Maintenance: Other Land Rover Discovery II

Check

1. Switch on side, head and tail lamps and check operation.
2. Check headlamp levelling operation.
3. Check turn signals and hazard warning lamps for correct operation.
4. Press brake pedal and check operation of brake lamps.
5. Check all exterior lamp lenses for clarity and condition. Pay particular attention to headlamp lenses for signs of stone chips or damage.
6. Check horn for loud, clear sound.
7. Switch on headlamps (with ignition switch at 'O' position) and check light reminder warning operates when door is opened.
8. Check operation of interior courtesy lights.
9. Check operation of all instrument pack warning and indicator lights.

Scheme 20

Scheme 21

1. Operate screen washer and switch on wipers. Ensure washer jets are correctly aimed and check for smooth, smear free operation of wiper blades across screen at all speeds including intermittent.
2. Repeat operation for rear screen washers/wipers.
3. Check all wiper blades for condition and signs of splits or damage.
4. Check security of wiper arms.

1. With the vehicle stationary, on a level surface, apply and release handbrake and check for correct operation.

Scheme 22

1. Insert the blade of a small, flat bladed screwdriver into the slot at the rear of the handset and pry the back from the handset.
2. Slide the battery out of the clip taking care not to touch the circuit board or the battery contacts.
3. Press and hold one of the buttons for at least 5 seconds.
4. Fit the replacement battery ensuring that correct polarity is maintained (+) side facing upwards. Avoid touching the flat surfaces of the battery.
5. Press the 2 halves of the handset together.
6. Check that handset operates correctly.

1. Check tires for compliance with manufacturer's specification; visually for cuts, lumps, bulges, uneven tread wear and depth.
2. Check tire pressures, condition and tread depth. Measure the tread depth across the width of the tire and around the circumference.

1. Check front and rear brake pads for wear, ensure all pads are wearing evenly.
2. Check brake discs for signs of cracking, excessive scoring or oil contamination.
3. Check calipers for signs of fluid leaks.
4. Clean excessive deposits of brake dust from pads, calipers and disc shields using brake cleaner.

Scheme 23

Front wheel

Scheme 24

Rear wheel

1. Inspect each sensor harness for damage.

Refit

1. Apply anti-seize compound to wheel hub center.
2. Refit road wheels to original hub position. Tighten wheel nuts to 140 Nm (103 lbf.ft).

1. Visually check radiator/intercooler for external obstructions, remove debris.
2. Visually check fan blades for damage.

Scheme 25

1. Check ambient air temperature and pressure sensor for damage.

1. Check operation of each door, door lock, bonnet catch and fuel filler flap. Ensure doors close securely.

Scheme 26

Scheme 27

1. Lubricate door locks, hinges, check straps, bonnet catch and fuel filler flap.

1. Check condition of filter and that filter is clean, replace if necessary. Refer to «FILTER INTAKE (SLS)»(ref-168357-S11291489842004122200000) .

1. Check cooling, intercooler and heating systems for leaks; hoses and oil pipes for security and condition.
2. Check accessible hose clips for tightness.
3. Check coolant level, top-up if necessary.

Scheme 28

1. With engine cold, remove expansion tank filler cap.
2. Top-up with recommended mixture of coolant until level reaches mark on expansion tank. Refer to «COOLING SYSTEM SPECIFICATIONS»(ref-139295-S37210015422002042900000) .
3. Fit expansion tank filler cap.

Clean

1. Clean the drain hole in filter casing.

Scheme 29

1. Replace air cleaner element.
2. Remove all dirt from dump valve.

Scheme 30

TD5 auxiliary belt

Scheme 31

V8 auxiliary belt

1. Check auxiliary drive belt for signs of splits, fraying, oil contamination and wear.

Auxiliary drive belt - V8 engine

1. Replace auxiliary drive belt. Refer to «DRIVE BELT ROUTING»(ref-139295-S20370064032004100500000) .

1. Check steering box for fluid leaks.

1. Clean and grease battery terminals with petroleum jelly.

Engine oil - V8 engine

Scheme 32

1. Position suitable container beneath sump.
2. Clean area around oil drain plug.
3. Remove oil drain plug, discard sealing washer.
4. Allow oil to drain.
5. Fit new sealing washer to oil drain plug.
6. Fit engine drain plug and tighten to 33 Nm (24 lbf.ft).
7. Fill engine with recommended grade of oil to correct mark on dipstick.

Engine oil - diesel engine

Scheme 33

1. Release fixings, remove underbelly panel.
2. Position suitable container beneath sump.
3. Clean area around drain plug.
4. Remove oil drain plug, discard sealing washer.
5. Allow oil to drain.
6. Fit new sealing washer to oil drain plug.
7. Fit engine drain plug and tighten to 23 Nm (17 lbf.ft).
8. Fill engine with recommended grade of oil to correct mark on dipstick.
9. Fit front underbelly panel, secure fixings.

