belt LAND ROVER DISCOVERY 2002 Owner's Guide

ENGINE - V8
12-2-30 REPAIRS
Refit
1.Clean mating faces of engine and gearbox,
dowel and dowel holes.
2.Lubricate splines and bearing surface on first
motion shaft with grease.
3.With assistance position engine in engine bay,
align to gearbox and locate on dowels.
4.Position support brackets, fit bell housing bolts
and tighten to 50 Nm (37 lbf.ft).
5.Position engine mountings, fit nuts and tighten
to 85 Nm (63 lbf.ft).
6.Lower lifting equipment and remove from
engine.
7. Models with automatic gearbox: Align torque
converter to drive plate, fit bolts and tighten to
50 Nm (37 lbf.ft). Fit access plug.
8.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
9.Position oil cooling pipe saddle clamps and
tighten bolts.
10.Position engine harness into foot well.
11.Connect 5 multiplugs to ECM.
12.Fit toe board and secure with trim fixings.
13.Connect engine harness earth to body and
secure with nut.
14.Connect engine harness to main harness
multiplug.
15.Connect multiplug to EVAP purge valve.
16.Connect engine harness multiplugs to fuse
box.
17.Connect starter lead to fuse box and secure
with nut.
18.Connect engine harness positive lead to
battery and tighten nut.
19.Fit fuse box cover.
20.Position engine earth lead and secure with
bolt.
21.Position coolant rail and secure with bolt.
22.Connect harness clips to coolant rail.
23.Connect hose to coolant rail and coolant pump
and secure with clips.
24.Connect PAS pump high and low pressure
pipes and secure with clips.
25.Position oil cooling pipe saddle clamp to PAS
pump housing and secure with bolt.
26.Clean A/C compressor and housing mating
faces, dowels and dowel holes. 27.Position A/C compressor, fit bolts and tighten
to 22 Nm (16 lbf.ft).
28.Connect multiplug to A/C compressor.
29.Clean ACE pump and housing mating faces,
dowels and dowel holes.
30.Position ACE pump, fit bolts and tighten to 22
Nm (16 lbf.ft).
31.Clean all pulley 'V's, fit auxiliary drive belt,
using a 15mm spanner, release belt tensioner
secure belt and re-tension drive belt .
32.Ensure auxiliary drive belt is correctly located
on all pulleys.
33.Fit radiator.

+ COOLING SYSTEM - V8, REPAIRS,
Radiator.
34.Fit top hose and secure with clips.
35.Connect fuel pipe to fuel rail.
36.Position ignition coils and connect ht leads.
37.Fit upper inlet manifold.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
38.Fit new oil filter and refill engine with oil.

+ ENGINE - V8, REPAIRS, Filter - oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - V8 engine.
39.Top up gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.

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
12-2-60 OVERHAUL
Reassembly
1.Reassemble rocker shafts, ensuring that
components are returned to their original
positions, secure plain washers with new split
pins.
2.Ensure shaft identification groove is positioned
at one o'clock, with push rod locations of rocker
arms to the right. Oil feed restriction will
result if rocker shafts are incorrectly
assembled.
3.Position rocker shaft assembly to cylinder
head ensuring push rods are engaged in
rocker arms.
4.Fit rocker shaft bolts and progressively tighten
to 40 Nm (30 lbf.ft).
5.Clean mating faces of rocker covers and
cylinder heads.
6.Fit new rocker cover gaskets, dry, position
rocker cover, fit bolts and working in diagonal
sequence, tighten to:
lStage 1 - 3 Nm (2.5 lbf.ft)
lStage 2 - 8 Nm (6 lbf.ft)
7.Ensure that gasket is correctly positioned
around periphery of rocker cover.
8.Secure ht leads to rocker cover.
Gasket - cylinder head
$% 12.29.02.01
Disassembly
1.Remove inlet manifold gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
inlet manifold.
2. RH cylinder head: Remove auxiliary drive belt
tensioner.
3. RH cylinder head: Remove bolts securing
alternator mounting bracket and remove
bracket.
4.Noting their fitted order, disconnect ht leads
from spark plugs.
5.Progressively remove 4 bolts securing the
rocker shaft and remove rocker shaft.
6.Remove push rods and store in their fitted
order.
7.Working in the sequence shown remove 10
bolts securing the cylinder head to block.
Discard the bolts.
8.Remove cylinder head.

