engine LAND ROVER DISCOVERY 2002 Workshop Manual

COOLING SYSTEM - V8
ADJUSTMENTS 26-2-13
ADJUST ME NTS
Drain and refill
$% 26.10.01
WARNING: Since injury such as scalding could
be caused by escaping steam or coolant, do not
remove the filler cap from the coolant expansion
tank while the system is hot.
Drain
1.Visually check engine and cooling system for
signs of coolant leaks.
2.Examine hoses for signs of cracking, distortion
and security of connections.
3.Position drain tray to collect coolant.
4.Remove expansion tank filler cap.
LH side
RH side5.Remove drain plugs from LH and RH sides of
cylinder block and allow cooling system to
drain.
6.Disconnect bottom hose from radiator and
allow cooling system to drain.
7.Disconnect top hose from thermostat and
position open end of hose below level of
coolant pump inlet, to allow coolant to drain
from the system.
Refill
1.Flush system with water under low pressure.
Do not use water under high pressure as it
could damage the radiator.
2.Apply Loctite 577 to cylinder block drain
plugs.Fit drain plugs to cylinder block and
tighten to 30 Nm (22 lbf.ft).
3.Connect bottom hose to radiator and top hose
to thermostat housing. Secure with hose clips.
4.Prepare coolant to required concentration.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Anti-Freeze Concentration.

COOLING SYSTEM - V8
26-2-14 ADJUSTMENTS
5.Release top hose from retaining lugs on the fan
cowl, leaving the hose to rest on the lugs.
6.Remove bleed screw from top hose.
l'A' From 03 MY
l'B' Up to 03 MY
7.Unclip the bleed hose from the battery box.
8.Remove expansion tank from its mounting
bracket. Slowly fill the expansion tank with
coolant, approx. 4 litres (7 pt).
9.Raise the expansion tank approx. 20 cm (8 in)
vertically, coolant will drain into the system.
10.Refill the coolant expansion tank until a steady
flow of coolant is emitted from the bleed hole.
11.Fit the bleed screw then, with the expansion
tank still raised, continue filling the system until
the coolant level reaches the base of the
expansion tank filler neck.12.Fit expansion tank filler cap, fit the expansion
tank to its mountings and clip the bleed hose to
the battery box.
13.Refit the top hose into its lugs on the fan cowl.
14.Start and run engine until normal operating
temperature is reached, and check for leaks.
15.Switch off engine and allow to cool.
16.Check for leaks and top-up coolant to cold level
mark on expansion tank

COOLING SYSTEM - V8
26-2-16 REPAIRS
8.Remove 6 scrivets and remove LH and RH air
deflectors from front panel. Disconnect
multiplug of gearbox oil temperature sensor
(arrowed).
9.Remove nut and move horn aside. 10.Remove 2 bolts securing radiator LH and RH
upper mounting brackets to body panel and
remove brackets.
11.Remove 4 screws securing air conditioning
condenser LH and RH upper mounting
brackets to condenser.
12.Remove brackets with rubber mounts from
radiator extension brackets.
13.Position absorbent cloth under each cooler
hose to collect oil spillage.
14.Push against coupling release rings and
disconnect hoses from gearbox oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
15. If fitted: Push against coupling release rings
and disconnect hoses from engine oil cooler.

COOLING SYSTEM - V8
REPAIRS 26-2-17
16.Remove radiator assembly.
17.Release clip and remove bottom hose from
radiator.
18.Remove 2 bolts and remove extension
brackets from radiator.
19.Remove 2 captive nuts from radiator.
20.Remove 2 screws and remove gearbox oil
cooler from radiator.
21. If fitted: Remove 2 screws and remove engine
oil cooler from radiator.
22.Remove 2 rubber mountings from radiator.
23.Remove sealing strip from bottom of radiator.
24.Remove 2 cowl retaining clips from radiator. Refit
1.Fit cowl retaining clips to radiator.
2.Fit sealing strip to radiator.
3.Fit rubber mountings to radiator.
4.Fit gearbox oil cooler to radiator and secure
with screws.
5. If fitted: Fit engine oil cooler to radiator and
secure with screws.
6.Fit captive nuts to radiator.
7.Fit extension brackets to radiator and secure
with bolts.
8.Fit bottom hose to radiator and secure with clip.
9.Fit radiator and engage lower mountings in
chassis.
10.Ensure connections are clean, then secure
hoses to oil coolers.
11.Fit air conditioning condenser brackets and
secure with screws.
12.Fit radiator upper mounting brackets and
secure with bolts.
13.Fit LH horn and secure with nut.
14.Fit air deflectors and secure with scrivets.
15.Connect multiplug of gearbox oil temperature
sensor.
16.Fit front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.
17.Connect bottom hose to thermostat housing
and secure with clip.
18.Connect top hose to radiator and secure with
clip.
19.Connect bleed hose to radiator and fit clip.
20.Fit lower fan cowl and secure with screws.
21.Fit viscous fan.

+ COOLING SYSTEM - V8, REPAIRS,
Fan - viscous.
22.Top up gearbox oil.
23.Top up engine oil.
24.Refill cooling system.

