clock LAND ROVER DISCOVERY 2002 Workshop Manual

CONTENTS
CONTENTS 25
NAVIGATION SYSTEM ............................................................................ 87-1
DESCRIPTION AND OPERATION
Navigation System Component Location ........................................................................................ 87-1
Description ...................................................................................................................................... 87-2
REPAIRS
Interface electronic control unit (ECU) - remote control ................................................................. 87-11
Display unit .................................................................................................................................... 87-12
INSTRUMENTS......................................................................................... 88-1
DESCRIPTION AND OPERATION
Instrument pack .............................................................................................................................. 88-1
Instrument component location - Engine compartment / underneath vehicle ................................. 88-2
Instrument component location - Passenger compartment............................................................. 88-3
Instrument block diagram................................................................................................................ 88-4
Description ...................................................................................................................................... 88-5
Interior rear view mirror with compass (where fitted) ..................................................................... 88-42
REPAIRS
Clock ............................................................................................................................................... 88-45
Instrument pack ............................................................................................................................ 88-45

GENERAL INFORMATION
03-12
Self-locking bolts and screws
Self-locking bolts and screws, i.e. nylon patched or
trilobular thread can be re-used providing resistance
can be felt when the locking portion enters the female
thread.
Nylon patched bolts and screws have a locking agent
pre-applied to the threads. They are identified by the
presence of a coloured section of thread which
extends for up to 180
° around the thread.
Trilobular bolts (i.e. Powerlok) have a special thread
form which creates a slight interference with the
thread of the hole or nut into which it is screwed.
DO NOT re-use self-locking fasteners in critical
locations (e.g. engine bearings, flywheel). Always
use the correct replacement self-locking nut, bolt or
screw.
DO NOT fit non self-locking fasteners in applications
where a self-locking nut, bolt or screw is specified.Nut identification
A nut with an ISO metric thread is marked on one
face or on one of the flats of the hexagon with the
strength grade symbol 8, 12, or 14. Some nuts with a
strength grade 4, 5 or 6 are also marked and some
have the metric symbol M on the flat opposite the
strength grade marking.
A clock face system is sometimes used as an
alternative method of indicating the strength grade.
The external chamfers or a face of the nut is marked
in a position relative to the appropriate hour mark on
a clock face to indicate the strength grade.
A dot is used to locate the 12 o'clock position and a
dash to indicate the strength grade. If the grade is
above 12, two dots identify the 12 o'clock position.
When tightening a slotted or castellated nut, never
loosen it to insert a split pin except where
recommended as part of an adjustment. If difficulty is
experienced, alternative washers or nuts should be
selected, or the washer thickness reduced.
Where bearing pre-load is involved, nuts should be
tightened in accordance with special instructions.

GENERAL DATA
04-1
GENERAL DATA
Engine - Td5
General
Type 2.5 litre in-line direct injection diesel, turbocharged and intercooled
Cylinder arrangement 5 in-line, No. 1 cylinder at front of engine
Bore 84.450 mm (3.3248 in)
Stroke 88.950 mm (3.5020 in)
Capacity 2498 cm
3 (152.5 in3)
Firing order 1 - 2 - 4 - 5 - 3
Compression ratio 19.5 : 1
Direction of rotation Clockwise viewed from the front of the engine
Dimensions:

Length 766 mm (30.1 in)

Width 708 mm (27.8 in)

Height 788 mm (31.0 in)
Injection timing Controlled by ECM
Injectors:

Make/Type Lucas EV1

Nominal operating pressure:

Pre EU3 models 1500 bar (21750 lbf.in
2)

EU3 models 1750 bar (25500 lbf.in
2)
Maximum governed speed 4850 rev/min
Maximum overrun speed 5460 rev/min
Idle speed:

Manual gearbox 740 ± 50 rev/min

Automatic gearbox 760 ± 50 rev/min
Glow plugs Beru 12 V. Four plugs in cylinders 1, 2, 3 and 4
Turbocharger Garrett GT 20
Emissions standard:

