2002 LAND ROVER DISCOVERY charging

ENGINE MANAGEMENT SYSTEM - V8
18-2-74 REPAIRS
5.Disconnect multiplug from ECT sensor.
6.Remove sensor from inlet manifold and discard
sealing washer.
Refit
1.Clean sealant from threads in manifold.
2.Apply Loctite 577 to sensor threads.
3.Fit new sealing washer to ECT sensor and
tighten sensor to 10 Nm (7 lbf.ft).
4.Connect multiplug to ECT sensor.
5.Position alternator, fit bolts and tighten to 45
Nm (33 lbf.ft).
6.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
7.Top up cooling system.
8.Connect battery earth lead.
9.Fit battery cover and secure with fixings.
Sensor - crankshaft position (CKP)
$% 18.30.12
Remove
1.Release fixings 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.Release fixings and remove underbelly panel.
5.Release CKP sensor multiplug from bracket.
6.Remove 2 bolts securing CKP sensor heat
shield and position aside.
7.Remove 2 nuts securing CKP sensor, remove
2 spacers, CKP sensor and sensor mounting.
8.Disconnect CKP sensor multiplug from engine
harness.
Refit
1.Ensure all components are clean.
2.Connect CKP sensor multiplug to engine
harness.
3.Fit sensor mounting, CKP sensor, 2 spacers
and tighten CKP sensor retaining nuts to 6 Nm
(5 lbf.ft).

COOLING SYSTEM - V8
26-2-18 REPAIRS
Thermostat
$% 26.45.09
Remove
1.Drain cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
2.Remove viscous fan.

+ COOLING SYSTEM - V8, REPAIRS,
Fan - viscous.
3.Release 3 clips and disconnect coolant hoses
from thermostat.
4.Remove thermostat.
Refit
1.Position thermostat, connect hoses and secure
with clips.
2.Fit viscous fan.

+ COOLING SYSTEM - V8, REPAIRS,
Fan - viscous.
3.Refill cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
Gasket - coolant pump
$% 26.50.02
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Drain cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
3.Remove 3 bolts securing pulley to coolant
pump and remove pulley.
4.Release clip and disconnect feed hose from
coolant pump.

COOLING SYSTEM - V8
REPAIRS 26-2-19
5.Remove 9 bolts securing coolant pump,
remove pump and discard gasket. Refit
1.Clean coolant pump and mating face.
2.Fit new gasket and coolant pump to cylinder
block. Fit bolts and tighten to 24 Nm (18 lbf.ft).
3.Connect feed hose to coolant pump and secure
with clip.
4.Ensure mating faces of coolant pump pulley
and flange are clean. Fit pulley and tighten
bolts to 22 Nm (16 lbf.ft).
5.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
6.Refill cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.

MANIFOLDS AND EXHAUST SYSTEMS - TD5
30-1-8 REPAIRS
Gasket - exhaust manifold
$% 30.15.12
Remove
Note: The following procedure covers engines
fitted with or without an EGR cooler. The EGR
cooler is bolted to the front of the cylinder head.
1.Remove turbocharger.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Turbocharger.
2. Models with air conditioning: Remove
auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
3. Models with air conditioning: Remove 4 bolts
securing compressor and move to one side.
4.Remove and discard 2 Allen screws securing
EGR pipe to exhaust manifold.
Note: Engine with EGR cooler illustrated.5.Remove 10 nuts securing exhaust manifold to
cylinder head.
6.Remove exhaust manifold and gasket.
Refit
1.Clean exhaust manifold and mating faces.
2.Fit new gasket.Fit exhaust manifold and,
working from the centre outwards, tighten nuts
to 25 Nm (18 lbf.ft) .
3. Models with air conditioning:
Positioncompressor and tighten bolts to 25 Nm
(18 lbf.ft).
4.Position EGR valve pipe, fit new Allen screws
and tighten to 9 Nm (7 lbf.ft).
5.Fit turbocharger.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Turbocharger.
6. Models with air conditioning: Fit auxiliary
drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.

MANIFOLDS AND EXHAUST SYSTEMS - V8
30-2-12 REPAIRS
Heat shield - brake servo - With
Secondary Air Injection
$% 30.10.48
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove nut securing heat shield bracket to
valance.
4.Remove 2 bolts securing heat shield and
remove heat shield.
Refit
1.Fit heat shield, tightening bolts to 25 Nm (18
lbf.ft) and nut to 10 Nm (7 lbf.ft).
2.Connect battery earth lead.
3.Fit battery cover and secure with fixings.
Gasket - inlet manifold - lower
$% 30.15.08
Remove
1.Remove both rocker covers.
l

+ ENGINE - V8, REPAIRS, Gasket
- rocker cover - LH.
l

+ ENGINE - V8, REPAIRS, Gasket
- rocker cover - RH.
2.Release and disconnect LH injector harness
and multiplugs.
3.Release 3 clips securing top hose and remove
top hose.
4.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.

