Oil cooler LAND ROVER DISCOVERY 2002 Workshop Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 2002, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 2002Pages: 1672, PDF Size: 46.1 MB
Page 6 of 1672
CONTENTS
CONTENTS 3
Alarm handset battery ..................................................................................................................... 10-6
Road wheels ................................................................................................................................... 10-7
Tyres .............................................................................................................................................. 10-7
Brake pads, discs and calipers ....................................................................................................... 10-7
Road wheel speed sensors ............................................................................................................. 10-7
Brake fluid ....................................................................................................................................... 10-8
Fuel filter - diesel engine ................................................................................................................. 10-8
Fuel filter sedimenter ...................................................................................................................... 10-8
Road wheels ................................................................................................................................... 10-8
Radiator/Intercooler ........................................................................................................................ 10-8
Ambient air Temperature and pressure sensor .............................................................................. 10-8
Doors, bonnet and fuel filler flap ..................................................................................................... 10-9
Air suspension intake filter .............................................................................................................. 10-9
Anti-freeze....................................................................................................................................... 10-9
Cooling system ............................................................................................................................... 10-9
Spark plugs - V8 engine.................................................................................................................. 10-10
Air cleaner - V8 engine ................................................................................................................... 10-11
Air cleaner and dump valve - diesel engine .................................................................................... 10-11
Auxiliary drive belt ........................................................................................................................... 10-11
Auxiliary drive belt - V8 engine ....................................................................................................... 10-12
Auxiliary drive belt - diesel engine .................................................................................................. 10-12
Fluid reservoirs ............................................................................................................................... 10-12
Steering box .................................................................................................................................... 10-13
Battery ............................................................................................................................................. 10-13
Intercooler - diesel engine............................................................................................................... 10-14
Engine oil - V8 engine ..................................................................................................................... 10-14
Engine oil - diesel engine ................................................................................................................ 10-14
Centrifuge rotor – diesel engine ...................................................................................................... 10-15
Engine oil filter - diesel engine ........................................................................................................ 10-15
Engine oil filter – V8 engine ............................................................................................................ 10-15
Manual gearbox .............................................................................................................................. 10-16
Automatic gearbox ......................................................................................................................... 10-17
Transfer box .................................................................................................................................... 10-18
Front and rear axle .......................................................................................................................... 10-19
Propeller shafts ............................................................................................................................... 10-19
Anti-roll bar links ............................................................................................................................. 10-20
ACE actuators ................................................................................................................................. 10-21
ACE filter ......................................................................................................................................... 10-21
Brake hose, brake, fuel, ACE, clutch pipes and unions/electrical harnesses ................................ 10-22
Engine, gearbox, transfer box and axles ........................................................................................ 10-23
Exhaust system............................................................................................................................... 10-23
Steering box and front suspension ................................................................................................. 10-23
Steering rod ball joints ................................................................................................................... 10-25
Dampers and SLS height sensors .................................................................................................. 10-25
Front and rear axle suspension links .............................................................................................. 10-26
Towing bracket................................................................................................................................ 10-27
Engine mountings - V8 engine ........................................................................................................ 10-27
Road/roller test................................................................................................................................ 10-28
