torque LAND ROVER DISCOVERY 2002 Owner's Guide

ENGINE - TD5
REPAIRS 12-1-51
45.Remove 8 bolts and remove front cross
member.
46.Remove 6 bolts securing gearbox housing to
engine.
47.Remove 4 bolts and nuts securing RH and LH
front engine mountings to chassis.
48.Lower vehicle ramp. 49.Remove 2 upper bolts securing gearbox
housing and oil cooler coolant pipe to engine.
50.Release clip, disconnect hose from engine oil
cooler and move aside.
51.Remove bolt securing engine closing panel to
gearbox.
52.Fit tool LRT-12-138 to lifting chains and
connect to lifting eyes on engine.
53.Remove 2 nuts from RH and LH front engine
mountings.
54.Position trolley jack to support gearbox.
55.With assistance, raise chains, remove engine
from vehicle and lower onto bench.
Refit
1.With assistance, raise engine from bench and
position in vehicle.
2.With assistance, align engine to gearbox and
torque converter.
3.Position engine RH and LH mountings to
brackets and fit nuts.
4.Position engine oil cooler pipe, connect hose to
oil cooler and secure with clip.

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
12-1-96 OVERHAUL
27.Fit tool LRT-51-003 to crankshaft pulley,
secure with 2 bolts. Using assistance, restrain
engine and using a torque multiplier tighten
bolt to 450 Nm (340 lbf.ft).
WARNING: DUE TO THE HIGH TORQUE
LOADING REQUIRED, IT IS ESSENTIAL
THAT ENGINE IS ADEQUATELY
RESTRAINED.
28.Remove tool LRT-51-003.
29.Position damper to crankshaft pulley, fit 3 bolts
and tighten to 80 Nm (60 lbf.ft).
30.Fit sump gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- engine sump.
31.Fit cylinder head gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- cylinder head.
Bearings - connecting rods
$% 12.17.16.01
Disassembly
1.Remove oil pump.

+ ENGINE - Td5, OVERHAUL, Pump -
oil.
2.Mark cylinder reference number on each
connecting rod big-end bearing cap.
3.Make suitable alignment marks between each
big-end bearing cap and connecting rod.
CAUTION: Due to the 'fracture split' method
of manufacturing connecting rods,
incorrect fitment of cap to rod will damage
mating faces and necessitate replacement
of connecting rod assembly.
4.Rotate crankshaft clockwise until No.1 big-end
is at BDC.
5.Remove and discard 2 bolts securing each
connecting rod big-end bearing cap.
6.Remove bearing cap, remove and discard big-
end bearing shell.
7.Push connecting rod up cylinder bore until
connecting rod is clear of crankshaft journals.
CAUTION: Ensure that connecting rod does
not contact cylinder bore or oil squirt jet and
piston does not contact the valves or EUI's
if the cylinder head is fitted.

ENGINE - V8
REPAIRS 12-2-29
30. Models with automatic gearbox: Remove
access plug and remove 4 bolts securing
torque converter to drive plate.
31.Rotate engine to access bolts.
32.Remove 12 bolts securing engine to gearbox.
DO NOT remove the top 2 bolts at this
stage.
33.Collect support brackets from bell housing
bolts.
34.Attach suitable lifting equipment to engine. 35.Remove 4 nuts securing engine mountings,
raise engine and remove engine mountings.
36.Lower engine, remove top bolts securing
engine to gearbox and collect bracket.
37.Support gearbox on a jack.
38.Release engine from gearbox dowels.
39.With assistance remove engine from engine
bay.

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
REPAIRS 12-2-33
6.Remove 4 bolts securing drive plate clamp ring
and remove ring.
7.Remove drive plate from hub.
8.Remove 6 Allen screws securing hub, remove
hub and collect spacer.
On early engines, balance weights are on
engine side of drive plate; replacement drive
plates will have balance weights on torque
converter side of drive plate.
Refit
1.Clean hub and mating face, spacer and clamp
ring.
2.Clean drive plate and ensure free from cracks
and distortion.
3.Fit spacer and hub to crankshaft, tighten Allen
screws to 78 Nm (58 lbf.ft).
4.Fit drive plate and clamp ring, tighten bolts to
45 Nm (33 lbf.ft).
5.Clean CKP sensor and mating face.
6.Fit crankshaft sensor and tighten nuts to 6 Nm
(5 lbf.ft).
7.Fit CKP sensor cover and tighten bolts to 6 Nm
(5 lbf.ft).
8.Fit CKP sensor multiplug to bracket.
9.Fit automatic gearbox.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gearbox - convertor and
transfer gearbox - V8.
Ring gear - starter
$% 12.53.19
Remove
1.Remove flywheel.

+ ENGINE - V8, REPAIRS, Flywheel.
2.Drill a 3 mm (0.12 in) diameter hole at root of 2
teeth.
3.Apply a cold chisel in root of one of ring gear
teeth, strike chisel with hammer to break ring
gear.
WARNING: SUITABLE EYE PROTECTION
MUST BE WORN.
4.Remove starter ring gear.
Refit
1.Clean flywheel and starter ring gear.
2.Heat new starter ring gear evenly to 350
°C
(660
°F), indicated when the ring is a light blue
colour.
3.Locate ring gear on flywheel and press ring
gear hard against flange on flywheel.

