2004 Land Rover Discovery 2 Service & Repair Manual

Workshop Manual Discovery Series II

Discovery Series II WORKSHOP MANUAL - 1999MY ON Publication Part No. VDR 100330 NAS (6) © Land Rover 2003 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form, electronic, mechanical, recording or other means without prior written permission from Land Rover.

CONTENTS CONTENTS 1 INTRODUCTION ...................................................................................... 01-1 How To Use This Manual ................................................................................................................ 01-1 Repairs and Replacements ............................................................................................................. 01-2 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 .................................................................................................................................. 03-27 GENERAL DATA ..................................................................................... 04-1 Engine - Td5 ................................................................................................................................... 04-1 Engine - V8 ..................................................................................................................................... 04-4 Fuel system - Td5 ........................................................................................................................... 04-8 Fuel system - V8 ............................................................................................................................. 04-8 Cooling system - Td5 ...................................................................................................................... 04-9 Cooling system - V8 ........................................................................................................................ 04-10 Clutch - Td5 .................................................................................................................................... 04-11 Clutch - V8 ...................................................................................................................................... 04-12 Manual gearbox - R380 .................................................................................................................. 04-13 Transfer box - LT230SE.................................................................................................................. 04-14 Automatic gearbox - ZF4HP22/24 .................................................................................................. 04-15 Rear axle......................................................................................................................................... 04-16 Front axle ........................................................................................................................................ 04-16 Steering........................................................................................................................................... 04-17 Suspension ..................................................................................................................................... 04-18 Brakes ............................................................................................................................................. 04-19 Wheels and tyres ............................................................................................................................ 04-20 Air conditioning ............................................................................................................................... 04-21 Electrical - Td5 ................................................................................................................................ 04-22 Electrical - V8 .................................................................................................................................. 04-22 Dimensions ..................................................................................................................................... 04-23 Weights ........................................................................................................................................... 04-24

CONTENTS 2 CONTENTS IDENTIFICATION NUMBERS .................................................................. 05-1 Vehicle Identification Number ......................................................................................................... 05-1 Identification Number Locations ..................................................................................................... 05-3 TORQUE WRENCH SETTINGS .............................................................. 06-1 Maintenance ................................................................................................................................... 06-1 Engine Td5 ..................................................................................................................................... 06-2 Engine V8 ....................................................................................................................................... 06-4 Emission control - Td5 .................................................................................................................... 06-5 Emission control - V8 ...................................................................................................................... 06-5 Engine management system - Td5 ................................................................................................. 06-6 Engine management system - V8................................................................................................... 06-6 Cooling system ............................................................................................................................... 06-7 Manifolds and exhaust systems - Td5 ............................................................................................ 06-8 Manifolds and exhaust systems - V8 .............................................................................................. 06-8 Clutch.............................................................................................................................................. 06-9 Manual gearbox - R380 .................................................................................................................. 06-10 Transfer box - LT230SE ................................................................................................................. 06-11 Automatic gearbox - ZF4HP22 ....................................................................................................... 06-12 Propeller shafts ............................................................................................................................... 06-13 Axles ............................................................................................................................................... 06-13 Steering .......................................................................................................................................... 06-14 Front suspension ............................................................................................................................ 06-15 Rear suspension ............................................................................................................................. 06-16 Brakes............................................................................................................................................. 06-17 Restraint systems ........................................................................................................................... 06-18 Body................................................................................................................................................ 06-19 Heating and air conditioning ........................................................................................................... 06-20 Wipers and washers ....................................................................................................................... 06-20 Electrical ......................................................................................................................................... 06-21 LIFTING AND TOWING ........................................................................... 08-1 LIFTING .......................................................................................................................................... 08-1 TOWING ......................................................................................................................................... 08-2 TRANSPORTING ........................................................................................................................... 08-4 CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS ...................... 09-1 Capacities ....................................................................................................................................... 09-1 Fluids .............................................................................................................................................. 09-2 Anti-Freeze Concentration .............................................................................................................. 09-2 Lubrication ...................................................................................................................................... 09-3 Sealants .......................................................................................................................................... 09-4