ENGINE - Td5 ........................................................................................... 12-1-1
DESCRIPTION AND OPERATION
Td5 Engine...................................................................................................................................... 12-1-1
Cylinder block components ............................................................................................................. 12-1-2
Page 7 of 1672
CONTENTS
4CONTENTS
Crankshaft, sump and oil pump ...................................................................................................... 12-1-4
Cylinder head components ............................................................................................................. 12-1-6
Camshaft cover and engine cover .................................................................................................. 12-1-8
Camshaft timing chain components................................................................................................ 12-1-10
Description ...................................................................................................................................... 12-1-12
Lubrication circuit ............................................................................................................................ 12-1-29
ADJUSTMENTS
Engine oil pressure check .............................................................................................................. 12-1-35
REPAIRS
Pulley - crankshaft ........................................................................................................................ 12-1-37
Seal - crankshaft - rear ................................................................................................................. 12-1-38
Gasket - cylinder head .................................................................................................................. 12-1-39
Rocker shaft assembly ................................................................................................................... 12-1-44
Gasket - cover - camshaft .............................................................................................................. 12-1-46
Engine and ancillaries ................................................................................................................... 12-1-47
Mounting - front - LH ...................................................................................................................... 12-1-53
Mounting - front - RH ..................................................................................................................... 12-1-54
Mounting - engine - rear - LH ........................................................................................................ 12-1-55
Mounting - engine - rear - RH ......................................................................................................... 12-1-55
Flywheel ........................................................................................................................................ 12-1-56
Plate - drive - automatic ................................................................................................................. 12-1-56
Filter - oil ........................................................................................................................................ 12-1-57
Strainer - oil pick-up ....................................................................................................................... 12-1-58
Pump - oil........................................................................................................................................ 12-1-58
Gasket - sump ................................................................................................................................ 12-1-60
Valve - relief - oil pressure ............................................................................................................. 12-1-62
Switch - oil pressure ...................................................................................................................... 12-1-62
Cooler - engine oil .......................................................................................................................... 12-1-63
Gasket - centrifuge oil drain pipe .................................................................................................... 12-1-64
Rotor - centrifuge ........................................................................................................................... 12-1-66
Seal - oil - timing cover .................................................................................................................. 12-1-66
OVERHAUL
Gasket - inlet manifold ................................................................................................................... 12-1-69
Gasket - exhaust manifold ............................................................................................................. 12-1-70
Gasket - cylinder head .................................................................................................................. 12-1-71
Cylinder head - overhaul ............................................................................................................... 12-1-74
Gasket - engine sump ................................................................................................................... 12-1-84
Seal - crankshaft - rear - manual models........................................................................................ 12-1-86
Seal - crankshaft - rear - automatic models .................................................................................... 12-1-87
Flywheel.......................................................................................................................................... 12-1-88
Drive plate....................................................................................................................................... 12-1-88
Starter ring gear .............................................................................................................................. 12-1-89
Pump - oil ...................................................................................................................................... 12-1-90
Timing chain and sprockets ........................................................................................................... 12-1-93
Bearings - connecting rods ........................................................................................................... 12-1-96
Pistons, connecting rods and cylinder bores ................................................................................ 12-1-98
Crankshaft .................................................................................................................................... 12-1-102
ENGINE - V8 ............................................................................................. 12-2-1
DESCRIPTION AND OPERATION
V8 Engine ....................................................................................................................................... 12-2-1
