Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: General Installation Instructions


Whenever possible, clean components and the surrounding area before removal.

  • Blank off openings exposed by component removal.
  • Following disconnection, seal fuel, oil or hydraulic lines immediately using suitable blanking plugs or caps.
  • Seal open ends of exposed oilways using suitable tapered hardwood plugs or conspicuous plastic plugs.
  • Immediately a component is removed, place it in a suitable container; use a separate container for each component and its associated parts.
  • Clean bench and provide marking materials, labels and containers before disassembling components.


Observe scrupulous cleanliness when disassembling components, particularly when brake, fuel, air suspension or hydraulic system parts are disassembled. A particle of dirt or cloth fragment could cause a serious malfunction if trapped in these systems.

  • Blow out all tapped holes, crevices, oilways and fluid passages with dry, compressed air.


Suitable eye protection must be worn.

  • Use suitable marker ink to identify mating parts, do not use a scriber or centre punch as they could initiate cracks or distortion.
  • Wire or tape mating parts together where necessary to prevent accidental interchange.
  • Suitably identify parts which are to be renewed and to those parts requiring further inspection. Keep these parts separate.
  • To make sure that the correct replacement part has been obtained, do not discard a part due for renewal until after comparing it with the new part.


Always use cleaning agents which are suitable for the work being undertaken and the components being cleaned. NEVER use gasoline (petrol) as a cleaning agent (degreaser). Always make sure that the component being cleaned is compatible with the cleaning agent.

Always follow the manufacturer's instructions regarding the use of cleaning agents and make sure that the environment in which the work is being undertaken is suitable. See Health and Safety Precautions for further information regarding cleaning.


All components should be inspected for wear or damage before reassembling.

  • Always make sure that component to be inspected is clean and free from oil or grease.
  • When a component is to be checked dimensionally against design specified values, use the appropriate measuring equipment i.e. micrometers, verniers, surface plates, dial test indicators (DTI).
  • Always make sure that all measuring equipment is correctly calibrated before use.
  • Reject a component which is not within specified values/limits or if it appears to be damaged.
  • A component may be reinstalled if dimensions obtained during checking are at the maximum tolerance limit and it is in an undamaged condition.
  • Bearing journal clearances should be checked where necessary using Plastigauge.


     Joints and Joint Faces

    All gaskets should be installed dry unless stated otherwise. Always apply the specified lubricant to O-rings and install O-rings using the fingers only. Use gasket removal spray and/or plastic scrape

     Screw Threads

    Damaged nuts, bolts and screws must always be discarded. Attempting to recut or repair damaged threads with a tap or die impairs the strength and fit of the threads and is not recommended. NOTES:

     Bolt and Nut Identification

    An ISO metric bolt or screw made of steel and larger than 6 mm in diameter can be identified by either of the symbols ISO M or M embossed or indented on top of the bolt head. In addition to marks i


     Engine System - General Information Bearing Inspection (G61255) / General Procedures

    GENERAL PROCEDURES Inspect bearings for the following defects. Cratering - fatigue failure Spot polishing - incorrect seating. Imbedded dirt engine oil. Scratching - dirty engine oil Base exposed - poor lubrication. Both edges worn - journal damaged. One edge worn - journal tapered or bear

     Speed-dependent mode

    Front wipers If the vehicle's speed drops below 8 km/ h (5 mph) with the wipers operating, the wipers will switch to the next lowest speed. When the vehicle's speed increases to over 8 km/h (5 mph), the original wiper speed setting is automatically restored. Vehicles without a rain sensor fitted wi

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