coolant LAND ROVER DISCOVERY 2002 User Guide

TORQUE WRENCH SETTINGS
06-7
Manifolds and exhaust systems - V8
Clutch
TORQUE DESCRIPTION METRIC IMPERIAL
Intermediate pipe/silencer nuts 25 Nm (18 lbf.ft)
Inlet manifold bolts - initial tighten 10 Nm (7 lbf.ft)
Inlet manifold gasket clamp bolts 18 Nm (13 lbf.ft)
Inlet manifold bolts - final tighten 51 Nm (38 lbf ft)
Tail pipe25 Nm (18 lbf.ft)
Coolant outlet pipe 22 Nm (16 lbf.ft)
Front pipe flange nuts 30 Nm (22 lbf.ft)
Exhaust manifold55 Nm (40 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Clutch bleed screw 9 Nm (7 lbf.ft)
Clutch cover nuts Td5 25 Nm (18 lbf.ft)
Clutch cover bolts V8 40 Nm (30 lbf.ft)
Clutch master cylinder to pedal box 25 Nm (18 lbf.ft)
Hydraulic pipe union 18 Nm (13 lbf.ft)
Clutch release bearing pivot point bolt 8 Nm (6 lbf.ft)
Slave cylinder25 Nm (18 lbf.ft)

TORQUE WRENCH SETTINGS
06-8
Manual gearbox - R380
Transfer box - LT230SE
Note: † New Patchlok nut must be fitted.
TORQUE DESCRIPTION METRIC IMPERIAL
Bias plate bolts25 Nm (18 lbf.ft)
Gearbox to engine bolts 45 Nm (33 lbf.ft)
Coolant pipe housing bolts 25 Nm (18 lbf.ft)
Breather pipe banjo bolt 15 Nm (11 lbf.ft)
Gear lever extension clamp bolt 25 Nm (18 lbf.ft)
Gearbox mounting bolts 85 Nm (63 lbf.ft)
Gearbox mounting nuts 48 Nm (37 lbf.ft)
Seal housing bolts 18 Nm (13 lbf.ft)
Bearing sleeve bolts 25 Nm (18 lbf.ft)
Fork bolt7 Nm (5.2 lbf.ft)
Reverse light switch 24 Nm (18 lbf.ft)
Extension housing bolts 25 Nm (18 lbf.ft)
Gear selector housing bolts 25 Nm (18 lbf.ft)
Oil pump to housing Torx screws 6 Nm (4.4 lbf.ft)
Gear change lever yoke Allen screw 25 Nm (18 lbf.ft)
5th gear stake nut 350 Nm (258 lbf.ft)
Spool retainer bolts 8 Nm (6 lbf.ft)
Centre plate detent spring and ball Torx screw 25 Nm (18 lbf.ft)
Selector lever to housing bolts 25 Nm (18 lbf.ft)
Clutch Bell housing bolts 73 Nm (54 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
High/low selector cable 30 Nm (22 lbf.ft)
Bottom plate bolts 25 Nm (18 lbf.ft)
Transfer box to gearbox 45 Nm (33 lbf.ft)
Rear cover plate25 Nm (18 lbf.ft)
Differential lock warning lamp switch locknut - Up to 03 MY
11 Nm(8 lbf.ft)
Differential lock warning lamp switches - 03 MY onwards
25 Nm (18 lbf.ft)
Drive flange nut148 Nm (109 lbf.ft)
Output shaft housing 45 Nm (33 lbf.ft)
Oil temperature sensor 42 Nm (31 lbf.ft)
Inhibitor switch to transfer box 26 Nm (19 lbf.ft)
Intermediate shaft nut †88 Nm (65 lbf.ft)
Side cover bolts25 Nm (18 lbf.ft)
Bearing retaining nut 72 Nm (53 lbf.ft)
Output flange nut 162 Nm (119 lbf.ft)
Selector housing bolts 25 Nm (18 lbf.ft)
Bearing housing/cover bolts 25 Nm (18 lbf.ft)