Cylinder head components ............................................................................................................. 12-2-2
Cylinder block components............................................................................................................. 12-2-4
Page 8 of 1672
CONTENTS
CONTENTS 5
Description ...................................................................................................................................... 12-2-6
ADJUSTMENTS
Engine oil pressure check .............................................................................................................. 12-2-11
REPAIRS
Seal - crankshaft - rear .................................................................................................................. 12-2-13
Gasket - cylinder head - LH ........................................................................................................... 12-2-14
Gasket - cylinder head - RH ............................................................................................................ 12-2-16
Gasket - rocker cover - LH ............................................................................................................ 12-2-19
Gasket - rocker cover - RH ............................................................................................................ 12-2-20
Mounting - front - LH ...................................................................................................................... 12-2-22
Mounting - front - RH ..................................................................................................................... 12-2-23
Mounting - rear - LH ....................................................................................................................... 12-2-24
Mounting - rear - RH ...................................................................................................................... 12-2-25
Engine assembly............................................................................................................................. 12-2-26
Flywheel ........................................................................................................................................ 12-2-31
Plate - drive - automatic ................................................................................................................ 12-2-32
Ring gear - starter ......................................................................................................................... 12-2-33
Filter - oil ....................................................................................................................................... 12-2-34
Strainer - oil pick-up ...................................................................................................................... 12-2-35
Pump - oil ...................................................................................................................................... 12-2-35
Gasket - sump ................................................................................................................................ 12-2-36
Switch - oil pressure ....................................................................................................................... 12-2-38
Cooler - engine oil .......................................................................................................................... 12-2-39
Gasket - timing gear cover ............................................................................................................ 12-2-40
Seal - cover - timing gears ............................................................................................................ 12-2-42
OVERHAUL
Gasket - inlet manifold ................................................................................................................... 12-2-45
Gasket - exhaust manifold ............................................................................................................. 12-2-48
Seal - crankshaft - rear - automatic models .................................................................................... 12-2-49
Seal - crankshaft - rear - manual models ........................................................................................ 12-2-50
Bearing - spigot - crankshaft .......................................................................................................... 12-2-52
Gasket - engine sump .................................................................................................................... 12-2-53
Strainer - oil pick-up ....................................................................................................................... 12-2-54
Seal - timing gear cover ................................................................................................................. 12-2-54
Gasket - timing gear cover ............................................................................................................. 12-2-55
Timing chain and gears .................................................................................................................. 12-2-57
Rocker shaft - overhaul ................................................................................................................. 12-2-59
Gasket - cylinder head .................................................................................................................... 12-2-60
Cylinder head - overhaul ................................................................................................................ 12-2-62
Piston assemblies ........................................................................................................................... 12-2-67
Bearings - connecting rods ............................................................................................................ 12-2-71
Crankshaft and main bearings ........................................................................................................ 12-2-72
Camshaft ....................................................................................................................................... 12-2-76
EMISSION CONTROL - Td5..................................................................... 17-1-1
DESCRIPTION AND OPERATION
EGR system components - type 1 .................................................................................................. 17-1-1
EGR system components - type 2 .................................................................................................. 17-1-2
Emission Control Systems .............................................................................................................. 17-1-4
Crankcase emission control ............................................................................................................ 17-1-4
Exhaust gas recirculation ................................................................................................................ 17-1-5
Page 10 of 1672
CONTENTS
CONTENTS 7
Operation ........................................................................................................................................ 18-1-38
