clutch LAND ROVER DISCOVERY 2002 Owner's Manual

ENGINE - TD5
DESCRIPTION AND OPERATION 12-1-3
1Oil dipstick tube
2Screw – oil dipstick tube to camshaft carrier
3Oil dipstick
42nd piston ring
5Piston
6Small-end bush
7Connecting rod
8Big-end bearing cap
9Connecting rod bolt (2 off per connecting rod)
10Top piston ring
11Oil control ring
12Circlips (2 off per gudgeon pin)
13Gudgeon pin
14Big-end bearing shells
15Dowels – cylinder head (2 off)
16Clutch housing shim plate
17 Crankshaft rear oil seal and housing
18Screws – crankshaft seal housing to engine
block (5 off)
19Bolts – clutch housing shim plate to engine
block (2 off)
20Main oil gallery plug (rear)
21Oil filter adaptor gasket
22Oil filter adaptor thermostat
23Oil filter adaptor assembly
24Oil filter adaptor insert25Oil filter adaptor to cylinder block bolts (3 off)
26Oil filter
27Oil pressure switch
28Oil cooler banjo bolts (2 off)
29O-rings – oil cooler banjo bolts (2 off)
30Oil cooler to cylinder block bolts (7 off)
31Centrifuge assembly
32Centrifuge to cylinder block bolts (3 off)
33Centrifuge oil drain pipe
34Oil drain pipe to sump gasket
35Centrifuge to oil drain pipe gasket
36Oil cooler plugs (3 off)
37Oil cooler assembly
38Oil cooler matrix 'O-rings' (2 off)
39Oil cooler matrix
40Oil cooler gasket
41Coolant and PAS pump assembly bracket
42Bracket bolts (5 off + 1 stud/nut)
43Cylinder block
44Dowels to timing block cover (2 off)
45Oil gallery delivery plug
46Cross drilling plug
47Coolant jacket plug
48Core plugs (3 off)

ENGINE - TD5
12-1-56 REPAIRS
Flywheel
$% 12.53.07
Remove
1.Remove clutch assembly.

+ CLUTCH - Td5, REPAIRS, Clutch
assembly.
2.Remove and discard 8 bolts securing flywheel
to crankshaft and remove flywheel.
Refit
1.Clean flywheel and mating face.
2.Position flywheel to crankshaft, fit new bolts
and working in a diagonal sequence tighten to
40 Nm (30 lbf.ft), then a further 90
°.
CAUTION: Do not carry out stages 1 and 2 in
one operation.
3.Fit clutch assembly.

+ CLUTCH - Td5, REPAIRS, Clutch
assembly.
Plate - drive - automatic
$% 12.53.13
Remove
1.Remove gearbox.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gearbox - convertor and
transfer gearbox - Diesel.
2.Remove and discard 8 bolts and remove
converter drive plate, spacer and starter ring
gear.
Refit
1.Clean drive plate, spacer and starter ring gear.
2.Fit starter ring gear, spacer and drive plate to
crankshaft, fit new bolts and working in a
diagonal sequence tighten to 40 Nm (30 lbf.ft),
then a further 90
°.
CAUTION: Do not carry out stages 1 and 2 in
one operation.
3.Refit gearbox.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gearbox - convertor and
transfer gearbox - Diesel.

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 - V8
REPAIRS 12-2-31
Flywheel
$% 12.53.07
Remove
1.Remove gearbox

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
2.Restrain flywheel.
3.Working in sequence, progressively slacken 6
bolts securing clutch cover to flywheel.
Remove bolts.
4.Remove clutch cover.
5.Remove clutch plate.
6.Release crankshaft sensor multiplug from
bracket.
7.Remove 2 bolts securing crankshaft sensor
cover. 8.Remove crankshaft sensor cover.
9.Remove 2 nuts securing crankshaft sensor.
10.Remove crankshaft sensor.
11.Remove 6 bolts securing flywheel.
12.Remove flywheel.
On early engines, balance weights are on
engine side of flywheel; replacement flywheels
will have balance weights on clutch side of
flywheel.
Refit
1.Clean mating faces of flywheel and crankshaft,
dowel and dowel hole.
2.Fit flywheel to crankshaft and tighten bolts to
78 Nm (58 lbf.ft).
3.Clean crankshaft sensor and mating face.
4.Fit crankshaft sensor and tighten nuts to 6 Nm
(4.4 lbf.ft).
5.Fit crankshaft sensor cover and tighten bolts to
6 Nm (5 lbf.ft).
6.Fit crankshaft sensor multiplug to bracket.
7.Clean clutch cover, drive plate and spigot bush
in end of crankshaft. Renew worn components
as necessary.
8.If refitting existing drive plate, apply 'Molycote
FB 180' to splines.

ENGINE - V8
12-2-32 REPAIRS
9.Fit alignment tool LRT-12-001 to spigot
bearing in crankshaft.
10.Fit drive plate onto tool LRT-12-001 ensure
side marked 'flywheel side' is towards flywheel.
11.Fit clutch cover and locate on dowels.
12.Fit clutch cover bolts and tighten in diagonal
sequence to 40 Nm (30 lbf.ft).
13.Fit gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
Plate - drive - automatic
$% 12.53.13
Remove
1.Remove automatic gearbox.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gearbox - convertor and
transfer gearbox - V8.
2.Remove 2 bolts securing CKP sensor cover.
3.Remove CKP sensor cover.
4.Remove 2 nuts securing CKP sensor.
5.Remove CKP sensor.

