ECU LAND ROVER DISCOVERY 2002 Repair Manual

ENGINE - TD5
REPAIRS 12-1-47
Engine and ancillaries
$% 12.41.01
Remove
1.Remove bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.
2.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Drain engine oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - diesel engine.
4.Remove radiator.

+ COOLING SYSTEM - Td5, REPAIRS,
Radiator.
5.Remove turbocharger.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Turbocharger.
6.Release clips and disconnect heater hoses
from fuel cooler and coolant rail.
7.Release clip and disconnect expansion tank
coolant hose from fuel cooler.
8.Disconnect fuel hoses, tank to fuel cooler and
connector block on cylinder head.
CAUTION: Always fit plugs to open
connections to prevent contamination.9.Disconnect fuel hose from fuel cooler and
secure to connector block on cylinder head.
This is to prevent contamination of the fuel
injection system.
10.Release servo vacuum pipe from clip on fuel
cooler and release hose from vacuum pump.
11.Release expansion tank from body mounting,
release clip, disconnect hose and remove tank.

ENGINE - TD5
12-1-48 REPAIRS
12.Disconnect vacuum hose from EGR valve.
13.Remove engine compartment fuse box cover.
14.Remove bolts securing battery and alternator
leads to fuse box.
15.Remove bolt securing glow plug lead to fuse
box.
16.Disconnect 2 engine harness multiplugs from
fuse box. 17.Disconnect 2 engine harness multiplugs from
ECM and main harness.
18.Remove bolt securing engine earth lead to
battery earth lead.
19.Disconnect multiplug from EGR modulator.

ENGINE - TD5
REPAIRS 12-1-49
20.Disconnect multiplug from CKP sensor.
21.Remove bolt securing CKP sensor to gearbox
housing and discard 'O' ring.
CAUTION: If fitted: Retain CKP sensor.
22.Loosen clip securing air inlet hose to
turbocharger and remove hose.
23.Disconnect multiplugs from compressor, MAF
sensor, turbocharger boost solenoid valve,
AAP & IAT sensor.
24.Release clip and disconnect hose from
turbocharger boost solenoid valve. 25.Loosen bolts securing PAS pulley.
26.Rotate ancillary drive belt tensioner anti-
clockwise, release and remove drive belt.
27.Release clips and remove air intake hose from
air cleaner.
28.Remove 4 bolts and move compressor aside.
29.Remove 3 bolts and move ACE pump aside.
30.Remove 3 bolts and remove PAS pump pulley.
31.Remove 4 bolts and move PAS pump aside.

ENGINE - TD5
12-1-50 REPAIRS
32.Release clip and disconnect hose from coolant
pump.
33.Release clip and disconnect heater hose from
coolant rail.
34.Remove bolt securing coolant rail to front
chassis member.
35.Raise vehicle on ramp.
36.Release coolant rail support brackets from
engine LH and RH mounting brackets.
37.Remove coolant rail.
38.Remove starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.39.Remove and discard 3 bolts securing torque
converter to drive plate.
40.Remove 2 bolts securing gearbox oil cooler
pipe clips from sump and alternator mounting
bracket.
41.Mark position of gearbox oil cooler pipe
clamps.
42.Remove 3 nuts and remove oil cooler pipe
clamps.
43.Loosen RH oil cooler pipe union.
44.Move pipes aside and tighten RH pipe union.

ENGINE - TD5
REPAIRS 12-1-51
45.Remove 8 bolts and remove front cross
member.
46.Remove 6 bolts securing gearbox housing to
engine.
47.Remove 4 bolts and nuts securing RH and LH
front engine mountings to chassis.
48.Lower vehicle ramp. 49.Remove 2 upper bolts securing gearbox
housing and oil cooler coolant pipe to engine.
50.Release clip, disconnect hose from engine oil
cooler and move aside.
51.Remove bolt securing engine closing panel to
gearbox.
52.Fit tool LRT-12-138 to lifting chains and
connect to lifting eyes on engine.
53.Remove 2 nuts from RH and LH front engine
mountings.
54.Position trolley jack to support gearbox.
55.With assistance, raise chains, remove engine
from vehicle and lower onto bench.
Refit
1.With assistance, raise engine from bench and
position in vehicle.
2.With assistance, align engine to gearbox and
torque converter.
3.Position engine RH and LH mountings to
brackets and fit nuts.
4.Position engine oil cooler pipe, connect hose to
oil cooler and secure with clip.

