2002 LAND ROVER DISCOVERY gearbox

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Page 604 of 1672

LAND ROVER DISCOVERY 2002 Workshop Manual COOLING SYSTEM - V8
DESCRIPTION AND OPERATION 26-2-3
1Heater matrix
2Heater return hose
3Heater inlet hose
4Heater inlet pipe
5Throttle housing
6Connecting hose
7Throttle housing inlet hose
8Throttle

Page 608 of 1672

LAND ROVER DISCOVERY 2002 Workshop Manual COOLING SYSTEM - V8
DESCRIPTION AND OPERATION 26-2-7
Inlet manifold - Cooling connections
Coolant leaves the cylinder block via an outlet pipe attached to the front of the air intake manifold. The pip

COOLING SYSTEM - V8
DESCRIPTION AND OPERATION 26-2-7
Inlet manifold - Cooling connections
Coolant leaves the cylinder block via an outlet pipe attached to the front of the air intake manifold. The pipe is
connected to the thermostat housing and the radiator by a branch hose off the radiator top hose.
Hot coolant from the engine is also directed from the inlet manifold via pipes and hoses into the heater matrix. Coolant
is circulated through the heater matrix at all times when the engine is running.
A further tapping from the inlet manifold supplies coolant to the throttle housing via a hose. The coolant circulates
through a plate attached to the bottom of the housing and is returned through a plastic bleed pipe to an expansion
tank. The hot coolant heats the air intake of the throttle housing preventing ice from forming.
An Engine Coolant Temperature (ECT) sensor is fitted in the inlet manifold adjacent to the manifold outlet pipe. The
sensor monitors coolant temperature emerging from the engine and sends signals to the ECM for engine
management and temperature gauge operation.

+ ENGINE MANAGEMENT SYSTEM - V8, DESCRIPTION AND OPERATION, Description - engine
management.
Expansion tank
The expansion tank is located in the engine compartment. The tank is made from moulded plastic and attached to
brackets on the right hand inner wing. A maximum coolant when cold level is moulded onto the tank.
Excess coolant created by heat expansion is returned to the expansion tank from the radiator bleed pipe at the top of
the radiator. An outlet pipe is connected into the pump feed hose and replaces the coolant displaced by heat
expansion into the system when the engine is cool.
The expansion tank is fitted with a sealed pressure cap. The cap contains a pressure relief valve which opens to allow
excessive pressure and coolant to vent through the overflow pipe. The relief valve opens at a pressure of 1.4 bar (20
lbf.in
2) and above.
Heater matrix
The heater matrix is fitted in the heater assembly inside the passenger compartment. Two pipes pass through the
bulkhead into the engine compartment and provide coolant flow to and from the matrix. The pipes from the bulkhead
are connected to the matrix, sealed with 'O' rings and clamped with circular rings.
The matrix is constructed from aluminium with two end tanks interconnected with tubes. Aluminium fins are located
between the tubes and conduct heat away from the hot coolant flowing through the tubes. Air from the heater
assembly is warmed as it passes through the matrix fins. The warm air is then distributed into the passenger
compartment as required.

+ HEATING AND VENTILATION, DESCRIPTION AND OPERATION, Description.When the engine is
running, coolant from the engine is constantly circulated through the heater matrix.
Radiator
The 45 row radiator is located at the front of the vehicle. The cross-flow type radiator is manufactured from aluminium
with moulded plastic end tanks interconnected with tubes. Aluminium fins are located between the tubes and conduct
heat from the hot coolant flowing through the tubes, reducing the cooling temperature as it flows through the radiator.
Air intake from the front of the vehicle when moving carries heat away from the fins. When the vehicle is stationary,
the viscous fan draws air through the radiator fins to prevent the engine from overheating.
Two connections at the top of the radiator provide for the attachment of the top hose and bleed pipe. A connection at
the bottom of the radiator allows for the attachment of the bottom hose to the thermostat housing.
Two smaller radiators are located in front of the cooling radiator. The lower radiator provides cooling of the gearbox
oil and the upper radiator provides cooling for the engine oil.

+ MANUAL GEARBOX - R380, DESCRIPTION AND OPERATION, Description.

