ac compre LAND ROVER DISCOVERY 2002 Owner's Guide

ENGINE - TD5
12-1-52 REPAIRS
5.Fit 2 upper bolts securing engine oil cooler pipe
and gearbox housing to engine and tighten to
50 Nm (37 lbf.ft) .
6.Lower engine onto mountings, and tighten nuts
to 85 Nm (63 lbf.ft) .
7.Remove tool LRT-12-138 from engine.
8.Fit and tighten bolt securing engine closing
panel to gearbox.
9.Raise vehicle on ramp.
10.Fit nuts and bolts securing engine LH and RH
mountings to chassis and tighten to 85 Nm (63
lbf.ft).
11.Fit remaining bolts securing gearbox housing to
engine and tighten to 50 Nm (37 lbf.ft).
12.Rotate crankshaft and align drive plate to
torque converter.
13.Using a magnetic socket, fit and tighten new
torque converter drive plate bolts to 50 Nm (37
lbf.ft) .
14.Fit front cross member and tighten bolts to 26
Nm (19 lbf.ft).
15.Align gearbox oil cooler pipes.
16.Fit oil cooler pipe clip and tighten bolts to 9 Nm
(7 lbf.ft).
17.Position gearbox oil cooler pipe clamps and
tighten nuts.
18.Position coolant rail and secure support bracket
in engine LH and RH mounting brackets.
19.Fit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
20.Lower ramp.
21.Position coolant rail to front chassis member, fit
and tighten bolt to 10 Nm (7 lbf.ft).
22.Connect heater hose to coolant rail and secure
with clip.
23.Connect hose to coolant pump and secure with
clip.
24.Position PAS pump and tighten bolts to 25 Nm
(18 lbf.ft).
25.Position PAS pump pulley and lightly tighten
bolts.
26.Position ACE pump, fit bolts and tighten to 25
Nm (18 lbf.ft).
27.Position A/C compressor, fit bolts and tighten
to 25 Nm (18 lbf.ft).
28.Position ancillary drive belt, rotate tensioner
anti-clockwise and locate belt to pulleys.
29.Tighten PAS pump pulley bolts to 10 Nm (7
lbf.ft).
30.Position air intake hose to air cleaner and
secure clips.
31.Position engine harness and connect
multiplugs to compressor, MAF sensor,
turbocharger boost solenoid, AAP & IAT
sensor.
32.Position air inlet hose to turbocharger and
tighten clip. 33.Connect hoses to turbocharger boost solenoid
and secure clips.
34.Clean CKP sensor and mating face.
CAUTION: If originally fitted: Fit spacer to
CKP sensor.
35.Using new 'O' ring, fit CKP sensor, tighten CKP
sensor bolt to 9 Nm (7 lbf.ft) and connect
multiplug.
36.Connect multiplug to EGR modulator.
37.Connect engine earth lead to battery earth lead
and tighten bolt.
38.Connect engine harness multiplug to ECM and
main harness.
39.Connect engine harness multiplugs to fuse
box.
40.Position glow plug lead to fusebox and secure
with bolt.
41.Position battery and alternator leads to fusebox
and secure with bolts.
42.Fit engine compartment fuse box cover.
43.Connect vacuum hose to EGR valve.
44.Connect hose to vacuum pump and secure
vacuum pipe to fuel cooler.
45.Disconnect fuel hose from connector block and
connect to fuel cooler.
46.Connect fuel hoses to fuel cooler and
connector block on cylinder head.
47.Position expansion tank, connect hose and
secure with clip. Secure tank to body mounting.
48.Connect coolant hoses to fuel cooler and
coolant rail and secure clips.
49.Fit turbocharger.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Turbocharger.
50. Fit radiator.

+ COOLING SYSTEM - Td5, REPAIRS,
Radiator.
51.Fill engine with oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - diesel engine.
52.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
53.Fit bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.