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

MANIFOLDS AND EXHAUST SYSTEMS - TD5
DESCRIPTION AND OPERATION 30-1-3
Description
General
The diesel engine has the inlet manifold attached to the right hand side of the engine and the exhaust manifold
attached to the left hand side of the engine. The inlet manifold directs cooled compressed air from the turbocharger
and intercooler into the cylinders, where it is mixed with fuel from the injectors. Exhaust gases from the exhaust
manifold can also be directed into the inlet manifold via a pipe from the exhaust manifold and an Exhaust Gas
Recirculation (EGR) valve on the inlet manifold. The exhaust manifold allows combustion gases from the cylinders to
leave the engine where they are directed into the exhaust system and turbocharger.
The exhaust system is attached to the turbocharger and is directed along the underside of the vehicle to emit exhaust
gases from a tail pipe at the rear of the vehicle. A silencer is installed midway along the system and a second tail
silencer is located at the rear of the vehicle.
Inlet manifold
The inlet manifold is a one piece aluminium casting. The manifold is secured to the cylinder head with two studs and
flanged nuts and eight flanged bolts. A one piece laminated gasket seals the manifold to the cylinder head.
Four threaded bosses on the manifold provide for the attachment of the fuel cooler. The fuel cooler is secured to the
manifold with four bolts. A boss with two threaded holes allows for the attachment of the combined intake air
temperature/pressure sensor. The sensor is secured to the manifold with two screws and sealed with a gasket.
At the forward end of the manifold, a machined face and four threaded holes provide for the attachment of the EGR
valve. The valve is sealed to the manifold with a gasket.

+ EMISSION CONTROL - Td5, DESCRIPTION AND OPERATION, Emission Control Systems.
Exhaust manifold
The exhaust manifold is made from cast iron. The manifold has five ports, one from each cylinder, which merge into
one flanged outlet connection positioned centrally on the manifold.
The manifold is attached to the cylinder head with ten studs and flanged nuts. A laminated metal gasket seals the
manifold to the cylinder head. The flanged outlet on the manifold provides the attachment for the turbocharger, which
is attached with three studs and flanged nuts and sealed with a metal laminated gasket.
A second flanged outlet, located at the forward end of the manifold, provides attachment for the EGR pipe. The EGR
pipe is secured to the manifold with two cap screws and connected to the EGR valve mounted on the inlet manifold.
There is no gasket used between the pipe and the exhaust manifold.

+ EMISSION CONTROL - Td5, DESCRIPTION AND OPERATION, Emission Control Systems.
Exhaust system
The exhaust system comprises a front pipe, an intermediate pipe which incorporates a silencer and a tail pipe
assembly which also has a silencer. The exhaust system is constructed mainly of 63 mm (2.48 in) diameter extruded
pipe with a 1.5 mm (0.06 in) wall thickness. All pipes are aluminized to resist corrosion and the silencers are fabricated
from stainless steel sheet.

MANIFOLDS AND EXHAUST SYSTEMS - TD5
30-1-4 DESCRIPTION AND OPERATION
Front pipe assembly
The front pipe is of welded and fabricated tubular construction. The front pipe is connected to a flange on the
turbocharger and secured with three flanged nuts and sealed with a metal laminated gasket. The front pipe
incorporates a flexible pipe near the connection with the turbocharger and terminates in a flanged connection with the
intermediate pipe.
The flexible pipe is formed into a concertina shape with woven metal strands around its outer diameter. The flexible
pipe allows for ease of exhaust system alignment and also absorbs engine vibration. The woven metal strands also
increase the longevity of the flexible pipe.
The front pipe is attached via a bracket and a mounting rubber to the chassis. The mounting rubber allows ease of
alignment and vibration absorption.
Intermediate pipe and silencer
The intermediate pipe is of welded and fabricated tubular construction. It connects at its forward end to the front pipe
flange. Two captive studs on the intermediate pipe flange allow for attachment to the front pipe with locknuts. The rear
section of intermediate pipe connects to the tail pipe assembly via a flanged joint, sealed with a metal gasket and
secured with locknuts and studs.
The forward and rear sections are joined by a silencer. The silencer is fabricated from stainless steel sheet to form
the body of the silencer. An end plate closes each end of the silencer and is attached to the body with seam joints.
Perforated baffle tubes, inside the silencer, are connected to the inlet and outlet pipes on each end plate. Internal
baffle plates support the baffle tubes and, together with a stainless steel fibre packing, absorb combustion noise as
the exhaust gases pass through the silencer.
The intermediate pipe is attached by two brackets, positioned at each end of the silencer, and two mounting rubbers
to the chassis. The mounting rubber allows for ease of alignment and vibration absorption.
Tail pipe assembly
The tail pipe is of welded and fabricated construction. The tail pipe connects to the intermediate pipe with a flanged
joint secured with locknuts and sealed with a metal gasket. The pipe is shaped to locate above the rear axle allowing
clearance for axle articulation. The pipe is also curved to clear the left hand side of the fuel tank which has a reflective
shield to protect the tank from heat generated from the pipe.
A fabricated silencer is located at the rear of the tail pipe. The silencer is circular in section and is constructed from
stainless steel sheet. A baffle tube is located inside the silencer and the space around the baffle tube is packed with
a stainless steel fibre. The holes in the baffle tube allow the packing to further reduce combustion noise from the
engine. The tail pipe from the silencer is curved downwards at the rear of the vehicle and directs exhaust gases
towards the ground. The curved pipe allows the exhaust gases to be dissipated by the airflow under the vehicle and
prevents the gases from being drawn behind the vehicle.
The tail pipe is attached by a bracket, positioned forward of the silencer, and a mounting rubber to the chassis. The
mounting rubber allows ease of alignment and vibration absorption.

