oil LAND ROVER DISCOVERY 2002 Owner's Manual

GENERAL INFORMATION
03-24
Air Conditioning System Precautions
General
The air conditioning system contains fluids and
components which could be potentially hazardous to
the service engineer or the environment if not
serviced and handled correctly. The following
guidelines are intended to alert the service engineer
to potential sources of danger and emphasise the
importance of ensuring the integrity of the Air
Conditioning operating conditions and components
fitted to the vehicle.
Where necessary, additional specific precautions are
detailed in the relevant sections of this Manual which
should be referred to prior to commencing repair
operations.
The refrigerant used in the air conditioning system is
HFC-134a (Hydrofluorocarbon) R134a.
WARNING: Servicing must only be carried out by
personnel familiar with both the vehicle system
and the charging and testing equipment. All
operations must be carried out in a well
ventilated area away from open flame and heat
sources.
WARNING: R134a is a hazardous liquid and when
handled incorrectly can cause serious injury.
Suitable protective clothing, consisting of face
protection, heat proof gloves, rubber boots and
rubber apron or waterproof overalls, must be
worn when carrying out operations on the air
conditioning system.
Remedial actions
If an accident involving R134a should occur, conduct
the following remedial actions:
lIf liquid R134a enters the eye, do not rub it.
Gently run large quantities of eye wash over
affected eye to raise the temperature. If an eye
wash is not available, cool, clean water may be
used to flush the eye. After rinsing, cover the
eye with a clean pad and seek immediate
medical attention.lIf liquid R134a is splashed onto the skin, run
large quantities of water over the affected area
to raise the temperature. Implement the same
action if the skin comes in contact with
discharging cylinders. Wrap the contaminated
body parts in blankets (or similar materials) and
seek immediate medical attention.
lIf the debilitating effects of inhalation of R134a
vapour is suspected, seek fresh air. If the
affected person is unconscious, move them
away from the contaminated area to fresh air
and apply artificial respiration and/or oxygen
and seek immediate medical attention.
WARNING: Due to its low evaporating
temperature, R134a must be handled with care.
R134a splashed on any part of the body will
cause immediate freezing of that area. Also,
refrigerant cylinders and replenishment trolleys
when discharging will freeze skin to them if
contact is made.
Service precautions
Observe the following precautions when handling
components used in the air conditioning system:
lAir conditioning units must not be lifted by their
hoses, pipes or capillary lines.
lHoses and lines must not be subjected to any
twist or stress; the efficiency of the system will
be impaired by kinks or restrictions. Ensure that
hoses are correctly positioned before tightening
couplings, and ensure that all clips and supports
are utilised.
lFlexible hoses should not be positioned close to
the exhaust manifold (less than 100mm) unless
protected by heat shielding.
lCompleted assemblies must be checked for
refrigeration lines touching metal panels. Any
direct contact of components and panels may
transmit noise and so must be eliminated.
lThe appropriate torque wrench must be used
when tightening refrigerant connections to the
stipulated value. An additional spanner must be
used to hold the union to prevent twisting of the
pipe when tightening connections.
lBefore connecting any hose or pipe, ensure that
refrigerant oil is applied to the seat of the new 'O'
rings, BUT NOT to the threads of the
connection.
lAll protective plugs must remain in place to seal
the component until immediately prior to
connection.
lEnsure components are at room temperature
before uncapping, to prevent condensation of
moisture from the air that enters it.

