2002 LAND ROVER DISCOVERY oil
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CONTENTS
CONTENTS 1
INTRODUCTION ...................................................................................... 01-1
How To Use This Manual................................................................................................................ 01-1
Repairs and Replacements ............................................................................................................. 01-1
Specifications .................................................................................................................................. 01-2
Abbreviations and Symbols ............................................................................................................ 01-3
GENERAL INFORMATION ...................................................................... 03-1
General Precautions ....................................................................................................................... 03-1
Safety Instructions .......................................................................................................................... 03-2
Environmental Precautions ............................................................................................................. 03-3
General Fitting Instructions ............................................................................................................. 03-6
Ball and Roller Bearings ................................................................................................................. 03-7
Oil Seals.......................................................................................................................................... 03-8
Joints and Joint Faces .................................................................................................................... 03-9
Locking Devices .............................................................................................................................. 03-9
Screw Threads ................................................................................................................................ 03-10
Bolt and Nut Identification ............................................................................................................... 03-11
Flexible Pipes and Hoses ............................................................................................................... 03-13
Rolling Road Testing....................................................................................................................... 03-15
Fuel Handling Precautions .............................................................................................................. 03-16
Electrical Precautions ..................................................................................................................... 03-17
Supplementary Restraint System Precautions ............................................................................... 03-18
SRS Component Replacement Policy ............................................................................................ 03-23
Air Conditioning System Precautions .............................................................................................. 03-24
Air Conditioning Compressor Replacement .................................................................................... 03-26
Body Repairs .................................................................................................................................. 03-26
GENERAL DATA ..................................................................................... 04-1
Engine - Td5 ................................................................................................................................... 04-1
Engine - V8 ..................................................................................................................................... 04-4
Fuel system - Td5 ........................................................................................................................... 04-8
Fuel system - V8 ............................................................................................................................. 04-9
Cooling system - Td5 ...................................................................................................................... 04-9
Cooling system - V8 ........................................................................................................................ 04-10
Clutch - Td5 .................................................................................................................................... 04-10
Clutch - V8 ...................................................................................................................................... 04-11
Manual gearbox - R380 .................................................................................................................. 04-12
Transfer box - LT230SE .................................................................................................................. 04-13
Automatic gearbox - ZF4HP22/24 .................................................................................................. 04-13
Rear axle......................................................................................................................................... 04-13
Front axle ........................................................................................................................................ 04-13
Steering........................................................................................................................................... 04-14
Suspension ..................................................................................................................................... 04-15
Brakes ............................................................................................................................................. 04-16
Wheels and tyres ............................................................................................................................ 04-16
Air conditioning ............................................................................................................................... 04-17
Electrical - Td5 ................................................................................................................................ 04-17
Electrical - V8 .................................................................................................................................. 04-17
Dimensions ..................................................................................................................................... 04-18
Weights ........................................................................................................................................... 04-18
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CONTENTS
CONTENTS 3
Alarm handset battery ..................................................................................................................... 10-6
Road wheels ................................................................................................................................... 10-7
Tyres .............................................................................................................................................. 10-7
Brake pads, discs and calipers ....................................................................................................... 10-7
Road wheel speed sensors ............................................................................................................. 10-7
Brake fluid ....................................................................................................................................... 10-8
Fuel filter - diesel engine ................................................................................................................. 10-8
Fuel filter sedimenter ...................................................................................................................... 10-8
Road wheels ................................................................................................................................... 10-8
Radiator/Intercooler ........................................................................................................................ 10-8
Ambient air Temperature and pressure sensor .............................................................................. 10-8
