check oil LAND ROVER DISCOVERY 2002 User Guide

GENERAL DATA
04-5
Idle speed:

All loads off 660 ± 50 rev/min

Base idle speed Non-adjustable

Idle air control (IAC) valve position Checked via TestBook
CO at idle:

Catalyst vehicles 0.5 %

Non-catalyst vehicles 0.5 - 1.0 %
Valve timing
Inlet valves:

Opens 28° BTDC

Closes 77° ABDC
Exhaust valves:

Opens 66° BBDC

Closes 39° ATDC
Fuel grade:

High compression catalyst vehicles 95 RON minimum unleaded

Low compression catalyst vehicles 91 RON minimum unleaded

Non-catalyst vehicles 97 RON leaded
Lubrication
Type Wet sump, pressure fed
Pump type Crankshaft driven eccentric rotor
Oil filter Disposable canister with full flow by-pass
Pressure at idle - minimum 0.7 bar (10 lbf.in
2)
Pressure at 2000 rev/min (hot) 3.4 bar (50 lbf.in
2)
Relief valve opening pressure 3.4 bar (50 lbf.in
2)
Low oil pressure switch opening pressure 0.24-0.41 bar (3.5-6.0 lbf.in
2)
Crankshaft
Main journal diameter 63.487 - 63.500 mm (2.4995 - 2.520 in)
Crankpin journal diameter 55.500 - 55.513 mm (2.20 - 2.22 in)
End float 0.08 - 0.26 mm (0.003 - 0.010 in)
Maximum ovality 0.040 mm (0.002 in)
Main bearings
Quantity 5
Material Glacier Vandervell / AS 15
Diametrical clearance 0.015 - 0.016 mm (0.00059 - 0.00063 in)
Connecting Rods
Type Horizontally split big-end, plain small end
Distance between centres 155.120 - 155.220 mm (6.1071 - 6.1110 in)

CAPACITIES, FLUIDS AND LUBRICANTS
09-2
Refrigerant - A/C system
Fluids
Anti-freeze
Use Havoline Extended Life Coolant (XLC), or any
ethylene glycol based anti-freeze (containing no
methanol) with only Organic Acid Technology
corrosion inhibitors, to protect the cooling system
CAUTION: No other anti-freeze should be used
with Havoline Extended Life Coolant.
The cooling system should be drained, flushed and
refilled with the correct amount of anti-freeze solution
at the intervals given on the Service Maintenance
Check Sheet.
After filling with anti-freeze solution, attach a warning
label to a prominent position on the vehicle stating
the type of anti-freeze contained in the cooling
system to ensure that the correct type is used for
topping-up.
Brake/Clutch fluid
Use only DOT 4 brake fluid.
PAS/ACE fluid
Use Texaco cold climate power assisted steering
fluid 14315.
Air conditioning
Use only refrigerant R134a.
Refrigerant oil
Use only NipponDenso ND-oil 8 or Unipart ND-oil 8.
Refrigerant oil absorbs water and must not be stored
for long periods. Do not pour unused oil back into the
container.
NOTE: The total quantity of refrigerant oil in the
system is 180 ml.
CAUTION: Do not use any other type of
refrigerant oil.

Refill3.4 pt

Fill from dry 3.6 pt
Cooling system - V8 Engine:

Refill24.2 pt

Fill from dry 26.2 ptComponent US Units

Front A/C 700 ± 25 g

Front/rear A/C 900 ± 25 g

MAINTENANCE
PROCEDURES 10-3
Seats and seat belts
Check
Front seat
Rear seat rear fixings
Rear seat front fixings
1.Check seat frames are secured to floor and
show no signs of movement.2.Check operation of seat slide and tilt
mechanisms, ensuring there is no excessive
play between seat cushion and seat back.
3.Fully extract seat belt and allow it to return
under its own recoil mechanism. Repeat for
other belts.
4. Check entire length of seat belt webbing for
signs of fraying or damage. Repeat for other
belts.