TORQUE WRENCH SETTINGS
06-10
Steering
TORQUE DESCRIPTION METRIC IMPERIAL
Drag link to drop arm 80 Nm (59 lbf.ft)
Track rod to steering knuckle 125 Nm (92 lbf.ft)
Tension collet to steering knuckle 5 Nm (3.7 lbf.ft)
Steering damper125 Nm (92 lbf.ft)
Steering knuckle to axle yoke upper ball joint 110 Nm (81 lbf.ft)
High pressure pipe union 20 Nm (15 lbf.ft)
Drag link/track rod M8 bolts 22 Nm (16 lbf.ft)
Drag link/track rod M10 bolts 33 Nm (24 lbf.ft)
Steering box90 Nm (66 lbf.ft)
Universal joint to intermediate shaft 25 Nm (18 lbf.ft)
Panhard rod230 Nm (170 lbf.ft)
Steering box output shaft 88 Nm (65 lbf.ft)
Drop arm240 Nm (177 lbf.ft)
Auxiliary housing bolts 40 Nm (30 lbf.ft)
Auxiliary housing nut 10 Nm (7 lbf.ft)
PAS pump - V822 Nm (16 lbf.ft)
PAS pump pipe bracket bolt 22 Nm (16 lbf.ft)
Jockey pulley bolt 50 Nm (37 lbf.ft)
PAS pump adaptor pipe 10 Nm (7 lbf.ft)
PAS pump to coolant pump bolts - Td5 25 Nm (18 lbf.ft)
Steering column to fascia 25 Nm (18 lbf.ft)
Universal joint to steering box 25 Nm (18 lbf.ft)
Ball joint to swivel hub 77 Nm (57 lbf.ft)
PAS pump pulley22 Nm (16 lbf.ft)
Steering wheel nut 43 Nm (32 lbf.ft)

CAPACITIES, FLUIDS AND LUBRICANTS
09-2
Refrigerant - A/C system
Fluids
Anti-freeze
Use Havoline Extended Life Coolant (XLC), or any
ethylene glycol based anti-freeze (containing no
methanol) with only Organic Acid Technology
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/ACE fluid
Use Texaco cold climate power assisted steering
fluid 14315.
Air conditioning
Use only refrigerant R134a.
Refrigerant oil
Use only NipponDenso ND-oil 8 or Unipart 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.

Refill3.4 pt

Fill from dry 3.6 pt
Cooling system - V8 Engine:

Refill24.2 pt

Fill from dry 26.2 ptComponent US Units

Front A/C 700 ± 25 g

Front/rear A/C 900 ± 25 g

CAPACITIES, FLUIDS AND LUBRICANTS
09-3
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
Lubrication
General
The engine and other lubricating systems are filled
with high-performance lubricants giving prolonged
life.
CAUTION: Always use a high quality oil of the
correct viscosity range in the engine. The use of
oil of the incorrect specification can lead to high
oil and fuel consumption and ultimately to
damaged components.
Oil to the correct specification contains additives
which disperse the corrosive acids formed by
combustion and prevent the formation of sludge
which can block the oil ways. Additional oil additives
should not be used.
Always adhere to the recommended servicing
intervals.
Engine oil viscosity
The above chart indicates the ambient temperature
ranges which each engine oil viscosity is suitable for.
Engine oil - V8 - low compression engine
Use a 10W/40 oil meeting specification ACEA: A2,
and having a viscosity band recommended for the
temperature range of your locality.
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 tank
6Battery
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 reservoirs
6Battery
7Auxiliary drive belt
8Air cleaner
9Windscreen washer reservoir

MAINTENANCE
PROCEDURES 10-9
Doors, bonnet and fuel filler flap
Check
1.Check operation of each door, door lock,
bonnet catch and fuel filler flap. Ensure doors
close securely.
Lubricate
1.Lubricate door locks, hinges, check straps,
bonnet catch and fuel filler flap.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
Air suspension intake filter
Check
1.Check condition of filter and that filter is clean,
replace if necessary.

