2002 LAND ROVER DISCOVERY Workshop Manual

GENERAL DATA
04-2
Lubrication
Type Wet sump, pressure fed
Pump type Eccentric rotor, crankshaft driven integral with stiffener plate.
Filter type:

Primary Centrifuge filter

Secondary Disposable canister with full flow by-pass
Pressure at idle (Cold) 3.0 bar (43.5 lbf.in
2)
Pressure at 3500 rev/min (Hot) 1.5-3.0 bar (21.75-43.5 lbf.in
2)
Relief valve opening pressure 4.0 bar (58 lbf.in
2)
Low oil pressure switch opening pressure 0.2-0.6 bar (3.0-8.8 lbf.in
2)
Crankshaft
Main journal diameter 61.9875-62.0125 mm (2.4404-2.4414 in)
Crankpin journal diameter 53.99-54.01 mm (2.125-2.131 in)
End float 0.020 - 0.250 mm (0.0008 - 0.0098 in)

Main bearings
Quantity 6 (5 main, 1 thrust)

Pistons
Type Graphite compound skirt with combustion chamber in crown
Clearance in cylinder bore.
Measured at bottom of skirt, 90° to gudgeon pin0.172-0.206 mm (0.007-0.008 in)
Diameter
(Measured at right angles to gudgeon pin and 40.0
mm (1.5 in) from bottom of skirt)84.270-85.254 mm (3.321-3.361 in)
Gudgeon pins Fully floating, offset towards piston thrust side
Piston rings
Type: 2 compression, 1 oil control

Upper compression ring Barrel edge, chrome plated

Lower compression ring Taper faced

Oil control ring Bevelled ring with spring
New ring to groove clearance:

Upper compression Not measured

Lower compression 0.050-0.082 mm (0.002-0.003 in)

Oil control 0.050-0.082 mm (0.002-0.003 in)
Piston ring fitted gap in cylinder bore:

Upper compression 0.30-0.45 mm (0.0118-0.0177 in)

Lower compression 0.40-0.60 mm (0.0157-0.0236 in)

Oil control 0.25-0.40 mm (0.0098-0.0157 in)

GENERAL DATA
04-3
Camshaft
Bearings 6
Drive Duplex chain
End float 0.06-0.16 mm (0.002-0.006 in)

Tappets
Type Hydraulic lash adjusters with followers

Valves
Stem diameter:

Exhaust 6.905 ± 0.008 mm (0.271 ± 0.0003 in)

Inlet 6.915 ± 0.008 mm (0.272 ± 0.0003 in)
Head diameter:

Exhaust 31.7 mm (1.25 in)

Inlet 34.7 mm (1.37 in)
Seat face angle:

Exhaust 45°

Inlet 30°
Valve face angle:

Exhaust 44° 48' ±12'

Inlet 29° 48' ±12'

Valve springs
Type Parallel, single coil

GENERAL DATA
04-4
Engine - V8
General
Cylinder arrangement 90° V8, numbered from the front of the engine:

Left bank cylinders 1, 3, 5 and 7

Right bank cylinders 2, 4, 6 and 8
Bore 94.00 mm (3.70 in)
Stroke:

4.0 litre

4.6 litre71.04 mm (2.80 in)
81.92 mm (3.22 in)
Capacity:

4.0 litre

4.6 litre3950 cm
3 (241 in3)
4554 cm3 (278 in3)
Firing order 1 - 8 - 4 - 3 - 6 - 5 - 7 - 2
Compression ratio:

Low - 4.0 litre 8.23:1

High - 4.0 and 4.6 litre 9.35:1
Direction of rotation Clockwise viewed from the front of the engine
Maximum power - 4.0 litre:

Low compression ratio 132 kW (177 bhp) at 4750 rev/min

High compression ratio - UK/Japan/ROW 136 kW (182 bhp) at 4750 rev/min

High compression ratio - NAS 140 kW (187 bhp) at 4750 rev/min
Maximum power - 4.6 litre 162 kW (217 bhp) at 4750 rev/min
Maximum engine speed:

Continuous5000 rev/min

Intermittent 5250 rev/min
Weight (fully dressed, wet)

Manual 194 Kg (435 lb)