MANIFOLDS AND EXHAUST SYSTEMS - V8
REPAIRS 30-2-15
Refit
1.Clean old RTV sealant from cylinder head and
cylinder block notches.
2.Clean mating faces of cylinder block, cylinder
head and inlet manifold.
3.Apply RTV sealant to cylinder head and
cylinder block notches.
4.Fit new gasket seals, ensuring ends engage
correctly in notches.
5.Fit new inlet manifold gasket.
6.Position gasket clamps and fit bolts, but do not
tighten at this stage.
7.Position inlet manifold to engine. Fit manifold
bolts and, working in the sequence shown,
tighten bolts initially to 10 Nm (7 lbf.ft) then to
51 Nm (38 lbf.ft).
8.Tighten gasket clamp bolts to 18 Nm (13 lbf.ft).
9.Connect fuel pipe.
10.Clean top hose outlet pipe mating faces.
11.Fit new 'O' ring to outlet pipe.
12.Position outlet pipe, fit bolts and tighten to 22
Nm (16 lbf.ft).
13.Position alternator, fit bolts and tighten to 45
Nm (33 lbf.ft).
14.Position PAS pump to auxiliary housing and
locate housing on engine. Fit bolts and tighten
to 40 Nm (30 lbf.ft).
15.Fit and tighten auxiliary housing nut to 10 Nm (7
lbf.ft).
16.Fit bolts securing PAS pump and tighten to 22
Nm (16 lbf.ft). 17.Position oil cooling pipe bracket fit bolt and
tighten to 22 Nm (16 lbf.ft).
18.Fit and tighten PAS pump high pressure pipe.
19.Position jockey pulley and tighten bolt to 50 Nm
(37 lbf.ft).
20.Clean PAS pump pulley mating faces.
21.Position PAS pump pulley, fit bolts and tighten
to 22 Nm (16 lbf.ft).
22.Clean ACE pump dowels and dowel holes.
23.Position ACE pump, fit bolts and tighten to 22
Nm (16 lbf.ft).
24.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
25.Secure injector harness and connect injector
multiplugs.
26.Position top hose and secure clips.
27.Fit rocker covers.
l

+ ENGINE - V8, REPAIRS, Gasket
- rocker cover - LH.
l

+ ENGINE - V8, REPAIRS, Gasket
- rocker cover - RH.
28.Check and top up PAS fluid

MANUAL GEARBOX - R380
37-16 REPAIRS
Gearbox - Diesel
$% 37.20.02.99
Remove
1.Release turn buckles and remove battery cover
and cooling fan cowl.
2.Disconnect battery earth lead.
3.Remove gear lever knob and gear lever trim.
4.Remove clamp bolt and remove gear lever
extension.
5.Apply a little lubricant to gear lever to aid
removal through grommet.
6.Remove exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.7.Remove starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
8.Drain gearbox oil.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.
9.Drain transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
10.Remove 3 nuts securing intermediate silencer
to tail pipe.
11.Release silencer from mounting rubbers,
remove silencer and discard gasket.
12.Remove front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
13.Remove rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.

MANUAL GEARBOX - R380
REPAIRS 37-19
32.Remove 8 bolts securing gearbox to engine.
33.With assistance, remove gearbox from engine.
Refit
1.Clean gearbox to engine mating faces, dowels
and dowel holes.
2.With assistance raise gearbox on jack and
align to clutch and engine.
3.Fit bolts securing gearbox to engine and
tighten to 50 Nm (37 lbf.ft).
4.Clean oil cooling pipe housing mating faces.
5.Lubricate and fit new 'O' rings to oil cooling
pipe housing.
6.Position cooling pipe housing, fit bolts and
tighten to 25 Nm (18 lbf.ft).
7. If fitted: Secure harness in retaining clips,
connect Lucars to differential lock warning
switch and multiplug to transfer box neutral
switch.
8.Position breather pipes and secure 'P' clip with
bolt.
9.Using new sealing washers fit breather pipe
banjo bolts and tighten to 15 Nm (11 lbf.ft).
10.Connect oil temperature sensor Lucars and
reverse lamp switch multiplug.
11.Position low ratio selector cable to housing and
secure with 'C' washer and clevis pin.
12.Secure cable to fuel pipes with new cable ties. 13.Raise gearbox, ensuring gear change lever is
located in grommet.
14.Fit gearbox mountings and tighten bolts to 85
Nm (63 lbf.ft).
15.Fit nuts to gearbox mountings and tighten to 48
Nm (37 lbf.ft).
16.Remove 3 bolts securing support plate to
gearbox.
17.Position clutch slave cylinder and heat shield,
fit bolts and tighten to 25 Nm (18 lbf.ft).
18.Clean handbrake back plate and mating face.
19.Position handbrake back plate, fit bolts and
tighten to 75 Nm (55 lbf.ft).
20.Clean handbrake drum.
21.Fit handbrake drum and tighten retaining
screw.
22.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front..
23.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
24.Clean exhaust silencer and tail pipe mating
faces.
25.Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).
26.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
27.Refit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
28.Refill gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.
29.Refill transfer gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
30.Fit gear lever extension, fit clamp bolt and
tighten to 25 Nm (18 lbf.ft).
31.Fit gear lever trim and gear change knob.
32.Connect battery earth lead.
33.Fit cooling fan cowl and battery cover and
secure fixings.