CONTENTS CONTENTS 3 MAINTENANCE ........................................................................................ 10-1 PROCEDURES V8 engine underbonnet view .......................................................................................................... 10-1 Diesel underbonnet view................................................................................................................. 10-2 Seats and seat belts ...................................................................................................................... 10-3 Lamps, horns and warning indicators ............................................................................................. 10-5 Wipers and washers ...................................................................................................................... 10-5 Handbrake .................................................................................................................................. 10-6 Alarm handset battery ..................................................................................................................... 10-6 Road wheels ................................................................................................................................... 10-6 Tyres .............................................................................................................................................. 10-6 Brake pads, discs and calipers ....................................................................................................... 10-6 Road wheel speed sensors ............................................................................................................. 10-7 Brake fluid ....................................................................................................................................... 10-7 Fuel filter - diesel engine ................................................................................................................. 10-7 Fuel filter sedimenter ...................................................................................................................... 10-7 Road wheels ................................................................................................................................... 10-8 Radiator/Intercooler ........................................................................................................................ 10-8 Ambient air Temperature and pressure sensor .............................................................................. 10-8 Doors, bonnet and fuel filler flap ..................................................................................................... 10-8 Air suspension intake filter .............................................................................................................. 10-9 Anti-freeze....................................................................................................................................... 10-9 Cooling system ............................................................................................................................... 10-9 Spark plugs - V8 engine.................................................................................................................. 10-10 Air cleaner - V8 engine ................................................................................................................... 10-10 Air cleaner and dump valve - diesel engine .................................................................................... 10-10 Auxiliary drive belt ........................................................................................................................... 10-11 Auxiliary drive belt - V8 engine ....................................................................................................... 10-11 Auxiliary drive belt - diesel engine .................................................................................................. 10-11 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 ................................................................................................................ 10-15 Centrifuge rotor – diesel engine ...................................................................................................... 10-15 Engine oil filter - diesel engine ........................................................................................................ 10-16 Engine oil filter – V8 engine ............................................................................................................ 10-16 Manual gearbox .............................................................................................................................. 10-17 Automatic gearbox ......................................................................................................................... 10-18 Transfer box .................................................................................................................................... 10-19 Front and rear axle .......................................................................................................................... 10-20 Propeller shafts ............................................................................................................................... 10-20 Anti-roll bar links ............................................................................................................................. 10-22 ACE actuators ................................................................................................................................. 10-23 ACE filter ......................................................................................................................................... 10-23

CONTENTS 4 CONTENTS Brake hose, brake, fuel, ACE, clutch pipes and unions/electrical harnesses ................................ 10-24 Engine, gearbox, transfer box and axles ........................................................................................ 10-25 Exhaust system .............................................................................................................................. 10-25 Steering box and front suspension ................................................................................................. 10-25 Steering rod ball joints ................................................................................................................... 10-27 Dampers and SLS height sensors .................................................................................................. 10-27 Front and rear axle suspension links .............................................................................................. 10-28 Towing bracket ............................................................................................................................... 10-29 Engine mountings - V8 engine........................................................................................................ 10-30 Road/roller test ............................................................................................................................... 10-31

CONTENTS CONTENTS 5 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 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 ......................................................................................................................... 12-2-34 Filter - oil ....................................................................................................................................... 12-2-35 Strainer - oil pick-up ...................................................................................................................... 12-2-35 Pump - oil ...................................................................................................................................... 12-2-36 Gasket - sump ................................................................................................................................ 12-2-37 Switch - oil pressure ....................................................................................................................... 12-2-39 Cooler - engine oil .......................................................................................................................... 12-2-39 Gasket - timing gear cover ............................................................................................................ 12-2-41 Seal - cover - timing gears ............................................................................................................ 12-2-43 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 ................................................................................................................. 12-2-55 Gasket - timing gear cover ............................................................................................................. 12-2-56 Timing chain and gears .................................................................................................................. 12-2-58 Rocker shaft - overhaul ................................................................................................................. 12-2-59 Gasket - cylinder head .................................................................................................................... 12-2-61 Cylinder head - overhaul ................................................................................................................ 12-2-63 Piston assemblies ........................................................................................................................... 12-2-67 Bearings - connecting rods ............................................................................................................ 12-2-72 Crankshaft and main bearings ........................................................................................................ 12-2-73 Camshaft ....................................................................................................................................... 12-2-77

