warning LAND ROVER DISCOVERY 2002 Manual PDF
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 2002, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 2002Pages: 1672, PDF Size: 46.1 MB
Page 562 of 1672
FUEL DELIVERY SYSTEM - TD5
REPAIRS 19-1-17
Tank - fuel
$% 19.55.01
Remove
1.Drain fuel tank.
+ FUEL DELIVERY SYSTEM - Td5,
ADJUSTMENTS, Fuel tank - drain.
2.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
3.Release clips securing filler and breather hoses
and release hoses from filler neck.
4.Disconnect fuel tank vent pipe from filler tube.
5.Support weight of fuel tank underneath cradle.
6.Remove 2 nuts and 2 bolts securing cradle to
chassis.
7.With assistance, lower LH side of fuel tank then
remove fuel tank from chassis.
8.Remove fuel tank from cradle.9.Remove 2 scrivets securing heat shield and
remove heat shield.
10.Release securing clip and remove breather
hose from fuel tank.
Refit
1.Fit breather hose to fuel tank and secure with
clip.
2.Position heat shield and secure with scrivets.
3.With assistance, position fuel tank and cradle.
4.Fit nuts and bolts securing cradle to chassis.
Tighten bolts to 50 Nm (37 lbf.ft) and nuts to 28
Nm (21 lbf.ft).
5.Connect fuel tank vent pipe to filler tube.
6.Connect breather and filler hoses and secure
with clips.
Page 576 of 1672
FUEL DELIVERY SYSTEM - V8
ADJUSTMENTS 19-2-11
ADJUST ME NTS
Fuel tank - drain
$% 19.55.02
Drain
1.Disconnect both leads from battery.
WARNING: Always disconnect the negative
lead first. Disconnection of the positive lead
while the negative lead is connected could
result in a short circuit through accidental
grounding and cause personal injury.
2.Connect TestBook to vehicle and depressurise
fuel system.
3.Remove fuel pump.
+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Pump - fuel.
4.Using a fuel recovery appliance, drain the fuel
from the tank into a sealed container. Follow
the manufacturers instructions for the
connection and safe use of the appliance.
Refill
1.Fit fuel pump unit.
+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Pump - fuel.
2.Refill fuel tank with extracted fuel.
3.Connect battery leads, positive lead first.
Page 580 of 1672
FUEL DELIVERY SYSTEM - V8
REPAIRS 19-2-15
Tank - fuel
$% 19.55.01
Remove
1.Drain fuel tank.
+ FUEL DELIVERY SYSTEM - V8,
ADJUSTMENTS, Fuel tank - drain.
2.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
3. All except NAS models:Release clips
securing filler and breather hoses. Release
hoses from filler tube.
4. NAS models: Loosen securing clip and
release filler tube from fuel tank.
5.Disconnect fuel tank vent pipe from filler tube.
6.Support weight of fuel tank underneath cradle. 7.Remove 2 nuts and 2 bolts securing cradle to
chassis.
8.With assistance, lower LH side of fuel tank then
remove fuel tank from chassis.
9.Remove cradle from fuel tank.
Non NAS fuel tank
10.Remove 2 scrivets securing heat shield and
remove heat shield.
11. All except NAS models: Release securing clip
and remove breather hose from fuel tank.
Refit
1.Fit breather hose to fuel tank and secure with
clip.
2.Position heat shield and secure with scrivets.
3.With assistance, position fuel tank and cradle.
4.Fit nuts and bolts securing cradle to chassis.
Tighten bolts to 45 Nm (33 lbf.ft) and nuts to 26
Nm (19 lbf.ft).
5.Connect vent hose.
6.Connect breather and filler hoses and secure
with clips.
Page 581 of 1672
FUEL DELIVERY SYSTEM - V8
19-2-16 REPAIRS
Filler tube - fuel
$% 19.55.07
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Ensure fuel tank is less than half full. If not,
drain fuel tank to less than half full.
+ FUEL DELIVERY SYSTEM - V8,
ADJUSTMENTS, Fuel tank - drain.
3.Remove filler cap.
Non NAS installation
4.Drill out rivet securing lower part of mud flap
support bracket and release bracket .
5. All except NAS models: Disconnect filler
hose, breather hose and vent pipe from filler
tube.
NAS installation
6. NAS models: Loosen securing clip and
release filler tube from fuel tank.7. NAS models: Disconnect vent pipes from filler
tube.
8. Release filler tube from grommet in body and
remove from under rear wing. Collect grommet.
9. NAS models: Remove cable tie securing
pressure sensor pipe to filler tube and remove
filler tube.
