wheel LAND ROVER DISCOVERY 2002 Owner's Manual

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
06-10
Steering
TORQUE DESCRIPTION METRIC IMPERIAL
Drag link to drop arm 80 Nm (59 lbf.ft)
Track rod to steering knuckle 125 Nm (92 lbf.ft)
Tension collet to steering knuckle 5 Nm (3.7 lbf.ft)
Steering damper125 Nm (92 lbf.ft)
Steering knuckle to axle yoke upper ball joint 110 Nm (81 lbf.ft)
High pressure pipe union 20 Nm (15 lbf.ft)
Drag link/track rod M8 bolts 22 Nm (16 lbf.ft)
Drag link/track rod M10 bolts 33 Nm (24 lbf.ft)
Steering box90 Nm (66 lbf.ft)
Universal joint to intermediate shaft 25 Nm (18 lbf.ft)
Panhard rod230 Nm (170 lbf.ft)
Steering box output shaft 88 Nm (65 lbf.ft)
Drop arm240 Nm (177 lbf.ft)
Auxiliary housing bolts 40 Nm (30 lbf.ft)
Auxiliary housing nut 10 Nm (7 lbf.ft)
PAS pump - V822 Nm (16 lbf.ft)
PAS pump pipe bracket bolt 22 Nm (16 lbf.ft)
Jockey pulley bolt 50 Nm (37 lbf.ft)
PAS pump adaptor pipe 10 Nm (7 lbf.ft)
PAS pump to coolant pump bolts - Td5 25 Nm (18 lbf.ft)
Steering column to fascia 25 Nm (18 lbf.ft)
Universal joint to steering box 25 Nm (18 lbf.ft)
Ball joint to swivel hub 77 Nm (57 lbf.ft)
PAS pump pulley22 Nm (16 lbf.ft)
Steering wheel nut 43 Nm (32 lbf.ft)

TORQUE WRENCH SETTINGS
06-11
Front suspension
TORQUE DESCRIPTION METRIC IMPERIAL
Wheel nuts140 Nm (103 lbf.ft)
Panhard rod230 Nm (170 lbf.ft)
Lower ball joint nut 135 Nm (100 lbf.ft)
Track rod and drag link 80 Nm (59 lbf.ft)
Damper to front axle 55 Nm (40 lbf.ft)
Anti-roll bar link - upper 100 Nm (74 lbf.ft)
Anti-roll bar link - lower 100 Nm (74 lbf.ft)
Turret to chassis23 Nm (17 lbf.ft)
Radius arm230 Nm (170 lbf.ft)
ACE pump pulley 25 Nm (18 lbf.ft)
ACE pump banjo bolt 28 Nm (21 lbf.ft)
Valve block to chassis 18 Nm (13 lbf.ft)
Valve block clamping plate 21 Nm (15 lbf.ft)
ACE valve block pipe clip 6 Nm (4.4 lbf.ft)
ACE valve block filter cap 35 Nm (26 lbf.ft)
Pressure transducer 20 Nm (15 lbf.ft)
Fluid pipes to actuator cap 29 Nm (21 lbf.ft)
Banjo to pump bolt 28 Nm (21 lbf.ft)
Actuator to long arm 48 Nm (35 lbf.ft)
Actuator to short arm 180 Nm (133 lbf.ft)
Torsion bar clamp plate bolts 45 Nm (33 lbf.ft)
Long arm to torsion bar bolt 185 Nm (136 lbf.ft)

