2002 LAND ROVER DISCOVERY engine

ENGINE - TD5
12-1-38 REPAIRS
Seal - crankshaft - rear
$% 12.21.20
Remove
1. Automatic models: Remove drive plate

+ ENGINE - Td5, REPAIRS, Plate -
drive - automatic.
2. Manual models: Remove flywheel.

+ ENGINE - Td5, REPAIRS, Flywheel.
3.Remove sump gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
sump.
4.Remove 5 bolts securing crankshaft oil seal
housing to cylinder block.
5.Remove crankshaft oil seal housing.
Refit
1.Clean interface between crankshaft oil seal
housing and cylinder block.
2.Position seal protector, LRT-12-061 over
crankshaft boss. Fit new seal and remove tool
LRT-12-061 .
CAUTION: Oil seal must be fitted dry.3.Fit crankshaft rear oil seal housing bolts and
using sequence shown, tighten to 9 Nm (7
lbf.ft).
4.Fit new sump gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
sump.
5. Automatic models: Fit drive plate

+ ENGINE - Td5, REPAIRS, Plate -
drive - automatic.
6. Manual models: Fit flywheel.

+ ENGINE - Td5, REPAIRS, Flywheel.

ENGINE - TD5
REPAIRS 12-1-39
Gasket - cylinder head
$% 12.29.02
Remove
Note: The following procedures cover engines
fitted with or without an EGR cooler. The EGR
cooler is bolted to the front of the cylinder head.
1.Remove bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.
2.Release turnbuckles and remove battery cover.
3.Disconnect battery earth lead.
4.Drain cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
5.Remove camshaft cover gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
cover - camshaft.
6.Remove cooling fan coupling.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
7.Remove 3 bolts and remove exhaust manifold
heat shield. 8.Remove turbocharger oil feed banjo bolt and
discard sealing washers.
9.Remove 3 nuts, release turbocharger from
exhaust manifold, discard gasket and tie
turbocharger aside.
10.Disconnect multiplugs from compressor, MAF
sensor, turbocharger wastegate modulator,
and AAP & IAT sensor.
11.Remove 2 bolts securing engine harness to
camshaft carrier.
12.Disconnect multiplug from EUI's and coolant
temperature sensor.

ENGINE - TD5
12-1-40 REPAIRS
13.Disconnect 4 glow plug connectors.
14.Disconnect MAP sensor multiplug from inlet
manifold.
15.Position engine harness clear of inlet manifold.
16.Disconnect vacuum hose from EGR valve.
17.Release 3 clips and disconnect coolant hoses
from fuel cooler.
18.Disconnect fuel hoses, tank to fuel cooler and
connector block on cylinder head.
CAUTION: Always fit plugs to open
connections to prevent contamination.19.Disconnect fuel hose from connector block on
cylinder head.
20.Disconnect fuel hose from fuel cooler and
secure to connector block on cylinder head.
This is to prevent contamination of the fuel
injection system.
Pre EU3 model shown
21.Loosen clip screw and disconnect air intake
hose from EGR valve.
22.Loosen vacuum pump oil feed pipe union from
cylinder head and discard 'O' ring.
23.Loosen 2 bolts and release alternator support
bracket from cylinder head.
24. Pre EU3 model: Remove bolt securing EGR
valve pipe clamp to cylinder head.
25. EU3 model: Release the clips and disconnect
the coolant hoses from the EGR cooler.
26.Remove nut and bolt securing cylinder head to
timing chain cover.
27.Release clips and disconnect top hose, heater
hose and heater feed hose.
28.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.

ENGINE - TD5
REPAIRS 12-1-41
29.Rotate engine clockwise to align mark on
camshaft sprocket between coloured links on
timing chain.
30.Position tool LRT-12-058 through camshaft
carrier to lock camshaft.
31.Position tool LRT-12-158 through gearbox bell
housing to lock crankshaft. 32.Remove timing chain tensioner and discard
sealing washer.
33.Remove timing chain fixed guide Allen screw
from front of cylinder head.
34.Lever out camshaft sprocket blanking plug and
'O'-ring seal from front of cylinder head and
discard.
35.Remove 3 bolts and release timing sprocket
from camshaft. Discard bolts.
36.Using sequence shown, progressively loosen
then remove and discard 12 cylinder head bolts
together with their captive washers.

ENGINE - TD5
12-1-42 REPAIRS
37.Using suitable lifting chains and tool LRT-12-
138 carefully remove cylinder head and place
on wooden blocks or stands.
CAUTION: Support both ends of cylinder
head on blocks of wood. With the camshaft
carrier bolted down, the injector nozzles
and some of the valves will protrude from
the face of the cylinder head.
38.Remove cylinder head gasket.
39.Note the gasket thickness indicator and ensure
the same thickness gasket is used on refitment
of cylinder head.
40.Remove and discard plastic dowels from
cylinder block.Refit
1.Clean mating faces of cylinder head and
cylinder block.
2.Check cylinder head for warping, across centre
and from corner to corner: – Maximum warp =
0.10 mm (0.0004 in)
CAUTION: Cylinder heads may not be
refaced, replace cylinder head if warping
exceeds figure given.
3.Ensure coolant and oil passages are clean.
4.Clean dowel holes and fit new plastic dowels.
5.Lightly lubricate threads and beneath heads of
cylinder head bolts with clean engine oil.
6.Fit new cylinder head gasket of the correct
thickness with the word 'TOP' uppermost.
7.Using assistance, fit cylinder head and locate
onto dowels.
8.Carefully enter cylinder head bolts, DO NOT
DROP. Lightly tighten bolts.
9.Using the sequence shown, progressively
tighten cylinder head bolts to 30 Nm (22 lbf.ft),
then to 65 Nm (48 lbf.ft), then a further 90
°, then
a further 180
° and finally a further 45°.
CAUTION: Ensure correct sequence is
followed for all 5 tightening stages. Do not
tighten bolts 315 degrees in one operation.
10.Fit nut and bolt securing cylinder head to timing
chain cover and tighten to 25 Nm (18 lbf.ft).