ENGINE - TD5
12-1-52 REPAIRS
5.Fit 2 upper bolts securing engine oil cooler pipe
and gearbox housing to engine and tighten to
50 Nm (37 lbf.ft) .
6.Lower engine onto mountings, and tighten nuts
to 85 Nm (63 lbf.ft) .
7.Remove tool LRT-12-138 from engine.
8.Fit and tighten bolt securing engine closing
panel to gearbox.
9.Raise vehicle on ramp.
10.Fit nuts and bolts securing engine LH and RH
mountings to chassis and tighten to 85 Nm (63
lbf.ft).
11.Fit remaining bolts securing gearbox housing to
engine and tighten to 50 Nm (37 lbf.ft).
12.Rotate crankshaft and align drive plate to
torque converter.
13.Using a magnetic socket, fit and tighten new
torque converter drive plate bolts to 50 Nm (37
lbf.ft) .
14.Fit front cross member and tighten bolts to 26
Nm (19 lbf.ft).
15.Align gearbox oil cooler pipes.
16.Fit oil cooler pipe clip and tighten bolts to 9 Nm
(7 lbf.ft).
17.Position gearbox oil cooler pipe clamps and
tighten nuts.
18.Position coolant rail and secure support bracket
in engine LH and RH mounting brackets.
19.Fit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
20.Lower ramp.
21.Position coolant rail to front chassis member, fit
and tighten bolt to 10 Nm (7 lbf.ft).
22.Connect heater hose to coolant rail and secure
with clip.
23.Connect hose to coolant pump and secure with
clip.
24.Position PAS pump and tighten bolts to 25 Nm
(18 lbf.ft).
25.Position PAS pump pulley and lightly tighten
bolts.
26.Position ACE pump, fit bolts and tighten to 25
Nm (18 lbf.ft).
27.Position A/C compressor, fit bolts and tighten
to 25 Nm (18 lbf.ft).
28.Position ancillary drive belt, rotate tensioner
anti-clockwise and locate belt to pulleys.
29.Tighten PAS pump pulley bolts to 10 Nm (7
lbf.ft).
30.Position air intake hose to air cleaner and
secure clips.
31.Position engine harness and connect
multiplugs to compressor, MAF sensor,
turbocharger boost solenoid, AAP & IAT
sensor.
32.Position air inlet hose to turbocharger and
tighten clip. 33.Connect hoses to turbocharger boost solenoid
and secure clips.
34.Clean CKP sensor and mating face.
CAUTION: If originally fitted: Fit spacer to
CKP sensor.
35.Using new 'O' ring, fit CKP sensor, tighten CKP
sensor bolt to 9 Nm (7 lbf.ft) and connect
multiplug.
36.Connect multiplug to EGR modulator.
37.Connect engine earth lead to battery earth lead
and tighten bolt.
38.Connect engine harness multiplug to ECM and
main harness.
39.Connect engine harness multiplugs to fuse
box.
40.Position glow plug lead to fusebox and secure
with bolt.
41.Position battery and alternator leads to fusebox
and secure with bolts.
42.Fit engine compartment fuse box cover.
43.Connect vacuum hose to EGR valve.
44.Connect hose to vacuum pump and secure
vacuum pipe to fuel cooler.
45.Disconnect fuel hose from connector block and
connect to fuel cooler.
46.Connect fuel hoses to fuel cooler and
connector block on cylinder head.
47.Position expansion tank, connect hose and
secure with clip. Secure tank to body mounting.
48.Connect coolant hoses to fuel cooler and
coolant rail and secure clips.
49.Fit turbocharger.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Turbocharger.
50. Fit radiator.

