engine LAND ROVER DISCOVERY 2002 Workshop 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
12-1-44 REPAIRS
Rocker shaft assembly
$% 12.29.29
Remove
1.Remove cooling fan.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
2.Remove camshaft cover gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
cover - camshaft.
3.Loosen lock nuts and fully retract rocker
adjusting screws to prevent damage on
reassembly. 4.Rotate engine clockwise, until camshaft
sprocket and timing chain marks are aligned
and fit tool LRT-12-058 through camshaft
carrier to lock camshaft.
5.Progressively loosen then remove and discard
6 bolts securing rocker shaft assembly.
6.Remove and discard lock nuts and rocker
adjusting screws.

ENGINE - TD5
REPAIRS 12-1-45
Refit
1.Clean rocker shaft and mating faces.
CAUTION: If rockers or rocker shaft are to
be replaced, ensure replacements are
correct. Engine Serial No. Prefixes 10P to
14P are fitted with type A rocker arms and
shaft. Engine Serial No. Prefixes 15P to 19P
are fitted with type B rocker arms and shaft.
Type B rocker arms and shaft may be fitted
to Engine Serial No. Prefixes 10P to 14P as
an assembly.
2.Fit new rocker adjusting screws fully into rocker
arm. Fit new lock nuts to screws but do not
tighten.
CAUTION: Ensure screws are correct for
type of rocker arms fitted. Replacement
screws for Engine Serial No. Prefixes 15P to
19P have a centre punch mark adjacent to
the adjusting slot. These screws are not
interchangeable with those fitted to Engine
Serial No. Prefixes 10P to 14P.
3.Fit rocker shaft ensuring it is located on dowel.
4.Fit and progressively tighten new rocker shaft
bolts to 33 Nm (24 lbf.ft). 5.Before refitting the camshaft cover the
electronic injection unit (EUI) rockers must be
adjusted.
6.Remove tool LRT-12-058 from camshaft.
7.Rotate engine clockwise until No 1 injector lobe
is at full lift.
8.Rotate rocker adjusting screw clockwise until
the injector plunger is felt to bottom out.
9.Rotate rocker adjusting screw anti-clockwise
one complete turn to give plunger the required
bump clearance and tighten rocker arm
adjusting screw locknut to 16 Nm (12 lbf.ft) .
CAUTION: Ensure screw does not turn as
locknut is tightened.
10.Carry out above procedure for the remaining 4
rocker arms.
11.After completion of rocker arm adjustment,
slowly rotate engine clockwise 2 complete
turns by hand to ensure that no injectors are
bottoming out on their plungers.
12.Fit camshaft cover gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
cover - camshaft.
13.Fit cooling fan coupling.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.

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
12-1-48 REPAIRS
12.Disconnect vacuum hose from EGR valve.
13.Remove engine compartment fuse box cover.
14.Remove bolts securing battery and alternator
leads to fuse box.
15.Remove bolt securing glow plug lead to fuse
box.
16.Disconnect 2 engine harness multiplugs from
fuse box. 17.Disconnect 2 engine harness multiplugs from
ECM and main harness.
18.Remove bolt securing engine earth lead to
battery earth lead.
19.Disconnect multiplug from EGR modulator.

ENGINE - TD5
REPAIRS 12-1-49
20.Disconnect multiplug from CKP sensor.
21.Remove bolt securing CKP sensor to gearbox
housing and discard 'O' ring.
CAUTION: If fitted: Retain CKP sensor.
22.Loosen clip securing air inlet hose to
turbocharger and remove hose.
23.Disconnect multiplugs from compressor, MAF
sensor, turbocharger boost solenoid valve,
AAP & IAT sensor.
24.Release clip and disconnect hose from
turbocharger boost solenoid valve. 25.Loosen bolts securing PAS pulley.
26.Rotate ancillary drive belt tensioner anti-
clockwise, release and remove drive belt.
27.Release clips and remove air intake hose from
air cleaner.
28.Remove 4 bolts and move compressor aside.
29.Remove 3 bolts and move ACE pump aside.
30.Remove 3 bolts and remove PAS pump pulley.
31.Remove 4 bolts and move PAS pump aside.

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.