ADJUSTMENTS
Glow plug ....................................................................................................................................... 18-1-45
REPAIRS
Engine control module (ECM) ........................................................................................................ 18-1-47
Sensor - engine coolant temperature (ECT) ................................................................................. 18-1-47
Sensor - crankshaft (CKP) .............................................................................................................. 18-1-48
Air filter assembly ........................................................................................................................... 18-1-48
Element - air filter ............................................................................................................................ 18-1-49
Sensor - fuel temperature .............................................................................................................. 18-1-50
Sensor - mass air flow (MAF) ....................................................................................................... 18-1-51
Sensor - combined MAP and IAT ................................................................................................. 18-1-51
Sensor - ambient air pressure (AAP) ............................................................................................ 18-1-52
Element - fuel filter ........................................................................................................................ 18-1-53
Cooler - fuel .................................................................................................................................. 18-1-53
Sensor - Throttle position (TP) ........................................................................................................ 18-1-54
Turbocharger ................................................................................................................................ 18-1-55
Intercooler ..................................................................................................................................... 18-1-56
Valve - solenoid boost control ........................................................................................................ 18-1-58
Regulator - fuel pressure .............................................................................................................. 18-1-59
Glow plugs ...................................................................................................................................... 18-1-60
Injectors .......................................................................................................................................... 18-1-61
Switch - cruise control (on/off) ........................................................................................................ 18-1-62
Switch - cruise control (set/resume) ................................................................................................ 18-1-63
Switch - clutch ................................................................................................................................. 18-1-63
ENGINE MANAGEMENT SYSTEM - V8 .................................................. 18-2-1
DESCRIPTION AND OPERATION
Engine management component location - Passenger compartment ............................................ 18-2-2
Engine management component location - Engine compartment .................................................. 18-2-3
Engine management block diagram ............................................................................................... 18-2-4
Description - engine management .................................................................................................. 18-2-6
Operation - engine management .................................................................................................... 18-2-43
DESCRIPTION AND OPERATION
Cruise control component layout .................................................................................................... 18-2-55
Cruise control block diagram .......................................................................................................... 18-2-56
Description - cruise control ............................................................................................................. 18-2-57
Operation - cruise control................................................................................................................ 18-2-66
ADJUSTMENTS
Cable - throttle ............................................................................................................................. 18-2-69
Cable - cruise control .................................................................................................................... 18-2-69
REPAIRS
Spark plugs .................................................................................................................................. 18-2-71
Coil - ignition ................................................................................................................................. 18-2-71
Engine control module (ECM) ......................................................................................................... 18-2-72
Sensor - engine coolant temperature (ECT) ................................................................................ 18-2-73
Sensor - crankshaft position (CKP) ............................................................................................... 18-2-74
Sensor - radiator temperature ....................................................................................................... 18-2-75
Sensor - camshaft position (CMP) ................................................................................................. 18-2-76
Page 14 of 1672
CONTENTS
CONTENTS 11
MANUAL GEARBOX - R380 .................................................................... 37-1
DESCRIPTION AND OPERATION
R380 gearbox ................................................................................................................................. 37-1
Gearbox casings, gear change and oil pump ................................................................................ 37-2
Selector shaft and forks, synchromesh assemblies and gear train ................................................ 37-4
R380 gearbox cross section ........................................................................................................... 37-6
Description ...................................................................................................................................... 37-7
Operation ........................................................................................................................................ 37-8
ADJUSTMENTS
Spring - gear lever bias .................................................................................................................. 37-9
REPAIRS
Housing - gear selector .................................................................................................................. 37-11