+ COOLING SYSTEM - Td5, REPAIRS,
Radiator.
51.Fill engine with oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - diesel engine.
52.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
53.Fit bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.

ENGINE - TD5
REPAIRS 12-1-53
Mounting - front - LH
$% 12.45.01
Remove
1.Remove centrifuge assembly.

+ ENGINE - Td5, REPAIRS, Gasket -
centrifuge oil drain pipe.
2.Remove 3 bolts, remove oil filter adaptor
housing and discard gasket.
3.Fit suitable lifting chains to support engine.
4.With assistance remove 2 bolts securing
engine mounting to chassis.
5.Remove 4 bolts securing engine mounting
bracket to cylinder block.
6.Remove nut securing mounting to mounting
bracket.
7.Remove mounting and mounting bracket.
8.Remove mounting shield.
Refit
1.Fit shield to mounting. 2.Fit mounting and mounting bracket.
3.Fit mounting bracket to cylinder block and
tighten – bolts securing front LH engine
mounting bracket to cylinder block to 48 Nm (35
lbf.ft).
4.With assistance, fit mounting to chassis and
tighten – bolts securing front LH engine
mounting to chassis to 85 Nm (63 lbf.ft).
5.Fit mounting to mounting bracket and tighten –
nut securing front LH mounting to mounting
bracket to 85 Nm (63 lbf.ft).
6.Remove engine support chains.
7.Clean oil filter adaptor housing and mating
face.
8.Fit oil filter adaptor housing to oil cooler
housing and tighten bolts to 25 Nm (18 lbf.ft).
9.Fit centrifuge assembly.

+ ENGINE - Td5, REPAIRS, Gasket -
centrifuge oil drain pipe.

ENGINE - TD5
12-1-54 REPAIRS
Mounting - front - RH
$% 12.45.03
Remove
1.Remove fixings and remove engine acoustic
cover.
2.Release fixings and remove battery cover.
3.Disconnect battery earth lead.
4.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.
5.Remove 4 bolts and move fuel cooler to one
side.
6.Fit suitable lifting chains to support engine.
7.With assistance remove 2 bolts securing
engine mounting to chassis.
8.Remove 4 bolts securing engine mounting
bracket to cylinder block.
9.Remove nut securing mounting to mounting
bracket.
10.Remove mounting and mounting bracket. Refit
1.Fit mounting and mounting bracket.
2.Fit front RH engine mounting bracket to
cylinder block and tighten bolts to 48 Nm (35
lbf.ft).
3.With assistance, fit front RH mounting to
chassis and tighten bolts to 85 Nm (63 lbf.ft).
4.Fit front RH mounting to mounting bracket and
tighten nut to 85 Nm (63 lbf.ft).
5.Remove engine support chains.
6.Position Fuel cooler to inlet manifold and
tighten bolts to 25 Nm (18 lbf.ft).
7.Remove stand(s) and lower vehicle.
8.Connect battery earth lead.
9.Fit battery cover and secure with fixings.
10.Fit engine acoustic cover and secure with
fixings.

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 12-1-57
Filter - oil
$% 12.60.04
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Remove 3 bolts and remove exhaust manifold
heat shield.
3.Clean area around filter head and place a
container beneath engine.
4.Using a strap wrench, unscrew and discard
filter. Refit
1.Clean mating face of filter head.
2.Lubricate sealing ring of new filter with clean
engine oil.
3.Fit filter and tighten by hand until it seats then
tighten a further three-quarters of a turn.
4.Start and run engine to check for leaks.
5.Stop engine, wait a few minutes, then check oil
level.
6.Top up engine oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - diesel engine.
7.Position exhaust manifold heatshield and
tighten M6 bolts to 9 Nm (7 lbf.ft) and M8 bolts
to 25 Nm (18 lbf.ft).
8.Fit engine acoustic cover and secure with
fixings.