oil filter LAND ROVER DISCOVERY 2002 User Guide

TORQUE WRENCH SETTINGS
06-2
Engine Td5
TORQUE DESCRIPTION METRIC IMPERIAL
ACE pump bolts25 Nm (18 lbf.ft)
A/C compressor bolts 25 Nm (18 lbf.ft)
Alternator support bracket to cylinder head bolts 25 Nm (18 lbf.ft)
Alternator/vacuum pump oil feed pipe union 10 Nm (7 lbf.ft)
Camshaft cover to camshaft carrier bolts 10 Nm (7 lbf.ft)
Camshaft sprocket to camshaft bolts 37 Nm (27 lbf.ft)
Centrifuge cover bolts 10 Nm (7 lbf.ft)
Centrifuge oil drain pipe to sump bolts (or nuts) 10 Nm (7 lbf.ft)
Centrifuge to oil drain pipe bolts 10 Nm (7 lbf.ft)
Centrifuge to oil cooler housing bolts 25 Nm (18 lbf.ft)
CKP sensor bolt10 Nm (7 lbf.ft)
Coolant pipe bolt50 Nm (37 lbf.ft)
Connecting rod bolts, then a further 80°20 Nm (15 lbf.ft)
Crankshaft pulley bolt 460 Nm (340 lbf.ft)
Crankshaft pulley TV damper bolts 80 Nm (59 lbf.ft)
Crankshaft rear oil seal housing bolts 10 Nm (7 lbf.ft)
Cylinder head bolts initial tighten 30 Nm (22 lbf.ft)
Cylinder head bolts final tighten, then a further 90°, then a further 180° and finally a
further 45°65 Nm (48 lbf.ft)
Dipstick tube to camshaft carrier bolt 10 Nm (7 lbf.ft)
Drive plate (automatic transmission) to crankshaft bolts 115 Nm (85 lbf.ft)
EGR pipe clamp to cylinder head bolt - if fitted 25 Nm (18 lbf.ft)
EGR pipe Allen screws 10 Nm (7 lbf.ft)
Engine mounting (front) to cylinder block bolts 48 Nm (35 lbf.ft)
Engine mounting (front) to chassis nuts 85 Nm (63 lbf.ft)
Engine mounting bracket (rear, LH & RH) to gearbox bolts 85 Nm (63 lbf.ft)
Engine mounting bracket (rear, LH & RH) nuts 45 Nm (33 lbf.ft)
Flywheel to crankshaft (manual transmission) bolts, then a further 90°40 Nm (30 lbf.ft)
Front crossmember bolts 26 Nm (20 lbf.ft)
Fuel connector block bolts 25 Nm (18 lbf.ft)
Fuel cooler to inlet manifold bolts 25 Nm (18 lbf.ft)
Gearbox housing to engine bolts 50 Nm (37 lbf.ft)
Heater pipe to cylinder head bolts 25 Nm (18 lbf.ft)
Main bearing cap bolts then a further 90°33 Nm (24 lbf.ft)
Oil cooler housing to cylinder block bolts 25 Nm (18 lbf.ft)
Oil cooler pipe clip bolts 10 Nm (7 lbf.ft)
Oil filter adaptor housing to oil cooler housing bolts 25 Nm (18 lbf.ft)
Oil pick-up strainer screws 10 Nm (7 lbf.ft)
Oil pressure switch 15 Nm (11 lbf.ft)
Oil pump drive sprocket bolt 25 Nm (18 lbf.ft)
Oil pump pressure relief valve plug 25 Nm (18 lbf.ft)
Oil pump and stiffener assembly to cylinder block bolts 13 Nm (10 lbf.ft)
Oil sump to cylinder block bolts 25 Nm (18 lbf.ft)
Oil sump to gearbox bell housing bolts 13 Nm (10 lbf.ft)
PAS pump bracket bolts 27 Nm (20 lbf.ft)
PAS pump pulley bolts 27 Nm (20 lbf.ft)
Rocker arm adjusting screw locknuts 16 Nm (12 lbf.ft)

