alternator belt LAND ROVER DISCOVERY 2002 Workshop Manual

CONTENTS
22 CONTENTS
Condenser .................................................................................................................................... 82-33
Receiver drier and dual pressure switch......................................................................................... 82-36
ECU - air temperature control ......................................................................................................... 82-37
Sensor - ambient air temperature ................................................................................................ 82-38
Sensor - solar light ........................................................................................................................ 82-38
Sensor - air temperature ............................................................................................................. 82-39
Evaporator, evaporator thermistor and thermal expansion valve (TXV) ........................................ 82-40
Expansion valve - (TXV) - rear ....................................................................................................... 82-42
Evaporator - rear............................................................................................................................. 82-43
Evaporator and motor assembly - rear ........................................................................................... 82-44
Blower motor assembly - rear ......................................................................................................... 82-46
Resistor - blower motor ................................................................................................................. 82-46
Duct - centre - rear.......................................................................................................................... 82-47
WIPERS AND WASHERS ........................................................................ 84-1
DESCRIPTION AND OPERATION
Wipers and washers component layout .......................................................................................... 84-1
Front wiper components ................................................................................................................. 84-2
Rear wiper components .................................................................................................................. 84-3
Washer components ....................................................................................................................... 84-4
Wipers and washers block diagram ................................................................................................ 84-6
Description ...................................................................................................................................... 84-8
Operation ........................................................................................................................................ 84-16
REPAIRS
Reservoir - washer - up to 03MY .................................................................................................... 84-19
Reservoir - washer - from 03MY ..................................................................................................... 84-20
Jet - washer - windscreen ............................................................................................................... 84-21
Pump - washer - screen and headlamp ....................................................................................... 84-21
Motor and linkage - wiper - windscreen .......................................................................................... 84-22
Switch - wiper and washer - windscreen ........................................................................................ 84-23
Jet - washer - headlamp ................................................................................................................ 84-24
Jet - washer - rear screen ............................................................................................................ 84-25
Switch - rear wash .......................................................................................................................... 84-25
Motor - wiper - rear screen ............................................................................................................ 84-26
Switch - wiper - rear - up to 03MY .................................................................................................. 84-27
Switch - wiper - rear - from 03MY ................................................................................................... 84-27
CHARGING AND STARTING ................................................................... 86-1-1
REPAIRS
Alternator - diesel .......................................................................................................................... 86-1-1
Alternator - V8................................................................................................................................. 86-1-2
Belt - auxiliary drive ........................................................................................................................ 86-1-3
Battery ........................................................................................................................................... 86-1-4
Battery carrier ................................................................................................................................ 86-1-4
Starter motor - diesel ...................................................................................................................... 86-1-5
Starter motor - V8 ........................................................................................................................... 86-1-6
LIGHTING.................................................................................................. 86-2-1
ADJUSTMENTS
Headlamps beam alignment - up to 03MY ..................................................................................... 86-2-1

TORQUE WRENCH SETTINGS
06-4
Engine V8
TORQUE DESCRIPTION METRIC IMPERIAL
Engine mounting bolts (rear, LH & RH) to gearbox bolts 85 Nm (63 lbf.ft)
Engine mounting (rear, LH & RH) nuts 45 Nm (33 lbf.ft)
Cylinder head bolts tighten, then 90°, then a further 90°20 Nm (15 lbf.ft)
Rocker shaft bolts 40 Nm (30 lbf.ft)
Alternator mounting bracket 40 Nm (30 lbf.ft)
Auxiliary drive belt tensioner 45 Nm (33 lbf.ft)
Engine earth lead 22 Nm (16 lbf.ft)
Rocker cover bolts 8 Nm (6 lbf.ft)
Torque converter to drive plate 50 Nm (37 lbf.ft)
A/C compressor 22 Nm (16 lbf.ft)
ACE pump 22 Nm (16 lbf.ft)
Flywheel to crankshaft 78 Nm (58 lbf.ft)
Crankshaft sensor 6 Nm (5 lbf.ft)
Crankshaft sensor cover 6 Nm (5 lbf.ft)
Spacer and hub to crankshaft 85 Nm (63 lbf.ft)
Drive plate and clamp ring 45 Nm (33 lbf.ft)
Oil pick up strainer 10 Nm (7 lbf.ft)
Filter head adaptor 13 Nm (10 lbf.ft)
Filter head 8 Nm (6 lbf.ft)
Sump bolts 22 Nm (16 lbf.ft)
Oil pressure switch 15 Nm (11 lbf.ft)
Timing gear cover to cylinder block 22 Nm (16 lbf.ft)
Oil cooler pipe to timing gear cover 15 Nm (11 lbf.ft)
Crankshaft pulley bolt 270 Nm (200 lbf.ft)
Coolant outlet elbow 22 Nm (16 lbf.ft)
Auxiliary housing 40 Nm (30 lbf.ft)
Jockey pulley 50 Nm (37 lbf.ft)
Camshaft gear 50 Nm (37 lbf.ft)
Rocker shaft bolts 40 Nm (30 lbf.ft)
Connecting rod bolts
Final torque - turn through 80 °20 Nm (15 lbf.ft)
Initial torque - all main bearing cap bolts and side bolts 13.5 Nm (10 lbf.ft)
Final torque - main bearing cap side bolts 11 to 15 45 Nm (33 lbf.ft)
Final torque - main bearing cap bolts 1 to 8 72 Nm (53 lbf.ft)
Final torque - main bearing cap bolts 9 and 10 92 Nm (68 lbf.ft)
Final torque - main bearing cap side bolts 16 to 20 45 Nm (33 lbf.ft)
Viscous fan nut 45 Nm (33 lbf.ft)
Camshaft thrust plate bolts 22 Nm (16 lbf.ft)
Secondary Air Injection adapters 33 Nm (24 lbf.ft)

