2002 LAND ROVER DISCOVERY check engine light

GENERAL INFORMATION
03-4
Spill kits
Special materials are available to absorb a number of
different substances. They can be in granular form,
ready to use and bought in convenient containers for
storage. Disposal of used spill-absorbing material is
dealt with in 'Waste Management' section.
Land contamination
Oils, fuels and solvents etc. can contaminate any soil
that they are allowed to contact. Such materials
should never be disposed of by pouring onto soil and
every precaution must be taken to prevent spillage
reaching soil. Waste materials stored on open
ground could also leak, or have polluting substances
washed off them that would contaminate the land.
Always store these materials in suitable skips or
other similarly robust containers.
Checklist
Always adhere to the following.
lDon't pour or spill anything onto the soil or bare
ground;
ldon't store waste materials on bare ground, see
'Spillage prevention' list.
Legal compliance
Some sites may have a discharge consent for
effluent discharge to the foul drain for a car wash etc.
It is important to know what materials are allowed in
the drain and to check the results of any monitoring
carried out by the Water Company.
Where paint-spraying operations are carried out it
may be necessary to apply to the Local Authority for
an air emissions licence to operate the plant. If such
a licence is in operation, additional precautions will
be necessary to comply with the requirements, and
the results of any air quality monitoring must be
checked regularly.
Checklist
Always adhere to the following.
lKnow what legal consents and licences apply to
the operations;
lcheck that the emissions and discharges
comply with legal requirements.
Local issues
A number of environmental issues will be of
particular concern to residents and other neighbours
close to the site. The sensitivity of these issues will
depend on the proximity of the site and the layout
and amount of activity carried on at the site.
Noise is a major concern and therefore
consideration should be given to the time spent
carrying out noisy activities and the location of those
activities that can cause excessive noise. Car alarm testing, panel beating, hammering and
other such noisy activities should, whenever
possible, be carried out indoors with doors and
windows shut or as far away from houses as
possible.
Running vehicle engines may be an outside activity
which could cause nuisance to neighbours because
of both noise and smell.
Be sensitive to the time of day when these activities
are carried out and minimise the time of the noisy
operation, particularly in the early morning and late
evening.
Another local concern will be the smell from the
various materials used. Using less solvent, paint
and petrol could help prevent this annoyance.
Local residents and other business users will also be
concerned about traffic congestion, noise and
exhaust fumes, be sensitive to these concerns and
try to minimise inconvenience from deliveries,
customers and servicing operations.
Checklist
Always adhere to the following.
lIdentify where the neighbours who are likely to
be affected are situated;
lminimise noise, smells and traffic nuisance;
lprevent litter by putting waste in the correct
containers;
lhave waste skips emptied regularly.
Use of resource
Another environmental concern is the waste of
materials and energy that can occur in day to day
activities.
Electricity for heating, lighting and compressed air
uses resources and releases pollution during its
generation.
Fuel used for heating, running cars or vans and
mobile plant is another limited resource which
consumes large amounts of energy during its
extraction and refining processes.
Water has to be cleaned, piped to site and disposed
of; all of which creates more potential pollution.
Oil, spares, paint etc., have all produced pollution in
the process of manufacture and they become a
waste disposal problem if discarded.
Checklist
Always adhere to the following.

GENERAL INFORMATION
03-5
Electricity and heating:
lkeep doors and windows closed in the winter;
lswitch off machinery or lights when not needed;
luse energy efficient heating systems;
lswitch off computers and photocopiers when
not needed.
Fuel:
ldon't run engines unnecessarily;
lthink about whether journeys are necessary and
drive to conserve fuel.
Water:
ldon't leave taps and hose pipes running;
lmend leaks quickly, don't be wasteful.
Compressed air:
ldon't leave valves open;
lmend leaks quickly;
ldon't leave the compressor running when not
needed.
Use of environmentally damaging materials:
lcheck whether a less toxic material is available.
Handling and storage of materials:
lhave the correct facilities available for handling
liquids to prevent spillage and wastage as listed
above;
lprovide suitable locations for storage to prevent
frost damage or other deterioration.
