2002 LAND ROVER DISCOVERY bonnet

TORQUE WRENCH SETTINGS
06-14
Body
TORQUE DESCRIPTION METRIC IMPERIAL
Front and rear door hinges 30 Nm (22 lbf.ft)
Tail door hinge bolts 34 Nm (25 lbf.ft)
Door frames10 Nm (7 lbf.ft)
Regulator to glass 6 Nm (4.4 lbf.ft)
Chassis cross member 25 Nm (18 lbf.ft)
Bulkhead to chassis bolts 45 Nm (33 lbf.ft)
Body to chassis bolts 45 Nm (33 lbf.ft)
Quarter light glass to frame 10 Nm (7 lbf.ft)
Glass lift motor to regulator 5 Nm (3.7 lbf.ft)
Tail door hand rail 10 Nm (7 lbf.ft)
Latch and motor assembly 7 Nm (5.2 lbf.ft)
Door handle7 Nm (5.2 lbf.ft)
Damper to step17 Nm (13 lbf.ft)
Throttle pedal assembly 13 Nm (10 lbf.ft)
Step assembly to chassis 45 Nm (33 lbf.ft)
Wing to sill finisher bracket 17 Nm (13 lbf.ft)
Front wing to body 17 Nm (13 lbf.ft)
Door mirror4 Nm (3 lbf.ft)
Roof bars32 Nm (24 lbf.ft)
Bonnet release lever 10 Nm (7 lbf.ft)
Front bumper to crash cans 13 Nm (10 lbf.ft)
Front bumper to side mountings 13 Nm (10 lbf.ft)
Mudshield10 Nm (7 lbf.ft)
Rear bumper45 Nm (33 lbf.ft)
Grab handle to body 3 Nm (2.2 lbf.ft)
Fascia26 Nm (19 lbf.ft)
Fascia to steering column bracket 11 Nm (8 lbf.ft)
Front seat to floor 45 Nm (33 lbf.ft)
Second row seats to floor 45 Nm (33 lbf.ft)
Third row seats to lower rear quarter 22 Nm (16 lbf.ft)
Sunroof tray to frame 2 Nm (1.5 lbf.ft)
Solenoid securing cap 11 Nm (8 lbf.ft)
Support stay to alternator 25 Nm (18 lbf.ft)
Sunroof glass3 Nm (2.2 lbf.ft)
Motor to sunroof tray 2 Nm (1.5 lbf.ft)
Drive cable assembly to frame 2.5 Nm (1.8 lbf.ft)
Front and rear door striker bolts 26 Nm (19 lbf.ft)
Tail door striker bolts 26 Nm (19 lbf.ft)

CAPACITIES, FLUIDS AND LUBRICANTS
09-4
Engine oil - V8 - high compression engine
Use a 5W/30 oil meeting specification ACEA: A1,
(API SJ or ILSAC GF2 for USA).
NOTE: ACEA: A2 can be used.
Engine oil - Td5
Use oil meeting specification ACEA: A1, B1 or B2.
Gearbox oil
Use of gearbox oils other than those specified may
result in serious damage to the gearbox,
Manual Gearbox
Use Texaco MTF 94 oil for refill and topping-up. If
MTF 94 is not available, ATF Dexron IID or ATF
Dexron III may be used.
Automatic Gearbox
Use ATF Dexron IID or Dexron III oil for refill or
topping-up.
Transfer box
Use Texaco Multi-Gear 75W/90R.
Front and rear axles
Use Texaco Multi-Gear 75W/90R.
Air Conditioning
Use lubricating oil Nippon Denso ND-8.
General Greasing
Use Multipurpose Lithium Base Grease N.L.G.I.
consistency No. 2.
Bonnet latch
Lubricate cable and latch with oil.
Locks, Latches and Hinges
Use Door Lock and Latch Lubricant, Part No. VWN
10075.

MAINTENANCE
PROCEDURES 10-1
MAINTENANCE PROCEDURES
V8 engine underbonnet view
1Brake/clutch fluid reservoir filler caps
2Engine oil filler cap
3Spark plug
4Engine oil dipstick
5Coolant header tank
6Battery
7Auxiliary drive belt
8ACE/PAS fluid reservoirs
9Windscreen washer reservoir

MAINTENANCE
10-2 PROCEDURES
Diesel underbonnet view
1Coolant header tank
2Brake/clutch fluid reservoir filler caps
3Engine oil dipstick
4Engine oil filler cap
5ACE/PAS fluid reservoirs
6Battery
7Auxiliary drive belt
8Air cleaner
9Windscreen washer reservoir

MAINTENANCE
PROCEDURES 10-9
Doors, bonnet and fuel filler flap
Check
1.Check operation of each door, door lock,
bonnet catch and fuel filler flap. Ensure doors
close securely.
Lubricate
1.Lubricate door locks, hinges, check straps,
bonnet catch and fuel filler flap.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
Air suspension intake filter
Check
1.Check condition of filter and that filter is clean,
replace if necessary.

