ECU LAND ROVER DISCOVERY 2002 Workshop Manual

ENGINE - V8
12-2-40 REPAIRS
11.Push against coupling release rings and
disconnect both hoses from oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
12.Remove screw securing oil cooler to radiator.
13.Release cooler from its location on radiator.
14.Release radiator lower mountings from
location in chassis and carefully move radiator
towards engine sufficiently only to release
engine oil cooler from radiator.
15.Remove engine oil cooler.
Refit
1.Fit engine oil cooler to radiator, engage in
location and secure with screw.
2.Fit radiator to location in chassis.
3.Ensure connections are clean, then secure
hoses to oil cooler.
4.Fit extension brackets to radiator and secure
with bolts.
5.Fit brackets with rubber mounts to extension
brackets and secure to air conditioning
condenser with screws.
6.Fit radiator upper mounting brackets and
secure to body with bolts.
7.Fit LH horn and secure with nut.
8.Fit LH and RH air deflectors to front panel and
secure with scrivets.
9.Fit front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY..
10.Fit cooling fan cowl and secure with fixings.
11.Fit battery cover and secure with fixings.
12.Top up engine oil.
Gasket - timing gear cover
$% 12.65.04
Remove
1.Remove oil pick-up strainer.

+ ENGINE - V8, REPAIRS, Strainer -
oil pick-up.
2.Remove timing gear cover oil seal.

+ ENGINE - V8, REPAIRS, Seal - cover
- timing gears.
3.Remove engine oil filter.

+ ENGINE - V8, REPAIRS, Filter - oil.
4.Remove and discard 3 bolts securing coolant
pump pulley and remove pulley.
5.Remove 3 bolts securing PAS pump pulley and
remove pulley.
6.Drain cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.

ENGINE - V8
REPAIRS 12-2-41
7.Release clip and disconnect coolant hose from
coolant pump.
8.Disconnect multiplug from oil pressure switch.
9.Disconnect multiplug from CMP sensor.
10. If fitted: Loosen union and disconnect oil
cooler pipe from timing gear cover. Remove
and discard 'O' ring.
CAUTION: Always fit plugs to open
connections to prevent contamination.11.Remove 9 bolts securing timing gear cover and
remove cover. Remove and discard gasket.
Refit
1.Clean mating faces of timing gear cover and
cylinder block. Clean dowels and dowel holes.
2.Fit new gasket, dry, to dowels in cylinder block.
3.Fit timing gear cover to cylinder block and,
working the sequence illustrated, tighten bolts
to 22 Nm (17 lbf.ft) . Ensure CMP sensor
multiplug bracket is secured by bolt.
4. If fitted: Fit new 'O' ring to oil cooler pipe,
connect pipe to timing gear cover and tighten
union to 15 Nm (11 lbf.ft).
5.Connect multiplug to oil pressure switch.
6.Connect multiplug to CMP sensor.
7.Connect coolant hose to coolant pump and
secure with clip.

ENGINE - V8
12-2-42 REPAIRS
8.Ensure mating faces of PAS pump pulley and
drive flange are clean, fit pulley and tighten
bolts to 22 Nm (16 lbf.ft).
9.Remove all traces of thread locking material
from coolant pump pulley drive flange bolt
holes using an M8 tap.
10.Ensure mating faces of coolant pump pulley
and drive flange are clean, fit pulley and tighten
new Patchlok bolts to 22 Nm (16 lbf.ft).
11.Ensure mating faces of oil filter and adaptor are
clean, smear clean engine oil onto seal and fit
filter.
12.Fit timing gear cover oil seal.

+ ENGINE - V8, REPAIRS, Seal - cover
- timing gears.
13.Fit oil pick-up strainer.

+ ENGINE - V8, REPAIRS, Strainer -
oil pick-up.
14.Refill cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
Seal - cover - timing gears
$% 12.65.05
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Secure tool LRT-12-080 to crankshaft pulley
with 2 bolts.
3.Remove crankshaft pulley bolt.
4.Remove crankshaft pulley.
5.Use tool LRT-12-088, to remove oil seal from
timing gear cover.