Waste Management
One of the major ways that pollution can be reduced
is by the careful handling, storage and disposal of all
waste materials that occur on sites. Legislation
makes it illegal to dispose of waste materials other
than to licensed waste carriers and disposal sites.
This means that it is necessary to not only know what
the waste materials are, but also to have the
necessary documentation and licenses.
Handling and storage of waste
Ensure that waste materials are not poured down the
drain or onto soils. They should be stored in such a
way as to prevent the escape of the material to land,
water or air.
They must also be segregated into different types of
waste e.g. oil, metals, batteries, used vehicle
components. This will prevent any reaction between
different materials and assist in disposal.
Disposal of waste
Disposal of waste materials must only be to waste
carriers who are licensed to carry those particular
waste materials and all the necessary
documentation must be completed. The waste
carrier is responsible for ensuring that the waste is
taken to the correct disposal sites.Dispose of waste in accordance with the following
guidelines.
lFuel, hydraulic fluid, anti-freeze and oil: keep
separate and dispose of to specialist contractor.
lRefrigerant: collect in specialist equipment and
reuse.
lDetergents: safe to pour down the foul drain if
diluted.
lPaint, thinners: keep separate and dispose of
to specialist contractor.
lComponents: send back to supplier for
refurbishment, or disassemble and reuse any
suitable parts. Dispose of the remainder in
ordinary waste.
lSmall parts: reuse any suitable parts, dispose
of the remainder in ordinary waste.
lMetals: can be sold if kept separate from
general waste.
lTyres: keep separate and dispose of to
specialist contractor.
lPackaging: compact as much as possible and
dispose of in ordinary waste.
lAsbestos-containing: keep separate and
dispose of to specialist contractor.
lOily and fuel wastes (e.g. rags, used spill kit
material): keep separate and dispose of to
specialist contractor.
lAir filters: keep separate and dispose of to
specialist contractor.
lRubber/plastics: dispose of in ordinary waste.
lHoses: dispose of in ordinary waste.
lBatteries: keep separate and dispose of to
specialist contractor.
lAirbags - explosives: keep separate and
dispose of to specialist contractor.
lElectrical components: send back to supplier
for refurbishment, or disassemble and reuse
any suitable parts. Dispose of the remainder in
ordinary waste.
lElectronic components: send back to supplier
for refurbishment, or disassemble and reuse
any suitable parts. Dispose of the remainder in
ordinary waste.
lCatalysts: can be sold if kept separate from
general waste
lUsed spill-absorbing material: keep separate
and dispose of to specialist contractor.
lOffice waste: recycle paper and toner and ink
cartridges, dispose of the remainder in ordinary
waste.

GENERAL INFORMATION
03-15
Hose clips
Markings (4) are usually provided on the hose to
indicate the correct clip position. If no markings are
provided, position the clip directly behind the
retaining lip at the end of the stub as shown. Worm
drive clips should be oriented with the crimped side
of the drive housing (5) facing towards the end of the
hose, or the hose may become pinched between the
clip and the stub pipe retaining lip. Worm drive clips
should be tightened to 3 Nm (2 lbf.ft) unless
otherwise stated. Ensure that hose clips do not foul
adjacent components.
Heat protection
Always ensure that heatshields and protective
sheathing are in good condition. Replace if damage
is evident. Particular care must be taken when
routing hoses close to hot engine components, such
as the exhaust manifold and the Exhaust Gas
Recirculation (EGR) pipe. Hoses will relax and
deflect slightly when hot; ensure this movement is
taken into account when routing and securing hoses.
Rolling Road Testing
General
IMPORTANT: Use a four wheel rolling road for
brake testing if possible.
WARNING: Do not attempt to test ABS function
on a rolling road.
Four wheel rolling road
Provided that front and rear rollers are rotating at
identical speeds and that normal workshop safety
standards are applied, there is no speed restriction
during testing except any that may apply to the tyres.