Gearbox - V8................................................................................................................................... 37-12
Gearbox - Diesel ............................................................................................................................. 37-16
Seal - gearbox mainshaft ............................................................................................................... 37-20
Seal - input shaft ............................................................................................................................ 37-21
Cooler - oil - gearbox - Diesel ......................................................................................................... 37-22
Cooler - oil - gearbox - V8 ............................................................................................................... 37-23
Switch - Reverse light ................................................................................................................... 37-24
OVERHAUL
Shaft - output ................................................................................................................................. 37-25
Synchroniser - gearbox - set ......................................................................................................... 37-29
Fork - set - selector shaft .............................................................................................................. 37-31
Shaft - gearbox - input .................................................................................................................. 37-32
Extension - gearbox rear ................................................................................................................ 37-35
Pump - gearbox oil ......................................................................................................................... 37-37
Filter - gearbox oil ......................................................................................................................... 37-38
Gear - 5th gear set ........................................................................................................................ 37-38
Synchronizer assembly - 5th/reverse ............................................................................................ 37-39
5th gear - layshaft ......................................................................................................................... 37-40
Bearing - layshaft rear support ...................................................................................................... 37-42
Bearing - output shaft rear support ............................................................................................... 37-43
Shaft - reverse idler ....................................................................................................................... 37-44
Housing - gear selector mechanism ............................................................................................. 37-46
Lever - gear change ...................................................................................................................... 37-47
Housing - clutch ............................................................................................................................ 37-48
Cover - front ................................................................................................................................... 37-49
TRANSFER BOX - LT230SE .................................................................... 41-1
DESCRIPTION AND OPERATION
LT230SE transfer box ..................................................................................................................... 41-1
Transfer box cross section .............................................................................................................. 41-2
Main casing components – Vehicles up to 03 model year .............................................................. 41-4
Main casing components – Vehicles from 03 model year ............................................................... 41-5
Differential components – Vehicles up to 03 model year ................................................................ 41-6
Differential components – Vehicles from 03 model year ................................................................. 41-7
Front output housing components – Vehicles up to 03 model year ................................................ 41-8
Front output housing components – Vehicles from 03 model year ................................................. 41-10
Rear output housing components ................................................................................................... 41-12
Description ...................................................................................................................................... 41-13
Page 15 of 1672
CONTENTS
12 CONTENTS
Operation ........................................................................................................................................ 41-19
ADJUSTMENTS
Cable - high/low selector ................................................................................................................ 41-21
REPAIRS
Bottom cover - transfer box ......................................................................................................... 41-23
Transfer box - Diesel ...................................................................................................................... 41-24
Transfer box - V8 ............................................................................................................................ 41-27
Gasket - rear cover plate ................................................................................................................ 41-30
Switch - differential lock - Up to 03 MY ........................................................................................... 41-30
Cable - high/low selector ................................................................................................................ 41-31
Oil seal - input shaft ...................................................................................................................... 41-32
Seal - front output shaft .................................................................................................................. 41-33
Seal - rear output shaft ................................................................................................................... 41-34
Gasket - rear output shaft housing ................................................................................................. 41-35
Solenoid - interlock - Up to 03 MY .................................................................................................. 41-36
Sensor - neutral ........................................................................................................................... 41-36
Sensor - oil temperature ................................................................................................................ 41-37