Pre EU3 models ECD 2

EU3 models ECD 3
Valve timing
Inlet valves:

Opens 14° BTDC

Closes 33° ABDC
Exhaust valves:

Opens 57° BBDC

Closes 14° ATDC

GENERAL DATA
04-4
Engine - V8
General
Cylinder arrangement 90° V8, numbered from the front of the engine:

Left bank cylinders 1, 3, 5 and 7

Right bank cylinders 2, 4, 6 and 8
Bore 94.00 mm (3.70 in)
Stroke:

4.0 litre

4.6 litre71.04 mm (2.80 in)
81.92 mm (3.22 in)
Capacity:

4.0 litre

4.6 litre3950 cm
3 (241 in3)
4554 cm3 (278 in3)
Firing order 1 - 8 - 4 - 3 - 6 - 5 - 7 - 2
Compression ratio:

Low - 4.0 litre 8.23:1

High - 4.0 and 4.6 litre 9.35:1
Direction of rotation Clockwise viewed from the front of the engine
Maximum power - 4.0 litre:

Low compression ratio 132 kW (177 bhp) at 4750 rev/min

High compression ratio - UK/Japan/ROW 136 kW (182 bhp) at 4750 rev/min

High compression ratio - NAS 140 kW (187 bhp) at 4750 rev/min
Maximum power - 4.6 litre 162 kW (217 bhp) at 4750 rev/min
Maximum engine speed:

Continuous5000 rev/min

Intermittent 5250 rev/min
Weight (fully dressed, wet)

Manual 194 Kg (435 lb)

Automatic 179 Kg (402 lb)
Dimensions:

Length - Manual 767 mm (30.2 in) (Including fan)

Length - Automatic 777 mm (30.5 in) (Including fan and drive plate)

Width 652 mm (25.7 in)

Height 746 mm (29.4 in)
Spark plugs:

Make/Type - 4.0 litre Champion RC11 PYP B4

Make/type - 4.6 litre Champion RN11 YCC

Gap - 4.0 and 4.6 litre 1.00 ± 0.05 mm (0.040 ± 0.002 in) Non-adjustable
Coils:

Make Bosch 0221 503 407

Type Twin coils
Fuel injection system:

Make Bosch Motronic 5.2.1 Type 4146

Type Multiport fuel injection, electronically controlled with electro-
mechanical injectors

MAINTENANCE
10-8 PROCEDURES
Brake fluid
Replace
1.Replace brake fluid.

+ BRAKES, ADJUSTMENTS, Brake
system bleeding.
Fuel filter - diesel engine
Replace
1.Replace filter element.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Element - fuel filter.
Fuel filter sedimenter
Drain
1.Position suitable container beneath fuel filter.
2.Disconnect multiplug from sedimenter.
3.Rotate sedimenter anti-clockwise until water
flows from drain tube.
4.Allow to drain until diesel fuel flows from drain
tube.
5.Rotate sedimenter fully clockwise.
6.Connect multiplug.
Road wheels
Refit
1.Apply anti-seize compound to wheel hub
centre.
2.Refit road wheels to original hub position.
Tighten wheel nuts to 140 Nm (103 lbf.ft).
Radiator/Intercooler
Check
1.Visually check radiator/intercooler for external
obstructions, remove debris.
2.Visually check fan blades for damage.
Ambient air Temperature and pressure
sensor
Check
1.Check ambient air temperature and pressure
sensor for damage.