ENGINE - V8
12-2-50 OVERHAUL
5.Clean hub and mating face, spacer and clamp
ring.
6.Clean drive plate and ensure free from cracks
and distortion.
7.Fit spacer and hub to crankshaft, tighten Allen
screws to 78 Nm (58 lbf.ft).
8.Fit drive plate and clamp ring, tighten bolts to
45 Nm (35 lbf.ft).
9.Fit CKP sensor.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Sensor - crankshaft position
(CKP).
Seal - crankshaft - rear - manual models
$% 12.21.20.01
Disassembly
1.Restrain flywheel.
2.Working in sequence, loosen and remove 6
bolts securing clutch cover to flywheel.
3.Remove clutch cover.
4.Remove clutch plate.
5.Remove CKP sensor.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Sensor - crankshaft position
(CKP).
6.Remove 6 bolts securing flywheel.
7.Remove flywheel.

ENGINE - V8
OVERHAUL 12-2-51
8.Carefully remove oil seal from cylinder block to
avoid damage to seal location or running
surface on crankshaft.
Reassembly
1.Ensure both seal location and running surface
on crankshaft are clean.
2.Fit tool LRT-12-095 to crankshaft.
3.Fit new seal squarely onto crankshaft and
guide.
CAUTION: Oil seal must be fitted dry.4.Fit seal into location using tools LRT-12-091
and LRT-99-003.
5.Clean mating faces of flywheel and crankshaft,
dowel and dowel hole.
6.Fit flywheel to crankshaft and, working in a
diagonal sequence, tighten bolts to 78 Nm (58
lbf.ft).
7.Fit CKP sensor.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Sensor - crankshaft position
(CKP).
8.Clean clutch cover, drive plate and spigot bush
in end of crankshaft.
9.Renew worn components as necessary.
10.If refitting existing drive plate, apply Molycote
FB 108 to splines.
11.Fit LRT-12-001 alignment tool to spigot bearing
in crankshaft.
12.Fit drive plate onto alignment tool, ensure side
marked 'flywheel side' is against flywheel.
13.Fit clutch cover and locate on dowels.
14.Fit clutch cover bolts and tighten in diagonal
sequence to 40 Nm (30 lbf.ft).

ENGINE - V8
12-2-52 OVERHAUL
Bearing - spigot - crankshaft
$% 12.21.45.01
Disassembly
1.Remove 6 bolts securing clutch cover.
2.Remove clutch cover.
3.Tap a thread in spigot bush to accommodate a
suitable impulse extractor.
4.Fit extractor to bush.
5.Remove bush from crankshaft. Reassembly
1.Clean bush register in rear of crankshaft.
2.Using a suitable drift, fit new bush to crankshaft
so that it is flush with or up to a maximum of 1.6
mm (0.06 in) below the end of the crankshaft.
3.Ream spigot bush to 19.117 + 0.025
− 0.00 mm
(0.75 + 0.001
− 0.00 in) .
4.Remove all traces of swarf on completion.
5.Clean mating faces of flywheel and crankshaft,
dowel and dowel hole.
6.Fit clutch cover to flywheel and tighten bolts by
diagonal slection to 40 Nm (30 lbf.ft).

ENGINE MANAGEMENT SYSTEM - TD5
DESCRIPTION AND OPERATION 18-1-3
Engine management component
location - engine compartment
LHD illustrated
1Ambient air pressure sensor
2Engine coolant temperature sensor
3Glow plugs
4Engine Control Module (ECM)
5Fuel pump relay
6Main relay
7A/C clutch and cooling fan relays
8Manifold absolute pressure/ inlet air
temperature sensor9Electronic vacuum regulator solenoid
10Fuel temperature sensor
11Crankshaft speed and position sensor
12Electronic unit injectors
13Turbocharger wastegate modulator
14Mass air flow sensor
15Clutch switch

ENGINE MANAGEMENT SYSTEM - TD5
DESCRIPTION AND OPERATION 18-1-5
1Mass air flow sensor
2Ambient air pressure sensor
3Manifold absolute pressure/ inlet air
temperature sensor
4Engine coolant temperature sensor
5Crankshaft speed and position sensor
6Throttle position sensor
7Fuel temperature sensor
8Brake pedal switch
9Clutch switch
10High/ Low ratio switch
11Main relay
12Malfunction indicator lamp
13Fuel pump relay
14Glow plug warning lamp
15Glow plugs16Electronic unit injectors
17Turbocharger wastegate modulator
18EGR modulator
19Diagnostic connector
20Engine control module
21Cruise control master switch
22Cruise control SET+ switch
23Cruise control RES switch
24Air conditioning clutch relay
25Air conditioning cooling fan relay
26Electronic automatic transmission ECU
27Self levelling and anti-lock brakes ECU
28Instrument cluster
29Body control unit