2002 LAND ROVER DISCOVERY engine

ENGINE - TD5
12-1-86 OVERHAUL
Seal - crankshaft - rear - manual models
$% 12.21.20.01
Disassembly
1.Remove flywheel.

+ ENGINE - Td5, OVERHAUL,
Flywheel.
2.Remove sump gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- engine sump.
3.Remove 5 bolts securing crankshaft rear oil
seal housing to cylinder block.
4.Release crankshaft rear oil seal housing from
locating dowels, discard rear oil seal and
housing.
Reassembly
1.Clean crankshaft oil seal housing mating face
on cylinder block, ensure bolt and dowel holes
are clean and dry. Remove all traces of oil from
oil seal running surface on crankshaft.
2.Position seal protector LRT-12-061 over
crankshaft boss. Fit new oil seal and housing
and remove tool LRT-12-061.
CAUTION: Oil seal must be fitted dry.3.Fit oil seal housing bolts and using sequence
shown, tighten to 9 Nm (7 lbf.ft).
4.Fit sump gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- engine sump.
5.Fit flywheel.

+ ENGINE - Td5, OVERHAUL,
Flywheel.

ENGINE - TD5
OVERHAUL 12-1-87
Seal - crankshaft - rear - automatic
models
$% 12.21.20.01
Disassembly
1.Remove sump gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- engine sump.
2.Remove drive plate.

+ ENGINE - Td5, OVERHAUL, Drive
plate.
3.Remove 5 bolts securing crankshaft rear oil
seal housing to cylinder block.
4.Release crankshaft rear oil seal housing from
locating dowels, discard rear oil seal and
housing.
Reassembly
1.Clean crankshaft oil seal housing mating face
on cylinder block, ensure bolt and dowel holes
are clean and dry. Remove all traces of oil from
oil seal running surface on crankshaft.2.Position seal protector LRT-12-061 over
crankshaft boss. Fit new oil seal and housing
and remove tool LRT-12-061.
CAUTION: Oil seal must be fitted dry.
3.Fit oil seal housing bolts and using sequence
shown, tighten to 9 Nm (7 lbf.ft).
4.Fit sump gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- engine sump.
5.Fit drive plate.

+ ENGINE - Td5, OVERHAUL, Drive
plate.

ENGINE - TD5
12-1-88 OVERHAUL
Flywheel
$% 12.53.07.01
Disassembly
1.Remove 3 bolts securing damper to crankshaft
pulley, fit LRT-51-003 to crankshaft pulley,
secure with 2 bolts.
2.Restrain crankshaft using LRT-51-003,
remove and discard 8 bolts securing flywheel
to crankshaft. Release flywheel from locating
dowels; remove flywheel.
Reassembly
1.Clean flywheel and crankshaft mating faces.
2.Position flywheel on crankshaft.
3.Fit new bolts to retain flywheel and tighten by
diagonal selection to:
lStage 1 - 40 Nm (30 lbf.ft)
lStage 2 - Further 90
°
CAUTION: Do not carry out stages 1 and 2 in
one operation.
4.Remove tool LRT-51-003, fit damper and
tighten bolts to 80 Nm (59 lbf.ft).
Drive plate
$% 12.53.13.01
Disassembly
1.Remove 3 bolts securing damper to crankshaft
pulley, fit LRT-51-003 to crankshaft pulley,
secure with 2 bolts.
2.Restrain crankshaft using LRT-51-003,
remove and discard 8 bolts securing drive
plate, spacer and starter ring gear to
crankshaft, release starter ring gear from
locating dowels and remove.

ENGINE - TD5
OVERHAUL 12-1-89
Reassembly
1.Clean drive plate, spacer, starter ring gear and
crankshaft mating faces.
2.Position starter ring gear on crankshaft, fit
spacer and drive plate.
3.Fit new bolts to retain assembly and tighten by
diagonal selection to:
lStage 1 - 40 Nm (30 lbf.ft)
lStage 2 - Further 90
°
CAUTION: Do not carry out stages 1 and 2 in
one operation.
4.Remove tool LRT-51-003, fit damper and
tighten bolts to 80 Nm (59 lbf.ft).
Starter ring gear
$% 12.53.19
Disassembly
1. Manual models: Remove flywheel.

+ ENGINE - Td5, OVERHAUL,
Flywheel.
2. Automatic models: Remove drive plate.

+ ENGINE - Td5, OVERHAUL, Drive
plate.
3.Drill a 3 mm (0.12 in) diameter hole at root of 2
teeth.
4.Apply a cold chisel to root of teeth, break ring
gear and remove from flywheel.
WARNING: SUITABLE EYE PROTECTION
MUST BE WORN.
Reassembly
1.Heat ring gear evenly to 350
° C, indicated by
light blue colour.
2.Locate ring gear on to flywheel and press on to
flange.
3.Allow ring gear to air cool.
4. Manual models: Fit flywheel.

