LAND ROVER DISCOVERY 2002 Workshop Manual

CHARGING AND STARTING
86-1-2 REPAIRS
Refit
1.Clean mating faces of alternator and vacuum
pump.
2.Fit vacuum pump to alternator and tighten
bolts to 8 Nm (6 lbf.ft).
3.Position alternator to engine and connect
multiplug.
4.Connect vacuum hose and oil drain hose to
vacuum pump and secure clips.
5.With assistance align alternator to mounting
bracket and fit but do not tighten bolt.
6.Fit bolt securing support stay to alternator and
tighten to 25 Nm (18 lbf.ft) .
7.Tighten bolt securing alternator to mounting
bracket to 45 Nm (33 lbf.ft).
8.Using new 'O' ring, connect oil supply pipe to
cylinder head and tighten to 10 Nm (7 lbf.ft).
9.Connect lead to alternator and tighten nut to 6
Nm (4.4 lbf.ft).
10.Fit auxiliary drive belt tensioner and tighten bolt
to 50 Nm (37 lbf.ft).
11.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
Alternator - V8
$% 86.10.02
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Remove 2 bolts securing alternator to
mounting bracket.
3.Release alternator from mounting bracket
4.Remove nuts securing alternator cables, and
release cables.

CHARGING AND STARTING
REPAIRS 86-1-3
5.Remove alternator from mounting bracket.
6.Remove pulley from alternator.
Refit
1.Fit alternator pulley and tighten nut to 80 Nm
(59 lbf.ft).
2.Position alternator to mounting bracket.
3.Connect alternator cables and tighten B+ nut to
18 Nm (13 lbf.ft), and D+ nut to 5 Nm (3.7 lbf.ft).
4.Locate alternator in mounting bracket.
5.Fit alternator mounting bolts and tighten to 45
Nm (33 lbf.ft).
6.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
Belt - auxiliary drive
$% 86.10.03
Remove
1.Remove viscous fan:
l

+ COOLING SYSTEM - V8,
REPAIRS, Fan - viscous.
l

+ COOLING SYSTEM - Td5,
REPAIRS, Fan - viscous.
2.Turn drive belt tensioner using a 15 mm ring
spanner and release belt from pulleys.
Refit
1.Clean drive belt pulley grooves and ensure
grooves are not damaged.
2.Fit new drive belt around pulleys, ensure belt is
correctly aligned in pulley grooves.
3.With assistance, hold tensioner fully clockwise
and fit drive belt around remaining pulley.
Release tensioner.
4.Fit viscous fan:
l

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

+ COOLING SYSTEM - V8,
REPAIRS, Fan - viscous.

CHARGING AND STARTING
86-1-4 REPAIRS
Battery
$% 86.15.01
Remove
1.Release fixings and remove battery cover.
2.Disconnect both battery leads, negative lead
first.
3.Remove lock nuts and retaining nuts securing
battery clamp.
4.Remove battery clamp.
5.Remove battery.
Refit
1.Clean battery terminals and coat with
petroleum jelly.
2.Fit battery.
3.Fit battery clamp and tighten retaining nuts and
lock nuts.
4.Fit both battery leads, negative lead last.
5.Fit battery cover and secure fixings.
Battery carrier
$% 86.15.11
Remove
1.Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
2.Release strap and remove jack.
3.Release coolant hose from clip.
4. Diesel models: Remove screw securing ECM,
release ECM and position aside.
5.Remove 7 bolts securing battery carrier.
6.Remove battery carrier.
NOTE: Do not carry out further dismantling if
component is removed for access only.
7.Remove jack retaining strap, speed nut and
clip.

CHARGING AND STARTING
REPAIRS 86-1-5
Refit
1.Fit jack retaining strap, speed nut and clip.
2.Fit battery carrier, fit bolts and tighten to 28 Nm
(21 lbf.ft).
3. Diesel models: Fit ECM and secure with
screw.
4.Secure coolant hose.
5.Fit and secure jack.
6.Fit battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
Starter motor - diesel
$% 86.60.01
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.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Disconnect Lucar connector from starter
solenoid.
6.Remove nut and disconnect battery lead from
starter solenoid.
7.Remove nut and 2 bolts securing starter motor
and remove starter motor from engine.
Refit
1.Clean starter motor and mating face on engine.
2.Fit starter motor and tighten nut and 2 bolts to
27 Nm (20 lbf.ft).
3.Connect lead to starter solenoid and tighten nut
to 10 Nm (7 lbf.ft).
4.Connect Lucar connector to starter solenoid.
5.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Remove stand(s) and lower vehicle.
7.Connect battery earth lead.
8.Fit battery cover and secure the fixings.

CHARGING AND STARTING
86-1-6 REPAIRS
Starter motor - V8
$% 86.60.01
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.Remove 3 nuts securing exhaust flange to
front pipe, release front pipe and collect
gasket.
5.Remove bolt securing heat shield to engine
mounting bracket, release heat shield from
starter motor and remove from vehicle.
6.Remove nut securing battery lead to starter
solenoid and release lead.
7.Disconnect Lucar connector from starter
solenoid.
8.Remove 2 Allen bolts securing starter motor
and remove starter motor from engine. Refit
1.Clean starter motor and mating face on engine.
2.Fit starter motor and tighten Allen bolts to 44
Nm (32 lbf.ft).
3.Connect Lucar connector to starter solenoid.
4.Fit battery lead to solenoid and tighten nut.
5.Position heat shield to starter motor, locate tag
in engine mounting bracket, fit bolt and tighten
to 10 Nm (7 lbf.ft).
6.Clean exhaust manifold and front pipe mating
faces.
7.Using a new gasket, position front pipe, fit nuts
and tighten to 30 Nm (22 lbf.ft).
8.Remove stand(s) and lower vehicle.
9.Connect battery earth lead.
10.Fit battery cover and secure fixings.