Refit
1. NAS models: Position filler tube to pressure
sensor pipe and secure with new cable tie.
2. Fit grommet to body, position filler tube under
rear wing and secure in grommet.
3. NAS models: Connect filler tube to fuel tank
and secure with clip. Connect vent pipes to filler
tube.
4. All except NAS models: Connect filler hose
and breather hose to filler tube and secure with
clips. Connect vent pipe to filler tube.
5. Position support bracket to mud flap and
secure with new rivet.
6.If applicable, refill fuel tank with extracted fuel.
7.Fit filler cap.
8.Remove stand(s) and lower vehicle.
Page 596 of 1672
COOLING SYSTEM - TD5
ADJUSTMENTS 26-1-13
ADJUST ME NTS
Drain and refill
$% 26.10.01
WARNING: Since injury such as scalding could
be caused by escaping steam or coolant, do not
remove the filler cap from the coolant expansion
tank while the system is hot.
Drain
1.Visually check engine and cooling system for
signs of coolant leaks.
2.Examine hoses for signs of cracking, distortion
and security of connections.
3.Position drain tray to collect coolant.
4.Remove expansion tank filler cap.
5.Remove drain plug access cover from
underbelly panel.
6.Remove drain plug from coolant pump feed
pipe and allow cooling system to drain. Discard
drain plug sealing washer.
Refill
1.Flush system with water under low pressure.
Do not use water under high pressure as it
could damage the radiator.
2.Fit new sealing washer to drain plug. Fit and
tighten drain plug in coolant pump feed pipe.
3.Fit access cover to underbelly panel.
4.Prepare coolant to required concentration.
+ CAPACITIES, FLUIDS AND
LUBRICANTS, Anti-Freeze Concentration.5.Remove bleed screw from top hose.
6.Unclip the bleed hose from the battery box.
7.Unclip the expansion tank from its mounting
bracket, remove the expansion tank cap and
raise the expansion tank vertically 10 cm (4 in).
Retain the tank in this position.
8.Slowly fill the system through the coolant
expansion tank until a steady flow of coolant is
emitted from the bleed hole.
9.Fit the bleed screw, then, with the expansion
tank still raised, continue filling the system until
coolant level reaches the cold level mark on
expansion tank.
10.Fit expansion tank filler cap, fit the expansion
tank to its mounting bracket and clip the bleed
hose to the battery box.
11.Start and run engine until normal operating
temperature is reached, and check for leaks.
12.Switch off engine and allow to cool.
13.Check for leaks and top-up coolant to the cold
level mark on expansion tank
Page 614 of 1672
COOLING SYSTEM - V8
ADJUSTMENTS 26-2-13
ADJUST ME NTS
Drain and refill
$% 26.10.01
WARNING: Since injury such as scalding could
be caused by escaping steam or coolant, do not
remove the filler cap from the coolant expansion
tank while the system is hot.
Drain
1.Visually check engine and cooling system for
signs of coolant leaks.
2.Examine hoses for signs of cracking, distortion
and security of connections.
3.Position drain tray to collect coolant.
4.Remove expansion tank filler cap.
LH side
RH side5.Remove drain plugs from LH and RH sides of
cylinder block and allow cooling system to
drain.
6.Disconnect bottom hose from radiator and
allow cooling system to drain.
7.Disconnect top hose from thermostat and
position open end of hose below level of
coolant pump inlet, to allow coolant to drain
from the system.
Refill
1.Flush system with water under low pressure.
Do not use water under high pressure as it
could damage the radiator.
2.Apply Loctite 577 to cylinder block drain
plugs.Fit drain plugs to cylinder block and
tighten to 30 Nm (22 lbf.ft).
3.Connect bottom hose to radiator and top hose
to thermostat housing. Secure with hose clips.
4.Prepare coolant to required concentration.
+ CAPACITIES, FLUIDS AND
LUBRICANTS, Anti-Freeze Concentration.
Page 645 of 1672
MANIFOLDS AND EXHAUST SYSTEMS - V8
30-2-16 REPAIRS
Gasket - exhaust manifold
$% 30.15.12
This procedure is the same for both exhaust manifold
gaskets.
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 3 nuts securing front pipe to exhaust
manifold, release front pipe and collect gasket.3.Remove 8 bolts and spacers securing exhaust
manifold.
4.Remove exhaust manifold.
5.Remove 2 manifold gaskets.
Refit
1.Clean exhaust manifold and cylinder head
mating face.
2.Position exhaust manifold and new gaskets on
cylinder head.
