ecm LAND ROVER DISCOVERY 2002 Workshop Manual

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

INTRODUCTION
01-3
Abbreviations and Symbols
A Amperes
AAP Ambient Air Pressure
AAT Ambient Air Temperature
ABDC After Bottom Dead Centre
ABS Anti-Lock Brake System
ABS / TC Anti-lock Brake System / Traction
Control
ac Alternating current
A/C Air Conditioning
ACE Active Cornering Enhancement
ACEA Association of Constructors of
European Automobiles
AFR Air Fuel Ratio
AP Ambient Pressure
ASC Anti-shunt Control
ATC Air Temperature Control
ATDC After Top Dead Centre
AUX Auxiliary
AVC Automatic Volume Control
BBDC Before Bottom Dead Centre
BBUS Battery Backed Up Sounder
BCU Body Control Unit
BDC Bottom Dead Centre
bhp Brake Horse Power
BP Boost Pressure
BPP Brake Pedal Position
BS British Standard
BTDC Before Top Dead Centre
BWD Backward
C Celsius
CAN Controller Area Network
CD Compact Disc
CDC Centre Differential Control
CDL Central Door Locking
CD - ROM Compact Disc - Read Only
Memory
CFC Chlorofluorocarbon
CHMSL Centre High Mounted Stop Lamp
CKP Crankshaft Position
CLV Calculated Load Value
cm Centimetre
cm
2Square centimetre
cm3Cubic centimetre
CMP Camshaft Position
CPP Clutch Pedal Position
CO Carbon Monoxide
CO
2Carbon Dioxide
COB Clear Over Base
CR Common Rail
CVS Canister Vent Solenoid
dB Decibels
DDM Driver's Door Module
deg. Degree, angle or temperature
DI Direct Injection
dia. DiameterDIN Deutsche Industrie Normen
(German Industrial Standards)
dc Direct current
DCV Directional Control Valve
DOHC Double Overhead Camshaft
DSP Digital Signal Processing
DTI Dial Test Indicator
DMF Dual Mass Flywheel
DVD Digital Versatile Disc
EACV Electronic Air Control Valve
EAT Electronic Automatic
Transmission
EBD Electronic Brake pressure
Distribution
ECD European Community Directive
ECM Engine Control Module
ECT Engine Coolant Temperature
ECU Electronic Control Unit
EDC Electronic Diesel Control
EEPROM Electronic Erasable
Programmable Read Only
Memory
EGR Exhaust Gas Recirculation
EKA Emergency Key Access
ELR Emergency Locking Retractor
EN European Norm
EOBD European On Board Diagnostics
EON Enhanced Other Network
ERL Electrical Reference Library
ETC Electronic Traction Control
EUI Electronic Unit Injector
EVAP Evaporative Emission
EVR Electronic Vacuum Regulator
F Fahrenheit
ft. Feet
FBH Fuel Burning Heater
FET Field Effect Transistor
FIP Fuel Injection Pump
FTC Fast Throttle Control
FWD Forward
> Greater than
g Gramme or Gravity
gal. Gallons
GMT Greenwich Mean Time
GPS Global Positioning System
hHour
hc High compression
HC Hydro Carbons
HDC Hill Descent Control
HDOP Height Dilation Of Precision
HDPE High Density Polyethylene
HFS Heated Front Screen
Hg Mercury
HO
2S Heated Oxygen Sensor
HMW High Molecular Weight

GENERAL DATA
04-1
GENERAL DATA
Engine - Td5
General
Type 2.5 litre in-line direct injection diesel, turbocharged and intercooled
Cylinder arrangement 5 in-line, No. 1 cylinder at front of engine
Bore 84.450 mm (3.3248 in)
Stroke 88.950 mm (3.5020 in)
Capacity 2498 cm
3 (152.5 in3)
Firing order 1 - 2 - 4 - 5 - 3
Compression ratio 19.5 : 1
Direction of rotation Clockwise viewed from the front of the engine
Dimensions:

