LAND ROVER DISCOVERY 2002 Workshop Manual

ENGINE - TD5
12-1-82 OVERHAUL
Reassembly
1.Lubricate new valve stem oil seals with engine
oil.
2.Using tool LRT-12-071 fit valve stem oil seals.
3.Lubricate valve guides, valve stems, valve
spring caps and springs with engine oil. 4.Assemble valves, springs and spring caps
ensuring they are in their original fitted order.
5.Compress valve springs using tool LRT-12-
034 , fit collets.
6.Using a wooden dowel and mallet, tap each
spring cap lightly to seat collets.
7.Lubricate new injector 'O' rings with engine oil.
8.Using tool LRT-12-154/2, fit new 'O' ring to
each injector.

ENGINE - TD5
OVERHAUL 12-1-83
9.Using tool LRT-12-154/3, fit new sealing
washer to each injector.
10.Support each end of cylinder head on blocks of
wood ensuring blocks are clear of valves.
11.Position reaction posts in their original fitted
order.
12.Carefully fit EUI's, ensuring they are in their
original fitted order and that each retainer is
located on its dowel.
CAUTION: If new EUI's are fitted, ensure
replacements are correct. Engine Serial No.
Prefixes 10P to 14P – Push rod bushes are
coloured BLACK or BLUE. Serial No.
Prefixes 15P to 19P – Push rod bushes are
coloured GREEN.
13.Fit new retainer bolts and tighten to 32 Nm (24
lbf.ft).
If new injectors are fitted they must be
programmed for use with the ECM using
TestBook.
14.Lubricate lash adjusters and bores with engine
oil.
15.Fit lash adjusters ensuring they are in their
original fitted order.
16.Lubricate finger followers with engine oil.
17.Fit finger followers ensuring they are in their
original fitted order.
18.Lubricate cams and bearing journals on
camshaft, cylinder head and camshaft carrier
with engine oil.
19.Position camshaft in cylinder head with the
timing pin hole in the vertical position.20.Apply an even film of sealant, Part No. STC
4600 to camshaft carrier face and spread to an
even film using a roller.
CAUTION: Ensure sealant does not block
oilways (arrowed) or contaminate camshaft
bearings. Assembly and bolt tightening
must be completed within 20 minutes of
applying sealant.
21.Fit camshaft carrier ensuring it is correctly
located on dowels.
22.Fit and lightly tighten new camshaft carrier
bolts.
23.Using sequence shown, progressively tighten
bolts to 25 Nm (18 lbf.ft).
24.Lubricate a new camshaft rear oil seal with
engine oil, fit seal using a suitable mandrel.
25.Position rocker shaft on camshaft carrier
ensuring rocker shaft is located on dowel.
26.Fit new rocker shaft retaining bolts and working
from the centre outwards, tighten rocker shaft
bolts to 32 Nm (24 lbf.ft).
27.Fit injector harness and connect multiplugs.
28.Clean fuel connector block and mating face.
29.Lubricate a new fuel filter 'O' ring with engine
oil.

ENGINE - TD5
12-1-84 OVERHAUL
30.Fit new fuel filter, 'O' ring, and gasket.
CAUTION: Gasket must be fitted dry.
31. If fitted: Fit fuel connector spacer block and
gasket.
32.Fit fuel connector block, fit bolts and tighten to
25 Nm (18 lbf.ft).
33.Clean glow plugs.
34.Fit glow plugs to cylinder head and tighten to
16 Nm (12 lbf.ft).
35.Fit new cylinder head gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- cylinder head.
36. Engine Serial No. Prefixes 15P to
19P:Lubricate new 'O' rings with engine oil and
fit to spill return pipe, fit pipe and tighten
connectors to 20 Nm (15 lbf.ft).
37.Before fitting the camshaft cover, the fuel
injector rockers must be adjusted following the
procedures given in Cylinder head gasket -
Refit.

