2002 LAND ROVER DISCOVERY engine

ENGINE - TD5
12-1-54 REPAIRS
Mounting - front - RH
$% 12.45.03
Remove
1.Remove fixings and remove engine acoustic
cover.
2.Release fixings and remove battery cover.
3.Disconnect battery earth lead.
4.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
5.Remove 4 bolts and move fuel cooler to one
side.
6.Fit suitable lifting chains to support engine.
7.With assistance remove 2 bolts securing
engine mounting to chassis.
8.Remove 4 bolts securing engine mounting
bracket to cylinder block.
9.Remove nut securing mounting to mounting
bracket.
10.Remove mounting and mounting bracket. Refit
1.Fit mounting and mounting bracket.
2.Fit front RH engine mounting bracket to
cylinder block and tighten bolts to 48 Nm (35
lbf.ft).
3.With assistance, fit front RH mounting to
chassis and tighten bolts to 85 Nm (63 lbf.ft).
4.Fit front RH mounting to mounting bracket and
tighten nut to 85 Nm (63 lbf.ft).
5.Remove engine support chains.
6.Position Fuel cooler to inlet manifold and
tighten bolts to 25 Nm (18 lbf.ft).
7.Remove stand(s) and lower vehicle.
8.Connect battery earth lead.
9.Fit battery cover and secure with fixings.
10.Fit engine acoustic cover and secure with
fixings.

ENGINE - TD5
REPAIRS 12-1-55
Mounting - engine - rear - LH
$% 12.45.07
Remove
1.Raise vehicle on ramp.
2.Position jack to support gearbox.
3.Remove 2 nuts and remove mounting.
4.Remove heat shield from mounting.
Refit
1.Clean mounting and mating faces.
2.Position heat shield to mounting.
3.Position engine rear LH mounting and tighten
nuts to 48 Nm (35 lbf.ft).
4.Lower support jack.
5.Lower vehicle.
Mounting - engine - rear - RH
$% 12.45.09
Remove
1.Raise vehicle on ramp.
2.Position jack to support gearbox.
3.Remove 2 nuts and remove mounting.
Refit
1.Clean mounting and mating faces.
2.Position engine rear RH mounting and tighten
nuts to 48 Nm (35 lbf.ft).
3.Lower support jack.
4.Lower vehicle.

ENGINE - TD5
12-1-56 REPAIRS
Flywheel
$% 12.53.07
Remove
1.Remove clutch assembly.

+ CLUTCH - Td5, REPAIRS, Clutch
assembly.
2.Remove and discard 8 bolts securing flywheel
to crankshaft and remove flywheel.
Refit
1.Clean flywheel and mating face.
2.Position flywheel to crankshaft, fit new bolts
and working in a diagonal sequence tighten to
40 Nm (30 lbf.ft), then a further 90
°.
CAUTION: Do not carry out stages 1 and 2 in
one operation.
3.Fit clutch assembly.

+ CLUTCH - Td5, REPAIRS, Clutch
assembly.
Plate - drive - automatic
$% 12.53.13
Remove
1.Remove gearbox.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gearbox - convertor and
transfer gearbox - Diesel.
2.Remove and discard 8 bolts and remove
converter drive plate, spacer and starter ring
gear.
Refit
1.Clean drive plate, spacer and starter ring gear.
2.Fit starter ring gear, spacer and drive plate to
crankshaft, fit new bolts and working in a
diagonal sequence tighten to 40 Nm (30 lbf.ft),
then a further 90
°.
CAUTION: Do not carry out stages 1 and 2 in
one operation.
3.Refit gearbox.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gearbox - convertor and
transfer gearbox - Diesel.

ENGINE - TD5
REPAIRS 12-1-57
Filter - oil
$% 12.60.04
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Remove 3 bolts and remove exhaust manifold
heat shield.
3.Clean area around filter head and place a
container beneath engine.
4.Using a strap wrench, unscrew and discard
filter. Refit
1.Clean mating face of filter head.
2.Lubricate sealing ring of new filter with clean
engine oil.
3.Fit filter and tighten by hand until it seats then
tighten a further three-quarters of a turn.
4.Start and run engine to check for leaks.
5.Stop engine, wait a few minutes, then check oil
level.
6.Top up engine oil.

