engine coolant LAND ROVER DISCOVERY 2002 Owner's Guide

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
12-1-72 OVERHAUL
16.Remove bolt and nut securing front of cylinder
head to timing chain cover.
17.Using sequence shown, progressively loosen
then remove 12 cylinder head bolts; discard
bolts together with their captive washers.
18.Using assistance, remove cylinder head and
support each end of cylinder head on 2 wooden
blocks.
19.Remove the cylinder head gasket.
20.Note the gasket thickness indicator and ensure
the same thickness gasket is used on refitment
of the cylinder head.
CAUTION: If new pistons, connecting rods
or crankshaft are to be fitted, it will be
necessary to measure piston stand proud in
order to determine thickness of gasket
required – See Pistons, Connecting Rods
and Cylinder Bores – Cylinder head gasket
selection.
21.Remove and discard 2 plastic locating dowels
from cylinder block.
22.Carry out cylinder head overhaul procedures.

+ ENGINE - Td5, OVERHAUL, Cylinder
head - overhaul.Reassembly
1.Thoroughly clean cylinder block and cylinder
head mating faces.
2.Ensure coolant and oil passageways are clear
and bolt holes are clean and dry.
3.Ensure locating dowel holes in cylinder block
are clean and dry.
4.Fit new plastic locating dowels in cylinder block.
5.Fit new cylinder head gasket of the correct
thickness with the word 'TOP' uppermost.
CAUTION: Gasket must be fitted dry.
6.Ensure that timing pin LRT-12-058 is still fitted
and using assistance, fit cylinder head.
7.Carefully enter new cylinder head bolts
together with their captive washers. DO NOT
DROP. Lightly tighten bolts.
8.Using sequence shown tighten cylinder head
bolts to:
lStage 1 - 30 Nm (23 lbf.ft)
lStage 2 - 65 Nm (48 lbf.ft)
lStage 3 - 90
°
lStage 4 - Further 180
°
lStage 5 - Further 45°
CAUTION: Ensure correct tightening
sequence is followed for all 5 tightening
stages, do not tighten bolts 315
° in one
operation.
9.Fit cylinder head to timing chain cover nut and
bolt and tighten to 25 Nm (18 lbf.ft).
10.Clean camshaft sprocket and mating face on
camshaft.

ENGINE - TD5
OVERHAUL 12-1-77
23.Remove 3 bolts and remove fuel connector
block from cylinder head.
24.Remove gasket, discard 'O' ring and fuel filter.
25. If fitted: Remove spacer block and gasket.
Inspect
1.Thoroughly clean cylinder head mating faces,
ensure that EUI drillings, oil and coolant
passages are clear and bolt holes are clean
and dry.
2.Using suitable solvent, remove all traces of
sealant and gasket material.
CAUTION: Do not use metal scrapers.
3.Remove all traces of oil from camshaft bearings
and journals.
4.Clean glow plug threads.
5.Check core plugs for signs of leakage and
corrosion, seal replacement plugs with Loctite
243.6.Check cylinder head for warping across centre
and from corner to corner:
l Maximum cylinder head warp = 0.1 mm
(0.004 in)
Cylinder heads must not be refaced.
Replace the head assembly if warping
exceeds the limit.
7.Check lash adjuster bores for scoring and signs
of wear or damage.
8.Check lash adjusters for signs of wear, scoring
and overheating, replace as necessary.
Ensure oil hole in each lash adjuster is clear.
Store lash adjusters upright and in their
fitted order.
9.Check finger followers for wear and that rollers
are free to rotate. Store finger followers in
their fitted order.
10.Check camshaft lobes and bearing journals for
signs of scoring and wear.
11.Check bearing surfaces in cylinder head and
camshaft carrier for signs of scoring and wear.
Cylinder head and camshaft carrier are
machined together as an assembly. If
bearing surfaces in either component are
damaged, both components must be
replaced as an assembly.
12.Check camshaft end-float using following
procedures.
13.Position camshaft in camshaft carrier.