TORQUE WRENCH SETTINGS
06-4
Engine V8
TORQUE DESCRIPTION METRIC IMPERIAL
Engine mounting bolts (rear, LH & RH) to gearbox bolts 85 Nm (63 lbf.ft)
Engine mounting (rear, LH & RH) nuts 45 Nm (33 lbf.ft)
Cylinder head bolts tighten, then 90°, then a further 90°20 Nm (15 lbf.ft)
Rocker shaft bolts 40 Nm (30 lbf.ft)
Alternator mounting bracket 40 Nm (30 lbf.ft)
Auxiliary drive belt tensioner 45 Nm (33 lbf.ft)
Engine earth lead 22 Nm (16 lbf.ft)
Rocker cover bolts 8 Nm (6 lbf.ft)
Torque converter to drive plate 50 Nm (37 lbf.ft)
A/C compressor 22 Nm (16 lbf.ft)
ACE pump 22 Nm (16 lbf.ft)
Flywheel to crankshaft 78 Nm (58 lbf.ft)
Crankshaft sensor 6 Nm (5 lbf.ft)
Crankshaft sensor cover 6 Nm (5 lbf.ft)
Spacer and hub to crankshaft 85 Nm (63 lbf.ft)
Drive plate and clamp ring 45 Nm (33 lbf.ft)
Oil pick up strainer 10 Nm (7 lbf.ft)
Filter head adaptor 13 Nm (10 lbf.ft)
Filter head 8 Nm (6 lbf.ft)
Sump bolts 22 Nm (16 lbf.ft)
Oil pressure switch 15 Nm (11 lbf.ft)
Timing gear cover to cylinder block 22 Nm (16 lbf.ft)
Oil cooler pipe to timing gear cover 15 Nm (11 lbf.ft)
Crankshaft pulley bolt 270 Nm (200 lbf.ft)
Coolant outlet elbow 22 Nm (16 lbf.ft)
Auxiliary housing 40 Nm (30 lbf.ft)
Jockey pulley 50 Nm (37 lbf.ft)
Camshaft gear 50 Nm (37 lbf.ft)
Rocker shaft bolts 40 Nm (30 lbf.ft)
Connecting rod bolts
Final torque - turn through 80 °20 Nm (15 lbf.ft)
Initial torque - all main bearing cap bolts and side bolts 13.5 Nm (10 lbf.ft)
Final torque - main bearing cap side bolts 11 to 15 45 Nm (33 lbf.ft)
Final torque - main bearing cap bolts 1 to 8 72 Nm (53 lbf.ft)
Final torque - main bearing cap bolts 9 and 10 92 Nm (68 lbf.ft)
Final torque - main bearing cap side bolts 16 to 20 45 Nm (33 lbf.ft)
Viscous fan nut 45 Nm (33 lbf.ft)
Camshaft thrust plate bolts 22 Nm (16 lbf.ft)
Secondary Air Injection adapters 33 Nm (24 lbf.ft)

TORQUE WRENCH SETTINGS
06-9
Automatic gearbox - ZF4HP22/24
Propeller shafts
Axles
TORQUE DESCRIPTION METRIC IMPERIAL
Selector lever to selector shaft nut 26 Nm (19 lbf.ft)
Starter inhibitor switch bolts 10 Nm (7 lbf.ft)
Engine to torque converter bolts - Td5 & V8 50 Nm (37 lbf.ft)
Closing plate to gearbox housing bolt - V8 7 Nm (5.2 lbf.ft)
Fluid pump to intermediate plate bolts 10 Nm (7 lbf.ft)
Intermediate plate Allen plugs (M14) 40 Nm (30 lbf.ft)
Intermediate plate Allen plugs (M20) 50 Nm (37 lbf.ft)
Oil cooler adaptors 42 Nm (31 lbf.ft)
Extension housing bolts 25 Nm (18 lbf.ft)
Oil sump to gearbox housing bolts 8 Nm (6 lbf.ft)
Oil filter Torx screws 8 Nm (6 lbf.ft)
Oil pick-up tube Torx screw 8 Nm (6 lbf.ft)
Parking pawl guide Torx screw 10 Nm (7 lbf.ft)
Pressure regulator to valve body assembly 8 Nm (6 lbf.ft)
Lock-up solenoid valve, retaining fork Torx screw 8 Nm (6 lbf.ft)
Lock-up solenoid valve assembly to valve body Torx screws 8 Nm (6 lbf.ft)
Gearbox bell housing (intermediate plate and converter housing to gearbox casing)
bolts46 Nm (34 lbf.ft)
Speed sensor bracket screws 8 Nm (6 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Propeller shaft to transfer gearbox 47 Nm (35 lbf.ft)
Propeller shaft to differential 47 Nm (35 lbf.ft)
Propeller shaft to flexible coupling 76 Nm (56 lbf.ft)
Flexible coupling to differential 76 Nm (56 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Differential to axle bolts 55 Nm (40 lbf.ft)
Hub to axle bolts 100 Nm (74 lbf.ft)
Pinion flange bolt 100 Nm (74 lbf.ft)
Drive shaft nut490 Nm (360 lbf.ft)