ENGINE - V8
OVERHAUL 12-2-61
9.Remove cylinder head gasket.
CAUTION: Support both ends of cylinder
head on blocks of wood.
Inspect
1.Clean mating faces of cylinder block and head
using suitable gasket removal spray and a
plastic scraper, ensure that bolt holes in block
are clean and dry.
CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.
2.Check head and block faces for warping and
pitting.
lMaximum cylinder head warp = 0.05 mm
(0.002 in).
Note: Cylinder head can be refaced to 0.50
mm (0.02 in) maximum below head height –
See cylinder head overhaul.Reassembly
1.Fit cylinder head gasket with the word TOP
uppermost.
CAUTION: Gaskets must be fitted dry.
2.Carefully fit cylinder head and locate on
dowels.
3.Lightly lubricate new cylinder head bolt threads
with clean engine oil.
4.Noting that bolts 1, 3 and 5 are longer than the
remainder, fit bolts and tighten in the sequence
shown to 20 Nm (15 lbf.ft) then turn through 90
°, then a further 90 °. CAUTION: Do not
tighten bolts 180
° in one operation.
5.Clean the push rods, Lubricate ends of push
rods with clean engine oil, and fit in their
removed order.
6.Clean bases of rocker pillars and mating faces
on cylinder head.
7.Clean contact surfaces on rockers, valves and
push rods.
8.Lubricate contact surfaces and rocker shaft
with clean engine oil.
9.Fit rocker shaft assembly and engage push
rods.
10.Fit rocker shaft bolts and progressively tighten
to 40 Nm (30 lbf.ft).
11.Connect ht leads to spark plugs in their correct
fitted order.
12. RH cylinder head: Position alternator
mounting bracket, fit bolts and tighten to 40 Nm
(30 lbf.ft).
13. RH cylinder head: Fit auxiliary drive belt
tensioner.
14.Fit inlet manifold gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
inlet manifold.

ENGINE - V8
OVERHAUL 12-2-75
19.Using the sequence shown, tighten main
bearing cap bolts as follows:
lInitial torque - all main bearing cap bolts and
side bolts - 13.5 Nm (10 lbf.ft).
lFinal torque - main bearing cap side bolts 11
to 15 - 45 Nm (34 lbf.ft).
lFinal torque - main bearing cap bolts 1 to 8
- 72 Nm (54 lbf.ft).
lFinal torque - main bearing cap bolts 9 and
10 - 92 Nm (68 lbf.ft).
lFinal torque - main bearing cap side bolts 16
to 20 - 45 Nm (34 lbf.ft).
20.Fit connecting rod bearings.

+ ENGINE - V8, OVERHAUL, Bearings
- connecting rods.
21.Clean timing chain and gears.
22.Clean ends of crankshaft and camshaft.
23.Lubricate timing chain assembly with clean
engine oil. 24.Align timing marks and fit timing chain
assembly.
25.Fit camshaft gear bolt and tighten to 50 Nm (37
lbf.ft).
26.Fit timing gear cover gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
timing gear cover.
27.Clean crankshaft pulley.
28.Fit crankshaft pulley.
29.Fit crankshaft pulley bolt and tighten to 270 Nm
(200 lbf.ft).
30.Remove tool LRT-12-080 from crankshaft
pulley.
31.Clean oil filter and mating face.
32.Lubricate oil filter seal and fit filter to oil pump.
33.Ensure coolant pump and pulley mating faces
are clean.
34.Fit coolant pump pulley and tighten bolts to 22
Nm (16 lbf.ft).
35.Ensure drive belt pulleys are clean and
damage free.
36.Fit auxiliary drive belt to pulleys.
37.Fit crankshaft rear oil seal.

+ ENGINE - V8, OVERHAUL, Seal -
crankshaft - rear - automatic models.

ENGINE MANAGEMENT SYSTEM - V8
REPAIRS 18-2-73
5.Remove 2 nuts and release ECM from studs
and location on 'A' post lower panel.
6.Lower ECM into footwell and disconnect 5
multiplugs.
7.Remove ECM.
Refit
1.Position new ECM and connect multiplugs.
2.Fit ECM and secure with nuts.
3.Fit lower trim panel to 'A' post and secure with
fixings.
4.Fit diagnostic socket to closing panel, fit closing
panel and secure with fixings.
5.Connect battery earth lead.
6.Fit battery cover and secure with fixings.
7.Programme ECM and reset adaptions using
TestBook.
Sensor - engine coolant temperature
(ECT)
$% 18.30.10
Remove
1.Release turnbuckles and remove battery cover.
2.Disconnect battery earth lead.
3.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
4.Remove 2 bolts securing alternator, release
alternator from support bracket and position
aside.

ENGINE MANAGEMENT SYSTEM - V8
18-2-74 REPAIRS
5.Disconnect multiplug from ECT sensor.
6.Remove sensor from inlet manifold and discard
sealing washer.
Refit
1.Clean sealant from threads in manifold.
2.Apply Loctite 577 to sensor threads.
3.Fit new sealing washer to ECT sensor and
tighten sensor to 10 Nm (7 lbf.ft).
4.Connect multiplug to ECT sensor.
5.Position alternator, fit bolts and tighten to 45
Nm (33 lbf.ft).
6.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
7.Top up cooling system.
8.Connect battery earth lead.
9.Fit battery cover and secure with fixings.
Sensor - crankshaft position (CKP)
$% 18.30.12
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.Release fixings and remove underbelly panel.
5.Release CKP sensor multiplug from bracket.
6.Remove 2 bolts securing CKP sensor heat
shield and position aside.
7.Remove 2 nuts securing CKP sensor, remove
2 spacers, CKP sensor and sensor mounting.
8.Disconnect CKP sensor multiplug from engine
harness.
Refit
1.Ensure all components are clean.
2.Connect CKP sensor multiplug to engine
harness.
3.Fit sensor mounting, CKP sensor, 2 spacers
and tighten CKP sensor retaining nuts to 6 Nm
(5 lbf.ft).

