fuel LAND ROVER DISCOVERY 2002 Owner's Manual

GENERAL DATA
04-9
Fuel system - V8
Cooling system - Td5
Type Multiport injection from pressure regulated, returnless supply
Pump Electric submersible
Regulated pump output pressure 3.5 bar (50.75 lbf.in
2)
Fuel pump delivery 120 litres/hr (211 pints/hr) (234 US pints/hr)
Filter In-line canister
Air filter Mann and Hummell P0036
Type Pressurised, spill return partial flow, thermostatically controlled
Cooling fans 11 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 110 °C (230 °F)

Off 105 °C (221 °F)
For engine cooling at ignition off (to counteract heat
soak):

On If, within 10 seconds of ignition off, engine coolant temperature is
105 °C (221 °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
Thermostat Waxstat with pressure relief valve
Thermostat opening temperature:

Initial opening 82 °C (179 °F)

Fully open 96 °C (204 °F)
Expansion tank cap relief valve - system operating
pressure1.4 bar (20.3 lbf.in
2)
Fuel cooler thermostat opening temperature 82°C (179°F)

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
06-3
Rocker shaft bolts 32 Nm (24 lbf. ft)
Timing chain adjustable guide bolt 25 Nm (18 lbf.ft)
Timing chain cover bolts 27 Nm (20 lbf.ft)
Timing chain cover to cylinder block stud 7 Nm (5.2 lbf.ft)
Timing chain fixed guide retaining pin 25 Nm (18 lbf.ft)
Timing chain cover to cylinder head nut and bolt 25 Nm (18 lbf.ft)
Timing chain fixed guide (M6) bolt 10 Nm (7 lbf.ft)
Timing chain fixed guide (M10) bolt 45 Nm (33 lbf.ft)
Timing chain lubrication jet bolt 10 Nm (7 lbf.ft)
Timing chain tensioner 45 Nm (33 lbf.ft)
Torque converter to drive plate (automatic transmission) bolts 50 Nm (37 lbf.ft)
Turbocharger heatshield bolts 10 Nm (7 lbf.ft)
Turbocharger oil feed pipe banjo bolt 25 Nm (18 lbf.ft)
Turbocharger to exhaust manifold nuts 30 Nm (22 lbf.ft)
Vacuum pump oil feed pipe to cylinder head union 10 Nm (7 lbf.ft)
Viscous fan nut45 Nm (33 lbf.ft)
Fuel spill return pipe unions - if fitted 20 Nm (15 lbf.ft)TORQUE DESCRIPTION METRIC IMPERIAL

TORQUE WRENCH SETTINGS
06-5
Emission control - Td5
Emission control - V8
Engine management system - Td5
TORQUE DESCRIPTION METRIC IMPERIAL
EGR valve pipe Allen screws 10 Nm (7 lbf.ft)
EGR valve to inlet manifold bolts 10 Nm (7 lbf.ft)
EGR intake pipe clip to cylinder head bolts - if fitted 25 Nm (18 lbf.ft)
EGR cooler to cylinder head nut and bolts - if fitted 25 Nm (18 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
HO
2S Sensors45 Nm (33 lbf.ft)
SAI air manifold union nuts 25 Nm (18 lbf.ft)
Rubber mountings to SAI pump bracket 10 Nm (7 lbf.ft)
SAI control valve to manifold bolts 10 Nm (7 lbf.ft)
SAI pump to bracket nuts 10 Nm (7 lbf.ft)
SAI pump bracket to body bolt 20 Nm (15 lbf.ft)
Vacuum reservoir to mounting bracket bolt 10 Nm (7 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
ECT sensor15 Nm (11 lbf.ft)
Fuel tank cradle45 Nm (33 lbf.ft)
CKP sensor10 Nm (7 lbf.ft)
MAP and IAT sensor 10 Nm (7 lbf.ft)
Fuel cooler to inlet manifold - upper bolts 25 Nm (18 lbf.ft)
Turbocharger to exhaust manifold 30 Nm (22 lbf.ft)
Turbocharger drain pipe 10 Nm (7 lbf.ft)
Banjo bolt to oil feed pipe 25 Nm (18 lbf.ft)
Fuel temperature sensor 14 Nm (10 lbf.ft)
Pressure regulator 25 Nm (18 lbf.ft)
Glow plugs16 Nm (12 lbf.ft)
EUI clamp bolts32 Nm (24 lbf.ft)
EGR valve to exhaust manifold 10 Nm (7 lbf.ft)
EGR valve to inlet manifold 10 Nm (7 lbf.ft)
EGR clip25 Nm (18 lbf.ft)