+ ENGINE - Td5, OVERHAUL, Gasket
- cylinder head.
Gasket - engine sump
$% 12.60.38.01
Disassembly
1.Remove 2 bolts securing centrifuge oil drain
pipe to sump, remove and discard gasket.
2.Using sequence shown and noting their fitted
positions, remove 20 bolts securing sump to
cylinder block.
3.Release sump from locating dowels, remove
sump; remove and discard gasket.
Reassembly
1.Clean sump and mating faces, ensure bolt
holes in cylinder block are clean and dry.
2.Using suitable solvent, remove all traces of
sealant from joint faces of timing chain cover
and crankshaft rear oil seal housing.
3.Clean centrifuge oil drain pipe and mating
faces.

ENGINE - TD5
OVERHAUL 12-1-85
4.Apply a bead of sealant, Part No. STC 3254 to
joint faces of timing chain cover and crankshaft
rear oil seal housing.
CAUTION: Assembly and bolt tightening
must be completed within 20 minutes of
applying sealant.
5.Position new sump gasket.
CAUTION: Gasket must be fitted dry.
6.Position sump, fit and lightly tighten bolts
ensuring they are in their original fitted
positions.
7.Using sequence shown, tighten sump bolts to
25 Nm (18 lbf.ft).8.Fit new centrifuge oil drain pipe gasket.
CAUTION: Gasket must be fitted dry.
9.Fit centrifuge oil drain pipe, fit bolts and tighten
to 10 Nm (7 lbf.ft).

ENGINE - TD5
12-1-86 OVERHAUL
Seal - crankshaft - rear - manual models
$% 12.21.20.01
Disassembly
1.Remove flywheel.

+ ENGINE - Td5, OVERHAUL,
Flywheel.
2.Remove sump gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- engine sump.
3.Remove 5 bolts securing crankshaft rear oil
seal housing to cylinder block.
4.Release crankshaft rear oil seal housing from
locating dowels, discard rear oil seal and
housing.
Reassembly
1.Clean crankshaft oil seal housing mating face
on cylinder block, ensure bolt and dowel holes
are clean and dry. Remove all traces of oil from
oil seal running surface on crankshaft.
2.Position seal protector LRT-12-061 over
crankshaft boss. Fit new oil seal and housing
and remove tool LRT-12-061.
CAUTION: Oil seal must be fitted dry.3.Fit oil seal housing bolts and using sequence
shown, tighten to 9 Nm (7 lbf.ft).
4.Fit sump gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- engine sump.
5.Fit flywheel.

+ ENGINE - Td5, OVERHAUL,
Flywheel.

ENGINE - TD5
OVERHAUL 12-1-87
Seal - crankshaft - rear - automatic
models
$% 12.21.20.01
Disassembly
1.Remove sump gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- engine sump.
2.Remove drive plate.

+ ENGINE - Td5, OVERHAUL, Drive
plate.
3.Remove 5 bolts securing crankshaft rear oil
seal housing to cylinder block.
4.Release crankshaft rear oil seal housing from
locating dowels, discard rear oil seal and
housing.
Reassembly
1.Clean crankshaft oil seal housing mating face
on cylinder block, ensure bolt and dowel holes
are clean and dry. Remove all traces of oil from
oil seal running surface on crankshaft.2.Position seal protector LRT-12-061 over
crankshaft boss. Fit new oil seal and housing
and remove tool LRT-12-061.
CAUTION: Oil seal must be fitted dry.
3.Fit oil seal housing bolts and using sequence
shown, tighten to 9 Nm (7 lbf.ft).
4.Fit sump gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- engine sump.
5.Fit drive plate.

+ ENGINE - Td5, OVERHAUL, Drive
plate.