ENGINE - V8
12-2-20 REPAIRS
8. Models with air conditioning: Position fan
cowl and secure clips.
9.Fit upper inlet manifold.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
Gasket - rocker cover - RH
$% 12.29.41
Remove
1.Drain cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
2.Remove upper inlet manifold gasket.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
3. Models with SAI: Disconnect 2 air manifold
unions from adapters in cylinder head and
remove manifold.
4.Remove 2 bolts securing coolant rails to inlet
manifold.

ENGINE - V8
REPAIRS 12-2-21
5.Release coolant rail from inlet manifold and
discard 'O' ring.
6.Remove nuts securing alternator cables and
release cables from alternator.
7.Disconnect multiplugs from RH bank of
injectors and release harness from fuel rail.
8.Release ht leads from clips on rocker cover.
9.Remove 4 bolts securing rocker cover.
10.Remove rocker cover and collect gasket. Refit
1.Clean mating faces of rocker cover and
cylinder head.
2.Using a new gasket, fitted dry, position rocker
cover ensuring gasket is correctly located.
3.Fit rocker cover bolts and working in diagonal
sequence, tighten to:
lStage 1 - 3 Nm (2.5 lbf.ft)
lStage 2 - 8 Nm (6 lbf.ft)
4.Ensure that outer rim of gasket is correctly
positioned around periphery of rocker cover.
5.Secure ht leads in rocker cover clips.
6.Secure injector harness to fuel rail and connect
multiplugs to injectors.
7.Position alternator cables, and tighten terminal
B+ nut to 18 Nm (13 lbf.ft) and terminal D+ nut
to 5 Nm (3 lbf.ft).
8.Clean coolant rail 'O' ring recess.
9.Lubricate and fit new 'O' ring to coolant rail,
position coolant rails, fit bolts and tighten to 22
Nm (16 lbf.ft).
10. Models with SAI: Clean air manifold unions,
position manifold and tighten unions nuts to 25
Nm (18 lbf.ft).
11.Fit upper inlet manifold.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
12.Refill cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.

ENGINE - V8
REPAIRS 12-2-27
11.Remove bolt securing oil cooling pipes to PAS
pump housing and remove saddle clamp.
12.Release PAS pump high and low pressure
pipes and position aside.
CAUTION: Always fit plugs to open
connections to prevent contamination.
13.Release clips securing hose to coolant pump
and coolant rail, release hose and position
aside.
14.Release 2 harness clips from coolant rail.
15.Remove bolt securing coolant rail and position
rail aside. 16.Remove bolt securing engine earth lead and
position earth lead aside.
17.Remove nut securing engine harness positive
lead to battery, release lead and position
aside.
18.Release clips and remove fuse box cover.
19.Remove bolt securing starter lead to fuse box,
release lead and position aside.
20.Disconnect 2 engine harness multiplugs from
fuse box.

ENGINE - V8
12-2-30 REPAIRS
Refit
1.Clean mating faces of engine and gearbox,
dowel and dowel holes.
2.Lubricate splines and bearing surface on first
motion shaft with grease.
3.With assistance position engine in engine bay,
align to gearbox and locate on dowels.
4.Position support brackets, fit bell housing bolts
and tighten to 50 Nm (37 lbf.ft).
5.Position engine mountings, fit nuts and tighten
to 85 Nm (63 lbf.ft).
6.Lower lifting equipment and remove from
engine.
7. Models with automatic gearbox: Align torque
converter to drive plate, fit bolts and tighten to
50 Nm (37 lbf.ft). Fit access plug.
8.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
9.Position oil cooling pipe saddle clamps and
tighten bolts.
10.Position engine harness into foot well.
11.Connect 5 multiplugs to ECM.
12.Fit toe board and secure with trim fixings.
13.Connect engine harness earth to body and
secure with nut.
14.Connect engine harness to main harness
multiplug.
15.Connect multiplug to EVAP purge valve.
16.Connect engine harness multiplugs to fuse
box.
17.Connect starter lead to fuse box and secure
with nut.
18.Connect engine harness positive lead to
battery and tighten nut.
19.Fit fuse box cover.
20.Position engine earth lead and secure with
bolt.
21.Position coolant rail and secure with bolt.
22.Connect harness clips to coolant rail.
23.Connect hose to coolant rail and coolant pump
and secure with clips.
24.Connect PAS pump high and low pressure
pipes and secure with clips.
25.Position oil cooling pipe saddle clamp to PAS
pump housing and secure with bolt.
26.Clean A/C compressor and housing mating
faces, dowels and dowel holes. 27.Position A/C compressor, fit bolts and tighten
to 22 Nm (16 lbf.ft).
28.Connect multiplug to A/C compressor.
29.Clean ACE pump and housing mating faces,
dowels and dowel holes.
30.Position ACE pump, fit bolts and tighten to 22
Nm (16 lbf.ft).
31.Clean all pulley 'V's, fit auxiliary drive belt,
using a 15mm spanner, release belt tensioner
secure belt and re-tension drive belt .
32.Ensure auxiliary drive belt is correctly located
on all pulleys.
33.Fit radiator.