ENGINE - TD5
REPAIRS 12-1-41
29.Rotate engine clockwise to align mark on
camshaft sprocket between coloured links on
timing chain.
30.Position tool LRT-12-058 through camshaft
carrier to lock camshaft.
31.Position tool LRT-12-158 through gearbox bell
housing to lock crankshaft. 32.Remove timing chain tensioner and discard
sealing washer.
33.Remove timing chain fixed guide Allen screw
from front of cylinder head.
34.Lever out camshaft sprocket blanking plug and
'O'-ring seal from front of cylinder head and
discard.
35.Remove 3 bolts and release timing sprocket
from camshaft. Discard bolts.
36.Using sequence shown, progressively loosen
then remove and discard 12 cylinder head bolts
together with their captive washers.

ENGINE - TD5
12-1-44 REPAIRS
Rocker shaft assembly
$% 12.29.29
Remove
1.Remove cooling fan.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
2.Remove camshaft cover gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
cover - camshaft.
3.Loosen lock nuts and fully retract rocker
adjusting screws to prevent damage on
reassembly. 4.Rotate engine clockwise, until camshaft
sprocket and timing chain marks are aligned
and fit tool LRT-12-058 through camshaft
carrier to lock camshaft.
5.Progressively loosen then remove and discard
6 bolts securing rocker shaft assembly.
6.Remove and discard lock nuts and rocker
adjusting screws.

ENGINE - TD5
REPAIRS 12-1-45
Refit
1.Clean rocker shaft and mating faces.
CAUTION: If rockers or rocker shaft are to
be replaced, ensure replacements are
correct. Engine Serial No. Prefixes 10P to
14P are fitted with type A rocker arms and
shaft. Engine Serial No. Prefixes 15P to 19P
are fitted with type B rocker arms and shaft.
Type B rocker arms and shaft may be fitted
to Engine Serial No. Prefixes 10P to 14P as
an assembly.
2.Fit new rocker adjusting screws fully into rocker
arm. Fit new lock nuts to screws but do not
tighten.
CAUTION: Ensure screws are correct for
type of rocker arms fitted. Replacement
screws for Engine Serial No. Prefixes 15P to
19P have a centre punch mark adjacent to
the adjusting slot. These screws are not
interchangeable with those fitted to Engine
Serial No. Prefixes 10P to 14P.
3.Fit rocker shaft ensuring it is located on dowel.
4.Fit and progressively tighten new rocker shaft
bolts to 33 Nm (24 lbf.ft). 5.Before refitting the camshaft cover the
electronic injection unit (EUI) rockers must be
adjusted.
6.Remove tool LRT-12-058 from camshaft.
7.Rotate engine clockwise until No 1 injector lobe
is at full lift.
8.Rotate rocker adjusting screw clockwise until
the injector plunger is felt to bottom out.
9.Rotate rocker adjusting screw anti-clockwise
one complete turn to give plunger the required
bump clearance and tighten rocker arm
adjusting screw locknut to 16 Nm (12 lbf.ft) .
CAUTION: Ensure screw does not turn as
locknut is tightened.
10.Carry out above procedure for the remaining 4
rocker arms.
11.After completion of rocker arm adjustment,
slowly rotate engine clockwise 2 complete
turns by hand to ensure that no injectors are
bottoming out on their plungers.
12.Fit camshaft cover gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
cover - camshaft.
13.Fit cooling fan coupling.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.

ENGINE - TD5
REPAIRS 12-1-49
20.Disconnect multiplug from CKP sensor.
21.Remove bolt securing CKP sensor to gearbox
housing and discard 'O' ring.
CAUTION: If fitted: Retain CKP sensor.
22.Loosen clip securing air inlet hose to
turbocharger and remove hose.
23.Disconnect multiplugs from compressor, MAF
sensor, turbocharger boost solenoid valve,
AAP & IAT sensor.
24.Release clip and disconnect hose from
turbocharger boost solenoid valve. 25.Loosen bolts securing PAS pulley.
26.Rotate ancillary drive belt tensioner anti-
clockwise, release and remove drive belt.
27.Release clips and remove air intake hose from
air cleaner.
28.Remove 4 bolts and move compressor aside.
29.Remove 3 bolts and move ACE pump aside.
30.Remove 3 bolts and remove PAS pump pulley.
31.Remove 4 bolts and move PAS pump aside.