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

ENGINE - TD5
12-1-58 REPAIRS
Strainer - oil pick-up
$% 12.60.20
Remove
1.Remove sump gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
sump.
2.Remove 3 Torx screws securing oil pick- up
strainer.
3.Remove and discard 'O' ring.
Refit
1.Clean oil pick up strainer faces.
2.Fit new 'O' ring to oil pick-up strainer.
3.Clean threads of Torx screws.
4.Fit oil pick-up strainer, apply Loctite 242 to
threads of Torx screws, fit screws and tighten to
10 Nm (7 lbf.ft).
5.Fit new sump gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
sump.
Pump - oil
$% 12.60.26
Remove
1.Remove sump gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
sump.
2.Hold oil pump drive sprocket and remove
retaining bolt.
3.Remove sprocket from oil pump.
4.Remove 3 Torx screws securing oil pick-up
strainer.
5.Remove and discard 'O' ring.

ENGINE - TD5
REPAIRS 12-1-59
6.Using sequence shown, remove and discard 22
bolts securing oil pump and stiffener assembly.
7.Remove oil pump and stiffener assembly from
cylinder block.
8.Remove and discard 'O' ring.
Refit
1.Clean mating faces of oil pump and stiffener
assembly, main bearing caps and cylinder
block.
2.Fit new 'O' ring to oil pump housing.
3.Position oil pump and stiffener assembly onto
cylinder block ensuring 2 dowels are correctly
located. 4.Fit new bolts and using sequence shown,
tighten to 13 Nm (10 lbf.ft) .
5.Clean threads of oil pick-up strainer Torx
screws.
6.Fit new 'O' ring to oil pick-up strainer.
7.Fit oil pick-up strainer, apply Loctite 242 to
threads of Torx screws, fit screws and tighten to
10 Nm (7 lbf.ft).
8.Position oil pump drive sprocket and chain
onto oil pump ensuring that the 'D' shape on
the drive sprocket is located on the oil pump
shaft.
9.Clean oil pump drive sprocket retaining bolt
and apply Loctite 242 to bolt threads.
10.Fit oil pump drive sprocket and tighten bolt to
25 Nm (18 lbf.ft).
11.Fit new sump gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
sump.

ENGINE - TD5
12-1-60 REPAIRS
Gasket - sump
$% 12.60.38
Remove
1.Remove battery cover.
2.Disconnect battery earth lead.
3.Remove exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
4.Drain engine oil.
5.Remove 2 bolts securing Active Cornering
Enhancement (ACE) pipes to front cross
member.
6.Remove bolt securing coolant pipe to front
cross member.
7.Remove bolt securing automatic gearbox oil
cooler pipe clip.
8.Remove 4 bolts securing sump to gearbox bell
housing. 9.Remove 2 bolts securing centrifuge drain pipe
to sump and discard gasket.
10.Using sequence shown and noting their
different lengths, remove 20 bolts securing
sump to engine.
11.Manoeuvre sump from beneath engine,
remove sump and discard gasket.

ENGINE - TD5
REPAIRS 12-1-61
Refit
1.Clean sump and mating faces.
2.Apply sealant, Part No. STC 3254 to joint faces
of timing chain cover and crankshaft rear oil
seal housing.
CAUTION: Assembly and bolt tightening
must be completed within 20 minutes of
applying sealant.
3.Position new gasket.
CAUTION: Gasket must be fitted dry.
4.Position sump and, noting the positions of the
longer bolts, fit and lightly tighten bolts.
5.Fit and lightly tighten bolts securing sump to
gearbox bell housing. 6.Working in the sequence shown, tighten bolts
securing sump to 25 Nm (18 lbf.ft).
7.Tighten – sump to gearbox bell housing bolts
to 13 Nm (10 lbf.ft).
8.Fit new gasket to centrifuge drain pipe, fit to
sump and tighten bolts to 10 Nm (7 lbf.ft ) .
CAUTION: Gasket must be fitted dry.
9.Fit bolts securing oil cooler pipe to sump and
tighten to 9 Nm (7 lbf.ft).
10.Fit and tighten bolt securing coolant pipe to
cross member.
11.Fit and tighten bolts securing ACE pipes to front
cross member.
12.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
13.Refill engine with oil.
14.Connect battery earth lead.
15.Refit battery cover and secure fixings.