LAND ROVER DISCOVERY 2002 Workshop Manual

ENGINE - V8
12-2-38 REPAIRS
8.Clean gearbox oil cooler pipe 'O' ring recess
and mating face.
9.Lubricate and fit new 'O' ring to gearbox oil
cooler pipe.
10.Position pipe and tighten nut.
11.Lower front of vehicle.
12.Position cross member to chassis, fit bolts and
tighten to 25 Nm (18 lbf.ft).
13.Refill engine oil and fit dipstick.
14.Connect battery earth lead.
15.Fit battery cover and retain with fixings.
Switch - oil pressure
$% 12.60.50
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 fixings and remove underbelly panel.
5.Disconnect multiplug from oil pressure switch.
6.Position container below switch to catch oil
spillage.
7.Remove oil pressure switch and discard
sealing washer.
Refit
1.Clean oil pressure switch threads.
2.Fit new sealing washer to switch.
3.Fit oil pressure switch and tighten to 15 Nm (11
lbf.ft) .
4.Connect multiplug to oil pressure switch.
5.Fit underbelly panel and secure with fixings.
6.Remove stand(s) and lower vehicle.
7.Connect battery earth lead.
8.Fit battery cover and retain with fixings.
9.Top up engine oil.

ENGINE - V8
REPAIRS 12-2-39
Cooler - engine oil
$% 12.60.68
Remove
1.Release fixings and remove battery cover.
2.Release fixings and remove cooling fan cowl.
3.Remove front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.
4.Remove 6 scrivets and remove LH and RH air
deflectors from front panel.
5.Remove nut and move LH horn aside. 6.Remove 2 bolts securing radiator LH and RH
upper mounting brackets to body panel and
remove brackets.
7.Remove 4 screws securing air conditioning
condenser LH and RH upper mounting
brackets to condenser.
8.Remove condenser upper mounting brackets
with rubber mounts from radiator extension
brackets.
9.Remove 2 bolts securing LH and RH extension
brackets to radiator and remove brackets.
10.Position absorbent cloth under each oil cooler
hose connection to collect oil spillage.

ENGINE - V8
12-2-40 REPAIRS
11.Push against coupling release rings and
disconnect both hoses from oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
12.Remove screw securing oil cooler to radiator.
13.Release cooler from its location on radiator.
14.Release radiator lower mountings from
location in chassis and carefully move radiator
towards engine sufficiently only to release
engine oil cooler from radiator.
15.Remove engine oil cooler.
Refit
1.Fit engine oil cooler to radiator, engage in
location and secure with screw.
2.Fit radiator to location in chassis.
3.Ensure connections are clean, then secure
hoses to oil cooler.
4.Fit extension brackets to radiator and secure
with bolts.
5.Fit brackets with rubber mounts to extension
brackets and secure to air conditioning
condenser with screws.
6.Fit radiator upper mounting brackets and
secure to body with bolts.
7.Fit LH horn and secure with nut.
8.Fit LH and RH air deflectors to front panel and
secure with scrivets.
9.Fit front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY..
10.Fit cooling fan cowl and secure with fixings.
11.Fit battery cover and secure with fixings.
12.Top up engine oil.
Gasket - timing gear cover
$% 12.65.04
Remove
1.Remove oil pick-up strainer.

+ ENGINE - V8, REPAIRS, Strainer -
oil pick-up.
2.Remove timing gear cover oil seal.

+ ENGINE - V8, REPAIRS, Seal - cover
- timing gears.
3.Remove engine oil filter.

+ ENGINE - V8, REPAIRS, Filter - oil.
4.Remove and discard 3 bolts securing coolant
pump pulley and remove pulley.
5.Remove 3 bolts securing PAS pump pulley and
remove pulley.
6.Drain cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.

ENGINE - V8
REPAIRS 12-2-41
7.Release clip and disconnect coolant hose from
coolant pump.
8.Disconnect multiplug from oil pressure switch.
9.Disconnect multiplug from CMP sensor.
10. If fitted: Loosen union and disconnect oil
cooler pipe from timing gear cover. Remove
and discard 'O' ring.
CAUTION: Always fit plugs to open
connections to prevent contamination.11.Remove 9 bolts securing timing gear cover and
remove cover. Remove and discard gasket.
Refit
1.Clean mating faces of timing gear cover and
cylinder block. Clean dowels and dowel holes.
2.Fit new gasket, dry, to dowels in cylinder block.
3.Fit timing gear cover to cylinder block and,
working the sequence illustrated, tighten bolts
to 22 Nm (17 lbf.ft) . Ensure CMP sensor
multiplug bracket is secured by bolt.
4. If fitted: Fit new 'O' ring to oil cooler pipe,
connect pipe to timing gear cover and tighten
union to 15 Nm (11 lbf.ft).
5.Connect multiplug to oil pressure switch.
6.Connect multiplug to CMP sensor.
7.Connect coolant hose to coolant pump and
secure with clip.