Engine oil filter - V8 engine

Scheme 34

1. Disconnect battery.
2. Position suitable container beneath oil filter.
3. Using a strap type filter wrench, remove filter element, discard element.
4. Smear sealing ring of replacement filter element with engine oil.
5. Fit filter element, tighten two thirds of a turn by hand or to 17 Nm (13 lbf.ft).
6. Top-up engine with recommended grade of oil to correct mark on dipstick.
7. Connect battery.
8. Run engine and check for oil leaks from filter.
9. Stop engine, wait for oil to return to sump.
10. Re-check oil level and top-up if necessary.

Manual gearbox

Scheme 35

1. Release fixings, remove rear underbelly panel.
2. Clean area around oil filler/level plug.
3. Remove oil filler/level plug.
4. Check that oil level is to bottom of oil filler/level plug hole.
5. Top-up level (if required) with recommended oil to bottom of filler/level plug hole.
6. Fit manual gearbox filler/level plug and tighten to 30 Nm (22 lbf.ft).
7. Remove all traces of oil from gear case.
8. Fit rear underbelly panel, secure fixings.

Scheme 36

1. Release fixings, remove rear underbelly panel.
2. Place a suitable container beneath gearbox drain plug.
3. Clean area around oil filler/level plug and drain plug.
4. Remove oil filler/level plug ("4" in illustration).
5. Remove oil drain plug ("5" in illustration) , remove and discard sealing washer ("5" in illustration).
6. Allow oil to drain.
7. Clean magnet in oil drain plug.
8. Fit new sealing washer to oil drain plug.
9. Fit manual gearbox drain plug and tighten to 50 Nm (37 lbf.ft).
10. Fill gearbox with recommended oil to bottom of filler/level plug hole.
11. Fit manual gearbox filler/level plug and tighten to 30 Nm (22 lbf.ft).
12. Remove all traces of oil from gear case.
13. Fit rear underbelly panel, secure fixings.

Automatic gearbox

Transfer box

Scheme 37

1. Release fixings, remove rear underbelly panel.
2. Clean area around oil filler/level plug.
3. Remove oil filler/level plug.
4. Check that oil level is to bottom of filler/level plug hole.
5. Top-up level (if required) with recommended oil to bottom of oil filler/level plug hole. Refer to «LUBRICATION»(ref-169354-S40370893592004120700000) .
6. Fit transfer box filler/level plug and tighten to 25 Nm (18 lbf.ft).
7. Remove all traces of oil from main casing.
8. Fit rear underbelly panel (if fitted), secure fixings.

Scheme 38

1. Release fixings, remove rear underbelly panel.
2. Place a suitable container beneath transfer box drain plug.
3. Clean area around oil filler/level and drain plugs.
4. Remove oil filler/level plug.
5. Remove oil drain plug.
6. Allow oil to drain.
7. Fit transfer box drain plug and tighten to 30 Nm (22 lbf.ft).
8. Fill transfer box with recommended oil to bottom of oil filler/level plug hole. Refer to «LUBRICATION»(ref-169354-S40370893592004120700000) .
9. Fit transfer box filler/level plug and tighten to 25 Nm (18 lbf.ft).
10. Remove all traces of oil from transfer box.
11. Fit rear underbelly panel (if fitted), secure fixings.

Front and rear axle

Scheme 39

1. Place a suitable container beneath differential housing of axle to be drained.
2. Clean area around oil filler/level and drain plugs.
3. Remove oil filler/level plug.
4. Remove and discard 'O' ring from oil filler/level plug.
5. Remove oil drain plug, allow oil to drain.
6. Fit axle drain plug and tighten to 64 Nm (47 lbf.ft).
7. Fill differential housing with recommended oil to bottom of oil filler/level plug hole. Refer to «LUBRICATION»(ref-164660-S24440400962004051200000) .
8. Lubricate a new 'O' ring with recommended oil and fit to oil filler/level plug.
9. Fit axle filler/level plug and tighten to 10 Nm (7 lbf.ft).
10. Remove all traces of oil from differential housing.

Scheme 40

Rear shaft

Scheme 41

1. Clean area around front universal joint grease nipple.
2. Apply recommended grease to the grease nipple. Refer to «LUBRICANTS»(ref-168563-S12730509992004111100000) . Front shaft
3. Remove blanking plug adjacent to sliding joint from propeller shaft.
4. Screw a 1/4in UNF grease nipple into blanking plug hole.
5. Apply recommended grease to the grease nipple. Refer to «LUBRICANTS»(ref-168563-S12730509992004111100000) .
6. Remove grease nipple.
7. Fit blanking plug.

