AUX LAND ROVER DISCOVERY 2002 Owner's Manual

ENGINE - V8
REPAIRS 12-2-43
Refit
1.Clean seal register in timing gear cover and
crankshaft pulley.
2.Apply Retinax LX grease to inner recess of new
oil seal until recess is half filled with grease. Do
not allow grease to coat any other part of
seal. Do not apply oil to seal.
3.Apply smear of Retinax LX grease to seal
running surface on crankshaft.
4.Fit seal to timing gear cover using tool LRT-12-
089 .
5.Fit crankshaft pulley bolt and tighten to 270 Nm
(200 lbf.ft).
6.Remove tool LRT-12-080 from crankshaft
pulley.
7.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.

ENGINE - V8
OVERHAUL 12-2-45
OVERHAUL
Gasket - inlet manifold
$% 30.15.08.01
Disassembly
1.Disconnect multiplug from coolant thermistor.
2.Disconnect multiplugs from injectors; release
injector harness from fuel rail and position
aside.
3.Remove 3 bolts securing PAS pump pulley and
remove pulley.
4.Loosen bolt securing jockey pulley and remove
pulley. 5.Remove 4 bolts and one nut securing auxiliary
housing and remove housing.
6.Remove 2 nuts securing alternator cables and
release the cables.
7.Remove two bolts securing alternator and
remove alternator.
8.Remove 4 bolts securing coolant outlet elbow
and remove outlet elbow.
9.Remove and discard 'O' ring.
10.Release ht leads from rocker covers.

ENGINE - V8
12-2-48 OVERHAUL
10.Clean mating faces of rocker covers and
cylinder heads.
11.Fit new rocker cover gaskets, dry, position
rocker cover, fit bolts and working in diagonal
sequence, tighten to:
lStage 1 - 3 Nm (2.5 lbf.ft)
lStage 2 - 8 Nm (6 lbf.ft)
12.Ensure that outer rim of gasket is correctly
positioned around periphery of rocker cover.
13.Secure ht leads to rocker cover.
14.Clean coolant outlet elbow mating faces.
15.Lubricate and fit new 'O' ring to outlet pipe.
16.Position coolant outlet elbow, fit bolts and
tighten to 22 Nm (17 lbf.ft).
17.Position alternator, fit mounting bolts and
tighten to 45 Nm (34 lbf.ft).
18.Position alternator cables and tighten terminal
B+ to 18 Nm (13 lbf.ft) and terminal D+ to 5 Nm
(3.5 lbf.ft).
19.Position auxiliary housing, fit bolts and tighten
to 40 Nm (30 lbf.ft). Fit nut and tighten to 22 Nm
(17 lbf.ft).
20.Clean jockey pulley mating faces.
21.Position jockey pulley and tighten bolt to 50 Nm
(37 lbf.ft).
22.Clean PAS pump pulley mating faces.
23.Position PAS pump pulley, fit bolts and tighten
to 22 Nm (17 lbf.ft).
24.Secure injector harness and connect injector
multiplugs.
25.Connect multiplug to coolant thermistor.
Gasket - exhaust manifold
$% 30.15.12.01
Disassembly
1.Remove 8 bolts securing exhaust manifold and
collect spacers. Discard the bolts.
2.Remove exhaust manifold.
3.Remove 2 manifold gaskets and discard.
Reassembly
1.Clean exhaust manifold and cylinder head
mating face.
CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.
2.Fit new gaskets, dry, fit exhaust manifold.
CAUTION: Ensure that link bar on gasket is
positioned below spark plugs.
LH bank illustrated
3.Fit spacers to new manifold bolts and, working
in the sequence illustrated, initially tighten bolts
to 15 Nm (11 lbf.ft), then finally tighten to 38 Nm
(28 lbf.ft).