CAPACITIES, FLUIDS AND LUBRICANTS
09-1
CAPACITIES, FLUIDS AND LUBRICANTS
Capacities
The following capacities are only an approximation of
the amount of fluid required to fill the respective
system.
Capacities - UK EURO ROW
Capacities - NAS
Component Metric Units
Fuel tank 95 litres
Engine - Td5:

Engine oil and filter change 7.2 litres

Fill from dry 8.2 litres
Engine - V8 with oil cooler:

Engine oil and filter change 6.27 litres

Engine oil refill from dry: 7 litres
Engine - V8 without oil cooler:

Engine oil and filter change 5.8 litres

Engine oil refill from dry 6.5 litres
Manual gearbox without oil cooler:

Refill 2.3 litres

Fill from dry 2.6 litres
Manual gearbox with oil cooler:

Refill 2.8 litres

Fill from dry 3.1 litres
Automatic gearbox fill from dry
9.7 litres
Transfer box:

Refill 2.0 litres

Fill from dry 2.3 litres
Front and rear axle:

Refill 1.6 litres

Fill from dry 1.7 litres
Cooling system - Td5 Engine:

Refill 8 litres

Fill from dry 13 litres
Cooling system - V8 Engine:

Refill 12 litres

Fill from dry 13 litres
Component US Units
Fuel tank25.5 gal
Engine - V8 with oil cooler:

Engine oil and filter change 6.6 qt

Engine oil refill from dry 7.4 qt
Engine - V8 without oil cooler:

Engine oil and filter change 6.1 qt

Engine oil refill from dry 6.9 qt
Automatic gearbox fill from dry
19.7 pt
Transfer box:

Refill4.1 pt

Fill from dry 4.8 pt
Front and rear axle:

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
PROCEDURES 10-17
Automatic gearbox
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Replace oil filter
1.Replace oil filter.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Filter - oil.
Replace oil
1. Ensure that gearbox is cool. Apply
handbrake and securely chock front and rear
wheels.
2.Place a suitable container beneath gearbox.
3.Clean area around oil filler/level and drain
plugs.
4.Remove oil drain plug, remove and discard
sealing washer.
5.Allow oil to drain.
6.Fit new sealing washer to oil drain plug.
7.Fit automatic gearbox drain plug and tighten to
15 Nm (11 lbf.ft).
8.Remove oil filler/level plug, remove and discard
sealing washer.9.Fill gearbox with recommended oil to bottom of
oil level/filler plug hole.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
10.Select 'P' (Park).
11.Ensure handbrake is applied.
12.Start engine and allow it to idle.
13.Apply footbrake.
14.Move selector lever through all gear positions,
while continuing to fill the gearbox. Select 'P'
(Park).
15.With engine idling, continue filling gearbox until
a 2 mm bead of oil runs from oil filler/level plug
hole.
16.Fit new sealing washer to automatic gearbox
filler/level plug, fit plug and tighten to 30 Nm (22
l b f . f t ) .
17.Stop engine.
18.Remove all traces of oil from gearbox casing.