Automatic 179 Kg (402 lb)
Dimensions:

Length - Manual 767 mm (30.2 in) (Including fan)

Length - Automatic 777 mm (30.5 in) (Including fan and drive plate)

Width 652 mm (25.7 in)

Height 746 mm (29.4 in)
Spark plugs:

Make/Type - 4.0 litre Champion RC11 PYP B4

Make/type - 4.6 litre Champion RN11 YCC

Gap - 4.0 and 4.6 litre 1.00 ± 0.05 mm (0.040 ± 0.002 in) Non-adjustable
Coils:

Make Bosch 0221 503 407

Type Twin coils
Fuel injection system:

Make Bosch Motronic 5.2.1 Type 4146

Type Multiport fuel injection, electronically controlled with electro-
mechanical injectors

GENERAL DATA
04-5
Idle speed:

All loads off 660 ± 50 rev/min

Base idle speed Non-adjustable

Idle air control (IAC) valve position Checked via TestBook
CO at idle:

Catalyst vehicles 0.5 %

Non-catalyst vehicles 0.5 - 1.0 %
Valve timing
Inlet valves:

Opens 28° BTDC

Closes 77° ABDC
Exhaust valves:

Opens 66° BBDC

Closes 39° ATDC
Fuel grade:

High compression catalyst vehicles 95 RON minimum unleaded

Low compression catalyst vehicles 91 RON minimum unleaded

Non-catalyst vehicles 97 RON leaded
Lubrication
Type Wet sump, pressure fed
Pump type Crankshaft driven eccentric rotor
Oil filter Disposable canister with full flow by-pass
Pressure at idle - minimum 0.7 bar (10 lbf.in
2)
Pressure at 2000 rev/min (hot) 3.4 bar (50 lbf.in
2)
Relief valve opening pressure 3.4 bar (50 lbf.in
2)
Low oil pressure switch opening pressure 0.24-0.41 bar (3.5-6.0 lbf.in
2)
Crankshaft
Main journal diameter 63.487 - 63.500 mm (2.4995 - 2.520 in)
Crankpin journal diameter 55.500 - 55.513 mm (2.20 - 2.22 in)
End float 0.08 - 0.26 mm (0.003 - 0.010 in)
Maximum ovality 0.040 mm (0.002 in)
Main bearings
Quantity 5
Material Glacier Vandervell / AS 15
Diametrical clearance 0.015 - 0.016 mm (0.00059 - 0.00063 in)
Connecting Rods
Type Horizontally split big-end, plain small end
Distance between centres 155.120 - 155.220 mm (6.1071 - 6.1110 in)

GENERAL DATA
04-6
Big-end bearings
Quantity 8
Material Glacier Vandervell GPL 2120/AS 124A
Diametrical clearance 0.015 - 0.016 mm (0.00059 - 0.00063 in)
End float 0.15 - 0.35 mm (0.0006 - 0.0138 in)
Gudgeon pins
Diameter 23.995 - 24.000 mm (0.9447 - 0.9449 in)
Clearance in piston 0.006 - 0.015 mm (0.00024 - 0.00059 in)
Fit in connecting rod Press fit
Length 60.00 - 60.50 mm (2.362 - 2.382 in)
Pistons
Type Solid skirt, elliptical open end with offset gudgeon pin
Material Aluminium AE413P
Clearance in cylinder bore.
Measured 10 mm (0.4 in) from bottom of skirt, 90° to
gudgeon pin.0.022 - 0.067 mm (0.0009 - 0.0026 in)
Diameter - Grade A 93.970 - 93.985 mm (3.6996 - 3.7002 in)
Diameter - Grade B 93.986 - 94.001 mm (3.7002 - 3.7008 in)
Piston rings
Type: 2 compression, 1 oil control

Top compression ring Barrel faced nitrided steel

2nd compression ring Tapered spherical

Oil control ring 3 piece AE Conoform
Piston ring fitted gap in cylinder bore:

Top compression ring gap 0.3 - 0.5 mm (0.012 - 0.020 in)

2nd compression ring gap 0.40 - 0.65 mm (0.016 - 0.026 in)

Oil control ring gap 0.38 - 1.40 mm (0.015 - 0.055 in)
Piston ring width:

Top compression ring width 1.21 - 1.23 mm (0.0476 - 0.0484 in)

2nd compression ring width 1.478 - 1.490 mm (0.0582 - 0.0587 in)

Oil control ring width 3.00 mm (0.1181 in)
Piston ring to groove clearance:

1st and 2nd compression rings 0.05 - 0.10 mm (0.002 - 0.004 in)
Camshaft
Bearings 5
Drive Chain, 9.52 mm (0.3748 in) pitch x 54 pitches
End float 0.075 - 0.25 mm (0.002 - 0.010 in)
Tappets
Type Hydraulic self adjusting
Outside diameter 21.386 - 21.407 mm (0.8420 - 0.8427 in)

GENERAL DATA
04-7
Valves
Stem diameter:

Inlet 8.664 - 8.679 mm (0.3411 - 0.3417 in)

Exhaust – 4.0 litre up to engine nos. 55D 05677A;
56D 50787A; 97D 05504A

Exhaust – 4.0 litre from engine nos. 55D 05678A;
56D 50788A; 97D 05505A and all 4.6 litre8.651 - 8.666 mm (0.3406 - 0.3412 in)
8.641 to 8.656 mm (0.340 to 0.341 in)
Head diameter:

Inlet 39.75 - 40.00 mm (1.5650 - 1.5748 in)

Exhaust 34.227 - 34.481 mm (1.3475 - 1.3575 in)
Seat face angle:

Inlet 46° 25' - 46° 00'

Exhaust 46° 25' - 46° 00'
Valve face angle:

Inlet 45° 00' - 45° 30'

Exhaust 45° 00' - 45° 30'
Valve springs
Free length 48.8 mm (1.92 in)
Fitted length 40.93 mm (1.61 in)

GENERAL DATA
04-8
Fuel system - Td5
Type Direct injection from pressure regulated supply with cooled return
flow and in-line pressure regulator
Pressure regulator setting 4 bar (58 lbf.in
2)
Pump Electric two stage submersible
Pump output:

Low pressure 30 l/h (6.6 gal/h) (7.93 US gal/h) at 0.5 bar (7.25 lbf.in
2)

High pressure 180 l/h (39.6 gal/h) (47.55 US gal/h) at 4 bar (58 lbf.in
2)
Maximum consumption 30 l/h (6.6 gal/h) (7.93 US gal/h)
Injectors Electronic unit injectors
Injector nominal operating pressure:

Pre EU3 models 1500 bar (21750 lbf.in
2)

EU3 models 1750 bar (25500 lbf.in
2)
Filter In-line canister filter/water separator with water detection
Air cleaner Mann and Hummell P0037

GENERAL DATA
04-9
Fuel system - V8
Cooling system - Td5
Type Multiport injection from pressure regulated, returnless supply
Pump Electric submersible
Regulated pump output pressure 3.5 bar (50.75 lbf.in
2)
Fuel pump delivery 120 litres/hr (211 pints/hr) (234 US pints/hr)
Filter In-line canister
Air filter Mann and Hummell P0036
Type Pressurised, spill return partial flow, thermostatically controlled
Cooling fans 11 blade axial flow on viscous coupling and 11 blade axial flow
electric
Electric cooling fan switching points:
For A/C system:

On When vehicle speed is 50 mph (80 km/h) or less and ambient
temperature is 28 °C (82 °F) or more

Off When vehicle speed increases to 62.5 mph (100 km/h) or ambient
temperature decreases to 25 °C (77 °F)
For engine cooling during normal running:

On 110 °C (230 °F)

Off 105 °C (221 °F)
For engine cooling at ignition off (to counteract heat
soak):

On If, within 10 seconds of ignition off, engine coolant temperature is
105 °C (221 °F) or more

Off After 10 minutes or if engine coolant temperature decreases to
100 °C (212 °F)
Coolant pump Centrifugal impeller, belt driven from crankshaft
Thermostat Waxstat with pressure relief valve
Thermostat opening temperature:

Initial opening 82 °C (179 °F)

Fully open 96 °C (204 °F)
Expansion tank cap relief valve - system operating
pressure1.4 bar (20.3 lbf.in
2)
Fuel cooler thermostat opening temperature 82°C (179°F)