LAND ROVER DISCOVERY 2002 Workshop Manual

ENGINE - TD5
12-1-62 REPAIRS
Valve - relief - oil pressure
$% 12.60.56
Remove
1.Remove sump gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
sump.
2.Remove and discard plug from oil pump
housing.
3.Remove spring and valve.
Refit
1.Clean valve, spring and plug.
2.Clean valve seating inside oil pump housing.
3.Check valve and bore for scoring and
corrosion. Light scoring may be removed using
grade 600 emery cloth soaked in oil.
4.Check spring for distortion, check free length of
spring: Spring free length = 42.00 mm (1.65 in).
CAUTION: Renew relief valve as an
assembly.
5.Lubricate valve and seating.
6.Fit valve and spring to pump.
7.Apply Loctite 243 sealant to threads of new
plug.
CAUTION: Do not attempt to fit original
plug.
8.Fit oil pump pressure relief valve plug and
tighten to 23 Nm (17 lbf.ft).
9.Fit sump gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
sump.
10.Check engine oil level, top-up if necessary.
Switch - oil pressure
$% 12.60.50
Remove
1.Remove fixings and remove engine acoustic
cover.
2.Remove 3 bolts and remove exhaust manifold
heat shield.
3.Disconnect multiplug from oil pressure switch.
4.Position container below switch to catch oil
spillage.
5.Remove oil pressure switch from oil cooler
housing.

ENGINE - TD5
REPAIRS 12-1-63
Refit
1.Clean oil pressure switch threads.
2.Fit oil pressure switch and tighten to 15 Nm (11
lbf.ft).
3.Connect multiplug to oil pressure switch.
4.Position exhaust manifold heatshield and
tighten M6 bolts to 9 Nm (7 lbf.ft) and M8 bolts
to 25 Nm (18 lbf.ft).
5.Fit and secure engine acoustic cover.
6.Top up engine oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - diesel engine.
Cooler - engine oil
$% 12.60.68
Remove
1.Drain cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
2.Remove centrifuge assembly.

+ ENGINE - Td5, REPAIRS, Gasket -
centrifuge oil drain pipe.
3.Remove clutch housing bolt and release
coolant pipe from rear of engine.
4.Release clip and coolant hose from oil cooler.
5.Disconnect multiplug from oil pressure switch.
6.Remove full-flow oil filter element using a
suitable strap wrench.
7.Remove 3 bolts, remove oil filter adaptor
housing and discard gasket.
8.Remove 7 bolts, remove oil cooler and discard
gasket.
9.Remove oil pressure switch.

ENGINE - TD5
12-1-64 REPAIRS
Refit
1.Clean oil cooler and mating faces.
2.Fit oil pressure switch and tighten to 9 Nm (7
lbf.ft).
3.Position new gasket and fit oil cooler housing,
tighten bolts to 25 Nm (18 lbf.ft).
4.Position and fit oil filter adaptor housing,
tighten bolts to 25 Nm (18 lbf. ft).
5.Fit oil filter, tighten hand tight then a further half
turn.
6.Position coolant hose to oil cooler and secure
clip.
7.Position coolant pipe bolt and tighten to 50 Nm
(37 lbf.ft) .
8.Connect multiplug to oil pressure switch.
9.Fit centrifuge assembly.

+ ENGINE - Td5, REPAIRS, Gasket -
centrifuge oil drain pipe.
10.Refill cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
11.Top up engine oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - diesel engine.
Gasket - centrifuge oil drain pipe
$% 12.60.90
Remove
1.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.
2.Remove fixings and remove underbelly panel.
3.Remove 2 bolts securing centrifuge drain to
engine sump and discard gasket. (Some
models are fitted with studs and nuts,
others with bolts).
4.Remove turbocharger.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Turbocharger.
5. Models with air conditioning: Remove
auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
6. Models with air conditioning: Remove 4 bolts
securing compressor and move to one side.

