2002 LAND ROVER DISCOVERY radiator

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

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

CONTENTS
CONTENTS 9
Solenoid - fuel filler flap release ...................................................................................................... 19-2-17
Switch - fuel filler flap release - up to 03MY .................................................................................... 19-2-17
Switch - fuel filler flap release - from 03MY..................................................................................... 19-2-18
COOLING SYSTEM - Td5 ........................................................................ 26-1-1
DESCRIPTION AND OPERATION
Cooling system component layout .................................................................................................. 26-1-2
Cooling system coolant flow ........................................................................................................... 26-1-4
Description ...................................................................................................................................... 26-1-5
Operation ........................................................................................................................................ 26-1-10
ADJUSTMENTS
Drain and refill ................................................................................................................................ 26-1-13
REPAIRS
Fan - viscous .................................................................................................................................. 26-1-15
Radiator ......................................................................................................................................... 26-1-15
Thermostat ..................................................................................................................................... 26-1-17
Pump - coolant ............................................................................................................................... 26-1-18
COOLING SYSTEM - V8 .......................................................................... 26-2-1
DESCRIPTION AND OPERATION
Cooling system component layout .................................................................................................. 26-2-2
Cooling system coolant flow ........................................................................................................... 26-2-4
Description ...................................................................................................................................... 26-2-6
Operation ........................................................................................................................................ 26-2-10
ADJUSTMENTS
Drain and refill ................................................................................................................................. 26-2-13
REPAIRS
Fan - viscous................................................................................................................................... 26-2-15
Radiator ......................................................................................................................................... 26-2-15
Thermostat ...................................................................................................................................... 26-2-18
Gasket - coolant pump .................................................................................................................. 26-2-18
MANIFOLDS AND EXHAUST SYSTEMS - Td5 ...................................... 30-1-1
DESCRIPTION AND OPERATION
Manifold component layout ............................................................................................................. 30-1-1
Exhaust system component layout ................................................................................................. 30-1-2
Description ...................................................................................................................................... 30-1-3
REPAIRS
Pipe - front ..................................................................................................................................... 30-1-5
Gasket - inlet manifold ................................................................................................................... 30-1-6
Gasket - exhaust manifold ............................................................................................................. 30-1-8

GENERAL DATA
04-10
Cooling system - V8
Clutch - Td5
Type Pressurised, spill return, thermostatically controlled water and
antifreeze mixture. Vertical flow radiator with remote header tank
and pump assisted
Cooling fans 9 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 100 °C (212 °F)

Off 94.5 °C (202 °F)
For engine cooling at ignition off (to counteract heat
soak):

On If, within 10 seconds of ignition off, intake air temperature is 60 °C
(140 °F) or more and engine coolant temperature is 110 °C (230
°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
Coolant pump drive ratio 1.293 : 1
Coolant pump output at 1000 rev/min 10 litres/min (2.64 US galls/min) at 0.7 bar (10 lbf.in
2)
Thermostat Waxstat with pressure relief valve
Thermostat operating temperature:

Initial opening 82 °C (179 °F)

Fully open 96 °C (204 °F)
Expansion tank cap relief valve - system operating
pressure1.4 bar (20 lbf.in
2)
Type Diaphragm spring, hydraulically operated with self-centering,
preloaded release bearing
Drive plate diameter 267 mm (10.5118 in)
Pressure plate diameter 267 mm (10.5118 in)
Clutch plate friction material Verto F202
Diaphragm finger height when clamped on a 8.5 mm
(0.33 in) thick gauge plate42.5 to 48.5 mm (1.673 to 1.904 in)
Diaphragm finger clearance (service limit) 1.00 mm (0.040 in)
Clutch plate thickness under 6500 N (1461 lb) axial
load:

New 8.2 to 8.8 mm (0.33 to 0.34 in)

Service limit 7.0 mm (0.27 in)

MAINTENANCE
10-8 PROCEDURES
Brake fluid
Replace
1.Replace brake fluid.

+ BRAKES, ADJUSTMENTS, Brake
system bleeding.
Fuel filter - diesel engine
Replace
1.Replace filter element.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Element - fuel filter.
Fuel filter sedimenter
Drain
1.Position suitable container beneath fuel filter.
2.Disconnect multiplug from sedimenter.
3.Rotate sedimenter anti-clockwise until water
flows from drain tube.
4.Allow to drain until diesel fuel flows from drain
tube.
5.Rotate sedimenter fully clockwise.
6.Connect multiplug.
Road wheels
Refit
1.Apply anti-seize compound to wheel hub
centre.
2.Refit road wheels to original hub position.
Tighten wheel nuts to 140 Nm (103 lbf.ft).
Radiator/Intercooler
Check
1.Visually check radiator/intercooler for external
obstructions, remove debris.
2.Visually check fan blades for damage.
Ambient air Temperature and pressure
sensor
Check
1.Check ambient air temperature and pressure
sensor for damage.

