maintenance LAND ROVER DISCOVERY 2002 Owner's Guide

MAINTENANCE
PROCEDURES 10-27
2.Check security of fixings.

+ TORQUE WRENCH SETTINGS,
Front suspension.

+ TORQUE WRENCH SETTINGS, Rear
suspension.
Towing bracket
Check
1.Check security of towing bracket.
Engine mountings - V8 engine
Check for security and condition
1.Check condition of Transfer box - RH mounting
rubber.
2.Check condition of Transfer box - LH mounting
rubber.
3.Check condition of Engine - LH mounting
rubber.

MAINTENANCE
10-28 PROCEDURES
4.Check condition of Engine - RH mounting
rubber
5.Check tightness of all mounting bolts.

+ TORQUE WRENCH SETTINGS,
Engine V8.
Road/roller test
WARNING: Roller test must be restricted to 3
mph (5 km/h). If 2 wheel rolling road is to be used,
disconnect propeller shaft from the transfer box
output shaft driving the axle which is NOT on the
rolling road.Testing
1. 2 wheel rolling road: Engage differential lock
using a 10 mm open ended spanner on flats
machined on differential lock selector
shaft.Switch on ignition and check that the
differential lock, electronic brake
distribution and hill descent warning lamps
are illuminated.
2.Check for correct operation of starter switch,
ensure engine starts correctly; leave the engine
running.
3.Check for correct operation of starter switch,
ensure engine starts correctly; leave the engine
running.
4.With vehicle stationary, turn steering from lock
to lock. Check for smooth operation and ensure
there is no undue noise from power steering
pump or drive belt.
5.Depress clutch and select all gears in turn,
check for smooth, notch free engagement.
6. Check all vehicle systems for correct
operation.
7.Check for unusual engine, gearbox and
suspension noises.
8.Check braking system operation.
9.Check for smooth gear engagement.
10.Check engine performance.
11.Check operation of all instruments and warning
devices where practicable.

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.

MAINTENANCE
10-30 PROCEDURES

ENGINE - TD5
REPAIRS 12-1-47
Engine and ancillaries
$% 12.41.01
Remove
1.Remove bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.
2.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Drain engine oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - diesel engine.
4.Remove radiator.

+ COOLING SYSTEM - Td5, REPAIRS,
Radiator.
5.Remove turbocharger.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Turbocharger.
6.Release clips and disconnect heater hoses
from fuel cooler and coolant rail.
7.Release clip and disconnect expansion tank
coolant hose from fuel cooler.
8.Disconnect fuel hoses, tank to fuel cooler and
connector block on cylinder head.
CAUTION: Always fit plugs to open
connections to prevent contamination.9.Disconnect fuel hose from fuel cooler and
secure to connector block on cylinder head.
This is to prevent contamination of the fuel
injection system.
10.Release servo vacuum pipe from clip on fuel
cooler and release hose from vacuum pump.
11.Release expansion tank from body mounting,
release clip, disconnect hose and remove tank.

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
REPAIRS 12-1-57
Filter - oil
$% 12.60.04
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Remove 3 bolts and remove exhaust manifold
heat shield.
3.Clean area around filter head and place a
container beneath engine.
4.Using a strap wrench, unscrew and discard
filter. Refit
1.Clean mating face of filter head.
2.Lubricate sealing ring of new filter with clean
engine oil.
3.Fit filter and tighten by hand until it seats then
tighten a further three-quarters of a turn.
4.Start and run engine to check for leaks.
5.Stop engine, wait a few minutes, then check oil
level.
6.Top up engine oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - diesel engine.
7.Position exhaust manifold heatshield and
tighten M6 bolts to 9 Nm (7 lbf.ft) and M8 bolts
to 25 Nm (18 lbf.ft).
8.Fit engine acoustic cover and secure with
fixings.

ENGINE - TD5
REPAIRS 12-1-63
Refit
1.Clean oil pressure switch threads.
2.Fit oil pressure switch and tighten to 15 Nm (11
lbf.ft).
3.Connect multiplug to oil pressure switch.
4.Position exhaust manifold heatshield and
tighten M6 bolts to 9 Nm (7 lbf.ft) and M8 bolts
to 25 Nm (18 lbf.ft).
5.Fit and secure engine acoustic cover.
6.Top up engine oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - diesel engine.
Cooler - engine oil
$% 12.60.68
Remove
1.Drain cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
2.Remove centrifuge assembly.

+ ENGINE - Td5, REPAIRS, Gasket -
centrifuge oil drain pipe.
3.Remove clutch housing bolt and release
coolant pipe from rear of engine.
4.Release clip and coolant hose from oil cooler.
5.Disconnect multiplug from oil pressure switch.
6.Remove full-flow oil filter element using a
suitable strap wrench.
7.Remove 3 bolts, remove oil filter adaptor
housing and discard gasket.
8.Remove 7 bolts, remove oil cooler and discard
gasket.
9.Remove oil pressure switch.

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 - V8
DESCRIPTION AND OPERATION 12-2-9
element. Oil from the filter passes into the main oil gallery and through internal drillings to the crankshaft where it is
directed to each main bearing and to the big-end bearings via numbers 1, 3 and 5 main bearings. An internal drilling
in the cylinder block directs oil to the camshaft where it passes through further internal drillings to the hydraulic
tappets, camshaft bearing journals and rocker shafts. Lubrication to the pistons, small ends and cylinder bores is by
oil grooves machined in the connecting rods and by splash.
Oil pressure switch
The oil pressure warning light switch registers low oil pressure in the main oil gallery on the outflow side of the filter.
Whilst the engine is running and oil pressure is correct, the switch is open. When the ignition is switched on or if oil
pressure drops below the pressure setting of the switch, the switch closes and the low oil pressure warning lamp
located in the instrument pack will illuminate.
Hydraulic tappets
1Clip
2Pushrod seat
3Inner sleeve
4Upper chamber5Non-return ball valve
6Spring
7Outer sleeve
8Lower chamber
The hydraulic tappet provides maintenance free, quiet operation of the valves. This is achieved by utilizing engine oil
pressure to eliminate the clearance between the rocker arms and valve stems. When the valve is closed, engine oil
pressure present in the upper chamber, passes through the non-return ball valve and into the lower chamber. When
the cam begins to lift the outer sleeve, the resistance of the valve spring, felt through the push rod and seat, causes
the tappet inner sleeve to move downwards inside the outer sleeve. This downwards movement closes the non-return
ball valve and increases the pressure in the lower chamber sufficiently to ensure that the valve is fully opened by the
push rod. As the tappet moves off the peak of the cam, the non-return ball valve opens thereby allowing the pressure
in both chambers to equalize. This ensures that the valve will be fully closed when the tappet is on the back of the
cam.
Crankcase ventilation
A positive crankcase ventilation system is used to vent crankcase gases to the air induction system. Gases are drawn
from the left hand rocker cover to a tapping in the throttle body. An oil separator is incorporated in the hose connection
stub pipe in the right hand rocker cover, gases from this connection are drawn to a tapping in the inlet manifold.

+ EMISSION CONTROL - V8, DESCRIPTION AND OPERATION, Crankcase emission control system.