Scheme 42

Rubber boots

Scheme 43

Fixings

1. Check anti-roll bar links for free play.
2. Check rubber boots for splits, damage and security.

Scheme 44

1. Check condition of mounting rubbers and security of fixings.

Scheme 45

Fixings

Scheme 46

Rubber mountings

1. Check condition of mounting rubbers and security of fixings.

Scheme 47

Actuator boots

1. Check ACE actuator gaiters for splits, damage and clips for security.

1. Check for oil leaks from engine, gearbox (manual and automatic), transfer box and front and rear axles; pay particular attention to areas around oil seals.

1. Check for signs of exhaust system leaks, damage and security.

Scheme 48

1. Check steering box fixings and tighten to 90 Nm (66 lbf.ft).

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

1. Check/tighten front suspension LH radius arm fixings.
2. Check/tighten front suspension RH radius arm fixings.
3. Check/tighten front suspension Panhard rod fixings

Scheme 54

Scheme 55

Scheme 56

1. Check and tighten if necessary all rear axle suspension fixings.

Scheme 57

Scheme 58

1. Check condition of ball joints and dust covers, and security of fixings. Refer to «DESCRIPTION»(ref-171786-S40313354472005021400000) .
2. Attempt to move the ball joints forwards, backwards, side to side and up and down. No end float in any direction should be detected. If end float is present, the ball joint must be renewed.

Scheme 59

Front dampers

Scheme 60

Rear dampers

1. Check dampers for security and signs of leakage.

Scheme 61

SLS height sensors

1. Check height sensors for condition and security.
2. Check electrical harness for chafing and damage.

Scheme 62

Rear suspension

Scheme 63

Front suspension

1. Check condition of front and rear axle suspension link mounting rubbers.
2. Check security of fixings.

Scheme 64

1. Check security of towing bracket.

Scheme 65

Scheme 66

Scheme 67

Scheme 68

1. Check condition of Transfer box - RH mounting rubber.
2. Check condition of Transfer box - LH mounting rubber.
3. Check condition of Engine - LH mounting rubber.
4. Check condition of Engine - RH mounting rubber
5. Check tightness of all mounting bolts. Refer to «TORQUE SPECIFICATIONS»(ref-158799-S30757069652003102100000) .

Procedure

1. Ensure that the handbrake is fully applied.
2. Automatic gearbox: Select 'D' check that the engine will not start.
3. Automatic gearbox: Select 'R' check that the engine will not start.
4. Automatic gearbox: Check that the engine will only start with 'P' or 'N' selected.
5. Automatic gearbox: Check for correct setting of the selector cable.
6. Check for correct operation of the starter switch. Ensure that the engine starts in a correct manner; leave the engine running.
7. Check that the 'low oil pressure warning' and 'no charge warning' lights are extinguished.
8. Check that throttle pedal movement is free and unrestricted.
9. Check that the engine is responsive to throttle movement.
10. Automatic gearbox: Select 'R' and check for smooth take up'
11. Automatic gearbox: Select 'D' and check for smooth up-changes of ratio from rest.
12. Automatic gearbox: Slow vehicle down and check for smooth down-changes of ratio.
13. Automatic gearbox: Stop vehicle on a slope, select 'P' and release the handbrake.
14. Automatic gearbox: Check that vehicle and that selector does not slip out of 'P'.
15. Automatic gearbox: Carry out a similar check with the vehicle facing in the opposite direction.
16. Manual gearbox: Depress clutch and select all gears in turn, check for smooth, notch free engagement.
17. Manual gearbox: Check that clutch engages smoothly without judder, slipping or noise.
18. Manual gearbox: Check for abnormal transmission noise.
19. Manual gearbox: Check for smooth, quiet gear changes and that gear selected engages easily.
20. With vehicle stationary and engine running, turn steering from lock to lock. Check for smooth operation and ensure that there is no undue noise from the power steering pump or drive belt.
21. Check for suspension noise, irregularity in ride (e.g. dampers) and wheel imbalance.
22. Check foot brake pedal effort and pedal for excessive travel.
23. Check braking efficiency, check brakes for pulling and binding.
24. Apply handbrake firmly, check travel and that ratchet holds and releases.
25. Check instruments and where practical, warning devices for correct operation
26. Check for abnormal body noise.
27. Check operation of seat belt inertia reels.
28. During road test, check for the following: Engine noise Gearbox noise Suspension noise Engine performance
29. Where possible, check for correct operation of hill descent control (HDC) mechanism. This should not be carried out if excessive journey time is required.
30. After road test, carry out a final inspection of vehicle, with vehicle on a ramp.
31. Check all underbonnet fluid levels and top-up if necessary.
32. Endorse Service Record with the following: Date and mileage of next service Current mileage Brake fluid replacement indicator Camshaft drive belt indicator - Td5 only Dealer stamp Dealer stamp Sign and date the service record
33. Sign and date the Maintenance Check Sheet.
34. Report any unusual features or items which require attention.