GENERAL INFORMATION
03-25
lComponents must not remain uncapped for
longer than 15 minutes. In the event of a delay,
the caps must be fitted.
lWhen disconnecting, immediately cap all air
conditioning pipes to prevent ingress of dirt and
moisture into the system.
lThe receiver/drier contains desiccant which
absorbs moisture. It must be positively sealed at
all times. A receiver/drier that has been left
uncapped must not be used, fit a new unit.
lThe receiver/drier should be the last component
connected to the system to ensure optimum
dehydration and maximum moisture protection
of the system.
lWhenever the refrigerant system is opened, the
receiver/drier must be renewed immediately
before evacuating and recharging the system.
lUse alcohol and a clean lint-free cloth to clean
dirty connections.
lEnsure that all new parts fitted are marked for
use with R134a.
When a major repair has been completed, a leak test
should be conducted; refer to the Air Conditioning
section of this manual for the correct procedure.
Refrigerant oil
Refrigerant oil easily absorbs water and must not
be stored for long periods. Do not pour unused
refrigerant oil back into the container. Always
use an approved refrigerant oil.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
When replacing components in the A/C system,
drain the refrigerant oil from the component being
replaced into a graduated container. On assembly,
add the quantity of refrigerant oil drained to the new
component.
Compressor
A new compressor is sealed and pressurised with
Nitrogen gas. When fitting a new compressor, slowly
release the sealing cap; gas pressure should be
heard to vent as the seal is broken.
CAUTION: A new compressor should always be
sealed and could be pressurised with nitrogen
gas. To avoid possible oil loss, release the
sealing cap(s) slowly. Do not remove the cap(s)
until immediately prior to connecting the air
conditioning pipes to the compressor.Rapid refrigerant discharge
If the air conditioning system is involved in accident
damage and the system is punctured, the refrigerant
will discharge rapidly. The rapid discharge of
refrigerant will also result in the loss of most of the oil
from the system. The compressor must be removed
and all the remaining oil in the compressor drained
and refilled as instructed in the air conditioning
section of this manual.
Precautions for refrigerant recovery, recycling
and recharging
When the air conditioning system is recharged, any
existing refrigerant is first recovered from the system
and recycled. The system is then charged with the
required weight of refrigerant and volume of
refrigerant oil.
WARNING: Refrigerant must always be recycled
before re-use to ensure that the purity of the
refrigerant is high enough for safe use in the air
conditioning system.
Recycling should always be carried out with
equipment which is design certified by
Underwriter Laboratory Inc. for compliance with
SAE J1991. Other equipment may not recycle
refrigerant to the required level of purity.
A R134a Refrigerant Recovery Recycling
Recharging Station must not be used with any
other type of refrigerant.
Refrigerant R134a from domestic and
commercial sources must not be used in motor
vehicle air conditioning systems.
CAUTION: The system must be evacuated
immediately before recharging commences.
Delay between evacuation and recharging is not
permitted.

GENERAL INFORMATION
03-26
Air Conditioning Compressor
Replacement
A new compressor is supplied filled with a full charge
(X cm3) of refrigerant oil.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Capacities.A calculated quantity of
oil must be drained from the new compressor before
fitting. To calculate the quantity of oil to be drained:
1Remove the drain plug from the old
compressor.
2Invert the compressor and gravity drain the oil
into a calibrated measuring cylinder. Rotate the
compressor clutch to ensure the compressor is
completely drained.
3Note the quantity of oil drained (Y cm
3).
4Calculate the quantity of oil to be drained from
the new compressor using the following
formula:
X cm
3 — (Y cm3 + 20 cm3) = Q cm3
5Remove the drain plug from the new
compressor and drain Q cm3 of oil. Fit and
tighten the compressor drain plug.
Body Repairs
General
Body shells are of welded construction and bolted to
a chassis frame. Front and rear sections of the shell
are designed as 'energy absorbing' zones. This
means they are designed to deform progressively
when subjected to impact in order to minimise the
likelihood of injury to vehicle occupants.
It is essential that design dimensions and strength
are restored in accident rectification. It is important
that neither structural weakness nor excessive local
stiffness are introduced into the vehicle during body
repair.
Repairs usually involve a combination of operations
ranging from straightening procedures to renewal of
individual panels or panel assemblies. The repairer
will determine the repair method and this decision will
take into account a balance of economics between
labour and material costs and the availability of repair
facilities in both equipment and skills. It may also
involve considerations of the vehicles' downtime,
replacement vehicle availability and repair turn-
around time.
It is expected that a repairer will select the best and
most economic repair method possible, making use
of the facilities available. The instructions given are
intended to assist a skilled body repairer by
expanding approved procedures for panel
replacement. The objective is to restore the vehicle
to a safe running condition by carrying out a repair
which is as close as is feasible to original standard.
The results should not advertise to the experienced
eye that the vehicle has been damaged, although the
repair might not be identical in all respects to the
original factory build. Commercial bodyshop repair
facilities cannot always duplicate methods of
construction used during production.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and suspension
geometry checked after completion. Where
necessary a road test of the vehicle should be carried
out, particularly where safety-related items are
concerned.
Where major units have been disconnected or
removed it is necessary to ensure that fluid levels are
checked and topped up where necessary. It is also
necessary to ensure that the repaired vehicle is in a
roadworthy condition in respect of tyre pressures,
lights, washer fluid etc.

GENERAL DATA
04-2
Lubrication
Type Wet sump, pressure fed
Pump type Eccentric rotor, crankshaft driven integral with stiffener plate.
Filter type:

Primary Centrifuge filter

Secondary Disposable canister with full flow by-pass
Pressure at idle (Cold) 3.0 bar (43.5 lbf.in
2)
Pressure at 3500 rev/min (Hot) 1.5-3.0 bar (21.75-43.5 lbf.in
2)
Relief valve opening pressure 4.0 bar (58 lbf.in
2)
Low oil pressure switch opening pressure 0.2-0.6 bar (3.0-8.8 lbf.in
2)
Crankshaft
Main journal diameter 61.9875-62.0125 mm (2.4404-2.4414 in)
Crankpin journal diameter 53.99-54.01 mm (2.125-2.131 in)
End float 0.020 - 0.250 mm (0.0008 - 0.0098 in)