ENGINE - V8
12-2-42 REPAIRS
8.Ensure mating faces of PAS pump pulley and
drive flange are clean, fit pulley and tighten
bolts to 22 Nm (16 lbf.ft).
9.Remove all traces of thread locking material
from coolant pump pulley drive flange bolt
holes using an M8 tap.
10.Ensure mating faces of coolant pump pulley
and drive flange are clean, fit pulley and tighten
new Patchlok bolts to 22 Nm (16 lbf.ft).
11.Ensure mating faces of oil filter and adaptor are
clean, smear clean engine oil onto seal and fit
filter.
12.Fit timing gear cover oil seal.

+ ENGINE - V8, REPAIRS, Seal - cover
- timing gears.
13.Fit oil pick-up strainer.

+ ENGINE - V8, REPAIRS, Strainer -
oil pick-up.
14.Refill cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
Seal - cover - timing gears
$% 12.65.05
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Secure tool LRT-12-080 to crankshaft pulley
with 2 bolts.
3.Remove crankshaft pulley bolt.
4.Remove crankshaft pulley.
5.Use tool LRT-12-088, to remove oil seal from
timing gear cover.

ENGINE - V8
REPAIRS 12-2-43
Refit
1.Clean seal register in timing gear cover and
crankshaft pulley.
2.Apply Retinax LX grease to inner recess of new
oil seal until recess is half filled with grease. Do
not allow grease to coat any other part of
seal. Do not apply oil to seal.
3.Apply smear of Retinax LX grease to seal
running surface on crankshaft.
4.Fit seal to timing gear cover using tool LRT-12-
089 .
5.Fit crankshaft pulley bolt and tighten to 270 Nm
(200 lbf.ft).
6.Remove tool LRT-12-080 from crankshaft
pulley.
7.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.

ENGINE - V8
12-2-44 REPAIRS

ENGINE - V8
OVERHAUL 12-2-45
OVERHAUL
Gasket - inlet manifold
$% 30.15.08.01
Disassembly
1.Disconnect multiplug from coolant thermistor.
2.Disconnect multiplugs from injectors; release
injector harness from fuel rail and position
aside.
3.Remove 3 bolts securing PAS pump pulley and
remove pulley.
4.Loosen bolt securing jockey pulley and remove
pulley. 5.Remove 4 bolts and one nut securing auxiliary
housing and remove housing.
6.Remove 2 nuts securing alternator cables and
release the cables.
7.Remove two bolts securing alternator and
remove alternator.
8.Remove 4 bolts securing coolant outlet elbow
and remove outlet elbow.
9.Remove and discard 'O' ring.
10.Release ht leads from rocker covers.

ENGINE - V8
12-2-46 OVERHAUL
11.Remove 4 bolts securing rocker cover and
remove cover.
12.Remove and discard rocker cover gaskets. 13.Using the sequence shown, remove 12 bolts
securing the inlet manifold.
14.Remove inlet manifold assembly.

ENGINE - V8
OVERHAUL 12-2-47
15.Remove 2 bolts securing manifold gasket and
collect gasket clamps.
16.Remove inlet manifold gasket.
17.Remove gasket seals. Reassembly
1.Clean sealant from cylinder head and from
notches in the cylinder block.
2.Clean mating faces of cylinder block, cylinder
head and manifold.
CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.
3.Apply sealant, Part No. STC 3254 to cylinder
head and notches in cylinder block.
4.Fit new gasket seals, ensuring the ends
engage correctly in notches.
5.Apply sealant, Part No. STC 3254 to gasket
seals above the notches in the cylinder block.
6.Fit new manifold gasket, dry.
7.Position gasket clamps, fit and lightly tighten
bolts.
8.Position inlet manifold assembly to cylinder
head.
9.Fit manifold bolts and, working in the sequence
illustrated, tighten as follows:
lInitially, tighten bolts numbered 1, 4, 9 and
12 in numerical order to 5 Nm (4 lbf.ft).
lInlet manifold bolts - initial tighten = 10 Nm
(8 lbf.ft).
lInlet manifold bolts - final tighten = 51 Nm
(38 lbf.ft).
lTighten inlet manifold gasket clamp bolts to
18 Nm (14 lbf.ft).
lTighten inlet manifold bolts to 51 Nm (38
lbf.ft)