ENGINE - TD5
REPAIRS 12-1-65
7.Remove 3 bolts securing centrifuge to engine
oil cooler.
8.Remove centrifuge and discard 'O' ring.
9.Remove 2 bolts, remove drain pipe from
centrifuge and discard gasket. Refit
1.Clean mating faces of centrifuge, oil cooler and
sump.
2.Position new gasket and fit oil drain pipe to
centrifuge, tighten bolts to 10 Nm (7 lbf.ft).
CAUTION: Gasket must be fitted dry.
3.Position new 'O' ring to oil cooler.
4.Position centrifuge to oil cooler housing and
tighten bolts to 25 Nm (18 lbf.ft).
5.Using a new gasket, align the centrifuge oil
drain pipe to sump and tighten bolts to 10 Nm
(7 lbf.ft).
CAUTION: Gasket must be fitted dry.
6. Models with air conditioning: Position A/C
compressor and tighten bolts to 25 Nm (18
lbf.ft).
7.Fit turbocharger.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Turbocharger.
8. Models with air conditioning: Fit auxiliary
drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
9.Fit underbelly panel and secure with fixings.
10.Remove stand(s) and lower vehicle.

ENGINE - TD5
12-1-66 REPAIRS
Rotor - centrifuge
$% 12.60.91
Remove
1.Remove 2 bolts and remove centrifuge cover.
2.Remove and discard 'O' ring and rotor.
Refit
1.Clean centrifuge body and cover.
2.Fit new rotor.
3.Using a new 'O' ring, fit centrifuge cover and
tighten bolts to 10 Nm (7 lbf.ft).
Seal - oil - timing cover
$% 12.65.05
Remove
1.Remove crankshaft pulley.

+ ENGINE - Td5, REPAIRS, Pulley -
crankshaft.
2.Position tool LRT-12-092 into crankshaft front
oil seal and discard seal.
Refit
1.Using a lint free cloth, thoroughly clean oil seal
recess and the running surface on crankshaft
pulley.
2.Position new seal into timing chain housing.
Drift seal into place using tool LRT-12-156.
CAUTION: Oil seal must be fitted dry.

ENGINE - TD5
REPAIRS 12-1-67
3.Remove tool LRT-12-156.
4.Fit crankshaft pulley.

+ ENGINE - Td5, REPAIRS, Pulley -
crankshaft.

ENGINE - TD5
12-1-68 REPAIRS

ENGINE - TD5
OVERHAUL 12-1-69
OVERHAUL
Gasket - inlet manifold
$% 30.15.08.01
Disassembly
Note: The following procedures cover engines
fitted with or without an EGR cooler. The EGR
cooler is bolted to the front of the cylinder head.
EU3 Engine in main illustration, Pre EU3 condition
shown in inset
1.Remove and discard 2 Allen screws securing
EGR pipe to exhaust manifold or EGR cooler.
2. Remove bolt securing EGR pipe to cylinder
head, (if fitted)
3.Disconnect multiplug from IAT and MAP
sensor.
4.Remove 4 bolts securing fuel cooler to inlet
manifold. and remove cooler.
5.Remove bolt securing engine dipstick tube to
camshaft carrier.
6.Release and remove engine dipstick tube.
7.Remove 'O' ring from dip stick tube.
8.Disconnect 4 leads from glow plugs.
9. Remove 2 bolts securing alternator strap
bracket, remove bracket, (if fitted)
10.Remove 2 nuts and 8 bolts and remove inlet
manifold.
11.Remove manifold gasket. Reassembly
1.Clean inlet manifold and mating face, clean
mating faces of EGR pipe, exhaust manifold or
EGR cooler – if fitted.
2.Fit new gasket.
3.Position inlet manifold and working from the
centre outwards, fit inlet manifold nuts and
bolts and tighten to 25 Nm (18 lbf.ft) .
4. Fit alternator strap bracket and tighten bolts to
25 Nm (18 lbf.ft), (if fitted)
5.Connect glow plug leads.
6.Clean engine dipstick tube.
7.Fit new 'O' ring to dipstick tube.
8.Fit engine dipstick tube to camshaft carrier and
tighten bolt to 10 Nm (7 lbf.ft).
9.Position fuel cooler and tighten bolts to 25 Nm
(18 lbf.ft).
10.Connect multiplug to IAT and MAP sensor.
11.Position EGR pipe to exhaust manifold or EGR
cooler and using new Allen screws tighten to 10
Nm (7 lbf.ft).
12. Fit EGR pipe clamp to cylinder head, (if fitted)
and tighten bolt to 10 Nm (7 lbf.ft).