3.Fit spacers and exhaust manifold securing
bolts and, working from the centre outwards,
tighten bolts to 38 Nm. (28 lbf.ft).
4.Clean front pipe and manifold mating faces.
5.Using a new gasket, position front pipe, fit nuts
and tighten to 30 Nm. (22 lbf.ft).
6.Remove stand(s) and lower vehicle.
Page 662 of 1672
CLUTCH - TD5
ADJUSTMENTS 33-1-11
ADJUST ME NTS
Clutch hydraulic system - bleed
$% 33.15.01
CAUTION: Ensure the fluid in the reservoir is
maintained between the minimum and maximum
levels throughout the bleed procedure using new
brake fluid.
CAUTION: Brake fluid will damage paint finished
surfaces. If spilled, immediately remove fluid and
clean area with water.
Bleeding
1.Top up reservoir.
2.Raise the front of the vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
3.Connect tube to bleed screw on clutch slave
cylinder and submerge free end in a clear
container containing brake fluid.
4.Loosen bleed screw, then apply steady
pressure to the clutch pedal, depressing it
through its full stroke. Allow the pedal to return
unassisted.5.Repeat the procedure until a flow of clean, air-
free fluid is purged into the container.
6.Hold the pedal to the floor and tighten the
clutch bleed screw to 9 Nm (7 lbf.ft).
7.Check and top up reservoir.
CAUTION: Never re-use fluid that has been
bled from the system.
8.Remove stands and lower the vehicle.
Page 665 of 1672
CLUTCH - TD5
33-1-14 REPAIRS
Master cylinder
$% 33.20.01
CAUTION: Brake fluid will damage paint finished
surfaces. If spilled, immediately remove fluid and
clean area with water.
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.Release spring clip securing clutch pedal
clevis pin and remove pin from push rod and
clutch pedal.
3.Position container to catch spillage. Disconnect
hydraulic pipe from clutch master cylinder.
CAUTION: Always fit plugs to open
connections to prevent contamination.4.Release clip and remove connecting hose from
clutch master cylinder.
5.Remove 2 bolts securing clutch master
cylinder to pedal box and remove clutch master
cylinder.
Refit
1.Clean master cylinder and pedal box mating
faces.
2.Position clutch master cylinder to pedal box, fit
bolts and tighten to 25 Nm (18 lbf.ft).
3.Position clevis pin to push-rod and clutch pedal
and secure with spring clip.
4.Fit connecting hose to brake master cylinder
and tighten clip.
5.Position hydraulic pipe and tighten union to 18
Nm (13 lbf.ft).
6.Bleed clutch.
+ CLUTCH - Td5, ADJUSTMENTS,
Clutch hydraulic system - bleed.
7.Remove stand(s) and lower vehicle.
Page 666 of 1672
CLUTCH - TD5
REPAIRS 33-1-15
Bearing and lever - clutch release
$% 33.25.12
Remove
1.Remove gearbox assembly.
+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - Diesel.
2.Remove retaining peg and remove release
bearing.
3.Remove bolt securing clutch release lever.
Remove retaining clip and clutch release lever.
Refit
1.Clean clutch release lever.
2.Examine clutch release lever pivot points for
wear.
3.Apply a smear of Molybdenum disulphide
grease to clutch release lever pivot points.
4.Fit retaining clip ensuring it locates over
release bearing pivot point washer, fit bolt and
tighten to 8 Nm (6 lbf.ft).
5.Clean release bearing and bearing sleeve
mating faces.
6.Apply a smear of Molybdenum disulphide
grease to release bearing sleeve.
7.Fit release bearing and secure with retaining
peg.
8.Fit gearbox assembly.
+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - Diesel.
Slave cylinder
$% 33.35.01
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.Position container to catch spillage.
3.Disconnect hydraulic pipe from slave cylinder.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Remove 2 bolts securing slave cylinder to
gearbox housing and collect heat shield.
5.Withdraw slave cylinder from gearbox housing
and push rod.
Refit
1.Clean ends of pipes, gearbox housing and
slave cylinder mating faces.
2.Lubricate end of push rod with Molybdenum
disulphide grease.
3.Locate slave cylinder to push rod and gearbox
housing.
4.Position heatshield. Fit bolts securing slave
cylinder and tighten to 25 Nm (18 lbf.ft).
5.Connect hydraulic pipe to slave cylinder.
6.Bleed clutch system.
+ CLUTCH - Td5, ADJUSTMENTS,
Clutch hydraulic system - bleed.
7.Remove stand(s) and lower vehicle.