Before testing a vehicle with anti-lock brakes on a
four wheel rolling road, disconnect the ABS
modulator. The ABS function will not work, the ABS
warning light will illuminate. Normal braking will be
available.
Two wheel rolling road
Up to 03MY
ABS will not function on a two wheel rolling road. The
ABS light will illuminate during testing. Normal
braking will be available.
If brake testing on a two wheel rolling road is
necessary, the following precautions should be
taken:
lPropeller shaft to the rear axle is removed.
lNeutral selected in gearbox.
When checking brakes, run engine at idle speed to
maintain servo vacuum.
From 03MY
The differential lock must be engaged for two wheel
rolling road testing. It will also be necessary to
disconnect the propeller shaft from the transfer box
output shaft driving the axle whose wheels are NOT
on the rolling road. Additionally, the ETC system
must be deactivated by either removing the 10 amp
fuse (Number 28, labelled ABS in the main fuse box)
or disconnecting the ABS modulator pump. This
must be done with the ignition OFF ; a fault in the
ABS system may still be recorded.
WARNING; VEHICLES NOT FITTED WITH A
DIFFERENTIAL LOCK MUST NOT BE TESTED
ON A ROLLING ROAD WHERE THE ROLLERS
ARE DRIVEN BY THE VEHICLE.

ENGINE - TD5
12-1-42 REPAIRS
37.Using suitable lifting chains and tool LRT-12-
138 carefully remove cylinder head and place
on wooden blocks or stands.
CAUTION: Support both ends of cylinder
head on blocks of wood. With the camshaft
carrier bolted down, the injector nozzles
and some of the valves will protrude from
the face of the cylinder head.
38.Remove cylinder head gasket.
39.Note the gasket thickness indicator and ensure
the same thickness gasket is used on refitment
of cylinder head.
40.Remove and discard plastic dowels from
cylinder block.Refit
1.Clean mating faces of cylinder head and
cylinder block.
2.Check cylinder head for warping, across centre
and from corner to corner: – Maximum warp =
0.10 mm (0.0004 in)
CAUTION: Cylinder heads may not be
refaced, replace cylinder head if warping
exceeds figure given.
3.Ensure coolant and oil passages are clean.
4.Clean dowel holes and fit new plastic dowels.
5.Lightly lubricate threads and beneath heads of
cylinder head bolts with clean engine oil.
6.Fit new cylinder head gasket of the correct
thickness with the word 'TOP' uppermost.
7.Using assistance, fit cylinder head and locate
onto dowels.
8.Carefully enter cylinder head bolts, DO NOT
DROP. Lightly tighten bolts.
9.Using the sequence shown, progressively
tighten cylinder head bolts to 30 Nm (22 lbf.ft),
then to 65 Nm (48 lbf.ft), then a further 90
°, then
a further 180
° and finally a further 45°.
CAUTION: Ensure correct sequence is
followed for all 5 tightening stages. Do not
tighten bolts 315 degrees in one operation.
10.Fit nut and bolt securing cylinder head to timing
chain cover and tighten to 25 Nm (18 lbf.ft).

ENGINE - TD5
12-1-62 REPAIRS
Valve - relief - oil pressure
$% 12.60.56
Remove
1.Remove sump gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
sump.
2.Remove and discard plug from oil pump
housing.
3.Remove spring and valve.
Refit
1.Clean valve, spring and plug.
2.Clean valve seating inside oil pump housing.
3.Check valve and bore for scoring and
corrosion. Light scoring may be removed using
grade 600 emery cloth soaked in oil.
4.Check spring for distortion, check free length of
spring: Spring free length = 42.00 mm (1.65 in).
CAUTION: Renew relief valve as an
assembly.
5.Lubricate valve and seating.
6.Fit valve and spring to pump.
7.Apply Loctite 243 sealant to threads of new
plug.
CAUTION: Do not attempt to fit original
plug.
8.Fit oil pump pressure relief valve plug and
tighten to 23 Nm (17 lbf.ft).
9.Fit sump gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
sump.
