brake LAND ROVER DISCOVERY 2002 Owner's Guide

MAINTENANCE
PROCEDURES 10-29
12.Where possible, check for correct operation of
hill descent control (HDC) mechanism. This
should not be carried out if excessive journey
time is required.
13.After road/roller test, carry out a final inspection
of vehicle, with vehicle on a ramp.
14.Check all fluid levels and top-up if necessary.
15. 2 wheel rolling road: Ensure differential lock is
disengaged and propeller shaft is connected on
completion of test. Switch on ignition and
check that differential lock, electronic brake
distribution and hill descent warning lamps
are extinguished.

ENGINE - V8
12-2-14 REPAIRS
Gasket - cylinder head - LH
$% 12.29.02
Remove
1.Remove inlet manifold gasket.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - lower.
2.Noting their fitted order, disconnect ht leads
from spark plugs.
3.Remove bolt securing engine harness to rear
of cylinder head.
4. LH drive models: Remove brake servo heat
shield.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Heat shield -
brake servo - Without Secondary Air
Injection.
5.Remove 8 bolts securing exhaust manifold to
cylinder head, release manifold and collect 2
gaskets.6.Progressively remove 4 bolts securing the
rocker shaft and remove rocker shaft.
7.Remove push rods. Store push rods in their
fitted order.
8. Models with SAI: Remove 2 air injection
adapters from cylinder head and discard.
9.In the sequence shown, remove 10 bolts
securing the cylinder head to block. Discard the
bolts.

ENGINE - V8
12-2-16 REPAIRS
17. LH drive models: Fit brake servo heat shield.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Heat shield -
brake servo - Without Secondary Air
Injection.
18.Fit engine harness bolt and tighten to 22 Nm
(16 lbf.ft).
19.Connect ht leads to spark plugs in their correct
fitted order.
20.Fit inlet manifold gasket.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - lower.
Gasket - cylinder head - RH
$% 12.29.03
Remove
1.Remove inlet manifold gasket.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - lower.
2.Remove bolt securing auxiliary drive belt
tensioner and remove tensioner.
3.Remove 4 bolts securing alternator mounting
bracket and remove bracket.
4.Noting their fitted order, disconnect ht leads
from spark plugs.
5.Remove bolt securing engine earth lead.

ENGINE - V8
REPAIRS 12-2-17
6. RH drive models: Remove brake servo heat
shield.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Heat shield -
brake servo - Without Secondary Air
Injection.
7.Remove 8 bolts securing exhaust manifold to
cylinder head, release manifold and collect 2
gaskets.
8.Progressively remove 4 bolts securing the
rocker shaft and remove rocker shaft.
9.Remove push rods. Store push rods in their
fitted order. 10. Models with SAI: Remove 2 air injection
adapters and discard.
11.In the sequence shown, remove 10 bolts
securing the cylinder head to block. Discard the
bolts.
12.Remove cylinder head.
CAUTION: Support both ends of cylinder
head on blocks of wood.
13.Remove cylinder head gasket.

ENGINE - V8
12-2-18 REPAIRS
Refit
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. Clean mating faces of
cylinder head and exhaust manifold.
CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.
2.Check head and block faces for warping and
pitting. If out of specification, renew head.
3.Fit cylinder head gasket with the word 'TOP'
uppermost.
CAUTION: Gaskets must be fitted dry.
4.Carefully fit cylinder head and locate on
dowels.
5.Lightly lubricate new cylinder head bolt threads
with clean engine oil.
6.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 90
°, and finally
a further 90
°.
CAUTION: Do not tighten bolts 180
° in one
operation.
7. Models with SAI: Fit new air injection adapters
and tighten to 33 Nm (24 lbf.ft).
8.Clean push rods.
9.Lubricate ends of push rods with clean engine
oil.
10.Fit push rods in their removed order.
11.Clean bases of rocker pillars and mating faces
on cylinder head.
12.Clean contact surfaces on rockers, valves and
push rods.
13.Lubricate contact surfaces and rocker shaft
with clean engine oil.
14.Fit rocker shaft assembly and engage push
rods.
15.Fit rocker shaft bolts and progressively tighten
to 40 Nm (30 lbf.ft). 16.Position alternator mounting bracket, fit bolts
and tighten to 40 Nm (30 lbf.ft).
17.Position auxiliary drive belt tensioner, fit bolt
and tighten to 45 Nm (33 lbf.ft).
18.Connect ht leads to spark plugs in their fitted
order.
19. Using new gaskets, fit exhaust manifold to
cylinder head. Fit bolts and using sequence
shown, tighten initially to 15 Nm (11 lbf.ft), then
finally tighten to 36 Nm (28 lbf.ft).
20. RH drive models: Fit brake servo heat shield.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Heat shield -
brake servo - Without Secondary Air
Injection.
21.Position engine earth lead, fit bolt and tighten to
22 Nm (16 lbf.ft).
22.Fit inlet manifold gasket.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - lower.