TORQUE WRENCH SETTINGS
06-12
Rear suspension
Brakes
TORQUE DESCRIPTION METRIC IMPERIAL
Wheel nuts140 Nm (103 lbf.ft)
Wheel hub to axle 100 Nm (74 lbf.ft)
Damper to axle125 Nm (92 lbf.ft)
SLS height sensor link to radius arm 25 Nm (18 lbf.ft)
Radius arm230 Nm (170 lbf.ft)
Transverse links to pivot housing 155 Nm (114 lbf.ft)
Pivot housing to axle bolts 230 Nm (170 lbf.ft)
Transverse link to chassis 140 Nm (103 lbf.ft)
SLS height sensor 6 Nm (4.4 lbf.ft)
SLS compressor25 Nm (18 lbf.ft)
ACE actuator to short arm 185 Nm (136 lbf.ft)
ACE actuator to long arm 48 Nm (35 lbf.ft)
ACE actuator pipe cap nuts 29 Nm (21 lbf.ft)
Anti-roll bar link - upper 50 Nm (37 lbf.ft)
Anti-roll bar link - lower 100 Nm (74 lbf.ft)
ACE long arm to torsion bar 180 Nm (133 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Brake caliper bleed screw 10 Nm (7 lbf.ft)
Brake disc to drive flange 13 Nm (10 lbf.ft)
Caliper bolts - Front 175 Nm (129 lbf.ft)
Caliper bolts - Rear 95 Nm (70 lbf.ft)
Master cylinder to servo 25 Nm (18 lbf.ft)
Master cylinder brake pipe, unions 25 Nm (18 lbf.ft)
Brake caliper pivot bolt 30 Nm (22 lbf.ft)
Vacuum pump8 Nm (6 lbf.ft)
Vacuum pump lubrication pipe union 10 Nm (7 lbf.ft)
Brake caliper guide pin bolts 30 Nm (22 lbf.ft)
Brake caliper banjo bolt 32 Nm (24 lbf.ft)
ABS modulator to mounting bracket nuts 9 Nm (7 lbf.ft)
ABS modulator - 13 mm unions 22 Nm (16 lbf.ft)
ABS modulator - 11 mm union 14 Nm (10 lbf.ft)
Handbrake lever to floor bolts 22 Nm (16 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.

LIFTING AND TOWING
08-2
Reverse procedure when removing vehicle from
stands.
Hydraulic ramps
Use only a 'drive on' type ramp which supports a
vehicle by it's own road wheels. If a 'wheel free'
condition is required, use a 'drive on' ramp
incorporating a 'wheel free' system that supports
under axle casings. Alternatively, place vehicle on a
firm, flat floor and support on axle stands.
TOWING
Towing
The vehicle has permanent four wheel drive. The
following towing instructions must be adhered
to:
Towing on 4 wheels with driver
Turn ignition key to position '1' to release steering
lock.
Select neutral in main gearbox and transfer gearbox.
Secure tow rope, chain or cable to towing eye.
Release the handbrake.
The brake servo and power assisted steering
system will not be functional without the engine
running. Greater pedal pressure will be required
to apply the brakes, the steering system will
require greater effort to turn the front road
wheels. The vehicle tow connection should be
used only in normal road conditions, 'snatch'
recovery should be avoided.Suspended tow
To prevent vehicle damage, front or rear
propeller shaft MUST BE removed, dependent
upon which axle is being trailed.
Mark propeller shaft drive flanges at transfer box and
axles with identification lines to enable the propeller
shaft to be refitted in its original position.
Remove the propeller shaft fixings, remove the shaft
from the vehicle.
If the front axle is to be trailed turn ignition key to
position '1' to release steering lock.
The steering wheel and/or linkage must be
secured in a straight ahead position. DO NOT use
the steering lock mechanism for this purpose.
Towing eyes
The towing eyes at the front and rear of the vehicle
are designed for vehicle recovery purposes only and
must NOT be used to tow a trailer or caravan.
Front:A single towing eye, set behind a removable
panel in the front spoiler. DO NOT use the front
lashing rings for towing.

LIFTING AND TOWING
08-3
Rear: A pair of towing eyes at the rear of the vehicle
can be used as lashing rings and for towing another
light vehicle.
TRANSPORTING
Transporting by trailer
Front lashing eyes
Rear lashing eyes
Lashing eyes are provided on the chassis
longitudinals, at the front (behind the front wheels)
and at the rear (behind the rear wheels).

MAINTENANCE
PROCEDURES 10-7
Road wheels
Remove
1.Mark the wheel to stud relationship to ensure
that the wheels are refitted in the same
position.
2.Loosen wheel nuts. Raise the vehicle to a
wheel-free condition and remove the wheel
nuts.
Tyres
Check
1.Check tyres for compliance with manufacturer's
specification; visually for cuts, lumps, bulges,
uneven tread wear and depth.
2.Check tyre pressures, condition and tread
depth. Measure the tread depth across the
width of the tyre and around the circumference.
Brake pads, discs and calipers
Check
1. Check front and rear brake pads for wear,
ensure all pads are wearing evenly.
2.Check brake discs for signs of cracking,
excessive scoring or oil contamination.
3.Check calipers for signs of fluid leaks.
4.Clean excessive deposits of brake dust from
pads, calipers and disc shields using brake
cleaner.
Road wheel speed sensors
Inspect
Front wheel
Rear wheel
1.Inspect each sensor harness for damage.

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.