MANIFOLDS AND EXHAUST SYSTEMS - TD5
30-1-6 REPAIRS
Gasket - inlet manifold
$% 30.15.08
Remove
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.
1.Remove battery cover.
2.Disconnect battery earth lead.
3.Remove 3 bolts and remove engine acoustic
cover.
4.Release retainers and remove upper fan cowl.
5.Disconnect leads from 4 glow plugs and
multiplug from MAP sensor.
6.Remove 4 bolts, release EGR valve from inlet
manifold and discard gasket. 7.Remove 4 bolts securing fuel cooler to inlet
manifold.
8.Remove 2 bolts and remove alternator support
bracket.
9.Remove bolt securing engine dip stick tube to
camshaft carrier.
10.Remove dip stick tube and discard 'O' ring.

MANIFOLDS AND EXHAUST SYSTEMS - TD5
REPAIRS 30-1-7
11.Remove 2 nuts and 8 bolts securing inlet
manifold to cylinder head.
12.Disconnect multiplugs from turbocharger
pressure sensor, ECT sensor, AAP sensor,
MAF sensor, A/C compressor and fuel injector
harness.
13.Remove 2 bolts securing harness to camshaft
carrier.
Note: Engine with EGR cooler illustrated.
14.Release harness from engine and inlet
manifold.
15.Remove inlet manifold and gasket. Refit
1.Clean inlet manifold and mating faces.
2.Fit new gasket.
3.Fitinlet manifold and, working from the centre
outwards, tighten nuts and bolts to 25 Nm (18
lbf.ft).
4.Position harness to sensors and connect
multiplugs.
5.Tighten bolts securing harness clip to camshaft
carrier to 9 Nm (7 lbf.ft).
6.Clean dip stick tube and fit new 'O' ring.
7.Fit dip stick tube and tighten bolt to 9 Nm (7
lbf.ft).
8.Connect leads to glow plugs.
9.Fit alternator support bracket and tighten bolts
to 45 Nm (33 lbf.ft).
10.Position fuel cooler and tighten bolts to 25 Nm
(18 lbf.ft).
11.Fit new gasket, position EGR valve and tighten
bolts to 9 Nm (7 lbf.ft).
12.Connect multiplug to MAP sensor.
13.Fit upper fan cowl.
14.Fit engine acoustic cover.
15.Connect battery earth lead.
16.Fit battery cover.

MANIFOLDS AND EXHAUST SYSTEMS - TD5
30-1-8 REPAIRS
Gasket - exhaust manifold
$% 30.15.12
Remove
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.
1.Remove turbocharger.

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

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
3. Models with air conditioning: Remove 4 bolts
securing compressor and move to one side.
4.Remove and discard 2 Allen screws securing
EGR pipe to exhaust manifold.
Note: Engine with EGR cooler illustrated.5.Remove 10 nuts securing exhaust manifold to
cylinder head.
6.Remove exhaust manifold and gasket.
Refit
1.Clean exhaust manifold and mating faces.
2.Fit new gasket.Fit exhaust manifold and,
working from the centre outwards, tighten nuts
to 25 Nm (18 lbf.ft) .
3. Models with air conditioning:
Positioncompressor and tighten bolts to 25 Nm
(18 lbf.ft).
4.Position EGR valve pipe, fit new Allen screws
and tighten to 9 Nm (7 lbf.ft).
5.Fit turbocharger.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Turbocharger.
6. Models with air conditioning: Fit auxiliary
drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.

MANIFOLDS AND EXHAUST SYSTEMS - V8
DESCRIPTION AND OPERATION 30-2-3
1Upper manifold
2Bolt 5 off
3Bolt 1 off
4Gasket
5IAC Valve
6IAC valve hose 2 off
7Bolt 4 off
8Bolt 4 off
9Schraeder valve
10Injector 8 off
11Retaining clip 8 off
12Bolt 12 off
13Bolt 2 off
14Clamp 2 off
15Seal 2 off
16Lower manifold/engine gasket
17Coolant pipe18Bolt 3 off
19Bolt
20Heater return pipe
21Pipe connection
22Lower manifold
23Gasket
24Hose clip 2 off
25Throttle housing coolant hose
26Fuel rail
27Throttle housing
28Gasket
29Bolt 4 off
30Plenum
31Rocker cover breather hose connection
32Brake servo vacuum pipe connection
33Hose clip 4 off