ENGINE - TD5
12-1-52 REPAIRS
5.Fit 2 upper bolts securing engine oil cooler pipe
and gearbox housing to engine and tighten to
50 Nm (37 lbf.ft) .
6.Lower engine onto mountings, and tighten nuts
to 85 Nm (63 lbf.ft) .
7.Remove tool LRT-12-138 from engine.
8.Fit and tighten bolt securing engine closing
panel to gearbox.
9.Raise vehicle on ramp.
10.Fit nuts and bolts securing engine LH and RH
mountings to chassis and tighten to 85 Nm (63
lbf.ft).
11.Fit remaining bolts securing gearbox housing to
engine and tighten to 50 Nm (37 lbf.ft).
12.Rotate crankshaft and align drive plate to
torque converter.
13.Using a magnetic socket, fit and tighten new
torque converter drive plate bolts to 50 Nm (37
lbf.ft) .
14.Fit front cross member and tighten bolts to 26
Nm (19 lbf.ft).
15.Align gearbox oil cooler pipes.
16.Fit oil cooler pipe clip and tighten bolts to 9 Nm
(7 lbf.ft).
17.Position gearbox oil cooler pipe clamps and
tighten nuts.
18.Position coolant rail and secure support bracket
in engine LH and RH mounting brackets.
19.Fit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
20.Lower ramp.
21.Position coolant rail to front chassis member, fit
and tighten bolt to 10 Nm (7 lbf.ft).
22.Connect heater hose to coolant rail and secure
with clip.
23.Connect hose to coolant pump and secure with
clip.
24.Position PAS pump and tighten bolts to 25 Nm
(18 lbf.ft).
25.Position PAS pump pulley and lightly tighten
bolts.
26.Position ACE pump, fit bolts and tighten to 25
Nm (18 lbf.ft).
27.Position A/C compressor, fit bolts and tighten
to 25 Nm (18 lbf.ft).
28.Position ancillary drive belt, rotate tensioner
anti-clockwise and locate belt to pulleys.
29.Tighten PAS pump pulley bolts to 10 Nm (7
lbf.ft).
30.Position air intake hose to air cleaner and
secure clips.
31.Position engine harness and connect
multiplugs to compressor, MAF sensor,
turbocharger boost solenoid, AAP & IAT
sensor.
32.Position air inlet hose to turbocharger and
tighten clip. 33.Connect hoses to turbocharger boost solenoid
and secure clips.
34.Clean CKP sensor and mating face.
CAUTION: If originally fitted: Fit spacer to
CKP sensor.
35.Using new 'O' ring, fit CKP sensor, tighten CKP
sensor bolt to 9 Nm (7 lbf.ft) and connect
multiplug.
36.Connect multiplug to EGR modulator.
37.Connect engine earth lead to battery earth lead
and tighten bolt.
38.Connect engine harness multiplug to ECM and
main harness.
39.Connect engine harness multiplugs to fuse
box.
40.Position glow plug lead to fusebox and secure
with bolt.
41.Position battery and alternator leads to fusebox
and secure with bolts.
42.Fit engine compartment fuse box cover.
43.Connect vacuum hose to EGR valve.
44.Connect hose to vacuum pump and secure
vacuum pipe to fuel cooler.
45.Disconnect fuel hose from connector block and
connect to fuel cooler.
46.Connect fuel hoses to fuel cooler and
connector block on cylinder head.
47.Position expansion tank, connect hose and
secure with clip. Secure tank to body mounting.
48.Connect coolant hoses to fuel cooler and
coolant rail and secure clips.
49.Fit turbocharger.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Turbocharger.
50. Fit radiator.

+ COOLING SYSTEM - Td5, REPAIRS,
Radiator.
51.Fill engine with oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - diesel engine.
52.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
53.Fit bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.