clutch LAND ROVER DISCOVERY 2002 User Guide

GENERAL DATA
04-10
Cooling system - V8
Clutch - Td5
Type Pressurised, spill return, thermostatically controlled water and
antifreeze mixture. Vertical flow radiator with remote header tank
and pump assisted
Cooling fans 9 blade axial flow on viscous coupling and 11 blade axial flow
electric
Electric cooling fan switching points:
For A/C system:

On When vehicle speed is 50 mph (80 km/h) or less and ambient
temperature is 28 °C (82 °F) or more

Off When vehicle speed increases to (62.5 mph (100 km/h) or
ambient temperature decreases to 25 °C (77 °F)
For engine cooling during normal running:

On 100 °C (212 °F)

Off 94.5 °C (202 °F)
For engine cooling at ignition off (to counteract heat
soak):

On If, within 10 seconds of ignition off, intake air temperature is 60 °C
(140 °F) or more and engine coolant temperature is 110 °C (230
°F) or more

Off After 10 minutes or if engine coolant temperature decreases to
100 °C (212 °F)
Coolant pump Centrifugal impeller, belt driven from crankshaft
Coolant pump drive ratio 1.293 : 1
Coolant pump output at 1000 rev/min 10 litres/min (2.64 US galls/min) at 0.7 bar (10 lbf.in
2)
Thermostat Waxstat with pressure relief valve
Thermostat operating temperature:

Initial opening 82 °C (179 °F)

Fully open 96 °C (204 °F)
Expansion tank cap relief valve - system operating
pressure1.4 bar (20 lbf.in
2)
Type Diaphragm spring, hydraulically operated with self-centering,
preloaded release bearing
Drive plate diameter 267 mm (10.5118 in)
Pressure plate diameter 267 mm (10.5118 in)
Clutch plate friction material Verto F202
Diaphragm finger height when clamped on a 8.5 mm
(0.33 in) thick gauge plate42.5 to 48.5 mm (1.673 to 1.904 in)
Diaphragm finger clearance (service limit) 1.00 mm (0.040 in)
Clutch plate thickness under 6500 N (1461 lb) axial
load:

New 8.2 to 8.8 mm (0.33 to 0.34 in)

Service limit 7.0 mm (0.27 in)

GENERAL DATA
04-11
Clutch - V8
Type Diaphragm spring, hydraulically operated with self-centering,
preloaded release bearing
Clutch plate friction material APTEC 385
Drive plate diameter 267 mm (10.5118 in)
Pressure plate diameter 268 mm (10.5512 in)
Clutch plate thickness (clamped state)

New 8.4-8.9 mm (0.33-0.35 in)

Service limit 7.1 mm (0.28 in)
Rivet depth:

New 1.73 mm (0.07 in)

Service limit 0.25 mm (0.01 in)
Clutch plate runout:

New 0.5 mm (0.02 in)

Service limit 0.5 mm (0.02 in)

TORQUE WRENCH SETTINGS
06-7
Manifolds and exhaust systems - V8
Clutch
TORQUE DESCRIPTION METRIC IMPERIAL
Intermediate pipe/silencer nuts 25 Nm (18 lbf.ft)
Inlet manifold bolts - initial tighten 10 Nm (7 lbf.ft)
Inlet manifold gasket clamp bolts 18 Nm (13 lbf.ft)
Inlet manifold bolts - final tighten 51 Nm (38 lbf ft)
Tail pipe25 Nm (18 lbf.ft)
Coolant outlet pipe 22 Nm (16 lbf.ft)
Front pipe flange nuts 30 Nm (22 lbf.ft)
Exhaust manifold55 Nm (40 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Clutch bleed screw 9 Nm (7 lbf.ft)
Clutch cover nuts Td5 25 Nm (18 lbf.ft)
Clutch cover bolts V8 40 Nm (30 lbf.ft)
Clutch master cylinder to pedal box 25 Nm (18 lbf.ft)
Hydraulic pipe union 18 Nm (13 lbf.ft)
Clutch release bearing pivot point bolt 8 Nm (6 lbf.ft)
Slave cylinder25 Nm (18 lbf.ft)

