2002 LAND ROVER DISCOVERY lock

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.

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.

MAINTENANCE
PROCEDURES 10-29
12.Where possible, check for correct operation of
hill descent control (HDC) mechanism. This
should not be carried out if excessive journey
time is required.
13.After road/roller test, carry out a final inspection
of vehicle, with vehicle on a ramp.
14.Check all fluid levels and top-up if necessary.
15. 2 wheel rolling road: Ensure differential lock is
disengaged and propeller shaft is connected on
completion of test. Switch on ignition and
check that differential lock, electronic brake
distribution and hill descent warning lamps
are extinguished.

ENGINE - TD5
12-1-2 DESCRIPTION AND OPERATION
Cylinder block components

ENGINE - TD5
DESCRIPTION AND OPERATION 12-1-3
1Oil dipstick tube
2Screw – oil dipstick tube to camshaft carrier
3Oil dipstick
42nd piston ring
5Piston
6Small-end bush
7Connecting rod
8Big-end bearing cap
9Connecting rod bolt (2 off per connecting rod)
10Top piston ring
11Oil control ring
12Circlips (2 off per gudgeon pin)
13Gudgeon pin
14Big-end bearing shells
15Dowels – cylinder head (2 off)
16Clutch housing shim plate
17 Crankshaft rear oil seal and housing
18Screws – crankshaft seal housing to engine
block (5 off)
19Bolts – clutch housing shim plate to engine
block (2 off)
20Main oil gallery plug (rear)
21Oil filter adaptor gasket
22Oil filter adaptor thermostat
23Oil filter adaptor assembly
24Oil filter adaptor insert25Oil filter adaptor to cylinder block bolts (3 off)
26Oil filter
27Oil pressure switch
28Oil cooler banjo bolts (2 off)
29O-rings – oil cooler banjo bolts (2 off)
30Oil cooler to cylinder block bolts (7 off)
31Centrifuge assembly
32Centrifuge to cylinder block bolts (3 off)
33Centrifuge oil drain pipe
34Oil drain pipe to sump gasket
35Centrifuge to oil drain pipe gasket
36Oil cooler plugs (3 off)
37Oil cooler assembly
38Oil cooler matrix 'O-rings' (2 off)
39Oil cooler matrix
40Oil cooler gasket
41Coolant and PAS pump assembly bracket
42Bracket bolts (5 off + 1 stud/nut)
43Cylinder block
44Dowels to timing block cover (2 off)
45Oil gallery delivery plug
46Cross drilling plug
47Coolant jacket plug
48Core plugs (3 off)

ENGINE - TD5
DESCRIPTION AND OPERATION 12-1-5
1Crankshaft pulley bolt
2TV Damper to crankshaft pulley bolts (3 off)
3TV Damper
4Crankshaft pulley
5Woodruff key
6Crankshaft
7Crankshaft to flywheel dowel
8Spigot bush
9Flywheel to crankshaft bolts (8 off)
10Flywheel assembly (Manual shown)
11Main bearing shells (6 pairs)
12Main bearing caps (6 off)
13Main bearing cap bolts (12 off)
14Thrust washer (2 off at No. 3 Main bearing)
15Piston lubrication jets (5 off)
16Piston lubrication jet cap head screw (5 off)
17Stiffener plate (oil pump integral)18Stiffener plate / oil pump assembly to cylinder
block bolts (22 off)
19Oil pick-up pipe O-ring
20Oil pick-up pipe inserts (2 x 6mm; 1 x 10mm)
21Upper oil pick-up pipe
22Oil pick-up pipe gauze
23Lower oil pick-up pipe
24Sump
25Oil drain plug seal
26Oil drain plug
27Sump to cylinder block bolts (20 off)
28Sump gasket
29Oil pick-up pipe bolts (3 off)
30Oil pump
31Chain lubrication jet
32Chain lubrication jet screw
33Stiffener to cylinder block dowel (2 off)

ENGINE - TD5
DESCRIPTION AND OPERATION 12-1-7
1Camshaft carrier
2Dowel – rocker shaft to camshaft carrier (1 off)
3Cylinder head bolts (12 off)
4Rocker shaft to camshaft carrier bolts (6 off)
5Rocker shaft
6Circlips (10 off)
7EUI Rocker arms (5 off)
8Camshaft carrier to cylinder head screws (13
off)
9Finger follower (10 off)
10Valve spring collets (20 off)
11Lash adjuster (10 off)
12Valve spring retainer (10 off)
13Valve spring (10 off)
14Valve stem seal (10 off)
15Valve guide (10 off)
16Valve seat insert (10 off)
17Inlet valve (5 off)
18Exhaust valve (5 off)
19Camshaft
20Camshaft bore seal (rear)21Coolant jacket core plug
22Cylinder head block
23Water jacket threaded plug
24Engine lifting bracket (LH)
25Engine lifting bracket bolts (2 off)
26Coolant outlet elbow to cylinder head bolts (3
off)
27Coolant outlet elbow
28Coolant outlet elbow gasket
29Cylinder head gasket
30Non-return valve (not removable, integral in
cylinder head)
31Camshaft bore end cap (front)
32End cap seal
33Cylinder head to cam carrier dowel (2 off)
34Engine lifting bracket (RH)
35Engine lifting bracket bolts (2 off)

ENGINE - TD5
DESCRIPTION AND OPERATION 12-1-11
1Vacuum pump stub pipe
2Cylinder head to timing chain cover bolt
3Cylinder head to timing chain cover nut
4Cylinder head to timing chain cover stud
5Tensioner assembly pivot screw
6Tensioner adjuster
7Tensioner arm assembly
8Duplex timing chain – crankshaft to camshaft
sprocket
9Camshaft sprocket bolts (3 off)
10Camshaft sprocket
11Fixed chain guide
12Fixed guide pin
13Fixed chain guide to cylinder block screws
14Oil pump drive chain
15Oil pump sprocket
16Oil pump sprocket screw
17Crankshaft sprockets
18Bearing to viscous fan shaft
19Viscous fan to cover bearing
20Circlip
21Hub – viscous fan to bearing flange
22Timing chain cover
23Timing chain cover to crankshaft seal
24Timing cover to cylinder head screws (8 off)