Doors, bonnet and fuel filler flap ..................................................................................................... 10-9
Air suspension intake filter .............................................................................................................. 10-9
Anti-freeze....................................................................................................................................... 10-9
Cooling system ............................................................................................................................... 10-9
Spark plugs - V8 engine.................................................................................................................. 10-10
Air cleaner - V8 engine ................................................................................................................... 10-11
Air cleaner and dump valve - diesel engine .................................................................................... 10-11
Auxiliary drive belt ........................................................................................................................... 10-11
Auxiliary drive belt - V8 engine ....................................................................................................... 10-12
Auxiliary drive belt - diesel engine .................................................................................................. 10-12
Fluid reservoirs ............................................................................................................................... 10-12
Steering box .................................................................................................................................... 10-13
Battery ............................................................................................................................................. 10-13
Intercooler - diesel engine............................................................................................................... 10-14
Engine oil - V8 engine ..................................................................................................................... 10-14
Engine oil - diesel engine ................................................................................................................ 10-14
Centrifuge rotor – diesel engine ...................................................................................................... 10-15
Engine oil filter - diesel engine ........................................................................................................ 10-15
Engine oil filter – V8 engine ............................................................................................................ 10-15
Manual gearbox .............................................................................................................................. 10-16
Automatic gearbox ......................................................................................................................... 10-17
Transfer box .................................................................................................................................... 10-18
Front and rear axle .......................................................................................................................... 10-19
Propeller shafts ............................................................................................................................... 10-19
Anti-roll bar links ............................................................................................................................. 10-20
ACE actuators ................................................................................................................................. 10-21
ACE filter ......................................................................................................................................... 10-21
Brake hose, brake, fuel, ACE, clutch pipes and unions/electrical harnesses ................................ 10-22
Engine, gearbox, transfer box and axles ........................................................................................ 10-23
Exhaust system............................................................................................................................... 10-23
Steering box and front suspension ................................................................................................. 10-23
Steering rod ball joints ................................................................................................................... 10-25
Dampers and SLS height sensors .................................................................................................. 10-25
Front and rear axle suspension links .............................................................................................. 10-26
Towing bracket................................................................................................................................ 10-27
Engine mountings - V8 engine ........................................................................................................ 10-27
Road/roller test................................................................................................................................ 10-28
ENGINE - Td5 ........................................................................................... 12-1-1
DESCRIPTION AND OPERATION
Td5 Engine...................................................................................................................................... 12-1-1
Cylinder block components ............................................................................................................. 12-1-2
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CONTENTS
4CONTENTS
Crankshaft, sump and oil pump ...................................................................................................... 12-1-4
Cylinder head components ............................................................................................................. 12-1-6
Camshaft cover and engine cover .................................................................................................. 12-1-8
Camshaft timing chain components................................................................................................ 12-1-10
Description ...................................................................................................................................... 12-1-12
Lubrication circuit ............................................................................................................................ 12-1-29
ADJUSTMENTS
Engine oil pressure check .............................................................................................................. 12-1-35
REPAIRS
Pulley - crankshaft ........................................................................................................................ 12-1-37
Seal - crankshaft - rear ................................................................................................................. 12-1-38
Gasket - cylinder head .................................................................................................................. 12-1-39
Rocker shaft assembly ................................................................................................................... 12-1-44
Gasket - cover - camshaft .............................................................................................................. 12-1-46
Engine and ancillaries ................................................................................................................... 12-1-47
Mounting - front - LH ...................................................................................................................... 12-1-53
Mounting - front - RH ..................................................................................................................... 12-1-54
Mounting - engine - rear - LH ........................................................................................................ 12-1-55
Mounting - engine - rear - RH ......................................................................................................... 12-1-55
Flywheel ........................................................................................................................................ 12-1-56
