2002 LAND ROVER DISCOVERY service

ENGINE MANAGEMENT SYSTEM - V8
DESCRIPTION AND OPERATION 18-2-39
Hill Decent Control (HDC)
Refer to Brakes for description of the hill descent control.

+ BRAKES, DESCRIPTION AND OPERATION, Description.
High/Low ratio switch
Refer to Transfer Box for description of the high/ low ratio switch transfer box components.

+ TRANSFER BOX - LT230SE, DESCRIPTION AND OPERATION, Description.
Malfunction Indicator Lamp (MIL)/ service engine soon warning lamp
The MIL/ service engine soon warning lamp is located in the instrument cluster. It illuminates to alert the driver to
system malfunctions. Service engine soon warning lamp is the name for this warning lamp in NAS only, it is called
MIL in all other markets.
During ignition a self-test function of the lamp is carried out. The lamp will illuminate for 3 seconds then it will
extinguish if no faults exist.

+ INSTRUMENTS, DESCRIPTION AND OPERATION, Description.
Input/Output
The MIL is supplied with battery voltage from the instrument cluster. When the ECM detects a fault, it provides an
earth path to illuminate the MIL. Output to the MIL is via pin 20 of connector C0637 of the ECM.

FUEL DELIVERY SYSTEM - V8
DESCRIPTION AND OPERATION 19-2-7
The fuel pump is a 'self priming' wet type pump which is immersed in fuel in the tank. The fuel pump operates at all
times when the ignition switch is in position II. If the engine is not started, the ECU will 'time-out' after 2 seconds and
de-energise the fuel pump relay to protect the pump. The pump receives a feed from the battery via fuse 10 in the
engine compartment fusebox and the fuel pump relay. The relay is energised by the ECM when the ignition switch is
moved to position II.
The fuel pump is retained with a locking ring and sealed with a rubber seal. The locking ring requires a special tool
for removal and fitment. An access panel for the fuel pump is located in the loadspace floor below the loadspace
carpet. The access panel is sealed to the floor with a rubber seal and retained by six self-tapping screws.
The fuel gauge sender is integral with the fuel pump. The sender is submerged in the fuel and is operated by a float
which moves with the fuel level in the tank.
Fuel pump
The fuel pump assembly comprises a top cover which locates the fuel pressure regulator, electrical connector and
fuel pipe coupling. The top cover is attached to a plastic cup shaped housing by two metal springs. The housing
locates the pump and the fuel gauge sender unit.
The lower part of the housing is the swirl pot, which maintains a constant fuel level at the fuel pick-up. A feed pipe
from the pump to the coupling connection and a return pipe from the regulator connect between the top cover and the
housing.
A coarse filter is attached to the base of the housing and prevents the ingress of large contaminants into the swirl pot.
A gauze filter prevents particles entering the fuel pump.
Surrounding the pump is a large fine paper filter element which further protects the fuel pressure regulator, engine
and injectors from particulate contamination. The paper filter is not a serviceable item and removes the requirement
for an external in-line filter.
A non-return valve is located in the base of the housing. When the fuel tank is full, fuel pressure keeps the valve lifted
from its seat allowing fuel to flow into the swirl pot. As the tank level reduces, the fuel pressure in the tank reduces
causing the valve to close. When the valve is closed fuel is retained in the swirl pot, ensuring that the swirl pot remains
full and maintains a constant supply to the fuel pump.
A four pin electrical connector is located on the top cover of the pump and provides power feed and return for fuel
pump and fuel gauge rotary potentiometer operation. A single quick release coupling connects the fuel feed pipe to
the outer top surface of the pump.
Two metal springs are attached to the top cover and the housing of the pump. When the pump is installed it seats on
the lower surface inside the tank. The springs exert a downward pressure on the pump and ensure that the pump is
located positively at the bottom of the fuel tank.
The fuel pump has a maximum current draw of 6.5 A at 12.5 V.
On NAS vehicles with vacuum type EVAP system leak detection capability only, the fuel pump top cover is fitted with
an On Board Diagnostics (OBD) pressure sensor. This sensor has a three pin electrical connector which provides a
connection between the sensor and the ECM. The sensor is sealed in the top cover with an 'O' ring and secured with
a clip. The sensor monitors tank pressure during OBD tests of the fuel evaporation system integrity. A hose is
connected to the sensor and is routed across the top of the fuel tank and terminates at the top of the fuel filler tube.
The pipe is open to atmosphere and provides atmospheric pressure for the sensor operation.