+ REAR SUSPENSION, REPAIRS,
Filter - intake - SLS.
Anti-freeze
Replace
1.Replace anti-freeze.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
Cooling system
Check
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.
Top-up
1.With engine cold, remove expansion tank filler
cap.
2.Top-up with recommended mixture of coolant
until level reaches mark on expansion tank.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Anti-Freeze Concentration.
3.Fit expansion tank filler cap.

ENGINE - TD5
DESCRIPTION AND OPERATION 12-1-3
1Oil dipstick tube
2Screw – oil dipstick tube to camshaft carrier
3Oil dipstick
42nd piston ring
5Piston
6Small-end bush
7Connecting rod
8Big-end bearing cap
9Connecting rod bolt (2 off per connecting rod)
10Top piston ring
11Oil control ring
12Circlips (2 off per gudgeon pin)
13Gudgeon pin
14Big-end bearing shells
15Dowels – cylinder head (2 off)
16Clutch housing shim plate
17 Crankshaft rear oil seal and housing
18Screws – crankshaft seal housing to engine
block (5 off)
19Bolts – clutch housing shim plate to engine
block (2 off)
20Main oil gallery plug (rear)
21Oil filter adaptor gasket
22Oil filter adaptor thermostat
23Oil filter adaptor assembly
24Oil filter adaptor insert25Oil filter adaptor to cylinder block bolts (3 off)
26Oil filter
27Oil pressure switch
28Oil cooler banjo bolts (2 off)
29O-rings – oil cooler banjo bolts (2 off)
30Oil cooler to cylinder block bolts (7 off)
31Centrifuge assembly
32Centrifuge to cylinder block bolts (3 off)
33Centrifuge oil drain pipe
34Oil drain pipe to sump gasket
35Centrifuge to oil drain pipe gasket
36Oil cooler plugs (3 off)
37Oil cooler assembly
38Oil cooler matrix 'O-rings' (2 off)
39Oil cooler matrix
40Oil cooler gasket
41Coolant and PAS pump assembly bracket
42Bracket bolts (5 off + 1 stud/nut)
43Cylinder block
44Dowels to timing block cover (2 off)
45Oil gallery delivery plug
46Cross drilling plug
47Coolant jacket plug
48Core plugs (3 off)

ENGINE - TD5
DESCRIPTION AND OPERATION 12-1-7
1Camshaft carrier
2Dowel – rocker shaft to camshaft carrier (1 off)
3Cylinder head bolts (12 off)
4Rocker shaft to camshaft carrier bolts (6 off)
5Rocker shaft
6Circlips (10 off)
7EUI Rocker arms (5 off)
8Camshaft carrier to cylinder head screws (13
off)
9Finger follower (10 off)
10Valve spring collets (20 off)
11Lash adjuster (10 off)
12Valve spring retainer (10 off)
13Valve spring (10 off)
14Valve stem seal (10 off)
15Valve guide (10 off)
16Valve seat insert (10 off)
17Inlet valve (5 off)
18Exhaust valve (5 off)
19Camshaft
20Camshaft bore seal (rear)21Coolant jacket core plug
22Cylinder head block
23Water jacket threaded plug
24Engine lifting bracket (LH)
25Engine lifting bracket bolts (2 off)
26Coolant outlet elbow to cylinder head bolts (3
off)
27Coolant outlet elbow
28Coolant outlet elbow gasket
29Cylinder head gasket
30Non-return valve (not removable, integral in
cylinder head)
31Camshaft bore end cap (front)
32End cap seal
33Cylinder head to cam carrier dowel (2 off)
34Engine lifting bracket (RH)
35Engine lifting bracket bolts (2 off)