Plate - drive - automatic ................................................................................................................. 12-1-56
Filter - oil ........................................................................................................................................ 12-1-57
Strainer - oil pick-up ....................................................................................................................... 12-1-58
Pump - oil........................................................................................................................................ 12-1-58
Gasket - sump ................................................................................................................................ 12-1-60
Valve - relief - oil pressure ............................................................................................................. 12-1-62
Switch - oil pressure ...................................................................................................................... 12-1-62
Cooler - engine oil .......................................................................................................................... 12-1-63
Gasket - centrifuge oil drain pipe .................................................................................................... 12-1-64
Rotor - centrifuge ........................................................................................................................... 12-1-66
Seal - oil - timing cover .................................................................................................................. 12-1-66
OVERHAUL
Gasket - inlet manifold ................................................................................................................... 12-1-69
Gasket - exhaust manifold ............................................................................................................. 12-1-70
Gasket - cylinder head .................................................................................................................. 12-1-71
Cylinder head - overhaul ............................................................................................................... 12-1-74
Gasket - engine sump ................................................................................................................... 12-1-84
Seal - crankshaft - rear - manual models........................................................................................ 12-1-86
Seal - crankshaft - rear - automatic models .................................................................................... 12-1-87
Flywheel.......................................................................................................................................... 12-1-88
Drive plate....................................................................................................................................... 12-1-88
Starter ring gear .............................................................................................................................. 12-1-89
Pump - oil ...................................................................................................................................... 12-1-90
Timing chain and sprockets ........................................................................................................... 12-1-93
Bearings - connecting rods ........................................................................................................... 12-1-96
Pistons, connecting rods and cylinder bores ................................................................................ 12-1-98
Crankshaft .................................................................................................................................... 12-1-102
ENGINE - V8 ............................................................................................. 12-2-1
DESCRIPTION AND OPERATION
V8 Engine ....................................................................................................................................... 12-2-1
Cylinder head components ............................................................................................................. 12-2-2
Cylinder block components............................................................................................................. 12-2-4
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CONTENTS
CONTENTS 5
Description ...................................................................................................................................... 12-2-6
ADJUSTMENTS
Engine oil pressure check .............................................................................................................. 12-2-11
REPAIRS
Seal - crankshaft - rear .................................................................................................................. 12-2-13
Gasket - cylinder head - LH ........................................................................................................... 12-2-14
Gasket - cylinder head - RH ............................................................................................................ 12-2-16
Gasket - rocker cover - LH ............................................................................................................ 12-2-19
Gasket - rocker cover - RH ............................................................................................................ 12-2-20
Mounting - front - LH ...................................................................................................................... 12-2-22
Mounting - front - RH ..................................................................................................................... 12-2-23
Mounting - rear - LH ....................................................................................................................... 12-2-24
Mounting - rear - RH ...................................................................................................................... 12-2-25
Engine assembly............................................................................................................................. 12-2-26
Flywheel ........................................................................................................................................ 12-2-31
Plate - drive - automatic ................................................................................................................ 12-2-32
Ring gear - starter ......................................................................................................................... 12-2-33
Filter - oil ....................................................................................................................................... 12-2-34
Strainer - oil pick-up ...................................................................................................................... 12-2-35
Pump - oil ...................................................................................................................................... 12-2-35
Gasket - sump ................................................................................................................................ 12-2-36
Switch - oil pressure ....................................................................................................................... 12-2-38
Cooler - engine oil .......................................................................................................................... 12-2-39
Gasket - timing gear cover ............................................................................................................ 12-2-40
Seal - cover - timing gears ............................................................................................................ 12-2-42
OVERHAUL
Gasket - inlet manifold ................................................................................................................... 12-2-45
Gasket - exhaust manifold ............................................................................................................. 12-2-48
Seal - crankshaft - rear - automatic models .................................................................................... 12-2-49
Seal - crankshaft - rear - manual models ........................................................................................ 12-2-50
Bearing - spigot - crankshaft .......................................................................................................... 12-2-52
