2002 LAND ROVER DISCOVERY earth

ENGINE - TD5
12-1-54 REPAIRS
Mounting - front - RH
$% 12.45.03
Remove
1.Remove fixings and remove engine acoustic
cover.
2.Release fixings and remove battery cover.
3.Disconnect battery earth lead.
4.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.
5.Remove 4 bolts and move fuel cooler to one
side.
6.Fit suitable lifting chains to support engine.
7.With assistance remove 2 bolts securing
engine mounting to chassis.
8.Remove 4 bolts securing engine mounting
bracket to cylinder block.
9.Remove nut securing mounting to mounting
bracket.
10.Remove mounting and mounting bracket. Refit
1.Fit mounting and mounting bracket.
2.Fit front RH engine mounting bracket to
cylinder block and tighten bolts to 48 Nm (35
lbf.ft).
3.With assistance, fit front RH mounting to
chassis and tighten bolts to 85 Nm (63 lbf.ft).
4.Fit front RH mounting to mounting bracket and
tighten nut to 85 Nm (63 lbf.ft).
5.Remove engine support chains.
6.Position Fuel cooler to inlet manifold and
tighten bolts to 25 Nm (18 lbf.ft).
7.Remove stand(s) and lower vehicle.
8.Connect battery earth lead.
9.Fit battery cover and secure with fixings.
10.Fit engine acoustic cover and secure with
fixings.

ENGINE - TD5
12-1-60 REPAIRS
Gasket - sump
$% 12.60.38
Remove
1.Remove battery cover.
2.Disconnect battery earth lead.
3.Remove exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
4.Drain engine oil.
5.Remove 2 bolts securing Active Cornering
Enhancement (ACE) pipes to front cross
member.
6.Remove bolt securing coolant pipe to front
cross member.
7.Remove bolt securing automatic gearbox oil
cooler pipe clip.
8.Remove 4 bolts securing sump to gearbox bell
housing. 9.Remove 2 bolts securing centrifuge drain pipe
to sump and discard gasket.
10.Using sequence shown and noting their
different lengths, remove 20 bolts securing
sump to engine.
11.Manoeuvre sump from beneath engine,
remove sump and discard gasket.

ENGINE - TD5
REPAIRS 12-1-61
Refit
1.Clean sump and mating faces.
2.Apply sealant, Part No. STC 3254 to joint faces
of timing chain cover and crankshaft rear oil
seal housing.
CAUTION: Assembly and bolt tightening
must be completed within 20 minutes of
applying sealant.
3.Position new gasket.
CAUTION: Gasket must be fitted dry.
4.Position sump and, noting the positions of the
longer bolts, fit and lightly tighten bolts.
5.Fit and lightly tighten bolts securing sump to
gearbox bell housing. 6.Working in the sequence shown, tighten bolts
securing sump to 25 Nm (18 lbf.ft).
7.Tighten – sump to gearbox bell housing bolts
to 13 Nm (10 lbf.ft).
8.Fit new gasket to centrifuge drain pipe, fit to
sump and tighten bolts to 10 Nm (7 lbf.ft ) .
CAUTION: Gasket must be fitted dry.
9.Fit bolts securing oil cooler pipe to sump and
tighten to 9 Nm (7 lbf.ft).
10.Fit and tighten bolt securing coolant pipe to
cross member.
11.Fit and tighten bolts securing ACE pipes to front
cross member.
12.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
13.Refill engine with oil.
14.Connect battery earth lead.
15.Refit battery cover and secure fixings.

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
12-2-22 REPAIRS
Mounting - front - LH
$% 12.45.01
Remove
1.Release turnbuckles and remove battery cover.
2.Disconnect battery earth lead.
3.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.
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Position a jack beneath the sump, and support
the engine on the jack.
CAUTION: To prevent damage to
components, cushion the jack pad with a
block of wood or hard rubber.
6.Remove 2 nuts securing engine mountings to
chassis.
7.Remove nut securing LH mounting to cylinder
block.
8.Raise engine sufficiently to allow engine
mounting to be removed, take care not to trap
any cables, pipes or harness.
9.Remove engine mounting. Collect heat shield,
if fitted.Refit
1.Fit heat shield to engine mounting, if fitted.
2.Fit engine mounting ensuring dowel is located.
3.Lower the jack and engage engine mounting
studs in chassis.
4.Fit nuts securing LH engine mounting and
tighten to 85 Nm (63 lbf.ft).
5.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Remove stand(s) and lower vehicle.
7.Connect battery earth lead.
8.Fit battery cover and secure turnbuckles.

ENGINE - V8
REPAIRS 12-2-23
Mounting - front - RH
$% 12.45.03
Remove
1.Release turnbuckles and remove battery cover.
2.Disconnect battery earth lead.
3.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.
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Position a jack beneath the sump, and support
the engine on the jack.
CAUTION: To prevent damage to
components, cushion the jack pad with a
block of wood or hard rubber.
6.Remove 2 nuts securing engine mountings to
chassis.
7.Remove nut securing RH mounting to cylinder
block.
8.Raise engine sufficiently to allow engine
mounting to be removed. Take care not to trap
any cables, pipes or harness.
9.Remove engine mounting.
10.Collect heat shield. Refit
1.Position heat shield.
2.Fit engine mounting ensuring dowel is located.
3.Lower the jack and engage engine mounting
studs in chassis.
4.Fit engine mounting nuts and tighten to 85 Nm
(63 lbf.ft).
5.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Remove stand(s) and lower vehicle.
7.Connect battery earth lead.
8.Fit battery cover and secure turnbuckles.

ENGINE - V8
REPAIRS 12-2-27
11.Remove bolt securing oil cooling pipes to PAS
pump housing and remove saddle clamp.
12.Release PAS pump high and low pressure
pipes and position aside.
CAUTION: Always fit plugs to open
connections to prevent contamination.
13.Release clips securing hose to coolant pump
and coolant rail, release hose and position
aside.
14.Release 2 harness clips from coolant rail.
15.Remove bolt securing coolant rail and position
rail aside. 16.Remove bolt securing engine earth lead and
position earth lead aside.
17.Remove nut securing engine harness positive
lead to battery, release lead and position
aside.
18.Release clips and remove fuse box cover.
19.Remove bolt securing starter lead to fuse box,
release lead and position aside.
20.Disconnect 2 engine harness multiplugs from
fuse box.