Length 766 mm (30.1 in)

Width 708 mm (27.8 in)

Height 788 mm (31.0 in)
Injection timing Controlled by ECM
Injectors:

Make/Type Lucas EV1

Nominal operating pressure:

Pre EU3 models 1500 bar (21750 lbf.in
2)

EU3 models 1750 bar (25500 lbf.in
2)
Maximum governed speed 4850 rev/min
Maximum overrun speed 5460 rev/min
Idle speed:

Manual gearbox 740 ± 50 rev/min

Automatic gearbox 760 ± 50 rev/min
Glow plugs Beru 12 V. Four plugs in cylinders 1, 2, 3 and 4
Turbocharger Garrett GT 20
Emissions standard:

Pre EU3 models ECD 2

EU3 models ECD 3
Valve timing
Inlet valves:

Opens 14° BTDC

Closes 33° ABDC
Exhaust valves:

Opens 57° BBDC

Closes 14° ATDC

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
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
OVERHAUL 12-1-83
9.Using tool LRT-12-154/3, fit new sealing
washer to each injector.
10.Support each end of cylinder head on blocks of
wood ensuring blocks are clear of valves.
11.Position reaction posts in their original fitted
order.
12.Carefully fit EUI's, ensuring they are in their
original fitted order and that each retainer is
located on its dowel.
CAUTION: If new EUI's are fitted, ensure
replacements are correct. Engine Serial No.
Prefixes 10P to 14P – Push rod bushes are
coloured BLACK or BLUE. Serial No.
Prefixes 15P to 19P – Push rod bushes are
coloured GREEN.
13.Fit new retainer bolts and tighten to 32 Nm (24
lbf.ft).
If new injectors are fitted they must be
programmed for use with the ECM using
TestBook.
14.Lubricate lash adjusters and bores with engine
oil.
15.Fit lash adjusters ensuring they are in their
original fitted order.
16.Lubricate finger followers with engine oil.
17.Fit finger followers ensuring they are in their
original fitted order.
18.Lubricate cams and bearing journals on
camshaft, cylinder head and camshaft carrier
with engine oil.
19.Position camshaft in cylinder head with the
timing pin hole in the vertical position.20.Apply an even film of sealant, Part No. STC
4600 to camshaft carrier face and spread to an
even film using a roller.
CAUTION: Ensure sealant does not block
oilways (arrowed) or contaminate camshaft
bearings. Assembly and bolt tightening
must be completed within 20 minutes of
applying sealant.
21.Fit camshaft carrier ensuring it is correctly
located on dowels.
22.Fit and lightly tighten new camshaft carrier
bolts.
23.Using sequence shown, progressively tighten
bolts to 25 Nm (18 lbf.ft).
24.Lubricate a new camshaft rear oil seal with
engine oil, fit seal using a suitable mandrel.
25.Position rocker shaft on camshaft carrier
ensuring rocker shaft is located on dowel.
26.Fit new rocker shaft retaining bolts and working
from the centre outwards, tighten rocker shaft
bolts to 32 Nm (24 lbf.ft).
27.Fit injector harness and connect multiplugs.
28.Clean fuel connector block and mating face.
29.Lubricate a new fuel filter 'O' ring with engine
oil.

ENGINE - V8
12-2-28 REPAIRS
21.Disconnect multiplug from EVAP purge valve.
22.Remove nut securing engine harness earth to
body and disconnect engine harness to main
harness multiplug.
23.Remove trim fixings securing toe board and
remove toe board. 24.Disconnect 5 multiplugs connecting engine
harness to ECM.
25.Release engine harness, pull into engine bay
and coil on top of engine.
26.Raise vehicle on ramp.
27.Remove 3 bolts securing oil cooling pipes to
sump and remove saddle clamps.
28.Tie oil cooling pipes aside.
29.Remove exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.

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

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

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

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

+ ENGINE - V8, REPAIRS, Filter - oil.

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

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.