ENGINE - TD5
12-1-70 OVERHAUL
Gasket - exhaust manifold
$% 30.15.12.01
Disassembly
Note: The following procedure covers engines
fitted with or without an EGR cooler. The EGR
cooler is bolted to the front of the cylinder head.
EU3 engine illustrated
1.Remove 3 bolts securing heater pipe to
cylinder head and turbocharger heat shield.
2.Remove heater pipe.
3.Remove bolt and remove turbocharger heat
shield.
4.Remove and discard 2 Allen screws securing
EGR pipe to exhaust manifold.
5.Remove banjo bolt securing oil feed pipe to
turbocharger and discard sealing washers.
6.Loosen turbocharger drain hose union at
cylinder block.
7.Remove 10 nuts and remove exhaust manifold
and turbocharger.
8.Remove manifold gasket.
Reassembly
1.Clean exhaust manifold mating faces.
2.Position exhaust manifold to cylinder head
using new gasket and fit manifold nuts.
Working from the centre outwards, fit and
tighten nuts to 25 Nm (18 lbf.ft).
3.Clean turbocharger drain and feed hose
unions. 4.Fit turbocharger oil drain hose to cylinder block
and tighten union to 48 Nm (35 lbf.ft) .
5.Fit new sealing washers to turbocharger oil
feed pipe, fit banjo bolt and tighten to 25 Nm
(18 lbf.ft).
6.Position EGR pipe to exhaust manifold. Fit new
Allen screws and tighten to 10 Nm (7 lbf.ft).
7.Position turbocharger heat shield.
8.Position heater pipe to cylinder head and
tighten bolts to 25 Nm (18 lbf.ft).
9.Position exhaust manifold heatshield and
tighten M6 bolts to 9 Nm (7 lbf.ft) and M8 bolt
to 25 Nm (18 lbf.ft).

ENGINE - TD5
OVERHAUL 12-1-71
Gasket - cylinder head
$% 12.29.02.01
Disassembly
Note: The following procedures cover engines
fitted with or without an EGR cooler. The EGR
cooler is bolted to the front of the cylinder head.
1.Remove exhaust manifold gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- exhaust manifold.
2.Remove inlet manifold gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- inlet manifold.
3. EGR cooler fitted: Remove and discard 2
Allen screws securing EGR pipe to cooler.
4.Progressively loosen then remove 13 bolts
securing camshaft cover, remove cover;
remove and discard gasket.
5.Remove isolators and sealing washers from
cover.
6.Disconnect injector multiplug from camshaft
carrier.
7.Disconnect multiplug from ECT sensor.
8.Remove bolt securing alternator strap bracket
to cylinder head.9.Using crankshaft pulley bolt, rotate crankshaft
and set engine to TDC No.1 cylinder firing -
coloured links on timing chain must be aligned
with timing mark on camshaft sprocket.
10.Fit timing pin LRT-12-058 into slot in camshaft.
11.Disconnect alternator/vacuum pump oil feed
pipe union from cylinder head, remove and
discard 'O' ring.
12.Remove camshaft sprocket access plug from
front of cylinder head, remove and discard 'O'
ring.
13.Remove timing chain fixed guide Allen screw.
14.Remove timing chain tensioner, remove and
discard sealing washer.
15.Remove and discard 3 bolts securing camshaft
sprocket to camshaft; release sprocket from
camshaft.