ENGINE - TD5
DESCRIPTION AND OPERATION 12-1-3
1Oil dipstick tube
2Screw – oil dipstick tube to camshaft carrier
3Oil dipstick
42nd piston ring
5Piston
6Small-end bush
7Connecting rod
8Big-end bearing cap
9Connecting rod bolt (2 off per connecting rod)
10Top piston ring
11Oil control ring
12Circlips (2 off per gudgeon pin)
13Gudgeon pin
14Big-end bearing shells
15Dowels – cylinder head (2 off)
16Clutch housing shim plate
17 Crankshaft rear oil seal and housing
18Screws – crankshaft seal housing to engine
block (5 off)
19Bolts – clutch housing shim plate to engine
block (2 off)
20Main oil gallery plug (rear)
21Oil filter adaptor gasket
22Oil filter adaptor thermostat
23Oil filter adaptor assembly
24Oil filter adaptor insert25Oil filter adaptor to cylinder block bolts (3 off)
26Oil filter
27Oil pressure switch
28Oil cooler banjo bolts (2 off)
29O-rings – oil cooler banjo bolts (2 off)
30Oil cooler to cylinder block bolts (7 off)
31Centrifuge assembly
32Centrifuge to cylinder block bolts (3 off)
33Centrifuge oil drain pipe
34Oil drain pipe to sump gasket
35Centrifuge to oil drain pipe gasket
36Oil cooler plugs (3 off)
37Oil cooler assembly
38Oil cooler matrix 'O-rings' (2 off)
39Oil cooler matrix
40Oil cooler gasket
41Coolant and PAS pump assembly bracket
42Bracket bolts (5 off + 1 stud/nut)
43Cylinder block
44Dowels to timing block cover (2 off)
45Oil gallery delivery plug
46Cross drilling plug
47Coolant jacket plug
48Core plugs (3 off)

ENGINE - TD5
12-1-12 DESCRIPTION AND OPERATION
Description
General
The Td5 diesel engine is a 2.5 litre, 5 cylinder, in-line direct injection unit having 2 valves per cylinder, operated by a
single overhead camshaft. The engine emissions, on pre EU3 models, comply with ECD2 (European Commission
Directive) and on EU3 models, comply with ECD3 legislative requirements. Both models employ electronic engine
management control, positive crankcase ventilation and exhaust gas recirculation to limit the emission of pollutants.
The unit is water cooled and turbo-charged and is controlled by an electronic engine management system.
The engine is a monobloc cast iron construction with an aluminium stiffening plate fitted to the bottom of the cylinder
block to improve lower structure rigidity. The cylinder head and sump are cast aluminium. An acoustic cover is fitted
over the upper engine to reduce engine generated noise.
The engine utilises the following features:
lElectronic Unit Injectors (EUI's) controlled by an Engine Management System for precise fuel delivery under
all prevailing operating conditions.
lTurbocharging which delivers compressed air to the combustion chambers via an intercooler for improved
power output.
lFuel Cooler
lOil Cooler
lCentrifuge Oil Filter
lHydraulic Lash Adjusters with independent finger followers
Cylinder block components
The cylinder block components are described below:
Cylinder Block
The cylinders and crankcase are contained in a single cast iron construction. The cylinders are direct bored and
plateau honed with lubrication oil supplied via lubrication jets for piston and gudgeon pin lubrication and cooling. It is
not possible to rebore the cylinder block if the cylinders become worn or damaged. Three metal core plugs are fitted
to the three centre cylinders on the right hand side of the cylinder block.
Lubrication oil is distributed throughout the block via the main oil gallery to critical moving parts through channels
bored in the block which divert oil to the main and big-end bearings via oil holes machined into the crankshaft. Oil is
also supplied from the cylinder block main gallery to the five lubrication jets which cool and lubricate the piston and
gudgeon pins. Plugs are used to seal both ends of the main oil gallery at front and rear of the engine block. An oil
cooler is fitted to the LH side of the engine block; ports in the oil cooler assembly mate with ports in the cylinder block
to facilitate coolant flow. Oil is diverted through the oil cooler, centrifuge filter and full-flow filter before supplying the
main oil gallery. A tapping in the oil filter housing provides a lubrication source for the turbocharger bearings and an
oil pressure switch is included in a tapping in the oil cooler housing which determines whether sufficient oil pressure
is available to provide engine lubrication and cooling.
Cylinder cooling is achieved by water circulating through chambers in the engine block casting. A threaded coolant
jacket plug is located at the front RH side of the cylinder block.
Cast mounting brackets are bolted to both sides of the engine block for mounting the engine to the chassis on the LH
and RH hydramount studs.
The gearbox bolts directly to the engine block; a gearbox shim plate is located between the adjoining faces of the
gearbox and the flywheel side of the engine block and is fixed to the rear of the engine block by two bolts. Two hollow
metal dowels locate the rear of the cylinder block to the gearbox shim plate. The gearbox casing provides the
mounting for the starter motor.
A port is included at the rear left hand side of the cylinder block which connects to the turbocharger oil drain pipe to
return lubrication oil to the sump.
A plug sealing the lubrication cross-drilling gallery is located at the front right hand side of the cylinder block and plugs
for the main lubrication gallery is included at the front and rear of the cylinder block.