EMISSION CONTROL - TD5
DESCRIPTION AND OPERATION 17-1-5
Exhaust gas recirculation
The exhaust gas recirculation (EGR) valve permits a controlled amount of exhaust gas to combine with the fresh air
entering the engine. The exhaust gas reduces the combustion temperature by delaying the fuel burning rate, which
assists in reducing the quantity of oxides of nitrogen.
On EU3 models, an EGR cooler is employed to further reduce the combustion temperature. By passing the exhaust
gas through a bundle of pipes flooded by coolant, the density of the exhaust gas going into the engine is increased.
This process further reduces the amount of oxygen, which in turn, further reduces the amount of NO
2 in the exhaust.
Recirculating too much exhaust gas can result in higher emissions of soot, HC and CO due to insufficient air. The
recirculated exhaust gas must be limited so that there is sufficient oxygen available for combustion of the injected fuel
in the combustion chamber, to do this the Engine Control Module (ECM) is used to control the precise quantity of
exhaust gas to be recirculated in accordance with the prevailing operating conditions. Influencing factors include:
lthe mass of air flow detected by the mass air flow sensor.

+ ENGINE MANAGEMENT SYSTEM - Td5, DESCRIPTION AND OPERATION, Description.
lthe ambient air pressure, determined by the ambient air pressure sensor which is used to initiate adjustments
to reduce the amount of smoke produced at high altitudes.

+ ENGINE MANAGEMENT SYSTEM - Td5, DESCRIPTION AND OPERATION, Description.
Other factors which are taken into consideration by the engine management system for determining the optimum
operating condition include:
lManifold inlet air temperature
lCoolant temperature
lEngine speed
lFuel delivered
The main components of the EGR system are as follows.
EGR Modulator
1Port to vacuum source (white band)
2Port to EGR valve (blue band)
3Port to atmosphere via in-line filter (green
band)4Harness connector (black)

EMISSION CONTROL - TD5
17-1-6 DESCRIPTION AND OPERATION
The EGR modulator is located on a plate fixed to the inner wing on the RH side of the engine. The modulator is
attached to the plate by two through-studs, each with two nuts which secure the modulator assembly to a rubber
mounting which helps to reduce noise. The modulator must be mounted in the vertical orientation with the two vacuum
ports uppermost.
The modulator operation is controlled by a signal from the ECM which determines the required amount of EGR
needed in response to inputs relating to air flow and engine operating and ambient conditions. The modulator has a
black two-pin connector at its base to connect it to the ECM through the engine harness.
Each modulator features three ports:
lThe top port of the EGR modulator is identified by a white band and connects to a 'T'-piece in the vacuum line
via a small-bore brown plastic hose. On type 2 systems the brown hose is connected in parallel with the vacuum
source to the ILT modulator.
The other two ports on the 'T'-piece connects vacuum line hoses of black vinyl tubing between the vacuum pump
and the brake-servo assembly attached to the bulkhead. The vacuum pump end of the vacuum line tubing
terminates in a rubber elbow, which gives a vacuum tight seal on the suction port of the vacuum pump. The
brake-servo end of the vacuum line tubing terminates with a non-return valve in a plastic housing which plugs
into the front face of the brake-servo housing.
lThe middle port of the EGR modulator is identified by a blue band and connects to the suction port on the EGR
valve through a small-bore blue plastic hose.
lThe lower port of the EGR modulator is identified by a green band and connects to atmosphere through an in-
line filter via a small-bore green plastic hose. On type 2 models a 3 way connector is fitted to vent both modulators
through a single filter. The other port of the in-line filter vents directly to atmosphere.
The blue and brown vacuum hoses are protected by corrugated plastic sheaths. The ends of the hoses are fitted with
rubber boots to ensure vacuum tight seals at the component ports.
Inlet Throttle (ILT) Modulator
1Port to vacuum source (white band)
2Port to ILT valve (blue band)
3Port to atmosphere via in-line filter (green
band)4Harness connector (green)