ENGINE - TD5
12-1-64 REPAIRS
Refit
1.Clean oil cooler and mating faces.
2.Fit oil pressure switch and tighten to 9 Nm (7
lbf.ft).
3.Position new gasket and fit oil cooler housing,
tighten bolts to 25 Nm (18 lbf.ft).
4.Position and fit oil filter adaptor housing,
tighten bolts to 25 Nm (18 lbf. ft).
5.Fit oil filter, tighten hand tight then a further half
turn.
6.Position coolant hose to oil cooler and secure
clip.
7.Position coolant pipe bolt and tighten to 50 Nm
(37 lbf.ft) .
8.Connect multiplug to oil pressure switch.
9.Fit centrifuge assembly.

+ ENGINE - Td5, REPAIRS, Gasket -
centrifuge oil drain pipe.
10.Refill cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
11.Top up engine oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - diesel engine.
Gasket - centrifuge oil drain pipe
$% 12.60.90
Remove
1.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.
2.Remove fixings and remove underbelly panel.
3.Remove 2 bolts securing centrifuge drain to
engine sump and discard gasket. (Some
models are fitted with studs and nuts,
others with bolts).
4.Remove turbocharger.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Turbocharger.
5. Models with air conditioning: Remove
auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
6. Models with air conditioning: Remove 4 bolts
securing compressor and move to one side.

ENGINE - TD5
REPAIRS 12-1-65
7.Remove 3 bolts securing centrifuge to engine
oil cooler.
8.Remove centrifuge and discard 'O' ring.
9.Remove 2 bolts, remove drain pipe from
centrifuge and discard gasket. Refit
1.Clean mating faces of centrifuge, oil cooler and
sump.
2.Position new gasket and fit oil drain pipe to
centrifuge, tighten bolts to 10 Nm (7 lbf.ft).
CAUTION: Gasket must be fitted dry.
3.Position new 'O' ring to oil cooler.
4.Position centrifuge to oil cooler housing and
tighten bolts to 25 Nm (18 lbf.ft).
5.Using a new gasket, align the centrifuge oil
drain pipe to sump and tighten bolts to 10 Nm
(7 lbf.ft).
CAUTION: Gasket must be fitted dry.
6. Models with air conditioning: Position A/C
compressor and tighten bolts to 25 Nm (18
lbf.ft).
7.Fit turbocharger.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Turbocharger.
8. Models with air conditioning: Fit auxiliary
drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
9.Fit underbelly panel and secure with fixings.
10.Remove stand(s) and lower vehicle.

ENGINE - TD5
12-1-76 OVERHAUL
16.Using tool LRT-12-034 compress valve
spring.
17.Remove 2 collets from valve stem using a stick
magnet.
18.Remove tool LRT-12-034 .
19.Remove valve spring cap, valve spring and
valve. Keep components in their fitted
order.
20.Using tool LRT-12-071, remove and discard
valve stem oil seal. 21.Repeat above operations to remove remaining
valves. Keep components in their fitted
order.
22. Engine Serial No. Prefixes 15P to
19P:Disconnect spill return pipe from cylinder
head and fuel connector block, remove and
discard 'O' rings.

ENGINE - TD5
12-1-82 OVERHAUL
Reassembly
1.Lubricate new valve stem oil seals with engine
oil.
2.Using tool LRT-12-071 fit valve stem oil seals.
3.Lubricate valve guides, valve stems, valve
spring caps and springs with engine oil. 4.Assemble valves, springs and spring caps
ensuring they are in their original fitted order.
5.Compress valve springs using tool LRT-12-
034 , fit collets.
6.Using a wooden dowel and mallet, tap each
spring cap lightly to seat collets.
7.Lubricate new injector 'O' rings with engine oil.
8.Using tool LRT-12-154/2, fit new 'O' ring to
each injector.

