battery LAND ROVER DISCOVERY 2002 Workshop Manual

COOLING SYSTEM - V8
26-2-14 ADJUSTMENTS
5.Release top hose from retaining lugs on the fan
cowl, leaving the hose to rest on the lugs.
6.Remove bleed screw from top hose.
l'A' From 03 MY
l'B' Up to 03 MY
7.Unclip the bleed hose from the battery box.
8.Remove expansion tank from its mounting
bracket. Slowly fill the expansion tank with
coolant, approx. 4 litres (7 pt).
9.Raise the expansion tank approx. 20 cm (8 in)
vertically, coolant will drain into the system.
10.Refill the coolant expansion tank until a steady
flow of coolant is emitted from the bleed hole.
11.Fit the bleed screw then, with the expansion
tank still raised, continue filling the system until
the coolant level reaches the base of the
expansion tank filler neck.12.Fit expansion tank filler cap, fit the expansion
tank to its mountings and clip the bleed hose to
the battery box.
13.Refit the top hose into its lugs on the fan cowl.
14.Start and run engine until normal operating
temperature is reached, and check for leaks.
15.Switch off engine and allow to cool.
16.Check for leaks and top-up coolant to cold level
mark on expansion tank

COOLING SYSTEM - V8
REPAIRS 26-2-15
REPAIRS
Fan - viscous
$% 26.25.19
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove upper fan cowl.
4.Remove viscous fan using tool LRT-12-093
and tool LRT-12-094.
RH thread.
Refit
1.Position viscous fan and tighten using tool
LRT-12-093 and tool LRT-12-094.
2.Fit upper fan cowl.
3.Connect battery earth lead.
4.Fit battery cover and secure fixings.
Radiator
$% 26.40.01
Remove
1.Remove viscous fan.

+ COOLING SYSTEM - V8, REPAIRS,
Fan - viscous.
2.Drain cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
3.Remove 2 screws and remove lower of fan
cowl.
4.Release clip and disconnect bottom hose from
thermostat housing.
5.Release clip and disconnect top hose from
radiator.
6.Remove clip and disconnect bleed hose from
radiator.
7.Remove front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.

MANIFOLDS AND EXHAUST SYSTEMS - TD5
30-1-6 REPAIRS
Gasket - inlet manifold
$% 30.15.08
Remove
Note: The following procedure covers engines
fitted with or without an EGR cooler. The EGR
cooler is bolted to the front of the cylinder head.
1.Remove battery cover.
2.Disconnect battery earth lead.
3.Remove 3 bolts and remove engine acoustic
cover.
4.Release retainers and remove upper fan cowl.
5.Disconnect leads from 4 glow plugs and
multiplug from MAP sensor.
6.Remove 4 bolts, release EGR valve from inlet
manifold and discard gasket. 7.Remove 4 bolts securing fuel cooler to inlet
manifold.
8.Remove 2 bolts and remove alternator support
bracket.
9.Remove bolt securing engine dip stick tube to
camshaft carrier.
10.Remove dip stick tube and discard 'O' ring.

MANIFOLDS AND EXHAUST SYSTEMS - TD5
REPAIRS 30-1-7
11.Remove 2 nuts and 8 bolts securing inlet
manifold to cylinder head.
12.Disconnect multiplugs from turbocharger
pressure sensor, ECT sensor, AAP sensor,
MAF sensor, A/C compressor and fuel injector
harness.
13.Remove 2 bolts securing harness to camshaft
carrier.
Note: Engine with EGR cooler illustrated.
14.Release harness from engine and inlet
manifold.
15.Remove inlet manifold and gasket. Refit
1.Clean inlet manifold and mating faces.
2.Fit new gasket.
3.Fitinlet manifold and, working from the centre
outwards, tighten nuts and bolts to 25 Nm (18
lbf.ft).
4.Position harness to sensors and connect
multiplugs.
5.Tighten bolts securing harness clip to camshaft
carrier to 9 Nm (7 lbf.ft).
6.Clean dip stick tube and fit new 'O' ring.
7.Fit dip stick tube and tighten bolt to 9 Nm (7
lbf.ft).
8.Connect leads to glow plugs.
9.Fit alternator support bracket and tighten bolts
to 45 Nm (33 lbf.ft).
10.Position fuel cooler and tighten bolts to 25 Nm
(18 lbf.ft).
11.Fit new gasket, position EGR valve and tighten
bolts to 9 Nm (7 lbf.ft).
12.Connect multiplug to MAP sensor.
13.Fit upper fan cowl.
14.Fit engine acoustic cover.
15.Connect battery earth lead.
16.Fit battery cover.

