box - CD/DVD player
HARNESSES
- REPAIRS
DRIVING AIDS
- DESCRIPTION AND OPERATION
- REPAIRS
NAVIGATION SYSTEM
- DESCRIPTION AND OPERATION
- DESCRIPTION AND OPERATION
- REPAIRS
  - Interface electronic control unit (ECU) - remote control
  - Display unit
INSTRUMENTS
- DESCRIPTION AND OPERATION
- REPAIRS
  - Clock
  - Instrument pack