+ REAR SUSPENSION, REPAIRS,
Filter - intake - SLS.
Anti-freeze
Replace
1.Replace anti-freeze.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
Cooling system
Check
1.Check cooling, intercooler and heating systems
for leaks; hoses and oil pipes for security and
condition.
2.Check accessible hose clips for tightness.
3.Check coolant level, top-up if necessary.
Top-up
1.With engine cold, remove expansion tank filler
cap.
2.Top-up with recommended mixture of coolant
until level reaches mark on expansion tank.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Anti-Freeze Concentration.
3.Fit expansion tank filler cap.

ENGINE - TD5
REPAIRS 12-1-39
Gasket - cylinder head
$% 12.29.02
Remove
Note: The following procedures cover engines
fitted with or without an EGR cooler. The EGR
cooler is bolted to the front of the cylinder head.
1.Remove bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.
2.Release turnbuckles and remove battery cover.
3.Disconnect battery earth lead.
4.Drain cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
5.Remove camshaft cover gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
cover - camshaft.
6.Remove cooling fan coupling.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
7.Remove 3 bolts and remove exhaust manifold
heat shield. 8.Remove turbocharger oil feed banjo bolt and
discard sealing washers.
9.Remove 3 nuts, release turbocharger from
exhaust manifold, discard gasket and tie
turbocharger aside.
10.Disconnect multiplugs from compressor, MAF
sensor, turbocharger wastegate modulator,
and AAP & IAT sensor.
11.Remove 2 bolts securing engine harness to
camshaft carrier.
12.Disconnect multiplug from EUI's and coolant
temperature sensor.

ENGINE - TD5
REPAIRS 12-1-43
11.Clean camshaft sprocket and mating face on
camshaft.
12.Ensure engine is set to TDC No. 1 cylinder and
mark on camshaft sprocket is positioned
between the 2 coloured links.
13.Position camshaft sprocket to camshaft; fit and
lightly tighten new bolts, then loosen bolts half
a turn.
14.Clean timing chain fixed guide retaining pin and
apply Loctite 242 to threads.
15.Fit timing chain fixed guide retaining pin 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
(22 lbf.ft).
18.Tighten bolts securing camshaft sprocket to
camshaft to 37 Nm (27 lbf.ft).
19.Remove tool LRT-12-058 from camshaft.
20.Remove tool LRT-12-158 from gearbox bell
housing.
21.Fit new camshaft bore blanking plug and 'O'-
ring seal in recess in cylinder head.
22.Clean vacuum pump union.
23.Tighten union securing vacuum pump oil feed
pipe to cylinder head to 10 Nm (7 lbf.ft) .
24.Fit bolts securing alternator support bracket to
cylinder head and tighten to 25 Nm (18 lbf.ft) .
25.Connect top hose and heater hoses and secure
with clips.
26. Pre EU3 model:Fit bolt securing EGR pipe
clamp to cylinder head bolt and tighten to 10
Nm (7 lbf.ft) .
27. EU3 model: Connect coolant hoses to EGR
cooler and secure with the clips.
28.Position air intake hose to EGR valve and
tighten clip screw.
29.Disconnect fuel hose from connector block and
connect to fuel cooler.
30.Connect fuel hoses to fuel cooler and
connector block on cylinder head.
31.Connect coolant hoses to fuel cooler and
secure clips.
32.Connect vacuum hose to EGR valve.
33.Position engine harness and connect multi
plugs and glow plug connectors.
34.Fit and tighten bolts, engine harness to
camshaft carrier.
35.Clean exhaust manifold and turbocharger
interface.
36.Fit new gasket to exhaust manifold, position
turbocharger and tighten – nuts securing
turbocharger to manifold to 30 Nm (22 lbf.ft).
37.Clean turbocharger oil feed hose bolt.
38.Position turbocharger oil feed hose using new
sealing washers. Fit banjo bolt securing
turbocharger oil feed hose and tighten to 25 Nm
(18 lbf.ft) . 39.Position exhaust manifold heatshield and
tighten M6 bolts to 9 Nm (7 lbf.ft) and M8 bolt to
25 Nm (18 lbf.ft).
40.Fit cooling fan coupling.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
41.Fit camshaft cover with new seal.

+ ENGINE - Td5, REPAIRS, Gasket -
cover - camshaft.
42.Refill cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
43.Connect battery earth lead.
44.Fit battery cover and secure fixings.
45.Fit bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.

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.