ECU LAND ROVER DISCOVERY 2002 Manual PDF
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 2002, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 2002Pages: 1672, PDF Size: 46.1 MB
Page 211 of 1672
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.
Page 212 of 1672
ENGINE - TD5
OVERHAUL 12-1-73
11.Ensure engine is set to TDC firing - No.1
cylinder.
12.Check that mark on camshaft sprocket is
positioned between the 2 coloured links on
timing chain.
13.Position sprocket to camshaft, fit and lightly
tighten 3 new bolts then loosen bolts half a
turn.
14.Clean fixed guide Allen screw and apply
Loctite 242 to screw threads.
15.Fit fixed timing chain guide Allen screw and
tighten to 25 Nm (18 lbf.ft).
16.Clean timing chain tensioner and fit new
sealing washer.
17.Fit timing chain tensioner and tighten to 45 Nm
(33 lbf.ft).
18.Tighten camshaft sprocket bolts to 37 Nm (27
lbf.ft).
19.Remove tool LRT-12-058 from camshaft.
20.Lubricate a new 'O' ring with engine oil and fit to
camshaft sprocket access plug.21.Fit camshaft sprocket access plug.
22.Clean alternator/vacuum pump oil hose union.
23.Lubricate a new 'O' ring with engine oil and fit to
alternator/vacuum pump oil hose union.
24.Fit and tighten alternator/vacuum pump oil
hose union to 10 Nm (7 lbf.ft).
25.Fit bolt securing alternator strap bracket to
cylinder head and tighten to 25 Nm (18 lbf.ft).
26.Connect multiplugs to ECT sensor and EUI's.
CAUTION: Following cylinder head
overhaul, it will be necessary, before fitting
the camshaft cover to adjust the fuel
injector rockers using the following
procedures:
27.Rotate engine clockwise until No.1 EUI lobe is
at full lift.
28.Tighten No.1 rocker adjusting screw until the
EUI plunger is felt to 'bottom out'.
29.Loosen rocker adjusting screw 1 complete turn
to give EUI plunger the required bump
clearance and tighten rocker adjusting screw
to 16 Nm (12 lbf.ft).
CAUTION: Ensure screw does not turn as
locknut is tightened.
30.Carry out the above procedures for the
remaining 4 rocker arms.
31.After completion of rocker adjustment, slowly
rotate engine clockwise 2 complete turns by
hand to ensure that no EUI's are bottoming out
on their plungers.
32.Clean camshaft cover and mating face.
33.Fit new sealing washers and isolators as
necessary to camshaft cover.
34.Fit new camshaft cover gasket to cover.
CAUTION: Gasket must be fitted dry.
Page 214 of 1672
ENGINE - TD5
OVERHAUL 12-1-75
5.Loosen locknuts and fully unscrew rocker
adjusting screws; discard locknuts and screws.
6.Remove and discard 6 bolts securing rocker
shaft, release shaft from locating dowel and
remove shaft.
7.Using sequence shown, progressively loosen
13 bolts securing camshaft carrier to cylinder
head until valve spring pressure is released;
remove bolts. Do not discard bolts at this
stage.
8.Gently tap camshaft carrier upwards to break
sealant bond, release carrier from locating
dowels; remove carrier.
9.Remove camshaft.
10.Remove and discard camshaft rear oil seal.11.Remove finger followers and lash adjusters.
CAUTION: Store lash adjusters in their fitted
order and store upright. Maintain absolute
cleanliness when handling lash adjusters.
Failure to observe these precautions can
result in engine failure.
12.Remove and discard 5 bolts securing EUI
retainers.
13.Using tool LRT-12-154/1 remove EUI units
from cylinder head and collect retainers;
remove reaction posts. Keep components in
their fitted order.
14.Using tool LRT-12-154/4, remove and discard
sealing washer and 'O' ring from each injector
unit.
15.Support cylinder head clear of valves, use a
hollow drift and tap each spring cap to free
collets.
Page 218 of 1672
ENGINE - TD5
OVERHAUL 12-1-79
24.Compare figures obtained with camshaft
bearing clearance:
lCamshaft bearing clearance = 0.04 to 0.10
mm (0.002 to 0.004 in)
25.If any bearing clearance is found to exceed
figures given, repeat the above procedures
using a new camshaft. If, after repeating the
clearance check using a new camshaft the
clearances are still excessive, a new cylinder
head and camshaft carrier assembly must be
fitted.
26.Remove all traces of Plastigage using an oily
cloth, do not use a scraper.
27.On completion, discard camshaft carrier bolts.
28.Check free length of valve springs:
lFree length = 46.75 to 47.25 mm (1.84 to
1.86 in)
29. Replace valve springs as a set, if springs
are to be refitted, keep them in their fitted
order.
30.Clean carbon from valves, check valves for
burning, pitting or cracking; replace as
necessary.
31.Clean carbon from valve seat inserts, remove
all loose particles on completion.
32.Check valve seat inserts for pitting and burning.
It is not permissible to recut or replace valve
seat inserts.
33.Remove carbon deposits from valve guides
using tool LRT-12-186 inserted from the
combustion chamber face side of cylinder
head. Ensure all loose particles of carbon are
removed on completion.
34.Check and record diameter of each valve stem:
lValve stem diameter - Inlet = 6.907 to 6.923
mm (0.2719 to 0.2725 in)
lValve stem diameter - Exhaust = 6.897 to
6.913 mm (0.2715 to 0.2721 in)35.Renew any valve if stem diameter is less than
specified.
36.Check and record valve stem to guide
clearance using the following procedures.
37.Insert each valve into its respective guide.
38.Extend valve head 10 mm (0.375 in) out of
valve seat and position a DTI gauge to rear of
valve head.
39.Move valve towards front of cylinder head and
zero DTI gauge ensuring that stylus of gauge
remains in contact with valve head.
40.Move valve towards rear of cylinder head,
record gauge reading to give valve stem to
guide clearance:
lInlet valve = 0.025 to 0.059 mm (0.0009 to
0.0023 in)
lExhaust valve = 0.035 to 0.069 mm (0.0013
to 0.0027 in)
41.If stem to guide clearance exceeds figures
given and valve stem diameters were as
specified, cylinder head assembly must be
replaced; it is not possible to replace valve
guides.
42.Repeat above procedures for remaining valves.
Keep valves in their fitted order.
43.Check face angle of each valve, renew any
valve with incorrect face angles, do not attempt
to recut.
lValve face angle - inlet = 29
° 48' ± 12'
lValve face angle - exhaust = 44
° 48' ± 12'
44.Lap each valve to its seat using grinding paste.
45.Apply Prussion Blue to valve seat, insert valve
into guide and press it firmly, without rotating
on to seat.
46.Remove valve and check that a continuous,
even line of Prussian Blue has been
transferred on to valve face. Note that line
does not have to be across whole width of
valve face.
47.Remove all traces of grinding paste on
completion.
48.Check valve head stand down using the
following procedures.
Page 223 of 1672
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.
Page 225 of 1672
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.
Page 226 of 1672
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.
Page 227 of 1672
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.
Page 229 of 1672
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.
Page 230 of 1672
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)