MANIFOLDS AND EXHAUST SYSTEMS - V8
REPAIRS 30-2-11
Tail pipe
$% 30.10.22
Remove
1.Raise vehicle on ramp.
2.Remove 3 nuts securing intermediate pipe/
silencer to tail pipe.
3.Release and remove tail pipe from mounting.
4.Collect intermediate pipe/silencer to tail pipe
gasket.
Refit
1.Clean silencer and tail pipe mating faces.
2.Position tail pipe and secure on mounting.
3.Using a new gasket, align tail pipe to
intermediate pipe/silencer.
4.Fit nuts to intermediate pipe/silencer and
tighten to 25 Nm (18 lbf.ft).
Heat shield - brake servo - Without
Secondary Air Injection
$% 30.10.48
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove nut securing heat shield bracket to
valance.
4.Remove 2 bolts securing heat shield and
remove heat shield.
Refit
1.Fit heat shield, tightening bolts to 25 Nm (18
lbf.ft) and nut to 10 Nm (7 lbf.ft).
2.Connect battery earth lead.
3.Fit battery cover and secure with fixings.

MANIFOLDS AND EXHAUST SYSTEMS - V8
30-2-12 REPAIRS
Heat shield - brake servo - With
Secondary Air Injection
$% 30.10.48
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove nut securing heat shield bracket to
valance.
4.Remove 2 bolts securing heat shield and
remove heat shield.
Refit
1.Fit heat shield, tightening bolts to 25 Nm (18
lbf.ft) and nut to 10 Nm (7 lbf.ft).
2.Connect battery earth lead.
3.Fit battery cover and secure with fixings.
Gasket - inlet manifold - lower
$% 30.15.08
Remove
1.Remove both rocker covers.
l

+ ENGINE - V8, REPAIRS, Gasket
- rocker cover - LH.
l

+ ENGINE - V8, REPAIRS, Gasket
- rocker cover - RH.
2.Release and disconnect LH injector harness
and multiplugs.
3.Release 3 clips securing top hose and remove
top hose.
4.Remove auxiliary drive belt.

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

MANIFOLDS AND EXHAUST SYSTEMS - V8
REPAIRS 30-2-17
Gasket - inlet manifold - upper - Without
Secondary Air Injection
$% 30.15.24
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.
4.Release MAF sensor harness from clip.
5.Loosen clips securing air intake hose. Release
and remove air intake hose.
Note: Pre 03 MY air intake hose illustrated.
6.Disconnect throttle and cruise control cables.
Release cables from abutment bracket and
position aside. 7.Disconnect EVAP pipe from inlet plenum.
8.Disconnect multiplug from throttle body.
9.Remove clip securing breather hose to throttle
body and release breather hose.
10.Position a drain tray beneath the engine to
collect coolant.
11.Release clips securing coolant hoses to
throttle body and disconnect hoses.
12.Disconnect brake servo vacuum pipe from inlet
plenum.

MANIFOLDS AND EXHAUST SYSTEMS - V8
30-2-18 REPAIRS
13.Disconnect breather hose from inlet plenum.
14.Remove bolt securing coolant rails.
15.Release engine harness from bulkhead clips
and position aside.
16.Remove 4 bolts securing ignition coils and
position ignition coils aside.
17.Release plug leads from upper manifold clips.
18.Disconnect multiplug from IACV.
19.Release and disconnect IACV hose.
20.Remove 6 bolts securing upper inlet manifold
and remove upper inlet manifold. 21.Collect upper inlet manifold gasket.
Refit
1.Clean upper and lower inlet manifold mating
faces, dowels and dowel holes.
2.Using a new gasket, position upper inlet
manifold. Fit bolts and, working in a diagonal
sequence, tighten to 22 Nm (16 lbf.ft).
3.Connect hose and multiplug to TP sensor.
4.Connect hose and multiplug to IACV. Secure
hose with clip.
5.Secure ht leads to upper inlet manifold.
6.Position ignition coils, fit bolts and tighten to 8
Nm (6 lbf.ft).
7.Ensure clip under ignition coils is located on
fuel pipe.
8.Secure engine harness in bulkhead clips.
9.Fit coolant rail bolt and tighten to 22 Nm (16
lbf.ft).
10.Connect breather hose to inlet plenum.
11.Connect brake servo vacuum pipe to inlet
plenum.
12.Connect EVAP pipe to inlet plenum.
13.Position coolant hoses to throttle body and
secure hose clips.
14.Fit breather hose to throttle body and secure
clip.
15.Connect multiplug to throttle body.
16.Connect throttle and cruise control cables and
secure in throttle body cams.
17.Adjust throttle and cruise control cables.
l