+ AUTOMATIC GEARBOX - ZF4HP22 - 24, DESCRIPTION AND OPERATION, Description.

+ ENGINE - V8, DESCRIPTION AND OPERATION, Description.

Page 617 of 1672

LAND ROVER DISCOVERY 2002 Workshop Manual COOLING SYSTEM - V8
26-2-16 REPAIRS
8.Remove 6 scrivets and remove LH and RH air
deflectors from front panel. Disconnect
multiplug of gearbox oil temperature sensor
(arrowed).
9.Remove nut and mov

Page 618 of 1672

LAND ROVER DISCOVERY 2002 Workshop Manual COOLING SYSTEM - V8
REPAIRS 26-2-17
16.Remove radiator assembly.
17.Release clip and remove bottom hose from
radiator.
18.Remove 2 bolts and remove extension
brackets from radiator.
19.Remove 2

Page 654 of 1672

LAND ROVER DISCOVERY 2002 Workshop Manual CLUTCH - TD5
DESCRIPTION AND OPERATION 33-1-3
1Brake/clutch reservoir
2Connecting hose
3Bolt 2 off
4Master cylinder
5Clutch pedal
6Gearbox housing
7Primary driveshaft
8Bolt 2 off
9Slave cylinder
10Ble

Page 657 of 1672

LAND ROVER DISCOVERY 2002 Workshop Manual 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 in

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.

Page 659 of 1672

LAND ROVER DISCOVERY 2002 Workshop Manual CLUTCH - TD5
33-1-8 DESCRIPTION AND OPERATION
The dual mass flywheel is used to insulate the gearbox from torsional and transient vibrations produced by the engine.
The flywheel comprises primary and

Page 660 of 1672

LAND ROVER DISCOVERY 2002 Workshop Manual CLUTCH - TD5
DESCRIPTION AND OPERATION 33-1-9
The pressure plate assembly comprises a pressure plate, cover and diaphragm and is mounted on and rotates with
the dual mass flywheel.
The pressure plate

CLUTCH - TD5
DESCRIPTION AND OPERATION 33-1-9
The pressure plate assembly comprises a pressure plate, cover and diaphragm and is mounted on and rotates with
the dual mass flywheel.
The pressure plate is forged from cast iron and machined to provide a smooth surface for the drive plate to engage
on. Three lugs on the outer diameter of the pressure plate connect it via three leaf spring to the cover. The leaf springs
have three tempered steel leaves which assist in pulling the pressure plate away from the drive plate when the clutch
pedal is depressed.
The cover is made from pressed steel and houses all pressure plate components. Shouldered rivets support the
diaphragm inside the cover. The rivets heads are chamfered to allow the diaphragm to pivot when pressure is applied
to it by the release bearing. Three holes in the cover locate on the dowels on the flywheel and six further holes provide
for the attachment of the cover to the flywheel with six nuts. Larger holes in the cover provide ventilation for the drive
plate and pressure plate and flywheel contact surfaces.
The diaphragm comprises a cast ring with eighteen fingers. The diaphragm is attached to the cover with nine
shouldered rivets. The inner head of each rivet is chamfered to allow the diaphragm to pivot when the clutch is
depressed or released. When pressure is applied to the fingers of the diaphragm by the release bearing, the
diaphragm pivots on the rivets and moves away from the pressure plate, releasing the force applied to the pressure
plate and allowing the drive plate to slip between the pressure plate and the flywheel.
Drive plate
1Friction material
2Inner plate
3Hub
4Spring steel plate
The drive plate is of the rigid centre type and is sandwiched between the flywheel and the pressure plate. The drive
plate has a splined hub which engages with the splines on the primary drive shaft from the gearbox. The hub is
attached to an inner plate which is pressed onto the hub. A spring steel plate is riveted to the inner plate with eight
rivets and provides the attachment surface for the drive plate friction material. The spring steel plate allows some axial
compliance and contributes to smooth clutch operation. The friction material comprises two 267 mm (10.5 in.) discs
which are secured with rivets to each side of the spring steel plate. The rivets are installed through recessed holes in
the disc and emerge in recessed holes in the opposite disc.

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