ENGINE - TD5
REPAIRS 12-1-43
11.Clean camshaft sprocket and mating face on
camshaft.
12.Ensure engine is set to TDC No. 1 cylinder and
mark on camshaft sprocket is positioned
between the 2 coloured links.
13.Position camshaft sprocket to camshaft; fit and
lightly tighten new bolts, then loosen bolts half
a turn.
14.Clean timing chain fixed guide retaining pin and
apply Loctite 242 to threads.
15.Fit timing chain fixed guide retaining pin 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
(22 lbf.ft).
18.Tighten bolts securing camshaft sprocket to
camshaft to 37 Nm (27 lbf.ft).
19.Remove tool LRT-12-058 from camshaft.
20.Remove tool LRT-12-158 from gearbox bell
housing.
21.Fit new camshaft bore blanking plug and 'O'-
ring seal in recess in cylinder head.
22.Clean vacuum pump union.
23.Tighten union securing vacuum pump oil feed
pipe to cylinder head to 10 Nm (7 lbf.ft) .
24.Fit bolts securing alternator support bracket to
cylinder head and tighten to 25 Nm (18 lbf.ft) .
25.Connect top hose and heater hoses and secure
with clips.
26. Pre EU3 model:Fit bolt securing EGR pipe
clamp to cylinder head bolt and tighten to 10
Nm (7 lbf.ft) .
27. EU3 model: Connect coolant hoses to EGR
cooler and secure with the clips.
28.Position air intake hose to EGR valve and
tighten clip screw.
29.Disconnect fuel hose from connector block and
connect to fuel cooler.
30.Connect fuel hoses to fuel cooler and
connector block on cylinder head.
31.Connect coolant hoses to fuel cooler and
secure clips.
32.Connect vacuum hose to EGR valve.
33.Position engine harness and connect multi
plugs and glow plug connectors.
34.Fit and tighten bolts, engine harness to
camshaft carrier.
35.Clean exhaust manifold and turbocharger
interface.
36.Fit new gasket to exhaust manifold, position
turbocharger and tighten – nuts securing
turbocharger to manifold to 30 Nm (22 lbf.ft).
37.Clean turbocharger oil feed hose bolt.
38.Position turbocharger oil feed hose using new
sealing washers. Fit banjo bolt securing
turbocharger oil feed hose and tighten to 25 Nm
(18 lbf.ft) . 39.Position exhaust manifold heatshield and
tighten M6 bolts to 9 Nm (7 lbf.ft) and M8 bolt to
25 Nm (18 lbf.ft).
40.Fit cooling fan coupling.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
41.Fit camshaft cover with new seal.

+ ENGINE - Td5, REPAIRS, Gasket -
cover - camshaft.
42.Refill cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
43.Connect battery earth lead.
44.Fit battery cover and secure fixings.
45.Fit bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.

ENGINE - TD5
12-1-44 REPAIRS
Rocker shaft assembly
$% 12.29.29
Remove
1.Remove cooling fan.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
2.Remove camshaft cover gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
cover - camshaft.
3.Loosen lock nuts and fully retract rocker
adjusting screws to prevent damage on
reassembly. 4.Rotate engine clockwise, until camshaft
sprocket and timing chain marks are aligned
and fit tool LRT-12-058 through camshaft
carrier to lock camshaft.
5.Progressively loosen then remove and discard
6 bolts securing rocker shaft assembly.
6.Remove and discard lock nuts and rocker
adjusting screws.

ENGINE - TD5
REPAIRS 12-1-45
Refit
1.Clean rocker shaft and mating faces.
CAUTION: If rockers or rocker shaft are to
be replaced, ensure replacements are
correct. Engine Serial No. Prefixes 10P to
14P are fitted with type A rocker arms and
shaft. Engine Serial No. Prefixes 15P to 19P
are fitted with type B rocker arms and shaft.
Type B rocker arms and shaft may be fitted
to Engine Serial No. Prefixes 10P to 14P as
an assembly.
2.Fit new rocker adjusting screws fully into rocker
arm. Fit new lock nuts to screws but do not
tighten.
CAUTION: Ensure screws are correct for
type of rocker arms fitted. Replacement
screws for Engine Serial No. Prefixes 15P to
19P have a centre punch mark adjacent to
the adjusting slot. These screws are not
interchangeable with those fitted to Engine
Serial No. Prefixes 10P to 14P.
3.Fit rocker shaft ensuring it is located on dowel.
4.Fit and progressively tighten new rocker shaft
bolts to 33 Nm (24 lbf.ft). 5.Before refitting the camshaft cover the
electronic injection unit (EUI) rockers must be
adjusted.
6.Remove tool LRT-12-058 from camshaft.
7.Rotate engine clockwise until No 1 injector lobe
is at full lift.
8.Rotate rocker adjusting screw clockwise until
the injector plunger is felt to bottom out.
9.Rotate rocker adjusting screw anti-clockwise
one complete turn to give plunger the required
bump clearance and tighten rocker arm
adjusting screw locknut to 16 Nm (12 lbf.ft) .
CAUTION: Ensure screw does not turn as
locknut is tightened.
10.Carry out above procedure for the remaining 4
rocker arms.
11.After completion of rocker arm adjustment,
slowly rotate engine clockwise 2 complete
turns by hand to ensure that no injectors are
bottoming out on their plungers.
12.Fit camshaft cover gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
cover - camshaft.
13.Fit cooling fan coupling.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.