TORQUE WRENCH SETTINGS
06-8
Manual gearbox - R380
Transfer box - LT230SE
Note: † New Patchlok nut must be fitted.
TORQUE DESCRIPTION METRIC IMPERIAL
Bias plate bolts25 Nm (18 lbf.ft)
Gearbox to engine bolts 45 Nm (33 lbf.ft)
Coolant pipe housing bolts 25 Nm (18 lbf.ft)
Breather pipe banjo bolt 15 Nm (11 lbf.ft)
Gear lever extension clamp bolt 25 Nm (18 lbf.ft)
Gearbox mounting bolts 85 Nm (63 lbf.ft)
Gearbox mounting nuts 48 Nm (37 lbf.ft)
Seal housing bolts 18 Nm (13 lbf.ft)
Bearing sleeve bolts 25 Nm (18 lbf.ft)
Fork bolt7 Nm (5.2 lbf.ft)
Reverse light switch 24 Nm (18 lbf.ft)
Extension housing bolts 25 Nm (18 lbf.ft)
Gear selector housing bolts 25 Nm (18 lbf.ft)
Oil pump to housing Torx screws 6 Nm (4.4 lbf.ft)
Gear change lever yoke Allen screw 25 Nm (18 lbf.ft)
5th gear stake nut 350 Nm (258 lbf.ft)
Spool retainer bolts 8 Nm (6 lbf.ft)
Centre plate detent spring and ball Torx screw 25 Nm (18 lbf.ft)
Selector lever to housing bolts 25 Nm (18 lbf.ft)
Clutch Bell housing bolts 73 Nm (54 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
High/low selector cable 30 Nm (22 lbf.ft)
Bottom plate bolts 25 Nm (18 lbf.ft)
Transfer box to gearbox 45 Nm (33 lbf.ft)
Rear cover plate25 Nm (18 lbf.ft)
Differential lock warning lamp switch locknut - Up to 03 MY
11 Nm(8 lbf.ft)
Differential lock warning lamp switches - 03 MY onwards
25 Nm (18 lbf.ft)
Drive flange nut148 Nm (109 lbf.ft)
Output shaft housing 45 Nm (33 lbf.ft)
Oil temperature sensor 42 Nm (31 lbf.ft)
Inhibitor switch to transfer box 26 Nm (19 lbf.ft)
Intermediate shaft nut †88 Nm (65 lbf.ft)
Side cover bolts25 Nm (18 lbf.ft)
Bearing retaining nut 72 Nm (53 lbf.ft)
Output flange nut 162 Nm (119 lbf.ft)
Selector housing bolts 25 Nm (18 lbf.ft)
Bearing housing/cover bolts 25 Nm (18 lbf.ft)

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 10-1
MAINTENANCE PROCEDURES
V8 engine underbonnet view
1Brake/clutch fluid reservoir filler caps
2Engine oil filler cap
3Spark plug
4Engine oil dipstick
5Coolant header tank
6Battery
7Auxiliary drive belt
8ACE/PAS fluid reservoirs
9Windscreen washer reservoir

MAINTENANCE
10-2 PROCEDURES
Diesel underbonnet view
1Coolant header tank
2Brake/clutch fluid reservoir filler caps
3Engine oil dipstick
4Engine oil filler cap
5ACE/PAS fluid reservoirs
6Battery
7Auxiliary drive belt
8Air cleaner
9Windscreen washer reservoir

MAINTENANCE
10-12 PROCEDURES
Auxiliary drive belt - V8 engine
1.Replace auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
Auxiliary drive belt - diesel engine
Replace
1.Replace auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
Fluid reservoirs
Check/top-up — Brake/Clutch reservoir
1.Check fluid level in brake/clutch fluid reservoirs.
2.Clean area around filler cap, remove cap.
3.Top-up if necessary to correct level on reservoir
using recommended fluid.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Fluids.
4.Fit filler cap.
Check/top-up — PAS/ACE reservoirs
1.Check fluid level in PAS and ACE fluid
reservoirs.
2.Clean area around filler cap, remove cap.
3.Top-up if necessary to correct level on reservoir
using recommended fluid.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Fluids.
4.Fit filler cap.

MAINTENANCE
10-22 PROCEDURES
Brake hose, brake, fuel, ACE, clutch
pipes and unions/electrical harnesses
Check – General
1.Check brake servo hose for cracks, leaks and
chafing.
2.Check brake, clutch pipes and unions for
chafing, leaks and corrosion and that all pipes
and hoses are correctly routed and secure.
3.Check electrical harnesses for chafing and
damage.
Check – V8 engine fuel pipes
1.Check fuel pipes and unions for chafing, leaks
and corrosion and that all pipes and hoses are
correctly routed and secure. Check – Diesel engine fuel pipes
1.Check fuel pipes and unions for chafing, leaks
and corrosion and that all pipes and hoses are
correctly routed and secure.

MAINTENANCE
10-28 PROCEDURES
4.Check condition of Engine - RH mounting
rubber
5.Check tightness of all mounting bolts.

+ TORQUE WRENCH SETTINGS,
Engine V8.
Road/roller test
WARNING: Roller test must be restricted to 3
mph (5 km/h). If 2 wheel rolling road is to be used,
disconnect propeller shaft from the transfer box
output shaft driving the axle which is NOT on the
rolling road.Testing
1. 2 wheel rolling road: Engage differential lock
using a 10 mm open ended spanner on flats
machined on differential lock selector
shaft.Switch on ignition and check that the
differential lock, electronic brake
distribution and hill descent warning lamps
are illuminated.
2.Check for correct operation of starter switch,
ensure engine starts correctly; leave the engine
running.
3.Check for correct operation of starter switch,
ensure engine starts correctly; leave the engine
running.
4.With vehicle stationary, turn steering from lock
to lock. Check for smooth operation and ensure
there is no undue noise from power steering
pump or drive belt.
5.Depress clutch and select all gears in turn,
check for smooth, notch free engagement.
6. Check all vehicle systems for correct
operation.
7.Check for unusual engine, gearbox and
suspension noises.
8.Check braking system operation.
9.Check for smooth gear engagement.
10.Check engine performance.
11.Check operation of all instruments and warning
devices where practicable.