+ ENGINE MANAGEMENT SYSTEM
- V8, ADJUSTMENTS, Cable - cruise
control.
l

+ ENGINE MANAGEMENT SYSTEM
- V8, ADJUSTMENTS, Cable - throttle.
18.Connect air intake hose and tighten clips.
Secure harness to air intake hose.
19.Top-up cooling system

+ MAINTENANCE, PROCEDURES,
Cooling system..
20.Fit bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.
21.Connect battery earth lead.
22.Fit battery cover and secure with fixings.

MANIFOLDS AND EXHAUST SYSTEMS - V8
REPAIRS 30-2-19
Gasket - inlet manifold - upper - With
Secondary Air Injection
$% 30.15.24
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.
4.Disconnect multiplug from MAF sensor.
5.Release clip on intake hose and release
harness.
Note: Pre 03 MY air intake hose illustrated.
6.Release and disconnect IACV hose.
7.Loosen clip securing air intake hose to throttle
body.
8.Release 2 clips securing MAF sensor.
9.Release and remove air intake hose.10.Disconnect vacuum hose from air valve.
11.Loosen clip securing air valve hose to air valve.
12.Remove 2 nuts securing air manifold support
bracket to upper inlet manifold.
13.Disconnect 2 air manifold unions from adapters
in cylinder head.
14.Remove LH air manifold.
15.Disconnect purge valve hose from inlet
manifold.
16.Release purge valve from clips and air control
valve from bracket and lay aside.
17.Disconnect multiplug from IACV.
18.Release clip and disconnect breather hose
from throttle housing.
19.Disconnect multiplug from TP sensor.

MANIFOLDS AND EXHAUST SYSTEMS - V8
REPAIRS 30-2-21
34.Release clip and disconnect IACV hose.
35.Remove 6 bolts securing upper manifold and
remove manifold.
36.Collect upper manifold gasket.
Refit
1.Clean upper and lower inlet manifold mating
faces, dowels and dowel holes.
2.Using a new gasket, position upper inlet
manifold. Fit bolts and, working in a diagonal
sequence, tighten to 22 Nm (16 lbf.ft).
3.Connect IACV hose and secure clip.
4.Connect hose to air valve and tighten clip.
5.Secure plug leads to clips.
6.Fit and tighten nuts securing RH air manifold
support bracket.
7.Align air pipe and coil bracket, fit bolts and
tighten to 8 Nm (6 lbf.ft).
8.Tighten 2 lower bolts securing coil bracket to 8
Nm (6 lbf.ft).
9.Fit bonnet seal.
10.Secure engine harness in bulkhead clips.11.Connect breather hose to manifold and secure
clip.
12.Connect vacuum hose to inlet manifold.
13.Connect brake servo hose to inlet manifold.
14.Connect throttle and cruise control cables.
15.Adjust throttle cable.

+ ENGINE MANAGEMENT SYSTEM -
V8, ADJUSTMENTS, Cable - throttle.
16.Adjust cruise control cable.

+ ENGINE MANAGEMENT SYSTEM -
V8, ADJUSTMENTS, Cable - cruise control.
17.Connect coolant hoses to throttle housing and
secure clips.
18.Connect multiplug to TP sensor.
19.Connect breather hose to throttle housing and
secure with clip.
20.Connect multiplug to IACV.
21.Secure purge valve and air control valve to clips
and bracket.
22.Connect purge hose to manifold.
23.Clean air manifold unions, position manifold
and start union nuts.
24.Fit and tighten nuts securing air manifold
support bracket.
25.Tighten air manifold union nuts to 25 Nm (18
lbf.ft)
26.Connect hose to air valve and tighten clip.
27.Connect vacuum hose to air valve.
28.Fit air intake hose.
29.Connect multiplug to MAF sensor.
30.Secure harness to clip.
31.Connect battery earth lead.
32.Fit battery cover and secure with fixings.
33.Top up cooling system.

+ MAINTENANCE, PROCEDURES,
Cooling system.
34.Fit bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.