+ COOLING SYSTEM - V8, REPAIRS,
Radiator.
34.Fit top hose and secure with clips.
35.Connect fuel pipe to fuel rail.
36.Position ignition coils and connect ht leads.
37.Fit upper inlet manifold.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
38.Fit new oil filter and refill engine with oil.

+ ENGINE - V8, REPAIRS, Filter - oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - V8 engine.
39.Top up gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.

ENGINE - V8
REPAIRS 12-2-35
Strainer - oil pick-up
$% 12.60.20
Remove
1.Remove sump gasket.

+ ENGINE - V8, REPAIRS, Gasket -
sump.
2.Remove 2 bolts and one nut securing oil pick-
up strainer.
3.Remove oil pick-up strainer.
4.Collect spacer from stud.
5.Remove and discard 'O'ring.
Refit
1.Clean oil pick up strainer and 'O' ring recess.
2.Lubricate and fit new 'O' ring.
3.Locate spacer on stud.
4.Position oil pick-up strainer, fit bolts and tighten
to 10 Nm (8 lbf.ft). Fit nut and tighten to 22 Nm
(16 lbf.ft).
5.Fit new sump gasket.

+ ENGINE - V8, REPAIRS, Gasket -
sump.
Pump - oil
$% 12.60.26
Remove
1.Remove timing gear cover gasket.

+ ENGINE - V8, REPAIRS, Gasket -
timing gear cover.
2.Remove bolt securing CMP sensor, remove
clamp and sensor.
3.Remove 6 bolts securing coolant pump,
remove pump and discard gasket.
4.Remove oil pressure switch and discard
sealing washer.
5.Remove 4 bolts securing oil filter head, remove
filter head and discard 2 'O' rings.
6.Remove filter head adaptor.
Refit
1.Ensure filter head adaptor is clean and apply
Loctite 577 sealant to thread.
2.Fit filter head adaptor and tighten bolts to 13
Nm (9 lbf.ft).
3.Clean filter head and mating face.
4.Fit new 'O' rings to filter head and filter head
adaptor.
5.Fit filter head and tighten bolts to 8 Nm (6 lbf.ft).
6.Ensure oil pressure switch and mating face is
clean.
7.Fit new sealing washer and tighten switch to 15
Nm (11 lbf.ft).

ENGINE - V8
12-2-36 REPAIRS
8.Clean coolant pump and mating face.
9.Use a new gasket and fit coolant pump.
Tighten bolts securing coolant pump to 25 Nm
(19 lbf.ft).
10.Ensure CMP sensor is clean and fit sensor to
cover.
11.Fit clamp to CMP sensor and tighten bolt to 8
Nm (6 lbf.ft).
12.Fit timing gear cover gasket.

+ ENGINE - V8, REPAIRS, Gasket -
timing gear cover.
Gasket - sump
$% 12.60.38
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove dipstick.
4.Raise the vehicle on a ramp.
5.Drain engine oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - V8 engine.
6.Remove 8 bolts securing cross member and
remove cross member.
7.Raise front of vehicle under body to increase
clearance between engine and front axle.
8.Disconnect and release gearbox oil cooler pipe
and discard 'O' ring.