Gasket - engine sump .................................................................................................................... 12-2-53
Strainer - oil pick-up ....................................................................................................................... 12-2-54
Seal - timing gear cover ................................................................................................................. 12-2-54
Gasket - timing gear cover ............................................................................................................. 12-2-55
Timing chain and gears .................................................................................................................. 12-2-57
Rocker shaft - overhaul ................................................................................................................. 12-2-59
Gasket - cylinder head .................................................................................................................... 12-2-60
Cylinder head - overhaul ................................................................................................................ 12-2-62
Piston assemblies ........................................................................................................................... 12-2-67
Bearings - connecting rods ............................................................................................................ 12-2-71
Crankshaft and main bearings ........................................................................................................ 12-2-72
Camshaft ....................................................................................................................................... 12-2-76
EMISSION CONTROL - Td5..................................................................... 17-1-1
DESCRIPTION AND OPERATION
EGR system components - type 1 .................................................................................................. 17-1-1
EGR system components - type 2 .................................................................................................. 17-1-2
Emission Control Systems .............................................................................................................. 17-1-4
Crankcase emission control ............................................................................................................ 17-1-4
Exhaust gas recirculation ................................................................................................................ 17-1-5
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CONTENTS
CONTENTS 7
Operation ........................................................................................................................................ 18-1-38
ADJUSTMENTS
Glow plug ....................................................................................................................................... 18-1-45
REPAIRS
Engine control module (ECM) ........................................................................................................ 18-1-47
Sensor - engine coolant temperature (ECT) ................................................................................. 18-1-47
Sensor - crankshaft (CKP) .............................................................................................................. 18-1-48
Air filter assembly ........................................................................................................................... 18-1-48
Element - air filter ............................................................................................................................ 18-1-49
Sensor - fuel temperature .............................................................................................................. 18-1-50
Sensor - mass air flow (MAF) ....................................................................................................... 18-1-51
Sensor - combined MAP and IAT ................................................................................................. 18-1-51
Sensor - ambient air pressure (AAP) ............................................................................................ 18-1-52
Element - fuel filter ........................................................................................................................ 18-1-53
Cooler - fuel .................................................................................................................................. 18-1-53
Sensor - Throttle position (TP) ........................................................................................................ 18-1-54
Turbocharger ................................................................................................................................ 18-1-55
Intercooler ..................................................................................................................................... 18-1-56
Valve - solenoid boost control ........................................................................................................ 18-1-58
Regulator - fuel pressure .............................................................................................................. 18-1-59
Glow plugs ...................................................................................................................................... 18-1-60
Injectors .......................................................................................................................................... 18-1-61
Switch - cruise control (on/off) ........................................................................................................ 18-1-62
Switch - cruise control (set/resume) ................................................................................................ 18-1-63
Switch - clutch ................................................................................................................................. 18-1-63
ENGINE MANAGEMENT SYSTEM - V8 .................................................. 18-2-1
DESCRIPTION AND OPERATION
Engine management component location - Passenger compartment ............................................ 18-2-2
Engine management component location - Engine compartment .................................................. 18-2-3
Engine management block diagram ............................................................................................... 18-2-4
Description - engine management .................................................................................................. 18-2-6
Operation - engine management .................................................................................................... 18-2-43
DESCRIPTION AND OPERATION
Cruise control component layout .................................................................................................... 18-2-55
Cruise control block diagram .......................................................................................................... 18-2-56
Description - cruise control ............................................................................................................. 18-2-57
Operation - cruise control................................................................................................................ 18-2-66
ADJUSTMENTS
Cable - throttle ............................................................................................................................. 18-2-69
Cable - cruise control .................................................................................................................... 18-2-69
REPAIRS
Spark plugs .................................................................................................................................. 18-2-71
Coil - ignition ................................................................................................................................. 18-2-71
Engine control module (ECM) ......................................................................................................... 18-2-72
Sensor - engine coolant temperature (ECT) ................................................................................ 18-2-73
Sensor - crankshaft position (CKP) ............................................................................................... 18-2-74
Sensor - radiator temperature ....................................................................................................... 18-2-75