10.Check engine oil level, top-up if necessary.
Switch - oil pressure
$% 12.60.50
Remove
1.Remove fixings and remove engine acoustic
cover.
2.Remove 3 bolts and remove exhaust manifold
heat shield.
3.Disconnect multiplug from oil pressure switch.
4.Position container below switch to catch oil
spillage.
5.Remove oil pressure switch from oil cooler
housing.

ENGINE - TD5
OVERHAUL 12-1-73
11.Ensure engine is set to TDC firing - No.1
cylinder.
12.Check that mark on camshaft sprocket is
positioned between the 2 coloured links on
timing chain.
13.Position sprocket to camshaft, fit and lightly
tighten 3 new bolts then loosen bolts half a
turn.
14.Clean fixed guide Allen screw and apply
Loctite 242 to screw threads.
15.Fit fixed timing chain guide Allen screw and
tighten to 25 Nm (18 lbf.ft).
16.Clean timing chain tensioner and fit new
sealing washer.
17.Fit timing chain tensioner and tighten to 45 Nm
(33 lbf.ft).
18.Tighten camshaft sprocket bolts to 37 Nm (27
lbf.ft).
19.Remove tool LRT-12-058 from camshaft.
20.Lubricate a new 'O' ring with engine oil and fit to
camshaft sprocket access plug.21.Fit camshaft sprocket access plug.
22.Clean alternator/vacuum pump oil hose union.
23.Lubricate a new 'O' ring with engine oil and fit to
alternator/vacuum pump oil hose union.
24.Fit and tighten alternator/vacuum pump oil
hose union to 10 Nm (7 lbf.ft).
25.Fit bolt securing alternator strap bracket to
cylinder head and tighten to 25 Nm (18 lbf.ft).
26.Connect multiplugs to ECT sensor and EUI's.
CAUTION: Following cylinder head
overhaul, it will be necessary, before fitting
the camshaft cover to adjust the fuel
injector rockers using the following
procedures:
27.Rotate engine clockwise until No.1 EUI lobe is
at full lift.
28.Tighten No.1 rocker adjusting screw until the
EUI plunger is felt to 'bottom out'.
29.Loosen rocker adjusting screw 1 complete turn
to give EUI plunger the required bump
clearance and tighten rocker adjusting screw
to 16 Nm (12 lbf.ft).
CAUTION: Ensure screw does not turn as
locknut is tightened.
30.Carry out the above procedures for the
remaining 4 rocker arms.
31.After completion of rocker adjustment, slowly
rotate engine clockwise 2 complete turns by
hand to ensure that no EUI's are bottoming out
on their plungers.
32.Clean camshaft cover and mating face.
33.Fit new sealing washers and isolators as
necessary to camshaft cover.
34.Fit new camshaft cover gasket to cover.
CAUTION: Gasket must be fitted dry.

ENGINE - TD5
12-1-92 OVERHAUL
9.Place a straight edge across pump body and
using feeler gauges, measure end-float of
outer rotor:
lOuter rotor end-float = 0.038 to 0.075 mm
(0.0001 to 0.003 in)
10.Check drive shaft bush in pump cover for signs
of scoring and wear.
11.Renew oil pump and stiffener plate assembly if
excessive scoring or wear exists.
12.Lubricate pump rotors and drive shaft bush with
engine oil.
13.Fit rotors ensuring reference marks are aligned
and identification mark on outer rotor is facing
outwards.
14.Fit cover to pump, fit 5 new screws and tighten
by diagonal selection to 6 Nm (4.5 lbf.ft).
15.Remove and discard oil pressure relief valve
plug.
16.Remove spring and relief valve plunger.
17.Clean valve plunger and spring.
18.Check valve plunger and relief valve bore for
scoring and corrosion, light scoring and
corrosion may be removed using grade 600
emery cloth soaked in oil.19.Check spring for distortion, check free length of
spring:
lSpring free length = 42.0 mm (1.65 in)
20.Lubricate valve plunger and seating.
21.Fit valve plunger and spring to oil pump.
