earth LAND ROVER DISCOVERY 2002 Workshop Manual

FUEL DELIVERY SYSTEM - TD5
REPAIRS 19-1-15
REPAIRS
Switch - inertia - fuel cut-off
$% 19.22.09
Remove
1.Disconnect multiplug from fuel cut-off switch.
2.Remove 2 screws securing fuel cut-off switch to
bulkhead.
3.Remove fuel cut-off switch from bulkhead.
Refit
1.Position fuel cut-off switch to bulkhead and
secure with screws.
2.Connect multiplug to fuel cut-off switch.
3.To set the fuel cut-off switch, depress the top of
the fuel cut-off switch.
Pump - fuel
$% 19.45.08
NOTE: The fuel pump and fuel gauge tank unit are
integral parts of the fuel pump housing and cannot be
renewed separately
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3. Models with third row seats: Remove RH
third row seat.

+ SEATS, REPAIRS, Seat - third row.
4.Remove 5 trim clips securing lower edge of RH
'D' post trim casing.
5. Models with rear ICE controls: Remove
screw securing remote ICE controls to RH side
trim casing.
6. Models with rear ICE controls: Release ICE
controls from RH side trim casing. Disconnect
multiplug and remove ICE controls.
7.Partially remove tail door aperture seal in the
area of the RH side trim casing.

FUEL DELIVERY SYSTEM - TD5
19-1-16 REPAIRS
8.Remove 2 trim clips securing RH side trim
casing to body.
9.Remove rear lamp access panel from RH side
trim casing.
10.Remove trim clip securing RH side trim casing
to lower 'E' post.
11. Models with third row seats:Remove bolt
securing lower mounting of RH third row seat
belt to body.
12.Remove RH side trim casing.
13.Pull back loadspace carpet from fuel pump
access panel.
14.Remove 6 screws securing access panel.
15.Remove access panel.
16.Disconnect multiplug and 4 fuel hoses from fuel
pump housing.
CAUTION: Always fit plugs to open
connections to prevent contamination.17.Use LRT-19-009 to remove locking ring from
fuel pump housing.
18.Remove fuel pump housing.
19.Remove and discard sealing ring from fuel
pump housing.
Refit
1.Clean fuel pump housing and mating face on
fuel tank.
2.Fit new seal to mating face on fuel tank.
3.Fit fuel pump housing to fuel tank and use LRT-
19-009 to fit locking ring.
4.Connect multiplug and fuel hoses to fuel pump
housing. Ensure each hose is installed in the
connector with the corresponding colour
code.
5.Fit access panel and secure with screws.
6.Reposition loadspace carpet.
7.Fit RH side trim casing.
8. Models with third row seats:Fit bolt securing
lower mounting of RH third row seat belt to
body and tighten to 50 Nm (37 lbf.ft).
9.Fit trim clip securing RH side trim casing to
lower 'E' post.
10.Fit rear lamp access panel to RH side trim
casing.
11.Fit trim clips securing RH side trim casing to
body.
12.Fit tail door aperture seal.
13. Models with rear ICE controls: Connect
multiplug to remote ICE controls.
14. Models with rear ICE controls: Fit ICE
controls to trim casing and secure with screw.
15.Fit trim clips securing lower edge of 'D' post
trim casing to body.
16. Models with third row seats: Fit RH third row
seat.

+ SEATS, REPAIRS, Seat - third row.
17.Connect battery earth lead.

FUEL DELIVERY SYSTEM - V8
REPAIRS 19-2-13
REPAIRS
Switch - inertia - fuel cut-off
$% 19.22.09
Remove
1.Disconnect multiplug from fuel cut-off switch.
2.Remove 2 screws securing fuel cut-off switch to
bulkhead.
3.Remove fuel cut-off switch from bulkhead.
Refit
1.Position fuel cut-off switch to bulkhead and
secure with screws.
2.Connect multiplug to fuel cut-off switch.
3.To set the fuel cut-off switch, depress the top of
the fuel cut-off switch.
Pump - fuel
$% 19.45.08
NOTE: The fuel pump and fuel gauge tank unit are
integral parts of the fuel pump housing and cannot be
renewed separately
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3. Models with third row seats: Remove RH
third row seat.

+ SEATS, REPAIRS, Seat - third row.
4.Remove 5 trim clips securing lower edge of RH
'D' post trim casing.
5. Models with rear ICE controls: Remove
screw securing remote ICE controls to RH side
trim casing.
6. Models with rear ICE controls: Release ICE
controls from RH side trim casing. Disconnect
multiplug and remove ICE controls.
7.Partially remove tail door aperture seal in the
area of the RH side trim casing.

FUEL DELIVERY SYSTEM - V8
19-2-14 REPAIRS
8.Remove 2 trim clips securing RH side trim
casing to body.
9.Remove rear lamp access panel from RH side
trim casing.
10.Remove trim clip securing RH side trim casing
to lower 'E' post.
11. Models with third row seats: Remove bolt
securing lower mounting of third row seat belt to
body.
12.Remove RH side trim casing.
13.Pull back loadspace carpet from fuel pump
access panel.
14.Remove 6 screws securing access panel.
15.Remove access panel.
16.Disconnect multiplug and fuel hose from fuel
pump housing.
CAUTION: Always fit plugs to open
connections to prevent contamination.
17. NAS models: Disconnect pressure sensor
pipe from fuel pump housing.
CAUTION: Always fit plugs to open
connections to prevent contamination.18.Use LRT-19-009 to remove locking ring from
fuel pump housing.
19.Remove fuel pump housing.
20.Remove and discard sealing ring from fuel
pump housing.
Refit
1.Clean fuel pump housing and mating face on
fuel tank.
2.Fit new seal to mating face on fuel tank.
3.Fit fuel pump housing to fuel tank and use LRT-
19-009 to fit locking ring.
4.Connect multiplug and fuel hose to fuel pump
housing.
5. NAS models: Connect pressure sensor pipe to
fuel pump housing.
6.Fit access panel and secure with screws.
7.Reposition loadspace carpet.
8.Fit RH side trim casing.
9. Models with third row seats: Fit bolt securing
lower mounting of third row seat belt to body
and tighten to 50 Nm (37 lbf.ft).
10.Fit trim clip securing RH side trim casing to
lower 'E' post.
11.Fit rear lamp access panel to RH side trim
casing.
12.Fit trim clips securing RH side trim casing to
body.
13.Fit tail door aperture seal.
14. Models with rear ICE controls: Connect
multiplug to remote ICE controls.
15. Models with rear ICE controls: Fit ICE
controls to RH side trim casing and secure with
screw.
16.Fit trim clips securing lower edge of RH 'D' post
trim casing to body.
17. Models with third row seats: Fit RH third row
seat.

+ SEATS, REPAIRS, Seat - third row.
18.Connect battery earth lead.
19.Fit battery cover and secure with fixings.

COOLING SYSTEM - TD5
REPAIRS 26-1-15
REPAIRS
Fan - viscous
$% 26.25.19
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove 3 bolts and remove engine acoustic
cover.
4.Remove upper fan cowl.
5.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. Fit engine acoustic cover and tighten bolts.
4.Connect battery earth lead.
5.Fit battery cover and secure with fixings.
Radiator
$% 26.40.01
Remove
1.Drain cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
2.Remove intercooler.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
3.Remove clip and disconnect bleed hose from
radiator.
4.Release clip and disconnect top hose from
radiator.
5.Release clip and disconnect bottom hose from
radiator.
6.Release clip and disconnect engine oil cooler
hose from radiator.
7.Release clip and disconnect fuel cooler hose
from radiator.

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.