Sensor - camshaft position (CMP) ................................................................................................. 18-2-76
Page 14 of 1672
CONTENTS
CONTENTS 11
MANUAL GEARBOX - R380 .................................................................... 37-1
DESCRIPTION AND OPERATION
R380 gearbox ................................................................................................................................. 37-1
Gearbox casings, gear change and oil pump ................................................................................ 37-2
Selector shaft and forks, synchromesh assemblies and gear train ................................................ 37-4
R380 gearbox cross section ........................................................................................................... 37-6
Description ...................................................................................................................................... 37-7
Operation ........................................................................................................................................ 37-8
ADJUSTMENTS
Spring - gear lever bias .................................................................................................................. 37-9
REPAIRS
Housing - gear selector .................................................................................................................. 37-11
Gearbox - V8................................................................................................................................... 37-12
Gearbox - Diesel ............................................................................................................................. 37-16
Seal - gearbox mainshaft ............................................................................................................... 37-20
Seal - input shaft ............................................................................................................................ 37-21
Cooler - oil - gearbox - Diesel ......................................................................................................... 37-22
Cooler - oil - gearbox - V8 ............................................................................................................... 37-23
Switch - Reverse light ................................................................................................................... 37-24
OVERHAUL
Shaft - output ................................................................................................................................. 37-25
Synchroniser - gearbox - set ......................................................................................................... 37-29
Fork - set - selector shaft .............................................................................................................. 37-31
Shaft - gearbox - input .................................................................................................................. 37-32
Extension - gearbox rear ................................................................................................................ 37-35
Pump - gearbox oil ......................................................................................................................... 37-37
Filter - gearbox oil ......................................................................................................................... 37-38
Gear - 5th gear set ........................................................................................................................ 37-38
Synchronizer assembly - 5th/reverse ............................................................................................ 37-39
5th gear - layshaft ......................................................................................................................... 37-40
Bearing - layshaft rear support ...................................................................................................... 37-42
Bearing - output shaft rear support ............................................................................................... 37-43
Shaft - reverse idler ....................................................................................................................... 37-44
Housing - gear selector mechanism ............................................................................................. 37-46
Lever - gear change ...................................................................................................................... 37-47
Housing - clutch ............................................................................................................................ 37-48
Cover - front ................................................................................................................................... 37-49
TRANSFER BOX - LT230SE .................................................................... 41-1
DESCRIPTION AND OPERATION
LT230SE transfer box ..................................................................................................................... 41-1
Transfer box cross section .............................................................................................................. 41-2
Main casing components – Vehicles up to 03 model year .............................................................. 41-4
Main casing components – Vehicles from 03 model year ............................................................... 41-5
Differential components – Vehicles up to 03 model year ................................................................ 41-6
Differential components – Vehicles from 03 model year ................................................................. 41-7
Front output housing components – Vehicles up to 03 model year ................................................ 41-8
Front output housing components – Vehicles from 03 model year ................................................. 41-10
Rear output housing components ................................................................................................... 41-12
Description ...................................................................................................................................... 41-13
Page 15 of 1672
CONTENTS
12 CONTENTS
Operation ........................................................................................................................................ 41-19
ADJUSTMENTS
Cable - high/low selector ................................................................................................................ 41-21
REPAIRS
Bottom cover - transfer box ......................................................................................................... 41-23
Transfer box - Diesel ...................................................................................................................... 41-24
Transfer box - V8 ............................................................................................................................ 41-27
Gasket - rear cover plate ................................................................................................................ 41-30
Switch - differential lock - Up to 03 MY ........................................................................................... 41-30
Cable - high/low selector ................................................................................................................ 41-31
Oil seal - input shaft ...................................................................................................................... 41-32
Seal - front output shaft .................................................................................................................. 41-33
Seal - rear output shaft ................................................................................................................... 41-34
Gasket - rear output shaft housing ................................................................................................. 41-35
Solenoid - interlock - Up to 03 MY .................................................................................................. 41-36
Sensor - neutral ........................................................................................................................... 41-36
Sensor - oil temperature ................................................................................................................ 41-37