22.Apply Loctite 243 sealant to threads of a new
plug. Do not attempt to fit original plug.
23.Fit plug and tighten to 23 Nm (17 lbf.ft).
Reassembly
1.Clean mating faces of oil pump, stiffener plate
assembly and cylinder block; ensure bolt and
dowel holes are clean and dry.
2.Lubricate a new 'O' ring with engine oil and fit to
oil pump housing outlet.
3.Position oil pump and stiffener plate assembly
on to cylinder block ensuring 2 dowels are
correctly located.
4.Fit new bolts and using sequence shown,
tighten to 13 Nm (10 lbf.ft).
5.Lubricate a new 'O' ring with engine oil and fit to
oil pick-up strainer.
6.Clean threads of oil pick-up strainer Torx
screws and apply Loctite 242 to screw
threads.
7.Fit oil pick-up strainer, fit Torx screws and
tighten to 10 Nm (8 lbf.ft).
8.Position oil pump drive sprocket to chain and oil
pump ensuring that the 'D' shape on the drive
sprocket is located on the flat on the oil pump
drive shaft.
9.Clean oil pump drive sprocket retaining bolt and
apply Loctite 242 to bolt threads.
10.Fit oil pump drive sprocket and tighten bolt to
25 Nm (18 lbf.ft).
11.Fit new sump gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- engine sump.

ENGINE - TD5
12-1-94 OVERHAUL
15.Remove bolt and remove timing chain
adjustable guide.
16.Remove bolt and remove timing chain
lubrication jet.
17.Using tool LRT-12-092, remove and discard oil
seal from timing cover.
Inspection
1.Clean all components.
2.Check condition of timing chain running
surfaces on adjustable and fixed guides.
CAUTION: Adjustable guide fitted to Engine
Serial No. Prefixes 15P to 19P may be fitted
to early engines provided that timing chain
tensioner having a YELLOW coloured body
is also fitted.
3.Check timing chains and sprockets for signs of
wear.
CAUTION: Timing chains and sprockets
fitted to Engine Serial No. Prefixes 15P to
19P may be fitted to early engines as an
assembly only, oil pump drive sprockets are
interchangeable. Later timing chains have
BRONZE coloured timing links.
4.Check that drilling in timing chain lubrication jet
is clear.
5.Clean oil seal recess in timing cover and oil seal
running surface on crankshaft.
6.Remove all traces of sealant from mating faces
of timing cover and cylinder block using
suitable solvent.
CAUTION: Do not use metal scrapers.
7.Ensure bolt and dowel holes are clean and dry.
8.Clean oil pump sprocket bolt threads.Reassembly
1.Fit timing chain lubrication jet.
2.Fit timing chain lubrication jet Torx screw and
tighten to 10 Nm (7 lbf.ft).
3.If crankshaft has been rotated, check that No.1
piston is at TDC using the following
procedures:
4.Temporarily fit and lightly tighten a new
crankshaft pulley bolt.
5.Assemble a magnetic base DTI to cylinder
block top face, position stylus to cylinder block
face and zero gauge.
6.Using crankshaft pulley bolt, rotate crankshaft
clockwise until No.1 piston is at top of its stroke
and woodruff key slot in crankshaft is at 12
o'clock position.
7.Position stylus of DTI to No.1 piston crown and
rotate crankshaft until highest reading is
indicated on DTI.
8.Check that Woodruff key slot is still at 12
o'clock position indicating No.1 piston is at
TDC firing.
9.Remove DTI.
10.Remove and retain crankshaft pulley bolt.
11.Fit Woodruff key to crankshaft.
12.Fit oil pump drive chain to rear row of teeth on
crankshaft sprocket - i.e. teeth furthest away
from timing mark on sprocket.
13.Fit sprocket to crankshaft ensuring that timing
mark on sprocket is facing towards front end of
crankshaft.
14.Fit oil pump drive sprocket to oil pump and drive
chain ensuring that 'D' shape on sprocket is
located on flat on oil pump drive shaft.