MAINTENANCE
PROCEDURES 10-7
Road wheels
Remove
1.Mark the wheel to stud relationship to ensure
that the wheels are refitted in the same
position.
2.Loosen wheel nuts. Raise the vehicle to a
wheel-free condition and remove the wheel
nuts.
Tyres
Check
1.Check tyres for compliance with manufacturer's
specification; visually for cuts, lumps, bulges,
uneven tread wear and depth.
2.Check tyre pressures, condition and tread
depth. Measure the tread depth across the
width of the tyre and around the circumference.
Brake pads, discs and calipers
Check
1. Check front and rear brake pads for wear,
ensure all pads are wearing evenly.
2.Check brake discs for signs of cracking,
excessive scoring or oil contamination.
3.Check calipers for signs of fluid leaks.
4.Clean excessive deposits of brake dust from
pads, calipers and disc shields using brake
cleaner.
Road wheel speed sensors
Inspect
Front wheel
Rear wheel
1.Inspect each sensor harness for damage.

MAINTENANCE
PROCEDURES 10-9
Doors, bonnet and fuel filler flap
Check
1.Check operation of each door, door lock,
bonnet catch and fuel filler flap. Ensure doors
close securely.
Lubricate
1.Lubricate door locks, hinges, check straps,
bonnet catch and fuel filler flap.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
Air suspension intake filter
Check
1.Check condition of filter and that filter is clean,
replace if necessary.

+ REAR SUSPENSION, REPAIRS,
Filter - intake - SLS.
Anti-freeze
Replace
1.Replace anti-freeze.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
Cooling system
Check
1.Check cooling, intercooler and heating systems
for leaks; hoses and oil pipes for security and
condition.
2.Check accessible hose clips for tightness.
3.Check coolant level, top-up if necessary.
Top-up
1.With engine cold, remove expansion tank filler
cap.
2.Top-up with recommended mixture of coolant
until level reaches mark on expansion tank.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Anti-Freeze Concentration.
3.Fit expansion tank filler cap.

MAINTENANCE
PROCEDURES 10-11
Air cleaner - V8 engine
Replace
1.Replace air cleaner element.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Element - air filter.
Clean
1.Clean the drain hole in filter casing.
Air cleaner and dump valve - diesel
engine
Replace/clean
1.Replace air cleaner element.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Element - air filter.
2.Remove all dirt from dump valve.
Auxiliary drive belt
Check
TD5 auxiliary belt
V8 auxiliary belt
1Tensioner pulley
2Alternator
3A/C compressor
4ACE pump
5Idler pulley - V8 only
6PAS pump
7Viscous fan pulley
8Crankshaft pulley
9Idler pulley - V8 only
1.Check auxiliary drive belt for signs of splits,
fraying, oil contamination and wear.

MAINTENANCE
PROCEDURES 10-15
Centrifuge rotor – diesel engine
Replace
1.Replace centrifuge rotor.

+ ENGINE - Td5, REPAIRS, Rotor -
centrifuge.
Engine oil filter - diesel engine
Replace
1.Replace oil filter.

+ ENGINE - Td5, REPAIRS, Filter - oil.
Engine oil filter – V8 engine
WARNING: Avoid excessive skin contact with
used engine oil. Used engine oil contains
potentially harmful contaminants which may
cause skin cancer or other serious skin
disorders.
Replace
1.Disconnect battery.
2.Position suitable container beneath oil filter.
3.Using a strap type filter wrench, remove filter
element, discard element.
4.Smear sealing ring of replacement filter
element with engine oil.
5.Fit filter element, tighten two thirds of a turn by
hand or to 17 Nm (13 lbf.ft).
6.Top-up engine with recommended grade of oil
to correct mark on dipstick.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
7.Connect battery.
8.Run engine and check for oil leaks from filter.
9.Stop engine, wait for oil to return to sump.
10.Re-check oil level and top-up if necessary.

