oil LAND ROVER DISCOVERY 2002 Owners Manual

ENGINE - TD5
12-1-42 REPAIRS
37.Using suitable lifting chains and tool LRT-12-
138 carefully remove cylinder head and place
on wooden blocks or stands.
CAUTION: Support both ends of cylinder
head on blocks of wood. With the camshaft
carrier bolted down, the injector nozzles
and some of the valves will protrude from
the face of the cylinder head.
38.Remove cylinder head gasket.
39.Note the gasket thickness indicator and ensure
the same thickness gasket is used on refitment
of cylinder head.
40.Remove and discard plastic dowels from
cylinder block.Refit
1.Clean mating faces of cylinder head and
cylinder block.
2.Check cylinder head for warping, across centre
and from corner to corner: – Maximum warp =
0.10 mm (0.0004 in)
CAUTION: Cylinder heads may not be
refaced, replace cylinder head if warping
exceeds figure given.
3.Ensure coolant and oil passages are clean.
4.Clean dowel holes and fit new plastic dowels.
5.Lightly lubricate threads and beneath heads of
cylinder head bolts with clean engine oil.
6.Fit new cylinder head gasket of the correct
thickness with the word 'TOP' uppermost.
7.Using assistance, fit cylinder head and locate
onto dowels.
8.Carefully enter cylinder head bolts, DO NOT
DROP. Lightly tighten bolts.
9.Using the sequence shown, progressively
tighten cylinder head bolts to 30 Nm (22 lbf.ft),
then to 65 Nm (48 lbf.ft), then a further 90
°, then
a further 180
° and finally a further 45°.
CAUTION: Ensure correct sequence is
followed for all 5 tightening stages. Do not
tighten bolts 315 degrees in one operation.
10.Fit nut and bolt securing cylinder head to timing
chain cover and tighten to 25 Nm (18 lbf.ft).

ENGINE - TD5
REPAIRS 12-1-43
11.Clean camshaft sprocket and mating face on
camshaft.
12.Ensure engine is set to TDC No. 1 cylinder and
mark on camshaft sprocket is positioned
between the 2 coloured links.
13.Position camshaft sprocket to camshaft; fit and
lightly tighten new bolts, then loosen bolts half
a turn.
14.Clean timing chain fixed guide retaining pin and
apply Loctite 242 to threads.
15.Fit timing chain fixed guide retaining pin and
tighten to 25 Nm (18 lbf.ft) .
16.Clean timing chain tensioner and fit new
sealing washer.
17.Fit timing chain tensioner and tighten to 45 Nm
(22 lbf.ft).
18.Tighten bolts securing camshaft sprocket to
camshaft to 37 Nm (27 lbf.ft).
19.Remove tool LRT-12-058 from camshaft.
20.Remove tool LRT-12-158 from gearbox bell
housing.
21.Fit new camshaft bore blanking plug and 'O'-
ring seal in recess in cylinder head.
22.Clean vacuum pump union.
23.Tighten union securing vacuum pump oil feed
pipe to cylinder head to 10 Nm (7 lbf.ft) .
24.Fit bolts securing alternator support bracket to
cylinder head and tighten to 25 Nm (18 lbf.ft) .
25.Connect top hose and heater hoses and secure
with clips.
26. Pre EU3 model:Fit bolt securing EGR pipe
clamp to cylinder head bolt and tighten to 10
Nm (7 lbf.ft) .
27. EU3 model: Connect coolant hoses to EGR
cooler and secure with the clips.
28.Position air intake hose to EGR valve and
tighten clip screw.
29.Disconnect fuel hose from connector block and
connect to fuel cooler.
30.Connect fuel hoses to fuel cooler and
connector block on cylinder head.
31.Connect coolant hoses to fuel cooler and
secure clips.
32.Connect vacuum hose to EGR valve.
33.Position engine harness and connect multi
plugs and glow plug connectors.
34.Fit and tighten bolts, engine harness to
camshaft carrier.
35.Clean exhaust manifold and turbocharger
interface.
36.Fit new gasket to exhaust manifold, position
turbocharger and tighten – nuts securing
turbocharger to manifold to 30 Nm (22 lbf.ft).
37.Clean turbocharger oil feed hose bolt.
38.Position turbocharger oil feed hose using new
sealing washers. Fit banjo bolt securing
turbocharger oil feed hose and tighten to 25 Nm
(18 lbf.ft) . 39.Position exhaust manifold heatshield and
tighten M6 bolts to 9 Nm (7 lbf.ft) and M8 bolt to
25 Nm (18 lbf.ft).
40.Fit cooling fan coupling.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
41.Fit camshaft cover with new seal.

+ ENGINE - Td5, REPAIRS, Gasket -
cover - camshaft.
42.Refill cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
43.Connect battery earth lead.
44.Fit battery cover and secure fixings.
45.Fit bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.