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
12-2-46 OVERHAUL
11.Remove 4 bolts securing rocker cover and
remove cover.
12.Remove and discard rocker cover gaskets. 13.Using the sequence shown, remove 12 bolts
securing the inlet manifold.
14.Remove inlet manifold assembly.

ENGINE - V8
OVERHAUL 12-2-47
15.Remove 2 bolts securing manifold gasket and
collect gasket clamps.
16.Remove inlet manifold gasket.
17.Remove gasket seals. Reassembly
1.Clean sealant from cylinder head and from
notches in the cylinder block.
2.Clean mating faces of cylinder block, cylinder
head and manifold.
CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.
3.Apply sealant, Part No. STC 3254 to cylinder
head and notches in cylinder block.
4.Fit new gasket seals, ensuring the ends
engage correctly in notches.
5.Apply sealant, Part No. STC 3254 to gasket
seals above the notches in the cylinder block.
6.Fit new manifold gasket, dry.
7.Position gasket clamps, fit and lightly tighten
bolts.
8.Position inlet manifold assembly to cylinder
head.
9.Fit manifold bolts and, working in the sequence
illustrated, tighten as follows:
lInitially, tighten bolts numbered 1, 4, 9 and
12 in numerical order to 5 Nm (4 lbf.ft).
lInlet manifold bolts - initial tighten = 10 Nm
(8 lbf.ft).
lInlet manifold bolts - final tighten = 51 Nm
(38 lbf.ft).
lTighten inlet manifold gasket clamp bolts to
18 Nm (14 lbf.ft).
lTighten inlet manifold bolts to 51 Nm (38
lbf.ft)

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
OVERHAUL 12-2-49
Seal - crankshaft - rear - automatic
models
$% 12.21.20.01
Disassembly
1.Remove CKP sensor.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Sensor - crankshaft position
(CKP).
2.Remove 4 bolts securing drive plate clamp ring
and remove ring.
3.Remove drive plate from hub.
4.Remove 6 Allen screws securing hub, remove
hub and collect spacer. 5.Carefully remove oil seal from cylinder block to
avoid damage to seal location or running
surface on crankshaft.
Reassembly
1.Ensure both seal location and running surface
on crankshaft are clean.
2.Fit seal guide LRT-12-095 to crankshaft.
3.Fit new seal squarely onto crankshaft and
remove guide.
CAUTION: Oil seal must be fitted dry.
4.Fit seal into location using tools LRT-12-091
and LRT-99-003.

ENGINE - V8
12-2-50 OVERHAUL
5.Clean hub and mating face, spacer and clamp
ring.
6.Clean drive plate and ensure free from cracks
and distortion.
7.Fit spacer and hub to crankshaft, tighten Allen
screws to 78 Nm (58 lbf.ft).
8.Fit drive plate and clamp ring, tighten bolts to
45 Nm (35 lbf.ft).
9.Fit CKP sensor.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Sensor - crankshaft position
(CKP).
Seal - crankshaft - rear - manual models
$% 12.21.20.01
Disassembly
1.Restrain flywheel.
2.Working in sequence, loosen and remove 6
bolts securing clutch cover to flywheel.
3.Remove clutch cover.
4.Remove clutch plate.
5.Remove CKP sensor.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Sensor - crankshaft position
(CKP).
6.Remove 6 bolts securing flywheel.
7.Remove flywheel.

ENGINE - V8
12-2-52 OVERHAUL
Bearing - spigot - crankshaft
$% 12.21.45.01
Disassembly
1.Remove 6 bolts securing clutch cover.
2.Remove clutch cover.
3.Tap a thread in spigot bush to accommodate a
suitable impulse extractor.
4.Fit extractor to bush.
5.Remove bush from crankshaft. Reassembly
1.Clean bush register in rear of crankshaft.
2.Using a suitable drift, fit new bush to crankshaft
so that it is flush with or up to a maximum of 1.6
mm (0.06 in) below the end of the crankshaft.
3.Ream spigot bush to 19.117 + 0.025
− 0.00 mm
(0.75 + 0.001
− 0.00 in) .
4.Remove all traces of swarf on completion.
5.Clean mating faces of flywheel and crankshaft,
dowel and dowel hole.
6.Fit clutch cover to flywheel and tighten bolts by
diagonal slection to 40 Nm (30 lbf.ft).