TORQUE WRENCH SETTINGS
06-15
Heating and air conditioning
Wipers and washers
Electrical
TORQUE DESCRIPTION METRIC IMPERIAL
Heater assembly16 Nm (12 lbf.ft)
Compressor bolts 22 Nm (16 lbf.ft)
Blower motor19 Nm (14 lbf.ft)
Compressor to mounting bracket bolts 25 Nm (18 lbf.ft)
A/C pipes to compressor bolts 10 Nm (7 lbf.ft)
Condenser pipe bolt 5 Nm (3.7 lbf.ft)
Receiver drier to bracket bolts 5 Nm (3.7 lbf.ft)
Adaptor block to receiver drier bolt 5 Nm (3.7 lbf.ft)
Evaporator pipe bolts 5 Nm (3.7 lbf.ft)
Dual pressure switch to receiver drier 10 Nm (7 lbf.ft)
Air conditioning pipes to receiver drier bolts 5 Nm (3.7 lbf.ft)
TX valve pressure pipe union 22 Nm (16 lbf.ft)
Evaporator pipe to TXV valve 32 Nm (24 lbf.ft)
Evaporator assembly to body bolts 16 Nm (12 lbf.ft)
High and low pressure pipe, bolts 10 Nm (7 lbf.ft)
Fuel burning heater Torx bolts 25 Nm (18 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Link to motor spindle 7 Nm (5.2 lbf.ft)
Front motor assembly 2.5 Nm (1.8 lbf.ft)
Spindle nut 3 Nm (2.2 lbf.ft)
Wiper arm nut13 Nm (10 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Alternator support stay 25 Nm (18 lbf.ft)
Alternator lead - Td5 6 Nm (4.4 lbf.ft)
Auxiliary drive belt tensioner bolt 50 Nm (37 lbf.ft)
Alternator pulley80 Nm (59 lbf.ft)
Alternator B+ nut - V8 18 Nm (13 lbf.ft)
Alternator B+ nut - V8 5 Nm (3.7 lbf.ft)
Starter motor - Td5 27 Nm (20 lbf.ft)
Starter motor solenoid 10 Nm (7 lbf.ft)
Starter motor - V8 44 Nm (32 lbf.ft)
Alternator45 Nm (33 lbf.ft)
Starter motor heat shield - V8 10 Nm (7 lbf.ft)
Horn13 Nm (10 lbf.ft)
Battery carrier bolts 28 Nm (21 lbf.ft)

MAINTENANCE
PROCEDURES 10-11
Air cleaner - V8 engine
Replace
1.Replace air cleaner element.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Element - air filter.
Clean
1.Clean the drain hole in filter casing.
Air cleaner and dump valve - diesel
engine
Replace/clean
1.Replace air cleaner element.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Element - air filter.
2.Remove all dirt from dump valve.
Auxiliary drive belt
Check
TD5 auxiliary belt
V8 auxiliary belt
1Tensioner pulley
2Alternator
3A/C compressor
4ACE pump
5Idler pulley - V8 only
6PAS pump
7Viscous fan pulley
8Crankshaft pulley
9Idler pulley - V8 only
1.Check auxiliary drive belt for signs of splits,
fraying, oil contamination and wear.

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 - 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
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.

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 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.