ENGINE - TD5
OVERHAUL 12-1-99
5.Starting with No.1 piston, invert piston and with
arrow on piston crown pointing towards REAR
of cylinder block, insert piston into No.1
cylinder bore.
6.Position piston with bottom of skirt 25 mm (1.0
in) from top of cylinder bore.
7.Using feeler gauges, measure and record
clearance between piston skirt and LEFT
HAND side of cylinder bore 60 mm (2.4 in)
from top of bore:
lPiston to cylinder bore clearance = 0.171 to
0.207 mm (0.007 to 0.008 in)
8.Repeat above procedures for remaining
pistons.
CAUTION: Oversize pistons are not
available, if piston to cylinder bore
clearance exceeds limits given, repeat
check using a new piston; if clearances are
still excessive, replace cylinder block.
Pistons and lst compression rings fitted to
Engine Serial No. Prefixes 15P to 19P may
be fitted to Engine Serial No. Prefixes 10P to
14P in engine sets only.
9.Check fit of each gudgeon pin in its respective
piston, pin must be a tight, sliding fit with no
perceptible side play.10.Measure gudgeon pin diameter at each end
and side of pin.
CAUTION: Renew gudgeon pin and piston
as an assembly if diameters are less than
specified or if excessive pin to piston side
play is evident.
lGudgeon pin diameter = 29.995 to 30.000
mm (1.180 to 1.181 in)
11.Check connecting rod small end bushes for
wear, check that gudgeon pin is a sliding fit in
bush with no perceptible side play.
CAUTION: Small end bushes cannot be
replaced, a new connecting rod must be
fitted.

ENGINE - TD5
12-1-100 OVERHAUL
12.Insert new compression and oil control rings in
turn into No.1 cylinder bore 30 mm (1.25 in)
from top of bore and check ring fitted gaps;
ensure rings are kept square to bore when
checking gaps:
l1st compression ring fitted gap = 0.30 to
0.40 mm (0.012 to 0.016 in).
l2nd compression ring fitted gap = 0.40 to
0.60 mm (0.016 to 0.024 in).
lOil control ring fitted gap = 0.25 to 0.50 mm
0.01 to 0.02 in).
CAUTION: 1st compression rings fitted to
Engine Serial No. Prefixes 10P to 14P are
not interchangeable with those fitted to
Engine Serial No. Prefixes 15P to 19P. The
later rings may, however, be fitted to early
engines together with the later type pistons
in engine sets only.
13.Repeat for each cylinder bore in turn.
CAUTION: Ensure rings are suitably
identified with the cylinder bore in which
they were checked and are fitted to the
piston for that bore.
14.Fit oil control expander and ring to piston.
15.Fit 2nd compression ring with 'TOP' marking
upwards. 16.Fit 1st compression ring with 'TOP' marking
upwards.
17.Check piston ring to groove clearance:
l1st compression ring = Not measured
l2nd compression ring = 0.050 to 0.082 mm
(0.02 to 0.003 in)
lOil control ring = 0.050 to 0.082 mm (0.02 to
0.003 in)
Reassembly
1.Lubricate gudgeon pin, gudgeon pin holes in
piston and small end bush with engine oil.
2.Position piston to connecting rod with arrow on
piston crown on the same side as the cast boss
on the connecting rod.
3.Fit gudgeon pin to its respective piston and
connecting rod; secure with new circlips
ensuring circlips are fully seated in their
grooves.
4.Repeat above procedures for remaining
pistons.
5.Lubricate piston rings and cylinder bores with
engine oil.
6.Check that rings are free to rotate, position ring
gaps at 120
° to each other and away from the
thrust, LEFT HAND side of piston - viewed
from front of piston.
7.Using a suitable ring clamp, compress piston
rings.
8.Insert connecting rod and piston into its
respective cylinder bore ensuring that the
arrow on piston crown and the cast boss on
connecting rod are facing towards the front of
the cylinder block.
9.Ensure that connecting rod does not contact
cylinder bore or oil squirt jet. Do not pull
connecting rod fully down cylinder bore at this
stage.
10.Check that cut-out in piston skirt is positioned
above oil squirt jet.