ENGINE - V8
12-2-60 OVERHAUL
Reassembly
1.Reassemble rocker shafts, ensuring that
components are returned to their original
positions, secure plain washers with new split
pins.
2.Ensure shaft identification groove is positioned
at one o'clock, with push rod locations of rocker
arms to the right. Oil feed restriction will
result if rocker shafts are incorrectly
assembled.
3.Position rocker shaft assembly to cylinder
head ensuring push rods are engaged in
rocker arms.
4.Fit rocker shaft bolts and progressively tighten
to 40 Nm (30 lbf.ft).
5.Clean mating faces of rocker covers and
cylinder heads.
6.Fit new rocker cover gaskets, dry, position
rocker cover, fit bolts and working in diagonal
sequence, tighten to:
lStage 1 - 3 Nm (2.5 lbf.ft)
lStage 2 - 8 Nm (6 lbf.ft)
7.Ensure that gasket is correctly positioned
around periphery of rocker cover.
8.Secure ht leads to rocker cover.
Gasket - cylinder head
$% 12.29.02.01
Disassembly
1.Remove inlet manifold gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
inlet manifold.
2. RH cylinder head: Remove auxiliary drive belt
tensioner.
3. RH cylinder head: Remove bolts securing
alternator mounting bracket and remove
bracket.
4.Noting their fitted order, disconnect ht leads
from spark plugs.
5.Progressively remove 4 bolts securing the
rocker shaft and remove rocker shaft.
6.Remove push rods and store in their fitted
order.
7.Working in the sequence shown remove 10
bolts securing the cylinder head to block.
Discard the bolts.
8.Remove cylinder head.

ENGINE - V8
OVERHAUL 12-2-61
9.Remove cylinder head gasket.
CAUTION: Support both ends of cylinder
head on blocks of wood.
Inspect
1.Clean mating faces of cylinder block and head
using suitable gasket removal spray and a
plastic scraper, ensure that bolt holes in block
are clean and dry.
CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.
2.Check head and block faces for warping and
pitting.
lMaximum cylinder head warp = 0.05 mm
(0.002 in).
Note: Cylinder head can be refaced to 0.50
mm (0.02 in) maximum below head height –
See cylinder head overhaul.Reassembly
1.Fit cylinder head gasket with the word TOP
uppermost.
CAUTION: Gaskets must be fitted dry.
2.Carefully fit cylinder head and locate on
dowels.
3.Lightly lubricate new cylinder head bolt threads
with clean engine oil.
4.Noting that bolts 1, 3 and 5 are longer than the
remainder, fit bolts and tighten in the sequence
shown to 20 Nm (15 lbf.ft) then turn through 90
°, then a further 90 °. CAUTION: Do not
tighten bolts 180
° in one operation.
5.Clean the push rods, Lubricate ends of push
rods with clean engine oil, and fit in their
removed order.
6.Clean bases of rocker pillars and mating faces
on cylinder head.
7.Clean contact surfaces on rockers, valves and
push rods.
8.Lubricate contact surfaces and rocker shaft
with clean engine oil.
9.Fit rocker shaft assembly and engage push
rods.
10.Fit rocker shaft bolts and progressively tighten
to 40 Nm (30 lbf.ft).
11.Connect ht leads to spark plugs in their correct
fitted order.
12. RH cylinder head: Position alternator
mounting bracket, fit bolts and tighten to 40 Nm
(30 lbf.ft).
13. RH cylinder head: Fit auxiliary drive belt
tensioner.
14.Fit inlet manifold gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
inlet manifold.

ENGINE - V8
OVERHAUL 12-2-75
19.Using the sequence shown, tighten main
bearing cap bolts as follows:
lInitial torque - all main bearing cap bolts and
side bolts - 13.5 Nm (10 lbf.ft).
lFinal torque - main bearing cap side bolts 11
to 15 - 45 Nm (34 lbf.ft).
lFinal torque - main bearing cap bolts 1 to 8
- 72 Nm (54 lbf.ft).
lFinal torque - main bearing cap bolts 9 and
10 - 92 Nm (68 lbf.ft).
lFinal torque - main bearing cap side bolts 16
to 20 - 45 Nm (34 lbf.ft).
20.Fit connecting rod bearings.