Main bearings
Quantity 6 (5 main, 1 thrust)

Pistons
Type Graphite compound skirt with combustion chamber in crown
Clearance in cylinder bore.
Measured at bottom of skirt, 90° to gudgeon pin0.172-0.206 mm (0.007-0.008 in)
Diameter
(Measured at right angles to gudgeon pin and 40.0
mm (1.5 in) from bottom of skirt)84.270-85.254 mm (3.321-3.361 in)
Gudgeon pins Fully floating, offset towards piston thrust side
Piston rings
Type: 2 compression, 1 oil control

Upper compression ring Barrel edge, chrome plated

Lower compression ring Taper faced

Oil control ring Bevelled ring with spring
New ring to groove clearance:

Upper compression Not measured

Lower compression 0.050-0.082 mm (0.002-0.003 in)

Oil control 0.050-0.082 mm (0.002-0.003 in)
Piston ring fitted gap in cylinder bore:

Upper compression 0.30-0.45 mm (0.0118-0.0177 in)

Lower compression 0.40-0.60 mm (0.0157-0.0236 in)

Oil control 0.25-0.40 mm (0.0098-0.0157 in)

GENERAL DATA
04-3
Camshaft
Bearings 6
Drive Duplex chain
End float 0.06-0.16 mm (0.002-0.006 in)

Tappets
Type Hydraulic lash adjusters with followers

Valves
Stem diameter:

Exhaust 6.905 ± 0.008 mm (0.271 ± 0.0003 in)

Inlet 6.915 ± 0.008 mm (0.272 ± 0.0003 in)
Head diameter:

Exhaust 31.7 mm (1.25 in)

Inlet 34.7 mm (1.37 in)
Seat face angle:

Exhaust 45°

Inlet 30°
Valve face angle:

Exhaust 44° 48' ±12'

Inlet 29° 48' ±12'

Valve springs
Type Parallel, single coil

GENERAL DATA
04-4
Engine - V8
General
Cylinder arrangement 90° V8, numbered from the front of the engine:

Left bank cylinders 1, 3, 5 and 7

Right bank cylinders 2, 4, 6 and 8
Bore 94.00 mm (3.70 in)
Stroke:

4.0 litre

4.6 litre71.04 mm (2.80 in)
81.92 mm (3.22 in)
Capacity:

4.0 litre

4.6 litre3950 cm
3 (241 in3)
4554 cm3 (278 in3)
Firing order 1 - 8 - 4 - 3 - 6 - 5 - 7 - 2
Compression ratio:

Low - 4.0 litre 8.23:1

High - 4.0 and 4.6 litre 9.35:1
Direction of rotation Clockwise viewed from the front of the engine
Maximum power - 4.0 litre:

Low compression ratio 132 kW (177 bhp) at 4750 rev/min

High compression ratio - UK/Japan/ROW 136 kW (182 bhp) at 4750 rev/min

High compression ratio - NAS 140 kW (187 bhp) at 4750 rev/min
Maximum power - 4.6 litre 162 kW (217 bhp) at 4750 rev/min
Maximum engine speed:

Continuous5000 rev/min

Intermittent 5250 rev/min
Weight (fully dressed, wet)

Manual 194 Kg (435 lb)

Automatic 179 Kg (402 lb)
Dimensions:

Length - Manual 767 mm (30.2 in) (Including fan)

Length - Automatic 777 mm (30.5 in) (Including fan and drive plate)

Width 652 mm (25.7 in)

Height 746 mm (29.4 in)
Spark plugs:

Make/Type - 4.0 litre Champion RC11 PYP B4

Make/type - 4.6 litre Champion RN11 YCC

Gap - 4.0 and 4.6 litre 1.00 ± 0.05 mm (0.040 ± 0.002 in) Non-adjustable
Coils:

Make Bosch 0221 503 407

Type Twin coils
Fuel injection system:

Make Bosch Motronic 5.2.1 Type 4146

Type Multiport fuel injection, electronically controlled with electro-
mechanical injectors

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)

GENERAL DATA
04-6
Big-end bearings
Quantity 8
Material Glacier Vandervell GPL 2120/AS 124A
Diametrical clearance 0.015 - 0.016 mm (0.00059 - 0.00063 in)
End float 0.15 - 0.35 mm (0.0006 - 0.0138 in)
Gudgeon pins
Diameter 23.995 - 24.000 mm (0.9447 - 0.9449 in)
Clearance in piston 0.006 - 0.015 mm (0.00024 - 0.00059 in)
Fit in connecting rod Press fit
Length 60.00 - 60.50 mm (2.362 - 2.382 in)
Pistons
Type Solid skirt, elliptical open end with offset gudgeon pin
Material Aluminium AE413P
Clearance in cylinder bore.
Measured 10 mm (0.4 in) from bottom of skirt, 90° to
gudgeon pin.0.022 - 0.067 mm (0.0009 - 0.0026 in)
Diameter - Grade A 93.970 - 93.985 mm (3.6996 - 3.7002 in)
Diameter - Grade B 93.986 - 94.001 mm (3.7002 - 3.7008 in)
Piston rings
Type: 2 compression, 1 oil control