Switch - high low - warning ........................................................................................................... 41-37
OVERHAUL
Intermediate gear assembly ......................................................................................................... 41-39
Differential assembly ................................................................................................................... 41-42
Dog clutch - differential lock .......................................................................................................... 41-57
Input gear/bearing .......................................................................................................................... 41-60
Low gear - differential ................................................................................................................... 41-62
AUTOMATIC GEARBOX - ZF4HP22 - 24 ................................................ 44-1
DESCRIPTION AND OPERATION
Automatic gearbox component layout ............................................................................................ 44-1
Control schematic ........................................................................................................................... 44-2
Description ...................................................................................................................................... 44-4
Operation ........................................................................................................................................ 44-17
ADJUSTMENTS
Cable - selector ............................................................................................................................. 44-21
Stall test .......................................................................................................................................... 44-21
REPAIRS
Cable and lever assembly - selector .............................................................................................. 44-23
Selector indicator .......................................................................................................................... 44-24
Switch - starter inhibitor ................................................................................................................. 44-24
Seal - selector shaft ........................................................................................................................ 44-25
Gearbox - convertor and transfer gearbox - Diesel ....................................................................... 44-26
Gearbox - convertor and transfer gearbox - V8 ............................................................................ 44-30
Torque converter and oil seal ......................................................................................................... 44-34
Housing - torque converter ............................................................................................................ 44-35
Gasket - intermediate plate ............................................................................................................ 44-37
Intermediate plate .......................................................................................................................... 44-38
Pump - fluid .................................................................................................................................... 44-40
Seal - rear extension housing ......................................................................................................... 44-41
Gasket - rear extension housing. .................................................................................................. 44-42
Parking pawl assembly. ................................................................................................................ 44-43
Gasket - oil sump ........................................................................................................................... 44-44
Filter - oil ........................................................................................................................................ 44-45
Cooler - fluid - Td5 .......................................................................................................................... 44-45
Page 16 of 1672
CONTENTS
CONTENTS 13
Cooler - fluid - V8 ........................................................................................................................... 44-46
Valve body assembly ..................................................................................................................... 44-47
Seal - valve body ........................................................................................................................... 44-49
Pressure regulator ......................................................................................................................... 44-50
Lock-up solenoid valve (MV 3) ....................................................................................................... 44-51
Solenoids - shift control valves (MV 1 & 2) .................................................................................... 44-51
Harness - solenoid valves .............................................................................................................. 44-52
Electronic control unit - automatic transmission .............................................................................. 44-53
PROPELLER SHAFTS ............................................................................. 47-1
DESCRIPTION AND OPERATION
Propeller shaft component layout ................................................................................................... 47-1
Description ...................................................................................................................................... 47-2
REPAIRS
Propeller shaft - front ..................................................................................................................... 47-5
Propeller shaft - rear ...................................................................................................................... 47-5
Flexible coupling ............................................................................................................................ 47-6
OVERHAUL
Propeller shaft ................................................................................................................................. 47-7
REAR AXLE .............................................................................................. 51-1
DESCRIPTION AND OPERATION
Rear axle component layout ........................................................................................................... 51-1
Description ...................................................................................................................................... 51-2
REPAIRS
Differential - assembly .................................................................................................................... 51-5
Seal - differential pinion ................................................................................................................. 51-7