ENGINE - V8
OVERHAUL 12-2-69
3.Clamp hexagon body of tool LRT-12-013 in
vice.
4.Loosen large nut and pull the centre screw 50
mm (2 in) out of hexagon body.
5.Fit piston adapter tool LRT-12-126/2 .
6.Position guide pin tool LRT-12-126/3 in LRT-
12-162/2 with groove towards piston, up to
shoulder on centre screw.
7.Lubricate gudgeon pin and bores of connecting
rod and piston with graphite oil.
8.Locate connecting rod and piston to centre
screw with connecting rod entered on sleeve
up to groove.
9.Fit gudgeon pin on to centre screw and into
piston bore up to connecting rod.
10.Fit remover/replacer tool LRT-12-126/1 with
flanged end towards gudgeon pin.
11.Screw the stop nut on to centre screw and
position piston against groove of tool LRT-12-
126/3.
12.Lubricate centre screw threads and thrust race
with graphite oil, screw large nut up to tool
LRT-12-013.
13.Lock the stop nut securely with lock screw.
14.Set torque wrench to 16 Nm (12 lbf.ft) and using
socket on large nut, pull gudgeon pin in until
flange of tool LRT-12-126/1 is 0.40 mm (0.016
in), dimension 'A' from face of piston. If
torque is exceeded during this procedure, fit of
gudgeon pin to connecting rod is not
acceptable and components must be replaced.
CAUTION: The centre screw and thrust race
must be kept well lubricated throughout the
operation.
15.Dismantle tool, remove piston and check no
damage has occurred during pressing and that
piston moves freely on gudgeon pin.
16.Remove compression rings, oil control rails
and expander from new piston. 17.Invert piston and with arrow pointing towards
rear of cylinder block, insert piston into cylinder
liner.
18.Position piston with bottom of skirt 30 mm (1.12
in) from top cylinder liner.
19.Using feeler gauges, measure and record
clearance between piston and left hand side of
cylinder- viewed from the front of cylinder
block.
lPiston to bore clearance = 0.020 to 0.045
mm (0.001 to 0.002 in).
20.Insert piston rings into cylinder bore, use the
piston to hold the rings square to bore and
check the ring gap.
l1st compression ring = 0.30 to 0.50 mm
(0.012 to 0.02 in).
l2nd compression ring = 0.40 to 0.65 mm
(0.016 to 0.026 in).
lOil control ring rails = 0.38 to 1.40 mm
(0.015 to 0.055 in).
21.Remove piston rings from bore.
22.Fit oil control ring rails and expander, ensuring
ends butt and do not overlap.

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.

EMISSION CONTROL - TD5
17-1-14 REPAIRS
Valve - EGR - Pre EU3 models
$% 17.45.01
On all vehicles up to VIN number 1A736339, the
EGR pipe assembly must be replaced every time the
system is disturbed.
Remove
1.Release turnbuckles and remove battery cover.
2.Disconnect battery earth lead.
3.Remove 3 bolts and remove engine acoustic
cover.
4.Remove cooling fan coupling.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
5.Disconnect vacuum hose(s) from EGR valve.
6.Loosen clip and release air intake from EGR
valve.
7.Remove 4 bolts, release EGR valve from inlet
manifold and discard gasket.
8.Remove 2 bolts and release EGR valve clip
from cylinder head.
9.Remove and discard 2 bolts securing EGR
valve pipe to exhaust manifold. 10.Remove EGR valve assembly.
11.Remove clip and remove pipe from EGR valve.
Refit
1.Clean EGR valve and mating face on pipe.
2.Position pipe to EGR valve and fit retaining clip.
Fit bolt but do not tighten at this stage.
3.Position EGR valve assembly, locate pipe
flange to exhaust manifold, fit new bolts but do
not tighten at this stage.
4.Clean inlet manifold and EGR valve mating
faces.
5.Using new gasket, position EGR valve to inlet
manifold fit bolts and tighten to 10 Nm (7 lbf.ft).
6.Align EGR pipe clip to cylinder head, fit bolts
but do not tighten at this stage.
7.Tighten EGR pipe bolts to correct torque in
following sequence:
lEGR pipe retaining clip bolt 6 Nm (4.5 lbf.ft)
lEGR pipe clip to cylinder head bolts 10 Nm
(7 lbf.ft)
lEGR pipe flange to exhaust manifold bolts
10 Nm (7 lbf.ft)
8.Position air intake hose and tighten clip.
9.Connect vacuum hoses to EGR valve.
10.Fit cooling fan coupling.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
11.Connect battery earth lead.
12.Fit battery cover and secure the fixings.

EMISSION CONTROL - V8
17-2-14 DESCRIPTION AND OPERATION
The heated oxygen sensors should be treated with extreme care, since the ceramic material within them can be easily
cracked if dropped, banged or over-torqued; the sensors should be torqued to the recommended values indicated in
the repair procedures. Apply anti-seize compound to the sensor's threads when refitting.
WARNING: Some types of anti-seize compound used in service are a health hazard. Avoid skin contact.
WARNING: To prevent personal injury from a hot exhaust system, do not attempt to disconnect any
components until the exhaust system has cooled down.
CAUTION: Do not allow anti-seize compound to come into contact with tip of sensor or enter exhaust system.
NOTE: A new HO2 sensor is supplied pre-treated with anti-seize compound.