Switch - high low - warning ........................................................................................................... 41-37
OVERHAUL
Intermediate gear assembly ......................................................................................................... 41-39
Differential assembly ................................................................................................................... 41-42
Dog clutch - differential lock .......................................................................................................... 41-57
Input gear/bearing .......................................................................................................................... 41-60
Low gear - differential ................................................................................................................... 41-62
AUTOMATIC GEARBOX - ZF4HP22 - 24 ................................................ 44-1
DESCRIPTION AND OPERATION
Automatic gearbox component layout ............................................................................................ 44-1
Control schematic ........................................................................................................................... 44-2
Description ...................................................................................................................................... 44-4
Operation ........................................................................................................................................ 44-17
ADJUSTMENTS
Cable - selector ............................................................................................................................. 44-21
Stall test .......................................................................................................................................... 44-21
REPAIRS
Cable and lever assembly - selector .............................................................................................. 44-23
Selector indicator .......................................................................................................................... 44-24
Switch - starter inhibitor ................................................................................................................. 44-24
Seal - selector shaft ........................................................................................................................ 44-25
Gearbox - convertor and transfer gearbox - Diesel ....................................................................... 44-26
Gearbox - convertor and transfer gearbox - V8 ............................................................................ 44-30
Torque converter and oil seal ......................................................................................................... 44-34
Housing - torque converter ............................................................................................................ 44-35
Gasket - intermediate plate ............................................................................................................ 44-37
Intermediate plate .......................................................................................................................... 44-38
Pump - fluid .................................................................................................................................... 44-40
Seal - rear extension housing ......................................................................................................... 44-41
Gasket - rear extension housing. .................................................................................................. 44-42
Parking pawl assembly. ................................................................................................................ 44-43
Gasket - oil sump ........................................................................................................................... 44-44
Filter - oil ........................................................................................................................................ 44-45
Cooler - fluid - Td5 .......................................................................................................................... 44-45
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CONTENTS
CONTENTS 13
Cooler - fluid - V8 ........................................................................................................................... 44-46
Valve body assembly ..................................................................................................................... 44-47
Seal - valve body ........................................................................................................................... 44-49
Pressure regulator ......................................................................................................................... 44-50
Lock-up solenoid valve (MV 3) ....................................................................................................... 44-51
Solenoids - shift control valves (MV 1 & 2) .................................................................................... 44-51
Harness - solenoid valves .............................................................................................................. 44-52
Electronic control unit - automatic transmission .............................................................................. 44-53
PROPELLER SHAFTS ............................................................................. 47-1
DESCRIPTION AND OPERATION
Propeller shaft component layout ................................................................................................... 47-1
Description ...................................................................................................................................... 47-2
REPAIRS
Propeller shaft - front ..................................................................................................................... 47-5
Propeller shaft - rear ...................................................................................................................... 47-5
Flexible coupling ............................................................................................................................ 47-6
OVERHAUL
Propeller shaft ................................................................................................................................. 47-7
REAR AXLE .............................................................................................. 51-1
DESCRIPTION AND OPERATION
Rear axle component layout ........................................................................................................... 51-1
Description ...................................................................................................................................... 51-2
REPAIRS
Differential - assembly .................................................................................................................... 51-5
Seal - differential pinion ................................................................................................................. 51-7
OVERHAUL
Differential assembly ...................................................................................................................... 51-9
FRONT AXLE............................................................................................ 54-1
DESCRIPTION AND OPERATION
Front axle component layout........................................................................................................... 54-1
Description ...................................................................................................................................... 54-2
REPAIRS
Differential - assembly .................................................................................................................... 54-5
Seal - differential pinion ................................................................................................................ 54-7
Seal - oil - front axle casing ........................................................................................................... 54-9
Constant velocity joint - drive shaft ................................................................................................ 54-11
STEERING ................................................................................................ 57-1
DESCRIPTION AND OPERATION