OVERHAUL
Differential assembly ...................................................................................................................... 51-9
FRONT AXLE............................................................................................ 54-1
DESCRIPTION AND OPERATION
Front axle component layout........................................................................................................... 54-1
Description ...................................................................................................................................... 54-2
REPAIRS
Differential - assembly .................................................................................................................... 54-5
Seal - differential pinion ................................................................................................................ 54-7
Seal - oil - front axle casing ........................................................................................................... 54-9
Constant velocity joint - drive shaft ................................................................................................ 54-11
STEERING ................................................................................................ 57-1
DESCRIPTION AND OPERATION
Page 87 of 1672
TORQUE WRENCH SETTINGS
06-2
Engine Td5
TORQUE DESCRIPTION METRIC IMPERIAL
ACE pump bolts25 Nm (18 lbf.ft)
A/C compressor bolts 25 Nm (18 lbf.ft)
Alternator support bracket to cylinder head bolts 25 Nm (18 lbf.ft)
Alternator/vacuum pump oil feed pipe union 10 Nm (7 lbf.ft)
Camshaft cover to camshaft carrier bolts 10 Nm (7 lbf.ft)
Camshaft sprocket to camshaft bolts 37 Nm (27 lbf.ft)
Centrifuge cover bolts 10 Nm (7 lbf.ft)
Centrifuge oil drain pipe to sump bolts (or nuts) 10 Nm (7 lbf.ft)
Centrifuge to oil drain pipe bolts 10 Nm (7 lbf.ft)
Centrifuge to oil cooler housing bolts 25 Nm (18 lbf.ft)
CKP sensor bolt10 Nm (7 lbf.ft)
Coolant pipe bolt50 Nm (37 lbf.ft)
Connecting rod bolts, then a further 80°20 Nm (15 lbf.ft)
Crankshaft pulley bolt 460 Nm (340 lbf.ft)
Crankshaft pulley TV damper bolts 80 Nm (59 lbf.ft)
Crankshaft rear oil seal housing bolts 10 Nm (7 lbf.ft)
Cylinder head bolts initial tighten 30 Nm (22 lbf.ft)
Cylinder head bolts final tighten, then a further 90°, then a further 180° and finally a
further 45°65 Nm (48 lbf.ft)
Dipstick tube to camshaft carrier bolt 10 Nm (7 lbf.ft)
Drive plate (automatic transmission) to crankshaft bolts 115 Nm (85 lbf.ft)
EGR pipe clamp to cylinder head bolt - if fitted 25 Nm (18 lbf.ft)
EGR pipe Allen screws 10 Nm (7 lbf.ft)
Engine mounting (front) to cylinder block bolts 48 Nm (35 lbf.ft)
Engine mounting (front) to chassis nuts 85 Nm (63 lbf.ft)
Engine mounting bracket (rear, LH & RH) to gearbox bolts 85 Nm (63 lbf.ft)
Engine mounting bracket (rear, LH & RH) nuts 45 Nm (33 lbf.ft)
Flywheel to crankshaft (manual transmission) bolts, then a further 90°40 Nm (30 lbf.ft)
Front crossmember bolts 26 Nm (20 lbf.ft)
Fuel connector block bolts 25 Nm (18 lbf.ft)
Fuel cooler to inlet manifold bolts 25 Nm (18 lbf.ft)
Gearbox housing to engine bolts 50 Nm (37 lbf.ft)
Heater pipe to cylinder head bolts 25 Nm (18 lbf.ft)
Main bearing cap bolts then a further 90°33 Nm (24 lbf.ft)
Oil cooler housing to cylinder block bolts 25 Nm (18 lbf.ft)
Oil cooler pipe clip bolts 10 Nm (7 lbf.ft)
Oil filter adaptor housing to oil cooler housing bolts 25 Nm (18 lbf.ft)
Oil pick-up strainer screws 10 Nm (7 lbf.ft)
Oil pressure switch 15 Nm (11 lbf.ft)
Oil pump drive sprocket bolt 25 Nm (18 lbf.ft)
Oil pump pressure relief valve plug 25 Nm (18 lbf.ft)
Oil pump and stiffener assembly to cylinder block bolts 13 Nm (10 lbf.ft)
Oil sump to cylinder block bolts 25 Nm (18 lbf.ft)
Oil sump to gearbox bell housing bolts 13 Nm (10 lbf.ft)
PAS pump bracket bolts 27 Nm (20 lbf.ft)
PAS pump pulley bolts 27 Nm (20 lbf.ft)
Rocker arm adjusting screw locknuts 16 Nm (12 lbf.ft)
Page 89 of 1672
TORQUE WRENCH SETTINGS
06-4
Engine V8
TORQUE DESCRIPTION METRIC IMPERIAL
Engine mounting bolts (rear, LH & RH) to gearbox bolts 85 Nm (63 lbf.ft)
Engine mounting (rear, LH & RH) nuts 45 Nm (33 lbf.ft)
Cylinder head bolts tighten, then 90°, then a further 90°20 Nm (15 lbf.ft)
Rocker shaft bolts 40 Nm (30 lbf.ft)
Alternator mounting bracket 40 Nm (30 lbf.ft)
Auxiliary drive belt tensioner 45 Nm (33 lbf.ft)
Engine earth lead 22 Nm (16 lbf.ft)
Rocker cover bolts 8 Nm (6 lbf.ft)
Torque converter to drive plate 50 Nm (37 lbf.ft)
A/C compressor 22 Nm (16 lbf.ft)
ACE pump 22 Nm (16 lbf.ft)
Flywheel to crankshaft 78 Nm (58 lbf.ft)
Crankshaft sensor 6 Nm (5 lbf.ft)
Crankshaft sensor cover 6 Nm (5 lbf.ft)
Spacer and hub to crankshaft 85 Nm (63 lbf.ft)
Drive plate and clamp ring 45 Nm (33 lbf.ft)
Oil pick up strainer 10 Nm (7 lbf.ft)
Filter head adaptor 13 Nm (10 lbf.ft)
Filter head 8 Nm (6 lbf.ft)
Sump bolts 22 Nm (16 lbf.ft)
Oil pressure switch 15 Nm (11 lbf.ft)
Timing gear cover to cylinder block 22 Nm (16 lbf.ft)
Oil cooler pipe to timing gear cover 15 Nm (11 lbf.ft)
Crankshaft pulley bolt 270 Nm (200 lbf.ft)
Coolant outlet elbow 22 Nm (16 lbf.ft)
Auxiliary housing 40 Nm (30 lbf.ft)
Jockey pulley 50 Nm (37 lbf.ft)
Camshaft gear 50 Nm (37 lbf.ft)
Rocker shaft bolts 40 Nm (30 lbf.ft)
Connecting rod bolts
Final torque - turn through 80 °20 Nm (15 lbf.ft)
Initial torque - all main bearing cap bolts and side bolts 13.5 Nm (10 lbf.ft)
Final torque - main bearing cap side bolts 11 to 15 45 Nm (33 lbf.ft)
Final torque - main bearing cap bolts 1 to 8 72 Nm (53 lbf.ft)
Final torque - main bearing cap bolts 9 and 10 92 Nm (68 lbf.ft)
Final torque - main bearing cap side bolts 16 to 20 45 Nm (33 lbf.ft)
Viscous fan nut 45 Nm (33 lbf.ft)
Camshaft thrust plate bolts 22 Nm (16 lbf.ft)
Secondary Air Injection adapters 33 Nm (24 lbf.ft)
Page 90 of 1672
TORQUE WRENCH SETTINGS
06-5
Emission control - Td5
Emission control - V8
Engine management system - Td5
TORQUE DESCRIPTION METRIC IMPERIAL
EGR valve pipe Allen screws 10 Nm (7 lbf.ft)
EGR valve to inlet manifold bolts 10 Nm (7 lbf.ft)
EGR intake pipe clip to cylinder head bolts - if fitted 25 Nm (18 lbf.ft)
EGR cooler to cylinder head nut and bolts - if fitted 25 Nm (18 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
HO
2S Sensors45 Nm (33 lbf.ft)
SAI air manifold union nuts 25 Nm (18 lbf.ft)
Rubber mountings to SAI pump bracket 10 Nm (7 lbf.ft)
SAI control valve to manifold bolts 10 Nm (7 lbf.ft)
SAI pump to bracket nuts 10 Nm (7 lbf.ft)
SAI pump bracket to body bolt 20 Nm (15 lbf.ft)
Vacuum reservoir to mounting bracket bolt 10 Nm (7 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
ECT sensor15 Nm (11 lbf.ft)
Fuel tank cradle45 Nm (33 lbf.ft)
CKP sensor10 Nm (7 lbf.ft)
MAP and IAT sensor 10 Nm (7 lbf.ft)
Fuel cooler to inlet manifold - upper bolts 25 Nm (18 lbf.ft)
Turbocharger to exhaust manifold 30 Nm (22 lbf.ft)
Turbocharger drain pipe 10 Nm (7 lbf.ft)
Banjo bolt to oil feed pipe 25 Nm (18 lbf.ft)
Fuel temperature sensor 14 Nm (10 lbf.ft)
Pressure regulator 25 Nm (18 lbf.ft)
Glow plugs16 Nm (12 lbf.ft)
EUI clamp bolts32 Nm (24 lbf.ft)
EGR valve to exhaust manifold 10 Nm (7 lbf.ft)
EGR valve to inlet manifold 10 Nm (7 lbf.ft)
EGR clip25 Nm (18 lbf.ft)