MAINTENANCE
10-16 PROCEDURES
Manual gearbox
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Check/top-up oil level
1.Release fixings, remove rear underbelly panel.
2.Clean area around oil filler/level plug.
3.Remove oil filler/level plug.
4.Check that oil level is to bottom of oil filler/level
plug hole.
5.Top-up level (if required) with recommended oil
to bottom of filler/level plug hole.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
6.Remove all traces of sealant from threads of oil
filler/level plug.
7.Apply Loctite 290 to threads of oil filler/level
plug.
8. Fit manual gearbox filler/level plug and tighten
to 30 Nm (22 lbf.ft).
9.Remove all traces of oil from gearcase.
10.Fit rear underbelly panel, secure fixings.
Replace oil
1.Release fixings, remove rear underbelly panel.
2.Place a suitable container beneath gearbox
drain plug.
3.Clean area around oil filler/level and drain
plugs.4.Remove oil filler/level plug.
5.Remove oil drain plug, remove and discard
sealing washer.
6.Allow oil to drain.
7.Clean magnet in oil drain plug.
8.Fit new sealing washer to oil drain plug.
9.Fit manual gearbox drain plug and tighten to 50
Nm (37 lbf.ft).
10.Fill gearbox with recommended oil to bottom of
filler/level plug hole.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
11.Remove all traces of sealant from threads of oil
filler/level plug.
12.Apply Loctite 290 to threads of oil filler/level
plug.
13. Fit manual gearbox filler/level plug and tighten
to 30 Nm (22 lbf.ft).
14.Remove all traces of oil from gearcase.
15.Fit rear underbelly panel, secure fixings.

MAINTENANCE
10-18 PROCEDURES
Transfer box
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Check/top-up oil level
1.Release fixings, remove rear underbelly panel.
2.Clean area around oil filler/level plug.
3.Remove oil filler/level plug.
4.Check that oil level is to bottom of filler/level
plug hole.
5.Top-up level (if required) with recommended oil
to bottom of oil filler/level plug hole.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
6.Remove all traces of sealant from threads of oil
filler/level plug.
7.Apply Loctite 290 to threads of oil filler/level
plug.
8. Fit transfer box filler/level plug and tighten to 25
Nm (18 lbf.ft).
9.Remove all traces of oil from main casing.
10.Fit rear underbelly panel (if fitted), secure
fixings.Replace oil
1. Release fixings, remove rear underbelly panel.
2.Place a suitable container beneath transfer box
drain plug.
3.Clean area around oil filler/level and drain
plugs.
4.Remove oil filler/level plug.
5.Remove oil drain plug.
6.Allow oil to drain.
7.Apply Loctite 290 to threads of oil drain plug.
8. Fit transfer box drain plug and tighten to 30
Nm (22 lbf.ft).
9.Fill transfer box with recommended oil to
bottom of oil filler/level plug hole.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
10.Remove all traces of sealant from threads of oil
filler/level plug.
11.Apply Loctite 290 to threads of oil filler/level
plug.
12. Fit transfer box filler/level plug and tighten to 25
Nm (18 lbf.ft).
13. Remove all traces of oil from transfer box.
14.Fit rear underbelly panel (if fitted), secure
fixings.

MAINTENANCE
PROCEDURES 10-23
Power steering, suspension
ACE pipes
1.Check for fluid leaks from power steering and
suspension systems.
2.Check ACE pipes and unions for chafing, leaks
and corrosion and that all pipes and hoses are
correctly routed and secure.
Engine, gearbox, transfer box and axles
Check
1.Check for oil leaks from engine, gearbox
(manual and automatic), transfer box and front
and rear axles; pay particular attention to areas
around oil seals.
Exhaust system
Check
1.Check for signs of exhaust system leaks,
damage and security.
Steering box and front suspension
Check/tighten steering box fixings
1.Check steering box fixings and tighten to 90
Nm (66 lbf.ft).
Check/tighten front axle suspension fixings