2002 LAND ROVER DISCOVERY torque

MAINTENANCE
10-24 PROCEDURES
1.Check/tighten front suspension LH radius arm
fixings.

+ TORQUE WRENCH SETTINGS,
Front suspension.
2.Check/tighten front suspension RH radius arm
fixings.3.Check/tighten front suspension Panhard rod
fixings
Check rear axle suspension fixings

MAINTENANCE
PROCEDURES 10-25
1.Check and tighten if necessary all rear axle
suspension fixings.

+ TORQUE WRENCH SETTINGS, Rear
suspension.
Steering rod ball joints
Check
1.Check condition of ball joints and dust covers,
and security of fixings.

+ TORQUE WRENCH SETTINGS,
Steering.
Dampers and SLS height sensors
Check – Dampers
Front dampers
Rear dampers
1.Check dampers for security and signs of
leakage.

MAINTENANCE
PROCEDURES 10-27
2.Check security of fixings.

+ TORQUE WRENCH SETTINGS,
Front suspension.

+ TORQUE WRENCH SETTINGS, Rear
suspension.
Towing bracket
Check
1.Check security of towing bracket.
Engine mountings - V8 engine
Check for security and condition
1.Check condition of Transfer box - RH mounting
rubber.
2.Check condition of Transfer box - LH mounting
rubber.
3.Check condition of Engine - LH mounting
rubber.

MAINTENANCE
10-28 PROCEDURES
4.Check condition of Engine - RH mounting
rubber
5.Check tightness of all mounting bolts.

+ TORQUE WRENCH SETTINGS,
Engine V8.
Road/roller test
WARNING: Roller test must be restricted to 3
mph (5 km/h). If 2 wheel rolling road is to be used,
disconnect propeller shaft from the transfer box
output shaft driving the axle which is NOT on the
rolling road.Testing
1. 2 wheel rolling road: Engage differential lock
using a 10 mm open ended spanner on flats
machined on differential lock selector
shaft.Switch on ignition and check that the
differential lock, electronic brake
distribution and hill descent warning lamps
are illuminated.
2.Check for correct operation of starter switch,
ensure engine starts correctly; leave the engine
running.
3.Check for correct operation of starter switch,
ensure engine starts correctly; leave the engine
running.
4.With vehicle stationary, turn steering from lock
to lock. Check for smooth operation and ensure
there is no undue noise from power steering
pump or drive belt.
5.Depress clutch and select all gears in turn,
check for smooth, notch free engagement.
6. Check all vehicle systems for correct
operation.
7.Check for unusual engine, gearbox and
suspension noises.
8.Check braking system operation.
9.Check for smooth gear engagement.
10.Check engine performance.
11.Check operation of all instruments and warning
devices where practicable.

ENGINE - TD5
REPAIRS 12-1-37
REPAIRS
Pulley - crankshaft
$% 12.21.01
Remove
1.Remove fixings and underbelly panel.
2.Remove radiator.

+ COOLING SYSTEM - Td5, REPAIRS,
Radiator.
3.Using a 15 mm ring spanner, release the
auxiliary drive belt tensioner.
4.Remove auxiliary drive belt.
5.Remove 3 bolts and remove crankshaft TV
damper.
6.Position tool LRT-51-003 to crankshaft pulley
and secure with 2 bolts.
7.Remove and discard crankshaft pulley bolt.
Remove crankshaft pulley.
8.Remove 2 bolts and remove tool LRT-51-003
Refit
1.Position new crankshaft pulley to vice.
2.Remove 3 bolts and remove TV damper from
new crankshaft pulley.
3.Using a lint free cloth, thoroughly clean oil seal
recess and the running surface on crankshaft
pulley.
4.Fit crankshaft pulley. 5.Fit tool LRT-51-003 to crankshaft pulley and
secure with 2 bolts.
6.Fit new crankshaft pulley bolt and tighten to
460 Nm (340 lbf.ft), using a torque multiplier.
7.Remove 2 bolts and remove tool LRT-51-003
from crankshaft pulley.
8.Fit TV damper to crankshaft pulley and tighten
– TV damper bolts to 80 Nm (59 lbf.ft) .
9.Fit auxiliary drive belt to pulleys.
10.Fit radiator.

+ COOLING SYSTEM - Td5, REPAIRS,
Radiator.
11.Fit underbelly panel and secure with fixings.

ENGINE - TD5
12-1-50 REPAIRS
32.Release clip and disconnect hose from coolant
pump.
33.Release clip and disconnect heater hose from
coolant rail.
34.Remove bolt securing coolant rail to front
chassis member.
35.Raise vehicle on ramp.
36.Release coolant rail support brackets from
engine LH and RH mounting brackets.
37.Remove coolant rail.
38.Remove starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.39.Remove and discard 3 bolts securing torque
converter to drive plate.
40.Remove 2 bolts securing gearbox oil cooler
pipe clips from sump and alternator mounting
bracket.
41.Mark position of gearbox oil cooler pipe
clamps.
42.Remove 3 nuts and remove oil cooler pipe
clamps.
43.Loosen RH oil cooler pipe union.
44.Move pipes aside and tighten RH pipe union.

ENGINE - TD5
REPAIRS 12-1-51
45.Remove 8 bolts and remove front cross
member.
46.Remove 6 bolts securing gearbox housing to
engine.
47.Remove 4 bolts and nuts securing RH and LH
front engine mountings to chassis.
48.Lower vehicle ramp. 49.Remove 2 upper bolts securing gearbox
housing and oil cooler coolant pipe to engine.
50.Release clip, disconnect hose from engine oil
cooler and move aside.
51.Remove bolt securing engine closing panel to
gearbox.
52.Fit tool LRT-12-138 to lifting chains and
connect to lifting eyes on engine.
53.Remove 2 nuts from RH and LH front engine
mountings.
54.Position trolley jack to support gearbox.
55.With assistance, raise chains, remove engine
from vehicle and lower onto bench.
Refit
1.With assistance, raise engine from bench and
position in vehicle.
2.With assistance, align engine to gearbox and
torque converter.
3.Position engine RH and LH mountings to
brackets and fit nuts.
4.Position engine oil cooler pipe, connect hose to
oil cooler and secure with clip.

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.