CONTENTS 6 CONTENTS EMISSION CONTROL - V8 ....................................................................... 17-2-1 DESCRIPTION AND OPERATION Crankcase emission control system ............................................................................................... 17-2-1 Exhaust emission control ................................................................................................................ 17-2-2 Evaporative emission system component layout ............................................................................ 17-2-3 Evaporative emission system (with positive pressure leak detection) component layout (NAS only) 17-2-4 Evaporative emission system control diagram ............................................................................... 17-2-5 Secondary air injection system component layout.......................................................................... 17-2-6 Secondary air injection system control diagram ............................................................................. 17-2-8 Emission Control Systems .............................................................................................................. 17-2-9 Crankcase Emission Control System ............................................................................................. 17-2-10 Exhaust Emission Control System.................................................................................................. 17-2-11 Evaporative Emission Control System............................................................................................ 17-2-15 Secondary Air Injection System...................................................................................................... 17-2-26 Crankcase Emission Control Operation.......................................................................................... 17-2-34 Exhaust Emission Control Operation .............................................................................................. 17-2-35 Evaporative Emission Control Operation ........................................................................................ 17-2-39 Secondary Air Injection System Operation ..................................................................................... 17-2-43 SAI System Fault Finding and Check Malfunctions ........................................................................ 17-2-44 REPAIRS Canister - EVAP ............................................................................................................................ 17-2-51 Canister - EVAP - Models with Fuel Leak Detection Pump - up to 03MY ...................................... 17-2-52 Canister - EVAP - Models with Fuel Leak Detection Pump - from 03MY ....................................... 17-2-53 Valve - purge control ..................................................................................................................... 17-2-54 Solenoid - evap canister vent solenoid (CVS) valve ..................................................................... 17-2-55 Sensor - heated oxygen (HO2S) - pre-catalytic converter .............................................................. 17-2-56 Sensor - heated oxygen (HO2S) - post-catalytic converter ............................................................ 17-2-57 Control Valve - Secondary Air Injection (SAI) ............................................................................... 17-2-58 Reservoir - Vacuum - Secondary Air Injection (SAI) - up to 03MY ................................................. 17-2-58 Reservoir - vacuum - Secondary Air Injection (SAI) - from 03MY .................................................. 17-2-59 Pump - Air - Secondary Air Injection (SAI) ..................................................................................... 17-2-59 Air Manifold - LH - Secondary Air Injection (SAI) ........................................................................... 17-2-60 Air Manifold - RH - Secondary Air Injection (SAI) .......................................................................... 17-2-61 Solenoid - Vacuum - Secondary Air Injection (SAI) ...................................................................... 17-2-62 Pipe - Secondary Air Injection (SAI) .............................................................................................. 17-2-62 Pump - Fuel Leak Detection - up to 03MY...................................................................................... 17-2-64 Pump - fuel leak detection - from 03MY ......................................................................................... 17-2-64 Filter - fuel leak detection pump - up to 03MY ................................................................................ 17-2-65 Filter - fuel leak detection pump - from 03MY ................................................................................. 17-2-65

CONTENTS CONTENTS 7 ENGINE MANAGEMENT SYSTEM - V8 .................................................. 18-2-1 DESCRIPTION AND OPERATION Engine management component location - Passenger compartment ............................................ 18-2-1 Engine management component location - Engine compartment .................................................. 18-2-2 Engine management block diagram ............................................................................................... 18-2-4 Description - engine management .................................................................................................. 18-2-6 Operation - engine management .................................................................................................... 18-2-49 DESCRIPTION AND OPERATION Cruise control component layout .................................................................................................... 18-2-61 Cruise control block diagram .......................................................................................................... 18-2-62 Description - cruise control ............................................................................................................. 18-2-63 Operation - cruise control ................................................................................................................ 18-2-74 ADJUSTMENTS Cable - throttle ............................................................................................................................. 18-2-77 Cable - cruise control .................................................................................................................... 18-2-77 REPAIRS Spark plugs .................................................................................................................................. 18-2-79 Coil - ignition ................................................................................................................................. 18-2-80 Engine control module (ECM) ......................................................................................................... 18-2-81 Sensor - engine coolant temperature (ECT) ................................................................................ 18-2-82 Sensor - crankshaft position (CKP) ............................................................................................... 18-2-83 Sensor - radiator temperature ....................................................................................................... 18-2-84 Sensor - camshaft position (CMP) ................................................................................................. 18-2-84 Knock sensor (KS) .......................................................................................................................... 18-2-85 Air cleaner assembly ..................................................................................................................... 18-2-86 Element - air filter .......................................................................................................................... 18-2-87 Cable - throttle ................................................................................................................................ 18-2-88 Sensor - Mass Air Flow (MAF) ...................................................................................................... 18-2-89 Throttle Body................................................................................................................................... 18-2-90 Plenum chamber ............................................................................................................................. 18-2-91 Sensor - throttle position (TP) ....................................................................................................... 18-2-91 Valve - idle air control (IACV) ........................................................................................................ 18-2-92 Injectors ......................................................................................................................................... 18-2-92 Actuator - cruise control ................................................................................................................ 18-2-94 Vacuum control unit - up to 03MY................................................................................................... 18-2-94 Vacuum control unit - from 03MY ................................................................................................... 18-2-95 Cable - cruise control ..................................................................................................................... 18-2-96 Switch - cruise control (on/off) ........................................................................................................ 18-2-96 Switch - cruise control (set/resume) ............................................................................................... 18-2-97 Switch - clutch pedal - cruise control ............................................................................................ 18-2-97 ECU - Cruise control ..................................................................................................................... 18-2-98

2004 Land Rover Discovery 2 Service & Repair Manual

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