ENGINE - TD5
12-1-46 REPAIRS
Gasket - cover - camshaft
$% 12.29.40
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Release clip and disconnect breather hose
from camshaft cover.
3.Remove 13 bolts securing camshaft cover.
4.Collect sealing washers and spacers.
5.Remove camshaft cover and gasket.
Refit
1.Clean camshaft cover and mating face.
2.Renew sealing washers and spacers as
necessary. 3. Not EU3 model:- Apply two 3 mm diameter
beads of sealant, STC 5433, to areas 'A' shown
on illustration.
Excessive use of sealant could result in
blockage of oil drain hole, arrowed 'B' on
illustration.
4.Fit new gasket, fit camshaft cover to camshaft
carrier and tighten – camshaft cover bolts to 9
Nm (7 lbf.ft).
5.Position breather hose to camshaft cover and
secure with clip.
6.Fit engine acoustic cover and secure with
fixings.
M12 7538
A
B
A

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.

ENGINE - TD5
12-1-50 REPAIRS
32.Release clip and disconnect hose from coolant
pump.
33.Release clip and disconnect heater hose from
coolant rail.
34.Remove bolt securing coolant rail to front
chassis member.
35.Raise vehicle on ramp.
36.Release coolant rail support brackets from
engine LH and RH mounting brackets.
37.Remove coolant rail.
38.Remove starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.39.Remove and discard 3 bolts securing torque
converter to drive plate.
40.Remove 2 bolts securing gearbox oil cooler
pipe clips from sump and alternator mounting
bracket.
41.Mark position of gearbox oil cooler pipe
clamps.
42.Remove 3 nuts and remove oil cooler pipe
clamps.
43.Loosen RH oil cooler pipe union.
44.Move pipes aside and tighten RH pipe union.

ENGINE - TD5
REPAIRS 12-1-51
45.Remove 8 bolts and remove front cross
member.
46.Remove 6 bolts securing gearbox housing to
engine.
47.Remove 4 bolts and nuts securing RH and LH
front engine mountings to chassis.
48.Lower vehicle ramp. 49.Remove 2 upper bolts securing gearbox
housing and oil cooler coolant pipe to engine.
50.Release clip, disconnect hose from engine oil
cooler and move aside.
51.Remove bolt securing engine closing panel to
gearbox.
52.Fit tool LRT-12-138 to lifting chains and
connect to lifting eyes on engine.
53.Remove 2 nuts from RH and LH front engine
mountings.
54.Position trolley jack to support gearbox.
55.With assistance, raise chains, remove engine
from vehicle and lower onto bench.
Refit
1.With assistance, raise engine from bench and
position in vehicle.
2.With assistance, align engine to gearbox and
torque converter.
3.Position engine RH and LH mountings to
brackets and fit nuts.
4.Position engine oil cooler pipe, connect hose to
oil cooler and secure with clip.

ENGINE - TD5
12-1-52 REPAIRS
5.Fit 2 upper bolts securing engine oil cooler pipe
and gearbox housing to engine and tighten to
50 Nm (37 lbf.ft) .
6.Lower engine onto mountings, and tighten nuts
to 85 Nm (63 lbf.ft) .
7.Remove tool LRT-12-138 from engine.
8.Fit and tighten bolt securing engine closing
panel to gearbox.
9.Raise vehicle on ramp.
10.Fit nuts and bolts securing engine LH and RH
mountings to chassis and tighten to 85 Nm (63
lbf.ft).
11.Fit remaining bolts securing gearbox housing to
engine and tighten to 50 Nm (37 lbf.ft).
12.Rotate crankshaft and align drive plate to
torque converter.
13.Using a magnetic socket, fit and tighten new
torque converter drive plate bolts to 50 Nm (37
lbf.ft) .
14.Fit front cross member and tighten bolts to 26
Nm (19 lbf.ft).
15.Align gearbox oil cooler pipes.
16.Fit oil cooler pipe clip and tighten bolts to 9 Nm
(7 lbf.ft).
17.Position gearbox oil cooler pipe clamps and
tighten nuts.
18.Position coolant rail and secure support bracket
in engine LH and RH mounting brackets.
19.Fit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
20.Lower ramp.
21.Position coolant rail to front chassis member, fit
and tighten bolt to 10 Nm (7 lbf.ft).
22.Connect heater hose to coolant rail and secure
with clip.
23.Connect hose to coolant pump and secure with
clip.
24.Position PAS pump and tighten bolts to 25 Nm
(18 lbf.ft).
25.Position PAS pump pulley and lightly tighten
bolts.
26.Position ACE pump, fit bolts and tighten to 25
Nm (18 lbf.ft).
27.Position A/C compressor, fit bolts and tighten
to 25 Nm (18 lbf.ft).
28.Position ancillary drive belt, rotate tensioner
anti-clockwise and locate belt to pulleys.
29.Tighten PAS pump pulley bolts to 10 Nm (7
lbf.ft).
30.Position air intake hose to air cleaner and
secure clips.
31.Position engine harness and connect
multiplugs to compressor, MAF sensor,
turbocharger boost solenoid, AAP & IAT
sensor.
32.Position air inlet hose to turbocharger and
tighten clip. 33.Connect hoses to turbocharger boost solenoid
and secure clips.
34.Clean CKP sensor and mating face.
CAUTION: If originally fitted: Fit spacer to
CKP sensor.
35.Using new 'O' ring, fit CKP sensor, tighten CKP
sensor bolt to 9 Nm (7 lbf.ft) and connect
multiplug.
36.Connect multiplug to EGR modulator.
37.Connect engine earth lead to battery earth lead
and tighten bolt.
38.Connect engine harness multiplug to ECM and
main harness.
39.Connect engine harness multiplugs to fuse
box.
40.Position glow plug lead to fusebox and secure
with bolt.
41.Position battery and alternator leads to fusebox
and secure with bolts.
42.Fit engine compartment fuse box cover.
43.Connect vacuum hose to EGR valve.
44.Connect hose to vacuum pump and secure
vacuum pipe to fuel cooler.
45.Disconnect fuel hose from connector block and
connect to fuel cooler.
46.Connect fuel hoses to fuel cooler and
connector block on cylinder head.
47.Position expansion tank, connect hose and
secure with clip. Secure tank to body mounting.
48.Connect coolant hoses to fuel cooler and
coolant rail and secure clips.
49.Fit turbocharger.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Turbocharger.
50. Fit radiator.