EMISSION CONTROL - TD5
DESCRIPTION AND OPERATION 17-1-1
EMISS ION CONTROL - Td5 DESCRIPTION AND OPERAT ION
EGR system components - type 1
1EGR valve modulator
2Vacuum hose (brown)
3'T'-piece
4Vacuum hose to brake-servo
5Non-return valve
6Brake-servo
7Inlet manifold
8Exhaust manifold
9EGR pipe10Vacuum pump/alternator assembly
11Air intake hose from intercooler
12EGR valve assembly
13Vacuum hose to vacuum pump
14Vacuum hose to EGR valve suction port (blue)
15To atmosphere
16In-line filter
17Vent hose – modulator to in-line filter (green)

EMISSION CONTROL - TD5
DESCRIPTION AND OPERATION 17-1-3
1ILT valve modulator
2ILT modulator vacuum hose (brown)
3EGR valve modulator
4EGR modulator vacuum hose (brown)
5Vent hose – EGR modulator to in-line filter
(green)
6Vacuum hose to ILT valve suction port (blue)
7Vacuum hose to EGR valve suction port (blue)
8'T'-piece (4–way)
9Vacuum hose to brake-servo
10Non-return valve
11Brake-servo
12Inlet manifold
13Exhaust manifold
14ILT valve
15EGR cooler - EU3 models
16Vacuum pump / alternator assembly
17Air intake hose from intercooler
18EGR valve (incorporating ILT valve) assembly
19Vacuum hose to vacuum pump
20Vent hose – ILT valve modulator to in-line filter
(green)
213–way connector
22Vent hose - to air cleaner
23ILT modulator harness connector (green)
24EGR modulator harness connector (black)
25To atmosphere - Pre EU3 models
26In-line filter - Pre EU3 models
27EGR pipe - Pre EU3 models

EMISSION CONTROL - TD5
17-1-6 DESCRIPTION AND OPERATION
The EGR modulator is located on a plate fixed to the inner wing on the RH side of the engine. The modulator is
attached to the plate by two through-studs, each with two nuts which secure the modulator assembly to a rubber
mounting which helps to reduce noise. The modulator must be mounted in the vertical orientation with the two vacuum
ports uppermost.
The modulator operation is controlled by a signal from the ECM which determines the required amount of EGR
needed in response to inputs relating to air flow and engine operating and ambient conditions. The modulator has a
black two-pin connector at its base to connect it to the ECM through the engine harness.
Each modulator features three ports:
lThe top port of the EGR modulator is identified by a white band and connects to a 'T'-piece in the vacuum line
via a small-bore brown plastic hose. On type 2 systems the brown hose is connected in parallel with the vacuum
source to the ILT modulator.
The other two ports on the 'T'-piece connects vacuum line hoses of black vinyl tubing between the vacuum pump
and the brake-servo assembly attached to the bulkhead. The vacuum pump end of the vacuum line tubing
terminates in a rubber elbow, which gives a vacuum tight seal on the suction port of the vacuum pump. The
brake-servo end of the vacuum line tubing terminates with a non-return valve in a plastic housing which plugs
into the front face of the brake-servo housing.
lThe middle port of the EGR modulator is identified by a blue band and connects to the suction port on the EGR
valve through a small-bore blue plastic hose.
lThe lower port of the EGR modulator is identified by a green band and connects to atmosphere through an in-
line filter via a small-bore green plastic hose. On type 2 models a 3 way connector is fitted to vent both modulators
through a single filter. The other port of the in-line filter vents directly to atmosphere.
The blue and brown vacuum hoses are protected by corrugated plastic sheaths. The ends of the hoses are fitted with
rubber boots to ensure vacuum tight seals at the component ports.
Inlet Throttle (ILT) Modulator
1Port to vacuum source (white band)
2Port to ILT valve (blue band)
3Port to atmosphere via in-line filter (green
band)4Harness connector (green)

EMISSION CONTROL - TD5
DESCRIPTION AND OPERATION 17-1-7
The ILT modulator is located on a plate fixed to the inner wing on the RH side of the engine below the EGR modulator.
The modulator is attached to the plate by two through-studs, each with two nuts which secure the modulator assembly
to a rubber mounting which helps to reduce noise. The modulator must be mounted in the vertical orientation with the
two vacuum ports uppermost.
The modulator operation is controlled by a signal from the ECM which determines the required ratio of exhaust gas
to fresh inlet air needed in response to inputs relating to air flow and engine operating and ambient conditions. The
modulator has a green two-pin connector at its base to connect it to the ECM through the engine harness.
The ILT valve modulator features three ports:
lThe top port is identified by a white band and connects to a 'T'-piece in the vacuum line via a small-bore brown
plastic hose where it is connected in parallel with the vacuum source line to the EGR valve modulator. The two
other ports on the 'T'-piece connect vacuum line hoses of black vinyl tubing between the vacuum pump attached
to the alternator and the brake-servo assembly attached to the bulkhead.
lThe middle port is identified by a blue band and connects to the suction port on the ILT valve through a small-
bore blue plastic hose.
lThe lower port is identified by a green band and connects to atmosphere through an in-line filter via a green
plastic hose and a three-way connector positioned in-line between the modulators and the filter. The ILT
modulator hose is connected opposite to the two parallel ports at the three-way connector which connect the vent
lines to the EGR valve modulator and the in-line filter. The other port of the in-line filter vents directly to
atmosphere.
The blue and brown vacuum hoses are protected by corrugated plastic sheaths. The ends of the hoses are fitted with
rubber boots to ensure vacuum tight seals at the component ports.
EGR Valve
1EGR valve vacuum port
2EGR valve assembly
3Gasket – EGR valve to inlet manifold
4EGR pipe connection
5Exhaust gas intake6Intake air
7EGR valve open (vacuum applied to EGR
valve)
8EGR valve closed (no vacuum to EGR valve)

ENGINE MANAGEMENT SYSTEM - TD5
18-1-2 DESCRIPTION AND OPERATION
Engine management component
location - passenger compartment
LHD illustrated
1Diagnostic connector
2Throttle position sensor
3Brake pedal switch