ENGINE - V8
DESCRIPTION AND OPERATION 12-2-5
1Core plugs
2Cylinder block
3Camshaft
4Dipstick tube, clamp and bolt
5Woodruff key
6Timing chain
7Camshaft timing gear
8Washer
9Bolt - camshaft timing gear
10Thrust plate - camshaft end-float
11Bolt - camshaft thrust plate
12Gasket - timing cover
13Timing cover
14Oil pressure switch
15Bolt
16Crankshaft front oil seal
17Oil filter element
18Crankshaft front pulley
19Washer
20Bolt - crankshaft front pulley
21Upper main bearing shell
22Upper centre main bearing shell and thrust
washer
23Crankshaft
24Woodruff key
25Crankshaft timing gear
26Lower main bearing shells
27Numbers 1, 2 and 3 main bearing caps
28Bolt - main bearing caps
29Oil pick-up pipe and strainer
30'O' ring31Bolt - oil pick-up pipe
32Gasket - sump
33Sump
34Bolt - sump
35Sump oil drain plug
36Sealing washer
37Spacer, washers and nut - oil pick-up pipe
38Number 4 main bearing cap
39Bolt - connecting rod big-end bearing cap
40Connecting rod big-end bearing shell - lower
41Connecting rod big-end bearing cap
42Number 5 - rear main bearing cap
43Cruciform seal - rear main bearing cap
44Number 5 - rear main bearing shell
45Crankshaft rear oil seal
46Crankshaft knock sensor
47Side bolt - main bearing cap
48Side Allen bolt - main bearing cap
49Dowty washers
50Connecting rod big-end bearing shell - upper
51Connecting rod
52Piston
53Gudgeon pin
54Oil control ring
55Top compression ring
562nd compression ring
57Flywheel/drive plate and starter ring gear
58Bolt - flywheel/drive plate

ENGINE - V8
DESCRIPTION AND OPERATION 12-2-7
Oil sump
The oil sump is bolted to the bottom of the cylinder block and the timing cover and is sealed to both components with
a one piece gasket. A removable baffle to prevent oil surge is fitted in the sump. The oil pick-up pipe and strainer
assembly is positioned within the sump and is attached at the pick-up end to a stud screwed into number four main
bearing cap and at the delivery end to the oil pump. The oil drain plug is located in the bottom of the sump and is
sealed with a washer.
Pistons and connecting rods
Each of the aluminium alloy pistons has two compression rings and an oil control ring. The pistons are secured to the
connecting rods by semi-floating gudgeon pins. Each gudgeon pin is offset by 0.5 mm (0.02 in). The top of each piston
is recessed, the depth of recess determining the compression ratio of the engine. Plain, big-end bearing shells are
fitted to each connecting rod and cap.

ENGINE - V8
REPAIRS 12-2-19
Gasket - rocker cover - LH
$% 12.29.40
Remove
1.Remove upper inlet manifold gasket.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
2. Models with air conditioning: Release 4
clips and remove fan cowl.
3. Models with air conditioning: Release
tension on auxiliary drive belt and remove belt
from air conditioning compressor. Disconnect
compressor multiplug. Remove 4 bolts
securing compressor and position compressor
aside. 4.Release ht leads from rocker cover clips.
5.Remove screw securing dip stick tube.
6.Remove 4 bolts securing rocker cover.
7.Remove rocker cover and collect gasket.
Refit
1.Clean mating faces of rocker cover and
cylinder head.
2.Using a new gasket, fitted dry, position rocker
cover ensuring gasket is correctly located.
3.Fit rocker cover bolts and working in diagonal
sequence, tighten to:
lStage 1 - 3 Nm (2.5 lbf.ft)
lStage 2 - 8 Nm (6 lbf.ft)
4.Ensure that outer rim of gasket is correctly
positioned around periphery of rocker cover.
5.Fit and tighten screw securing dip stick tube.
6.Secure ht leads in rocker cover clips.
7. Models with air conditioning: Clean
compressor dowels and dowel holes. Position
compressor, fit bolts and tighten to 22 Nm (16
lbf.ft). Release auxiliary drive belt tensioner
and fit belt to compressor.