Top compression ring Barrel faced nitrided steel

2nd compression ring Tapered spherical

Oil control ring 3 piece AE Conoform
Piston ring fitted gap in cylinder bore:

Top compression ring gap 0.3 - 0.5 mm (0.012 - 0.020 in)

2nd compression ring gap 0.40 - 0.65 mm (0.016 - 0.026 in)

Oil control ring gap 0.38 - 1.40 mm (0.015 - 0.055 in)
Piston ring width:

Top compression ring width 1.21 - 1.23 mm (0.0476 - 0.0484 in)

2nd compression ring width 1.478 - 1.490 mm (0.0582 - 0.0587 in)

Oil control ring width 3.00 mm (0.1181 in)
Piston ring to groove clearance:

1st and 2nd compression rings 0.05 - 0.10 mm (0.002 - 0.004 in)
Camshaft
Bearings 5
Drive Chain, 9.52 mm (0.3748 in) pitch x 54 pitches
End float 0.075 - 0.25 mm (0.002 - 0.010 in)
Tappets
Type Hydraulic self adjusting
Outside diameter 21.386 - 21.407 mm (0.8420 - 0.8427 in)

GENERAL DATA
04-15
Suspension
* Measurement taken with vehicle at unladen weight.
Type - Front Beam axle with coil springs, longitudinal radius arms,
Panhard rod, twin tube dampers and either anti-roll
bar or active cornering enhancement (ACE)
Nominal height from hub centre to wheel arch (not liner)* 500 ± 15 mm (19.7 ± 0.6 in)
Front road spring colour codes:

V8 LHS Pink/orange

V8 RHS - LHD Pink/orange

V8 RHS - RHD White/purple

Td5 LHS White/purple

Td5 RHS - LHD White/purple

Td5 RHS - RHD White/purple
Rear road spring colour codes:
5 seat, LHS Purple
5 seat, RHS - LHD Purple
5 seat, RHS - RHD Purple/purple
7 seat, LHS - LHD Grey/blue
7 seat, LHS - RHD Grey/green
7 seat, RHS - LHD Grey/blue
7 seat, RHS - RHD Grey/white
Bump stop height (top of bump stop to axle bracket) 44.5 mm (1.75 in)
Anti-roll bar diameter - front

With ACE fitted 35 mm (1.38 in)

Without ACE 30 mm (1.18 in)
Type - Rear Beam axle with coil or air springs, longitudinal radius
arms, Watts linkage, twin tube dampers and either
anti-roll bar or active cornering enhancement (ACE)
Nominal height from hub centre to wheel arch (not liner):*

Coil spring 483 ± 15 mm (19.0 ± 0.6 in)

Air spring 473 ± 15 mm (18.6 ± 0.6 in)
Road spring colour code Purple (all models)
Bump stop height (top of bump stop to axle bracket):

Coil spring 71.5 mm (2.8 in)

Air spring 61.5 mm (2.4 in)
Anti-roll bar diameter - rear

With ACE fitted 35 mm (1.38 in)

Without ACE - SLS fitted 29 mm (1.14 in)

Without ACE - SLS not fitted 5 seats = 19 mm (0.75 in)
7 seats = 16 mm (0.63 in)

GENERAL DATA
04-17
Air conditioning
Electrical - Td5
Electrical - V8
Type CFC free, sealed closed loop
Compressor:

Displacement 177.7 cm
3/rev (10.84 in3/rev)

Relief valve operating pressure 34.3 to 41.4 bar (497 to 600 lbf.in
2)

Refrigerant oil quantity 180ml (6.3 fl.oz)
Dual pressure switch operating pressures (nominal):

Low pressure switch Opens 2.0 bar (29.0 lbf.in
2), pressure decreasing

Low pressure switch Closes 2.3 bar (33.4 lbf.in
2), pressure increasing

High pressure switch Opens 32 bar (464 lbf.in
2), pressure increasing

High pressure switch Closes 26 bar (377 lbf.in
2), pressure decreasing
System 12 volt, negative earth
Battery:

Type Delco Freedom

Capacity 110 amp hour
Alternator:

Type Nippon Denso

Maximum output 120 amp
Starter motor:

Type Nippon Denso

Power 2 kW
System 12 volt, negative earth
Battery:

Type Delco Freedom

Capacity 72 amp hour
Alternator:

Type Bosch NC65/130

Maximum output 130 amp
Starter motor

Type Nippon Denso

Power 1.8 kW