TORQUE WRENCH SETTINGS
06-6
Engine management system - V8
Cooling system
Manifolds and exhaust systems - Td5
TORQUE DESCRIPTION METRIC IMPERIAL
Spark plugs20 Nm (15 lbf.ft)
Fuel tank cradle45 Nm (33 lbf.ft)
ECT sensor10 Nm (7 lbf.ft)
CKP sensor6 Nm (4.4 lbf.ft)
CMP sensor8 Nm (6 lbf.ft)
KS sensor22 Nm (16 lbf.ft)
Throttle body10 Nm (7 lbf.ft)
Plenum chamber22 Nm (16 lbf.ft)
Breather adaptor6 Nm (4.4 lbf.ft)
Throttle cable abutment bracket 10 Nm (7 lbf.ft)
TP sensor 2.2 Nm (1.6 lbf.ft)
IACV sensor8 Nm (6 lbf.ft)
HO
2S sensor45 Nm (33 lbf.ft)
Ignition coils8 Nm (6 lbf.ft)
Fuel rail9 Nm (7 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Cylinder block drain plug 30 Nm (22 lbf.ft)
Coolant pump24 Nm (18 lbf.ft)
Coolant pump pulley 22 Nm (16 lbf.ft)
Coolant pump cover - Td5 10 Nm (7 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Front pipe to turbocharger 27 Nm (20 lbf.ft)
Inlet manifold25 Nm (18 lbf.ft)
Tail pipe25 Nm (18 lbf.ft)
Fuel cooler25 Nm (18 lbf.ft)
EGR valve10 Nm (7 lbf.ft)
Exhaust manifold25 Nm (18 lbf.ft)
Exhaust manifold heatshield (M6) bolts 10 Nm (7 lbf.ft)
Exhaust manifold heatshield (M8) bolts 25 Nm (18 lbf.ft)
EGR pipe Allen screws 10 Nm (7 lbf.ft)

TORQUE WRENCH SETTINGS
06-15
Heating and air conditioning
Wipers and washers
Electrical
TORQUE DESCRIPTION METRIC IMPERIAL
Heater assembly16 Nm (12 lbf.ft)
Compressor bolts 22 Nm (16 lbf.ft)
Blower motor19 Nm (14 lbf.ft)
Compressor to mounting bracket bolts 25 Nm (18 lbf.ft)
A/C pipes to compressor bolts 10 Nm (7 lbf.ft)
Condenser pipe bolt 5 Nm (3.7 lbf.ft)
Receiver drier to bracket bolts 5 Nm (3.7 lbf.ft)
Adaptor block to receiver drier bolt 5 Nm (3.7 lbf.ft)
Evaporator pipe bolts 5 Nm (3.7 lbf.ft)
Dual pressure switch to receiver drier 10 Nm (7 lbf.ft)
Air conditioning pipes to receiver drier bolts 5 Nm (3.7 lbf.ft)
TX valve pressure pipe union 22 Nm (16 lbf.ft)
Evaporator pipe to TXV valve 32 Nm (24 lbf.ft)
Evaporator assembly to body bolts 16 Nm (12 lbf.ft)
High and low pressure pipe, bolts 10 Nm (7 lbf.ft)
Fuel burning heater Torx bolts 25 Nm (18 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Link to motor spindle 7 Nm (5.2 lbf.ft)
Front motor assembly 2.5 Nm (1.8 lbf.ft)
Spindle nut 3 Nm (2.2 lbf.ft)
Wiper arm nut13 Nm (10 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Alternator support stay 25 Nm (18 lbf.ft)
Alternator lead - Td5 6 Nm (4.4 lbf.ft)
Auxiliary drive belt tensioner bolt 50 Nm (37 lbf.ft)
Alternator pulley80 Nm (59 lbf.ft)
Alternator B+ nut - V8 18 Nm (13 lbf.ft)
Alternator B+ nut - V8 5 Nm (3.7 lbf.ft)
Starter motor - Td5 27 Nm (20 lbf.ft)
Starter motor solenoid 10 Nm (7 lbf.ft)
Starter motor - V8 44 Nm (32 lbf.ft)
Alternator45 Nm (33 lbf.ft)
Starter motor heat shield - V8 10 Nm (7 lbf.ft)
Horn13 Nm (10 lbf.ft)
Battery carrier bolts 28 Nm (21 lbf.ft)