+ ENGINE - V8, OVERHAUL, Bearings
- connecting rods.
21.Clean timing chain and gears.
22.Clean ends of crankshaft and camshaft.
23.Lubricate timing chain assembly with clean
engine oil. 24.Align timing marks and fit timing chain
assembly.
25.Fit camshaft gear bolt and tighten to 50 Nm (37
lbf.ft).
26.Fit timing gear cover gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
timing gear cover.
27.Clean crankshaft pulley.
28.Fit crankshaft pulley.
29.Fit crankshaft pulley bolt and tighten to 270 Nm
(200 lbf.ft).
30.Remove tool LRT-12-080 from crankshaft
pulley.
31.Clean oil filter and mating face.
32.Lubricate oil filter seal and fit filter to oil pump.
33.Ensure coolant pump and pulley mating faces
are clean.
34.Fit coolant pump pulley and tighten bolts to 22
Nm (16 lbf.ft).
35.Ensure drive belt pulleys are clean and
damage free.
36.Fit auxiliary drive belt to pulleys.
37.Fit crankshaft rear oil seal.

+ ENGINE - V8, OVERHAUL, Seal -
crankshaft - rear - automatic models.

ENGINE MANAGEMENT SYSTEM - V8
REPAIRS 18-2-73
5.Remove 2 nuts and release ECM from studs
and location on 'A' post lower panel.
6.Lower ECM into footwell and disconnect 5
multiplugs.
7.Remove ECM.
Refit
1.Position new ECM and connect multiplugs.
2.Fit ECM and secure with nuts.
3.Fit lower trim panel to 'A' post and secure with
fixings.
4.Fit diagnostic socket to closing panel, fit closing
panel and secure with fixings.
5.Connect battery earth lead.
6.Fit battery cover and secure with fixings.
7.Programme ECM and reset adaptions using
TestBook.
Sensor - engine coolant temperature
(ECT)
$% 18.30.10
Remove
1.Release turnbuckles and remove battery cover.
2.Disconnect battery earth lead.
3.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
4.Remove 2 bolts securing alternator, release
alternator from support bracket and position
aside.

ENGINE MANAGEMENT SYSTEM - V8
18-2-74 REPAIRS
5.Disconnect multiplug from ECT sensor.
6.Remove sensor from inlet manifold and discard
sealing washer.
Refit
1.Clean sealant from threads in manifold.
2.Apply Loctite 577 to sensor threads.
3.Fit new sealing washer to ECT sensor and
tighten sensor to 10 Nm (7 lbf.ft).
4.Connect multiplug to ECT sensor.
5.Position alternator, fit bolts and tighten to 45
Nm (33 lbf.ft).
6.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
7.Top up cooling system.
8.Connect battery earth lead.
9.Fit battery cover and secure with fixings.
Sensor - crankshaft position (CKP)
$% 18.30.12
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
4.Release fixings and remove underbelly panel.
5.Release CKP sensor multiplug from bracket.
6.Remove 2 bolts securing CKP sensor heat
shield and position aside.
7.Remove 2 nuts securing CKP sensor, remove
2 spacers, CKP sensor and sensor mounting.
8.Disconnect CKP sensor multiplug from engine
harness.
Refit
1.Ensure all components are clean.
2.Connect CKP sensor multiplug to engine
harness.
3.Fit sensor mounting, CKP sensor, 2 spacers
and tighten CKP sensor retaining nuts to 6 Nm
(5 lbf.ft).

