Discovery 2. Manual — part 729

CHARGING AND STARTING

REPAIRS

86-1-3

5. Remove alternator from mounting bracket.
6. Remove pulley from alternator.

Refit

1. Fit alternator pulley and tighten nut to 80 Nm

(59 lbf.ft).

2. Position alternator to mounting bracket.
3. Connect alternator cables and tighten B+ nut to

18 Nm (13 lbf.ft), and D+ nut to 5 Nm (3.7 lbf.ft).

4. Locate alternator in mounting bracket.
5. Fit alternator mounting bolts and tighten to 45

Nm (33 lbf.ft).

6. Fit auxiliary drive belt.

+

CHARGING AND STARTING,

REPAIRS, Belt - auxiliary drive.

Belt - auxiliary drive

$% 86.10.03

Remove

1. Remove viscous fan:

l

+

COOLING SYSTEM - V8,

REPAIRS, Fan - viscous.

l

+

COOLING SYSTEM - Td5,

REPAIRS, Fan - viscous.

2. Turn drive belt tensioner using a 15 mm ring

spanner and release belt from pulleys.

Refit

1. Clean drive belt pulley grooves and ensure

grooves are not damaged.

2. Fit new drive belt around pulleys, ensure belt is

correctly aligned in pulley grooves.

3. With assistance, hold tensioner fully clockwise

and fit drive belt around remaining pulley.
Release tensioner.

4. Fit viscous fan:

l

+

COOLING SYSTEM - Td5,

REPAIRS, Fan - viscous.

l

+

COOLING SYSTEM - V8,

REPAIRS, Fan - viscous.

CHARGING AND STARTING

86-1-4

REPAIRS

Battery

$% 86.15.01

Remove

1. Release fixings and remove battery cover.
2. Disconnect both battery leads, negative lead

first.

3. Remove lock nuts and retaining nuts securing

battery clamp.

4. Remove battery clamp.
5. Remove battery.

Refit

1. Clean battery terminals and coat with

petroleum jelly.

2. Fit battery.
3. Fit battery clamp and tighten retaining nuts and

lock nuts.

4. Fit both battery leads, negative lead last.
5. Fit battery cover and secure fixings.

Battery carrier

$% 86.15.11

Remove

1. Remove battery.

+

CHARGING AND STARTING,

REPAIRS, Battery.

2. Release strap and remove jack.
3. Release coolant hose from clip.
4. Diesel models: Remove screw securing ECM,

release ECM and position aside.

5. Remove 7 bolts securing battery carrier.
6. Remove battery carrier.

NOTE: Do not carry out further dismantling if
component is removed for access only.

7. Remove jack retaining strap, speed nut and

clip.

CHARGING AND STARTING

REPAIRS

86-1-5

Refit

1. Fit jack retaining strap, speed nut and clip.
2. Fit battery carrier, fit bolts and tighten to 28 Nm

(21 lbf.ft).

3. Diesel models: Fit ECM and secure with

screw.

4. Secure coolant hose.
5. Fit and secure jack.
6. Fit battery.

+

CHARGING AND STARTING,

REPAIRS, Battery.

Starter motor - diesel

$% 86.60.01

Remove

1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Raise front of vehicle.

WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.

4. Remove underbelly panel.

+

EXTERIOR FITTINGS, REPAIRS,

Panel - underbelly.

5. Disconnect Lucar connector from starter

solenoid.

6. Remove nut and disconnect battery lead from

starter solenoid.

7. Remove nut and 2 bolts securing starter motor

and remove starter motor from engine.

Refit

1. Clean starter motor and mating face on engine.
2. Fit starter motor and tighten nut and 2 bolts to

27 Nm (20 lbf.ft).

3. Connect lead to starter solenoid and tighten nut

to 10 Nm (7 lbf.ft).

4. Connect Lucar connector to starter solenoid.
5. Fit underbelly panel.

+

EXTERIOR FITTINGS, REPAIRS,

Panel - underbelly.

6. Remove stand(s) and lower vehicle.
7. Connect battery earth lead.
8. Fit battery cover and secure the fixings.

CHARGING AND STARTING

86-1-6

REPAIRS

Starter motor - V8

$% 86.60.01

Remove

1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Raise front of vehicle.

WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.

4. Remove 3 nuts securing exhaust flange to

front pipe, release front pipe and collect
gasket.

5. Remove bolt securing heat shield to engine

mounting bracket, release heat shield from
starter motor and remove from vehicle.

6. Remove nut securing battery lead to starter

solenoid and release lead.

7. Disconnect Lucar connector from starter

solenoid.

8. Remove 2 Allen bolts securing starter motor

and remove starter motor from engine.

Refit

1. Clean starter motor and mating face on engine.
2. Fit starter motor and tighten Allen bolts to 44

Nm (32 lbf.ft).

3. Connect Lucar connector to starter solenoid.
4. Fit battery lead to solenoid and tighten nut.
5. Position heat shield to starter motor, locate tag

in engine mounting bracket, fit bolt and tighten
to 10 Nm (7 lbf.ft).

6. Clean exhaust manifold and front pipe mating

faces.

7. Using a new gasket, position front pipe, fit nuts

and tighten to 30 Nm (22 lbf.ft).

8. Remove stand(s) and lower vehicle.
9. Connect battery earth lead.

10. Fit battery cover and secure fixings.