LIFTING AND TOWING
08-1
LIFTING AND TOWING
LIFTING
The following instructions must be carried out before
raising the vehicle off the ground.
lUse a solid level ground surface.
lApply hand brake.
lSelect 'P' (Automatic gearbox) or 1st gear
(Manual gearbox) in main gearbox.
lSelect Low range in transfer gearbox.
To avoid damage occurring to the under body
components of the vehicle the following jacking
procedures must be adhered to.
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS:
lBody structure
lBumpers
lFuel lines
lBrake lines
lFront radius arms
lPanhard rod
lSteering linkage
lRear trailing arms
lFuel tank
lEngine sump
lGearbox bell housing
Vehicle jack
The jack provided with the vehicle is only intended for
use in an emergency, for changing a tyre. DO NOT
use the jack for any other purpose. Refer to Owner's
Handbook for vehicle jack location points and
procedure. Never work under a vehicle supported
solely by the vehicle jack.
Hydraulic jack
A hydraulic jack with a minimum 1500 kg, 3,300 lbs
load capacity must be used. Do not commence
work on the underside of the vehicle until
suitable axle stands have been positioned under
the axle.
WARNING: Always chock the wheels when
jacking. The hand brake acts on the
transmission, not the rear wheels, and may be
ineffective when the wheels are off the ground.Raising and supporting the vehicle
Position cup of hydraulic arm under differential
casing (1).The differential casing is not central to
the axle. Care should be taken when raising the
front road wheels off the ground as the rear axle
has less sway stiffness.
Raise vehicle to enable an axle stand to be installed
under left hand axle tube (2).
Position an axle stand under right hand axle tube (4).
Carefully lower jack until vehicle sits securely on both
axle stands, remove jack.
Alternatively, the axle stands can be positioned
under the chassis longitudinals at the front and/or
rear of the vehicle.
Before commencing work on underside of vehicle re-
check security of vehicle on stands.
WARNING: Always chock the wheels when
jacking. The hand brake acts on the the
transmission, not the rear wheels, and may be
ineffective when the wheels are off the ground.

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:

CAPACITIES, FLUIDS AND LUBRICANTS
09-3
Anti-Freeze Concentration
The overall anti-freeze concentration should not fall,
by volume, below 50% to ensure that the anti-
corrosion properties of the coolant are maintained.
Anti-freeze concentrations greater than 60% are not
recommended as cooling efficiency will be impaired.
The following recommended quantities of anti-freeze
will provide frost protection to -48
°C (-53°F):
Engine - TD5
Engine - V8
Lubrication
General
The engine and other lubricating systems are filled
with high-performance lubricants giving prolonged
life.
CAUTION: Always use a high quality oil of the
correct viscosity range in the engine. The use of
oil of the incorrect specification can lead to high
oil and fuel consumption and ultimately to
damaged components.
Oil to the correct specification contains additives
which disperse the corrosive acids formed by
combustion and prevent the formation of sludge
which can block the oil ways. Additional oil additives
should not be used.
Always adhere to the recommended servicing
intervals.
Engine oil viscosity
The above chart indicates the ambient temperature
ranges which each engine oil viscosity is suitable for.
Engine oil - V8 - low compression engine
Use a 10W/40 oil meeting specification ACEA: A2,
and having a viscosity band recommended for the
temperature range of your locality.
Concentration 50%
Amount of Anti-freeze 4 litres
Concentration 50%
Amount of Anti-freeze 6.5 litres
13.5 pts (US)

MAINTENANCE
10-8 PROCEDURES
Brake fluid
Replace
1.Replace brake fluid.

+ BRAKES, ADJUSTMENTS, Brake
system bleeding.
Fuel filter - diesel engine
Replace
1.Replace filter element.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Element - fuel filter.
Fuel filter sedimenter
Drain
1.Position suitable container beneath fuel filter.
2.Disconnect multiplug from sedimenter.
3.Rotate sedimenter anti-clockwise until water
flows from drain tube.
4.Allow to drain until diesel fuel flows from drain
tube.
5.Rotate sedimenter fully clockwise.
6.Connect multiplug.
Road wheels
Refit
1.Apply anti-seize compound to wheel hub
centre.
2.Refit road wheels to original hub position.
Tighten wheel nuts to 140 Nm (103 lbf.ft).
Radiator/Intercooler
Check
1.Visually check radiator/intercooler for external
obstructions, remove debris.
2.Visually check fan blades for damage.
Ambient air Temperature and pressure
sensor
Check
1.Check ambient air temperature and pressure
sensor for damage.