+ ENGINE MANAGEMENT SYSTEM - V8, DESCRIPTION AND OPERATION, Description - engine
management.

CLUTCH - TD5
33-1-6 DESCRIPTION AND OPERATION
Description
General
The clutch system is a diaphragm type clutch operated by a hydraulic cylinder. The drive plate is of the rigid centre
type with no integral damping springs. The flywheel is of the dual mass type with damping springs integral with the
flywheel. The clutch requires no adjustment to compensate for wear.
Hydraulic clutch
The hydraulic clutch comprises a master cylinder, slave cylinder and a hydraulic reservoir. The master and slave
cylinders are connected to each other hydraulically by plastic and metal pipes. The plastic section of the pipe allows
ease of pipe routing and also absorbs engine movements and vibrations.
The master cylinder comprises a body with a central bore. Two ports in the body connect the bore to the hydraulic
feed pipe to the slave cylinder and the fluid reservoir. The bore is also connected to a damper which prevents engine
pulses being transferred hydraulically to the clutch pedal. A piston is fitted in the bore and has an external rod which
is attached to the clutch pedal with a pin. Two coil springs on the clutch pedal reduce the effort required to depress
the pedal.
The master cylinder is mounted on the bulkhead and secured with two bolts. The cylinder is connected to the shared
brake/clutch reservoir on the brake servo by a braided connecting hose.
The slave cylinder is located on the left hand side of the gearbox housing and secured with two bolts. A heat shield
is fitted to protect the underside of the slave cylinder from heat generated from the exhaust system. The slave cylinder
comprises a cylinder with a piston and a rod. A port in the cylinder body provides the attachment for the hydraulic feed
pipe from the master cylinder. A second port is fitted witha bleed nipple used for removing air from the hydraulic
system after servicing. The piston rod locates on a clutch release lever located in the gearbox housing. The rod is
positively retained on the release lever with a clip.
Clutch mechanism
The clutch mechanism comprises a flywheel, drive plate, pressure plate, release lever and a release bearing. The
clutch mechanism is fully enclosed at the rear of the engine by the gearbox housing.
A clutch release bearing sleeve is attached in the gearbox housing with two bolts and located on two dowels. A spigot
with a ball end is formed on the release bearing sleeve and provides amounting and pivot point for the clutch release
lever. A dished pivot washer is located on the ball of the spigot. When the release lever is located on the ball, the pivot
washer seats against the rear face of the release lever. A spring clip is located on the lever and the pivot washer and
secures the lever on the spigot. A small bolt retains the spring clip in position.
The release lever is forked at its inner end and locates on the clutch release bearing carrier. The outer end of the
release lever has a nylon seat which locates the slave cylinder piston rod. A second nylon seat, positioned centrally
on the release lever, locates on the ball spigot of the release bearing sleeve and allows the release lever to pivot freely
around the ball.
The clutch release bearing locates on the clutch release lever and release bearing sleeve. The bearing is retained on
a carrier which has two flats to prevent the carrier rotating on the release lever. A clip retains the release lever on the
carrier. The bearing and carrier are not serviceable individually.

CLUTCH - TD5
DESCRIPTION AND OPERATION 33-1-7
Dual mass flywheel
1Ring gear
2Primary flywheel
3Inner drive plate
4Spring housing
5Secondary flywheel
6Rivet
7Ball bearing8Dowel location hole
9Mounting hole
10Inner spring
11Outer spring
12Crankshaft position sensing holes
13Pressure plate locating dowel
The dual mass flywheel is bolted on the rear of the crankshaft with eight bolts. A dowel on the crankshaft flange
ensures that the flywheel is correctly located. A ring gear is fitted on the outer diameter of the flywheel. The ring gear
is not serviceable. Thirty blind holes are drilled in the outer diameter of the flywheel adjacent to the ring gear. The
holes are positioned at 10
° intervals with four 20° spaces. The holes are used by the crankshaft position sensor for
engine management.