COOLING SYSTEM - TD5
DESCRIPTION AND OPERATION 26-1-5
Description
General
The cooling system used on the Diesel engine is a pressure relief by-pass type system which allows coolant to
circulate around the engine block and heater circuit when the thermostat is closed. With coolant not passing through
the by-pass or the radiator promotes faster heater warm-up which in turn improves passenger comfort.
A coolant pump is mounted on a casting behind the PAS pump and is driven from the PAS pump at crankshaft speed
by the auxiliary drive belt. The pump mounting casting connects with passages in the cylinder block and pumps
coolant from the radiator through the cylinder block.
A viscous fan is attached to an idler pulley at the front of the engine. The fan is attached to a threaded spigot on the
pulley with a left hand threaded nut. The fan draws air through the radiator to assist in cooling when the vehicle is
stationary. The fan rotational speed is controlled relative to the running temperature of the engine by a thermostatic
valve regulated by a bi-metallic coil.
The cooling system uses a 50/50 mix of anti-freeze and water.
A Fuel Burning Heater (FBH) is available as an optional item for Diesel engine variants. The FBH is located on the
bulkhead and is connected in series in the coolant supply to the heater. The FBH is used to compensate for the
relatively low coolant temperatures inherent in the Diesel engine.

+ HEATING AND VENTILATION, DESCRIPTION AND OPERATION, Description.
Thermostat housing
A plastic thermostat housing is located behind the radiator. The housing has three connections which locate the
radiator bottom hose, top hose and coolant pump feed pipe. The housing contains a wax element thermostat and a
spring loaded by-pass flow valve.
Thermostat - Main valve
The thermostat is used to maintain the coolant at the optimum temperature for efficient combustion and to aid engine
warm-up. The thermostat is closed at temperatures below approximately 82
°C (179°F). When the coolant
temperature reaches approximately 82
°C the thermostat starts to open and is fully open at approximately 96°C
(204
°F). In this condition the full flow of coolant is directed through the radiator.
The thermostat is exposed to 90% hot coolant from the engine on one side and 10% cold coolant returning from the
radiator bottom hose on the other side.
Hot coolant from the engine passes from the by-pass pipe through four sensing holes in the flow valve into a tube
surrounding 90% of the thermostat sensitive area. Cold coolant returning from the radiator, cooled by the ambient air,
conducts through 10% of the thermostat sensitive area.
In cold ambient temperatures, the engine temperature is raised approximately 10
°C (50°F) to compensate for the heat
loss of 10% exposure to the cold coolant returning from the radiator bottom hose.
By-pass flow valve
The by-pass flow valve is held closed by a light spring. It operates to further aid heater warm-up. When the main valve
is closed and the engine speed is below 1500 rev/min, the coolant pump does not produce sufficient flow and pressure
to open the valve. In this condition the valve prevents coolant circulating through the by-pass circuit and forces the
coolant through the heater matrix only. This provides a higher flow of warm coolant through the heater matrix to
improve passenger comfort in cold conditions.
When the engine speed increases above 1500 rev/min the coolant pump produces a greater flow and pressure than
the heater circuit can take. The pressure acts on the flow valve and overcomes the valve spring pressure, opening
the valve and limiting the pressure in the heater circuit. The valve modulates to provide maximum coolant flow through
the heater matrix and yet allowing excess coolant to flow into the by-pass circuit to provide the engines cooling needs
at higher engine rev/min.

COOLING SYSTEM - TD5
26-1-8 DESCRIPTION AND OPERATION
The coolant pump is attached on the left hand side of the engine, behind the PAS pump. A cast housing, bolted to the
cylinder block provides a common attachment point for both pumps. The housing has galleries which connect the
coolant pump to the cylinder block and the oil cooler housing. The coolant pump comprises a shaft, a housing and a
cover.
The shaft, which passes through the alloy housing, is supported at each end by bearings. Seals at each end of the
shaft protect the bearings from the coolant. The forward end of the shaft has two lugs which engage with the PAS
pump shaft. The opposite end of the shaft is fitted with an impeller which draws coolant from the feed pipe and
circulates it through galleries in the cylinder block. The shaft is driven by the auxiliary drive belt at the same rotational
speed as the crankshaft by a pulley attached to the PAS pump.
The pump is sealed in the cast housing with two 'O' rings. An outer cover is positioned over the pump and secured
with six bolts and sealed to the pump with an 'O' ring. The cover provides the attachment for the feed pipe connecting
hose.