LIGHTING
ADJUSTMENTS 86-2-1
LIGHTING ADJUST ME NTS
Headlamps beam alignment - up to 03MY
$% 86.40.17
Check
1.Ensure vehicle is unladen and tyres are at
correct pressures.
2. Models with SLS: Ensure vehicle is at
standard ride height.
3. Models with headlamp levelling: Ensure
headlamp levelling switch is set to '0'.
4.Align suitable beam setting equipment to
headlamp.
5.Switch headlamps on and measure main beam
settings. Beam must be 1.4% below the
horizontal and parallel to the vehicle centre line.
If necessary, adjust headlamp to get correct
beam settings.
6.Align beam setting equipment to 2nd headlamp
and repeat check.
7.Switch off headlamps and remove beam setting
equipment.
Adjust
1. For RH headlamps: Release fixings and
remove battery cover
2.Remove headlamp access cover.3.Turn vertical adjuster as necessary to get
correct beam setting. Use a 7 mm Allen key for
models with headlamp levelling, or a 10 mm
spanner for models without headlamp levelling.
4.Turn horizontal adjuster as necessary to get
correct beam setting. Use a 10 mm spanner.
5.Fit headlamp access cover.
6. For RH headlamp adjustment: Fit battery
cover and secure fixings.

LIGHTING
86-2-2 ADJUSTMENTS
Headlamps beam alignment - from 03MY
$% 86.40.17
Check
1.Ensure vehicle is unladen and tyres are set at
the correct pressures.
2. Models with SLS: Ensure vehicle is at the
standard ride height.
3. Models without SLS: Set headlamp leveling
switch to zero.
4.Align beam setting equipment to headlamp.
5.Switch on headlamps. Headlamp setting 1.2%
below horizontal and parallel.
6.Align beam setting equipment to second
headlamp and repeat the check.
Adjust
1.Using a flat blade screwdriver rotate the
headlamp adjusters until correct alignment is
achieved
2.Rotate inboard adjuster for verticle alignment.
3.Rotate outboard adjuster for horizontal
alignment.
4.Adjust 2nd headlamp as detailed above.
5.Switch off headlamps and remove beam setting
equipment.

LIGHTING
REPAIRS 86-2-3
REPAIRS
Lamp - front repeater
$% 86.40.42
Remove
1. For RH repeater lamp: Release fixings and
remove battery cover.
2.Remove headlamp access cover from body.
3.Remove screw securing repeater lamp to body
and release lamp from 2 locating peg sockets in
wing.
4.Disconnect 2 multiplugs from repeater lamp
and remove lamp. Refit
1.Position new repeater lamp and connect
multiplugs.
2.Fit repeater lamp to body and tighten screw.
3.Fit headlamp access cover.
4. For RH repeater lamp: Fit battery cover and
secure fixings.

LIGHTING
86-2-4 REPAIRS
Headlamp - up to 03MY
$% 86.40.49
Remove
1. For RH headlamp: Release fixings and
remove battery cover.
2.Remove headlamp access cover from body.
3.Release headlamp from locating sockets.
4.Disconnect multiplugs from headlamp and side
lamp bulbs.
5.Remove headlamp.
NOTE: Do not carry out further dismantling if
component is removed for access only.6.Remove side lamp bulb holder from headlamp.
7.Remove rubber cover from headlamp.
8.Release headlamp bulb retaining clip and
remove headlamp bulb.
9.Remove 6 screws and remove headlamp
retaining sockets.
Refit
1.Fit retaining sockets to new headlamp and
secure with screws.
2.Fit headlamp bulb and secure with clip.
3.Fit rubber cover.
4.Fit side lamp bulb holder.
5.Position headlamp and connect multiplugs.
6.Fit headlamp onto locating pins.
7.Check headlamp beam alignment.

+ LIGHTING, ADJUSTMENTS,
Headlamps beam alignment - up to 03MY.
8.Fit headlamp access cover.
9. For RH headlamp: Fit battery cover and
secure with fixings.

LIGHTING
REPAIRS 86-2-5
Headlamp - from 03MY
$% 86.40.49
Remove
1.Remove front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - from 03MY.
2.Protect bumper.
CAUTION: Always protect paintwork when
removing or refitting any body trims or
bumpers.
3.Open air deflector access panel and remove
Torx screw securing headlamp assembly to the
front panel.
4.Remove 2 screws securing headlamp
assembly to the bonnet locking platform.5.Release headlamp assembly from wing,
disconnect multiplug and remove the headlamp
assembly.
NOTE: Do not carry out further dismantling if
component is removed for access only.
6.Remove scrivet securing headlamp finisher to
headlamp assembly, release and remove the
finisher.
Refit
1.Fit and secure headlamp finisher to the
headlamp assembly.
2.Position headlamp assembly to front panel and
connect the multiplug.
3.Secure headlamp assembly to the front wing.
4.Fit and tighten screws securing headlamp
assembly to the bonnet locking platform.
5.Fit and tighten Torx screw securing headlamp
assembly to the front panel. Close the air
deflector access panel.
6.Remove bumper protection.
7.Fit front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - from 03MY.
8.Check headlamp alignment - adjust if
necessary.

+ LIGHTING, ADJUSTMENTS,
Headlamps beam alignment - from 03MY.