+ ENGINE MANAGEMENT SYSTEM - Td5, DESCRIPTION AND OPERATION, Description.

CLUTCH - V8
33-2-6 DESCRIPTION AND OPERATION
Description
General
The clutch system is a conventional diaphragm type clutch operated by a hydraulic cylinder. The clutch requires no
adjustment to compensate for wear.
Hydraulic clutch
The hydraulic clutch comprises a master cylinder, slave cylinder and a hydraulic reservoir, which is also shared with
the braking system. The master and slave cylinders are connected to each other hydraulically by plastic and metal
pipes. The plastic section of the pipe allows ease of pipe routing and also absorbs engine movements and vibrations.
The master cylinder comprises a body with a central bore. Two ports in the body connect the bore to the hydraulic
feed pipe to the slave cylinder and the brake/clutch fluid reservoir. A piston is fitted in the bore and has an external
rod which is attached to the clutch pedal with a pin. Two coiled springs on the clutch pedal reduce the effort required
to depress the pedal.
The master cylinder is mounted on the bulkhead in the engine compartment and secured with two bolts. The cylinder
is connected to the shared brake/clutch reservoir on the brake servo by a braided connecting hose.
The slave cylinder is located on the left hand side of the gearbox housing and secured with two bolts. A heat shield
protects the underside of the cylinder from heat generated from the exhaust system. The slave cylinder comprises a
cylinder with a piston and a rod. A port in the cylinder body provides the attachment for the hydraulic feed pipe from
the master cylinder. A second port is fitted with a bleed nipple for removing air from the hydraulic system after
servicing. The piston rod locates on a clutch release lever located in the gearbox housing. The rod is positively
retained on the release lever with a clip.
Clutch mechanism
The clutch mechanism comprises a flywheel, drive plate, pressure plate, release lever and a release bearing. The
clutch mechanism is fully enclosed at the rear of the engine by the gearbox housing.
A clutch release bearing sleeve is attached in the gearbox housing with two bolts and located on two dowels. A spigot
with a ball end is formed on the release bearing sleeve and provides a mounting and pivot point for the clutch release
lever. A dished pivot washer is located on the ball of the spigot. When the release lever is located on the ball, the pivot
washer seats against the rear face of the release lever. A spring clip is located on the lever and the pivot washer and
secures the lever on the spigot. A small bolt retains the spring clip in position.
The release lever is forked at its inner end and locates on the clutch release bearing carrier. The outer end of the
release lever has a nylon seat which locates the slave cylinder piston rod. A second nylon seat, positioned centrally
on the release lever, locates on the ball spigot of the release bearing sleeve and allows the release lever to pivot freely
around the ball.
The clutch release bearing locates on the clutch release lever and the release bearing sleeve. The bearing is retained
on a carrier which has two flats to prevent the carrier rotating on the release lever. A clip retains the release lever on
the carrier. The bearing and carrier are not serviceable individually.

CLUTCH - V8
DESCRIPTION AND OPERATION 33-2-7
Flywheel
The flywheel is bolted to a flange on the rear of the crankshaft with six bolts. A dowel on the crankshaft flange ensures
that the flywheel is correctly located. A ring gear is fitted on the outside diameter of the flywheel and seats against a
flange. The ring gear is an interference fit on the flywheel and is installed by heating the ring and cooling the flywheel.
The ring gear is a serviceable item and can be replaced if damaged or worn.
The operating face of the flywheel is machined to provide a smooth surface for the drive plate to engage on. Three
dowels and six threaded holes provide for the location and attachment of the pressure plate. The flywheel is balanced
to ensure that it does not produce vibration when rotating. A machined slot, with a series of holes within the slot, is
located on the engine side of the flywheel. The slot accommodates the tip of the crankshaft position sensor which is
used by the Engine Control Module (ECM) for engine management.