ENGINE - TD5
12-1-88 OVERHAUL
Flywheel
$% 12.53.07.01
Disassembly
1.Remove 3 bolts securing damper to crankshaft
pulley, fit LRT-51-003 to crankshaft pulley,
secure with 2 bolts.
2.Restrain crankshaft using LRT-51-003,
remove and discard 8 bolts securing flywheel
to crankshaft. Release flywheel from locating
dowels; remove flywheel.
Reassembly
1.Clean flywheel and crankshaft mating faces.
2.Position flywheel on crankshaft.
3.Fit new bolts to retain flywheel and tighten by
diagonal selection to:
lStage 1 - 40 Nm (30 lbf.ft)
lStage 2 - Further 90
°
CAUTION: Do not carry out stages 1 and 2 in
one operation.
4.Remove tool LRT-51-003, fit damper and
tighten bolts to 80 Nm (59 lbf.ft).
Drive plate
$% 12.53.13.01
Disassembly
1.Remove 3 bolts securing damper to crankshaft
pulley, fit LRT-51-003 to crankshaft pulley,
secure with 2 bolts.
2.Restrain crankshaft using LRT-51-003,
remove and discard 8 bolts securing drive
plate, spacer and starter ring gear to
crankshaft, release starter ring gear from
locating dowels and remove.

ENGINE - TD5
OVERHAUL 12-1-89
Reassembly
1.Clean drive plate, spacer, starter ring gear and
crankshaft mating faces.
2.Position starter ring gear on crankshaft, fit
spacer and drive plate.
3.Fit new bolts to retain assembly and tighten by
diagonal selection to:
lStage 1 - 40 Nm (30 lbf.ft)
lStage 2 - Further 90
°
CAUTION: Do not carry out stages 1 and 2 in
one operation.
4.Remove tool LRT-51-003, fit damper and
tighten bolts to 80 Nm (59 lbf.ft).
Starter ring gear
$% 12.53.19
Disassembly
1. Manual models: Remove flywheel.

+ ENGINE - Td5, OVERHAUL,
Flywheel.
2. Automatic models: Remove drive plate.

+ ENGINE - Td5, OVERHAUL, Drive
plate.
3.Drill a 3 mm (0.12 in) diameter hole at root of 2
teeth.
4.Apply a cold chisel to root of teeth, break ring
gear and remove from flywheel.
WARNING: SUITABLE EYE PROTECTION
MUST BE WORN.
Reassembly
1.Heat ring gear evenly to 350
° C, indicated by
light blue colour.
2.Locate ring gear on to flywheel and press on to
flange.
3.Allow ring gear to air cool.
4. Manual models: Fit flywheel.

+ ENGINE - Td5, OVERHAUL,
Flywheel.
5. Automatic models: Fit drive plate.

+ ENGINE - Td5, OVERHAUL, Drive
plate.

ENGINE - TD5
12-1-90 OVERHAUL
Pump - oil
$% 12.60.26.02
Disassembly
1.Remove sump gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- engine sump.
2.Remove bolt securing oil pump drive sprocket.
3.Release drive sprocket from chain, remove
sprocket.
4.Remove 3 Torx screws securing oil pick-up
strainer, remove strainer.
5.Remove and discard 'O' ring.6.Using sequence shown, remove and discard 22
bolts securing oil pump and stiffener plate
assembly to cylinder block.
7.Release stiffener plate from locating dowels,
remove oil pump and stiffener plate assembly.
8.Remove and discard 'O' ring from oil pump
housing outlet.
Inspection
1. Inspection/overhaul procedures for the oil
pump are limited to carrying out
dimensional checks. In the event of wear or
damage being found, a replacement pump
and stiffener plate assembly must be fitted.

ENGINE - TD5
OVERHAUL 12-1-91
2.Remove and discard 5 screws securing cover
to oil pump, remove cover.
3.Using a felt tipped pen, make suitable
alignment marks between inner and outer
rotors and oil pump body.
4.Remove inner and outer rotors.
5.Check rotors and pump body for signs of
scoring and wear.
6.Fit rotors ensuring that marks are aligned and
identification mark on inner rotor is facing
outwards.7.Using feeler gauges, check pump outer rotor to
body clearance:
lOuter rotor to body clearance = 0.295 to
0.375 mm (0.012 to 0.015 in)
8.Using feeler gauges, check clearance of inner
to outer rotor in 2 positions; both clearances
must be within limit given:
lInner to outer rotor clearance = 0.13 mm
(0.05 in)