ENGINE - TD5
12-1-22 DESCRIPTION AND OPERATION
The camshaft carrier and cylinder head assembly is attached to the cylinder block by twelve cylinder head retaining
bolts which pass through the camshaft carrier and the cylinder head to secure the assembly to the cylinder block.
CAUTION: The valve heads, tips of the injectors and glow plugs protrude below the face of the cylinder head
and will be damaged if the cylinder head is stored face down.
The camshaft is located between the cylinder head and the camshaft carrier, and the bearing journals are line bored
between the two components to form a matched pair.
CAUTION: Always fit plugs to open connections to prevent contamination.
The valve guides and valve seat inserts are sintered components which are interference fit to the cylinder head. The
cylinder head machining also provide the locations for the electronic unit injectors, glow plugs, hydraulic lash
adjusters, finger followers and low pressure fuel rail.
Cooling to the cylinder head is provided by coolant flow through a water jacket machined into the cylinder head.
Drillings through the block provide lubrication channels for pressurised oil supply to cylinder head components such
as the lash adjusters, finger followers, rocker arms and camshaft bearings.
A coolant outlet elbow is fitted to the front LH side of the cylinder head to allow flow of coolant from the cylinder head
back to the radiator. A metal gasket is used to seal the joint between the water outlet elbow and the cylinder head. A
coolant temperature sensor is located in a port in the side of the water outlet elbow for monitoring coolant temperature.
A stub pipe is connected at the front RH side of the cylinder block above the timing cover which connects a pipe to
supply oil to the vacuum pump. The timing chain tensioner adjuster is screwed in a thread in the cylinder head at a
location on the front RH side of the engine below the oil feed port for the vacuum pump.
An access hole for the camshaft gear is included at the front of the cylinder head which is sealed with a plastic plug
and rubber 'O'-ring. A press-fit core plug for the chain chest is located on the front face of the cylinder head.
A press-fit core plug for the cylinder head water jacket is located at the rear of the cylinder head and a threaded brass
plug for the water jacket is located on the LH side of the cylinder head beneath the exhaust manifold assembly.

ENGINE - TD5
REPAIRS 12-1-37
REPAIRS
Pulley - crankshaft
$% 12.21.01
Remove
1.Remove fixings and underbelly panel.
2.Remove radiator.

+ COOLING SYSTEM - Td5, REPAIRS,
Radiator.
3.Using a 15 mm ring spanner, release the
auxiliary drive belt tensioner.
4.Remove auxiliary drive belt.
5.Remove 3 bolts and remove crankshaft TV
damper.
6.Position tool LRT-51-003 to crankshaft pulley
and secure with 2 bolts.
7.Remove and discard crankshaft pulley bolt.
Remove crankshaft pulley.
8.Remove 2 bolts and remove tool LRT-51-003
Refit
1.Position new crankshaft pulley to vice.
2.Remove 3 bolts and remove TV damper from
new crankshaft pulley.
3.Using a lint free cloth, thoroughly clean oil seal
recess and the running surface on crankshaft
pulley.
4.Fit crankshaft pulley. 5.Fit tool LRT-51-003 to crankshaft pulley and
secure with 2 bolts.
6.Fit new crankshaft pulley bolt and tighten to
460 Nm (340 lbf.ft), using a torque multiplier.
7.Remove 2 bolts and remove tool LRT-51-003
from crankshaft pulley.
8.Fit TV damper to crankshaft pulley and tighten
– TV damper bolts to 80 Nm (59 lbf.ft) .
9.Fit auxiliary drive belt to pulleys.
10.Fit radiator.

+ COOLING SYSTEM - Td5, REPAIRS,
Radiator.
11.Fit underbelly panel and secure with fixings.

ENGINE - TD5
REPAIRS 12-1-47
Engine and ancillaries
$% 12.41.01
Remove
1.Remove bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.
2.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Drain engine oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - diesel engine.
4.Remove radiator.

+ COOLING SYSTEM - Td5, REPAIRS,
Radiator.
5.Remove turbocharger.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Turbocharger.
6.Release clips and disconnect heater hoses
from fuel cooler and coolant rail.
7.Release clip and disconnect expansion tank
coolant hose from fuel cooler.
8.Disconnect fuel hoses, tank to fuel cooler and
connector block on cylinder head.
CAUTION: Always fit plugs to open
connections to prevent contamination.9.Disconnect fuel hose from fuel cooler and
secure to connector block on cylinder head.
This is to prevent contamination of the fuel
injection system.
10.Release servo vacuum pipe from clip on fuel
cooler and release hose from vacuum pump.
11.Release expansion tank from body mounting,
release clip, disconnect hose and remove tank.