+ ENGINE MANAGEMENT SYSTEM - V8, DESCRIPTION AND OPERATION, Description - engine
management.
Pressure plate
1Leaf spring
2Fulcrum ring
3Fulcrum ring
4Drive plate
5Pressure plate6Diaphragm
7Cover
8Rivet
9Retractor clip
The pressure plate assembly comprises a pressure plate, cover and diaphragm and is mounted on and rotates with
the flywheel.

MANUAL GEARBOX - R380
37-28 OVERHAUL
6.Fit layshaft bearing track to front cover.
7.Using tool LRT-99-002 and a suitable mandrel,
fit pilot bearing outer track to input shaft.
8.Clean synchroniser hubs, gears and bearings.
9.Position output shaft in protected vice jaws,
output end upwards.
10.Fit 2nd gear bearing, 2nd gear and
synchromesh baulk rings onto output shaft.
11.Position 1st / 2nd synchroniser hub onto output
shaft. Ensure that baulk rings are correctly
located in hub.
12.Position 1st gear synchromesh baulk rings,
needle roller bearing, 1st gear and bearing
collar onto output shaft. Ensure baulk rings are
correctly located in hub.
13.Remove output shaft from vice.
14.Using tool LRT-37-001, LRT-37-044 and
LRT-99-002, press taper bearing onto output
shaft.
15.Using a feeler gauge, check end float of 1st
gear between gear and collar flange:
lNew = 0.05 - 0.20 mm (0.002 - 0.008 in)
lService limit = 0.327 mm (0.012 in) 16.Using a feeler gauge, check end float of 2nd
gear between gear and output shaft flange:
lNew = = 0.04 - 0.21 mm (0.0016 - 0.0083
in)
lService limit = 0.337 mm (0.013 in)
17.Invert output shaft in vise and fit 3rd gear,
bearing, baulk rings, 3rd / 4th synchroniser and
spacer.
18.Remove output shaft from vice.
19.Using tool LRT-99-002 and a suitable mandrel,
press pilot bearing onto output shaft.

MANUAL GEARBOX - R380
OVERHAUL 37-29
20.Check end float of 3rd gear between gear and
flange on output shaft:
lNew = 0.11 - 0.21 mm (0.004 - 0.0083 in)
lService limit = 0.337 mm (0.013 in)
21.Check output shaft and layshaft end float as
follows.
22.The end float setting for both shafts is:
lNew = 0.00 to 0.05 mm (0.0 to - 0.002 in)
lService limit = 0.05 mm (0.002 in)
23.Fit front cover to gearbox case without the oil
seal and tighten bolts by diagonal selection to
25 Nm (18 lbf.ft).
24.Position in vice with front cover facing
downwards.
25.Fit input shaft to gearbox case less 4th gear
baulk ring.
26.Fit output shaft assembly to input shaft.
27.Fit output shaft bearing track and shim to centre
plate.
28.Fit centre plate to gearbox case and secure
using 8 slave bolts.
29.Rotate output shaft to settle bearings.
30.Fit a suitably large ball bearing into end of
output shaft.
31.Position a suitable DTI and zero probe on ball
bearing.
32.Lift output shaft and note DTI reading.
33.If reading is incorrect, dismantle and fit shim to
give correct end float.
34.Repeat above procedure.
35.Repeat procedure for layshaft end float.
36.Remove and discard 6 bolts and remove
gearbox front cover.
37.Fit gearbox selector fork - set.

+ MANUAL GEARBOX - R380,
OVERHAUL, Fork - set - selector shaft.
38.Fit gearbox front cover.

+ MANUAL GEARBOX - R380,
OVERHAUL, Cover - front.
Synchroniser - gearbox - set
$% 37.20.07
Disassembly
1.Remove gearbox selector fork set.

+ MANUAL GEARBOX - R380,
OVERHAUL, Fork - set - selector shaft.
2.Using tool LRT-99-002 and support bars
under 1st gear, press output shaft bearing from
output shaft.
3.Remove 1st gear, bearing collar, needle roller
bearing and synchromesh rings.
4.Noting its fitted position, remove 1st / 2nd gear
synchroniser hub, 2nd gear synchromesh
rings, 2nd gear and needle roller bearing.