+ COOLING SYSTEM - Td5, REPAIRS,
Radiator.
51.Fill engine with oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - diesel engine.
52.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
53.Fit bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.

ENGINE - TD5
REPAIRS 12-1-53
Mounting - front - LH
$% 12.45.01
Remove
1.Remove centrifuge assembly.

+ ENGINE - Td5, REPAIRS, Gasket -
centrifuge oil drain pipe.
2.Remove 3 bolts, remove oil filter adaptor
housing and discard gasket.
3.Fit suitable lifting chains to support engine.
4.With assistance remove 2 bolts securing
engine mounting to chassis.
5.Remove 4 bolts securing engine mounting
bracket to cylinder block.
6.Remove nut securing mounting to mounting
bracket.
7.Remove mounting and mounting bracket.
8.Remove mounting shield.
Refit
1.Fit shield to mounting. 2.Fit mounting and mounting bracket.
3.Fit mounting bracket to cylinder block and
tighten – bolts securing front LH engine
mounting bracket to cylinder block to 48 Nm (35
lbf.ft).
4.With assistance, fit mounting to chassis and
tighten – bolts securing front LH engine
mounting to chassis to 85 Nm (63 lbf.ft).
5.Fit mounting to mounting bracket and tighten –
nut securing front LH mounting to mounting
bracket to 85 Nm (63 lbf.ft).
6.Remove engine support chains.
7.Clean oil filter adaptor housing and mating
face.
8.Fit oil filter adaptor housing to oil cooler
housing and tighten bolts to 25 Nm (18 lbf.ft).
9.Fit centrifuge assembly.

+ ENGINE - Td5, REPAIRS, Gasket -
centrifuge oil drain pipe.

ENGINE - TD5
REPAIRS 12-1-57
Filter - oil
$% 12.60.04
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Remove 3 bolts and remove exhaust manifold
heat shield.
3.Clean area around filter head and place a
container beneath engine.
4.Using a strap wrench, unscrew and discard
filter. Refit
1.Clean mating face of filter head.
2.Lubricate sealing ring of new filter with clean
engine oil.
3.Fit filter and tighten by hand until it seats then
tighten a further three-quarters of a turn.
4.Start and run engine to check for leaks.
5.Stop engine, wait a few minutes, then check oil
level.
6.Top up engine oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - diesel engine.
7.Position exhaust manifold heatshield and
tighten M6 bolts to 9 Nm (7 lbf.ft) and M8 bolts
to 25 Nm (18 lbf.ft).
8.Fit engine acoustic cover and secure with
fixings.

ENGINE - TD5
12-1-58 REPAIRS
Strainer - oil pick-up
$% 12.60.20
Remove
1.Remove sump gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
sump.
2.Remove 3 Torx screws securing oil pick- up
strainer.
3.Remove and discard 'O' ring.
Refit
1.Clean oil pick up strainer faces.
2.Fit new 'O' ring to oil pick-up strainer.
3.Clean threads of Torx screws.
4.Fit oil pick-up strainer, apply Loctite 242 to
threads of Torx screws, fit screws and tighten to
10 Nm (7 lbf.ft).
5.Fit new sump gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
sump.
Pump - oil
$% 12.60.26
Remove
1.Remove sump gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
sump.
2.Hold oil pump drive sprocket and remove
retaining bolt.
3.Remove sprocket from oil pump.
4.Remove 3 Torx screws securing oil pick-up
strainer.
5.Remove and discard 'O' ring.