FUEL DELIVERY SYSTEM - TD5
19-1-16 REPAIRS
8.Remove 2 trim clips securing RH side trim
casing to body.
9.Remove rear lamp access panel from RH side
trim casing.
10.Remove trim clip securing RH side trim casing
to lower 'E' post.
11. Models with third row seats:Remove bolt
securing lower mounting of RH third row seat
belt to body.
12.Remove RH side trim casing.
13.Pull back loadspace carpet from fuel pump
access panel.
14.Remove 6 screws securing access panel.
15.Remove access panel.
16.Disconnect multiplug and 4 fuel hoses from fuel
pump housing.
CAUTION: Always fit plugs to open
connections to prevent contamination.17.Use LRT-19-009 to remove locking ring from
fuel pump housing.
18.Remove fuel pump housing.
19.Remove and discard sealing ring from fuel
pump housing.
Refit
1.Clean fuel pump housing and mating face on
fuel tank.
2.Fit new seal to mating face on fuel tank.
3.Fit fuel pump housing to fuel tank and use LRT-
19-009 to fit locking ring.
4.Connect multiplug and fuel hoses to fuel pump
housing. Ensure each hose is installed in the
connector with the corresponding colour
code.
5.Fit access panel and secure with screws.
6.Reposition loadspace carpet.
7.Fit RH side trim casing.
8. Models with third row seats:Fit bolt securing
lower mounting of RH third row seat belt to
body and tighten to 50 Nm (37 lbf.ft).
9.Fit trim clip securing RH side trim casing to
lower 'E' post.
10.Fit rear lamp access panel to RH side trim
casing.
11.Fit trim clips securing RH side trim casing to
body.
12.Fit tail door aperture seal.
13. Models with rear ICE controls: Connect
multiplug to remote ICE controls.
14. Models with rear ICE controls: Fit ICE
controls to trim casing and secure with screw.
15.Fit trim clips securing lower edge of 'D' post
trim casing to body.
16. Models with third row seats: Fit RH third row
seat.

+ SEATS, REPAIRS, Seat - third row.
17.Connect battery earth lead.

FUEL DELIVERY SYSTEM - V8
19-2-14 REPAIRS
8.Remove 2 trim clips securing RH side trim
casing to body.
9.Remove rear lamp access panel from RH side
trim casing.
10.Remove trim clip securing RH side trim casing
to lower 'E' post.
11. Models with third row seats: Remove bolt
securing lower mounting of third row seat belt to
body.
12.Remove RH side trim casing.
13.Pull back loadspace carpet from fuel pump
access panel.
14.Remove 6 screws securing access panel.
15.Remove access panel.
16.Disconnect multiplug and fuel hose from fuel
pump housing.
CAUTION: Always fit plugs to open
connections to prevent contamination.
17. NAS models: Disconnect pressure sensor
pipe from fuel pump housing.
CAUTION: Always fit plugs to open
connections to prevent contamination.18.Use LRT-19-009 to remove locking ring from
fuel pump housing.
19.Remove fuel pump housing.
20.Remove and discard sealing ring from fuel
pump housing.
Refit
1.Clean fuel pump housing and mating face on
fuel tank.
2.Fit new seal to mating face on fuel tank.
3.Fit fuel pump housing to fuel tank and use LRT-
19-009 to fit locking ring.
4.Connect multiplug and fuel hose to fuel pump
housing.
5. NAS models: Connect pressure sensor pipe to
fuel pump housing.
6.Fit access panel and secure with screws.
7.Reposition loadspace carpet.
8.Fit RH side trim casing.
9. Models with third row seats: Fit bolt securing
lower mounting of third row seat belt to body
and tighten to 50 Nm (37 lbf.ft).
10.Fit trim clip securing RH side trim casing to
lower 'E' post.
11.Fit rear lamp access panel to RH side trim
casing.
12.Fit trim clips securing RH side trim casing to
body.
13.Fit tail door aperture seal.
14. Models with rear ICE controls: Connect
multiplug to remote ICE controls.
15. Models with rear ICE controls: Fit ICE
controls to RH side trim casing and secure with
screw.
16.Fit trim clips securing lower edge of RH 'D' post
trim casing to body.
17. Models with third row seats: Fit RH third row
seat.

+ SEATS, REPAIRS, Seat - third row.
18.Connect battery earth lead.
19.Fit battery cover and secure with fixings.