+ ENGINE - Td5, OVERHAUL,
Flywheel.
5. Automatic models: Fit drive plate.

+ ENGINE - Td5, OVERHAUL, Drive
plate.

ENGINE - TD5
12-1-90 OVERHAUL
Pump - oil
$% 12.60.26.02
Disassembly
1.Remove sump gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- engine sump.
2.Remove bolt securing oil pump drive sprocket.
3.Release drive sprocket from chain, remove
sprocket.
4.Remove 3 Torx screws securing oil pick-up
strainer, remove strainer.
5.Remove and discard 'O' ring.6.Using sequence shown, remove and discard 22
bolts securing oil pump and stiffener plate
assembly to cylinder block.
7.Release stiffener plate from locating dowels,
remove oil pump and stiffener plate assembly.
8.Remove and discard 'O' ring from oil pump
housing outlet.
Inspection
1. Inspection/overhaul procedures for the oil
pump are limited to carrying out
dimensional checks. In the event of wear or
damage being found, a replacement pump
and stiffener plate assembly must be fitted.

ENGINE - TD5
OVERHAUL 12-1-91
2.Remove and discard 5 screws securing cover
to oil pump, remove cover.
3.Using a felt tipped pen, make suitable
alignment marks between inner and outer
rotors and oil pump body.
4.Remove inner and outer rotors.
5.Check rotors and pump body for signs of
scoring and wear.
6.Fit rotors ensuring that marks are aligned and
identification mark on inner rotor is facing
outwards.7.Using feeler gauges, check pump outer rotor to
body clearance:
lOuter rotor to body clearance = 0.295 to
0.375 mm (0.012 to 0.015 in)
8.Using feeler gauges, check clearance of inner
to outer rotor in 2 positions; both clearances
must be within limit given:
lInner to outer rotor clearance = 0.13 mm
(0.05 in)

ENGINE - TD5
12-1-92 OVERHAUL
9.Place a straight edge across pump body and
using feeler gauges, measure end-float of
outer rotor:
lOuter rotor end-float = 0.038 to 0.075 mm
(0.0001 to 0.003 in)
10.Check drive shaft bush in pump cover for signs
of scoring and wear.
11.Renew oil pump and stiffener plate assembly if
excessive scoring or wear exists.
12.Lubricate pump rotors and drive shaft bush with
engine oil.
13.Fit rotors ensuring reference marks are aligned
and identification mark on outer rotor is facing
outwards.
14.Fit cover to pump, fit 5 new screws and tighten
by diagonal selection to 6 Nm (4.5 lbf.ft).
15.Remove and discard oil pressure relief valve
plug.
16.Remove spring and relief valve plunger.
17.Clean valve plunger and spring.
18.Check valve plunger and relief valve bore for
scoring and corrosion, light scoring and
corrosion may be removed using grade 600
emery cloth soaked in oil.19.Check spring for distortion, check free length of
spring:
lSpring free length = 42.0 mm (1.65 in)
20.Lubricate valve plunger and seating.
21.Fit valve plunger and spring to oil pump.
22.Apply Loctite 243 sealant to threads of a new
plug. Do not attempt to fit original plug.
23.Fit plug and tighten to 23 Nm (17 lbf.ft).
Reassembly
1.Clean mating faces of oil pump, stiffener plate
assembly and cylinder block; ensure bolt and
dowel holes are clean and dry.
2.Lubricate a new 'O' ring with engine oil and fit to
oil pump housing outlet.
3.Position oil pump and stiffener plate assembly
on to cylinder block ensuring 2 dowels are
correctly located.
4.Fit new bolts and using sequence shown,
tighten to 13 Nm (10 lbf.ft).
5.Lubricate a new 'O' ring with engine oil and fit to
oil pick-up strainer.
6.Clean threads of oil pick-up strainer Torx
screws and apply Loctite 242 to screw
threads.
7.Fit oil pick-up strainer, fit Torx screws and
tighten to 10 Nm (8 lbf.ft).
8.Position oil pump drive sprocket to chain and oil
pump ensuring that the 'D' shape on the drive
sprocket is located on the flat on the oil pump
drive 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, OVERHAUL, Gasket
- engine sump.

ENGINE - TD5
OVERHAUL 12-1-93
Timing chain and sprockets
$% 12.65.13.01
Disassembly
1.Remove cylinder head gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- cylinder head.
CAUTION: If timing chain tensioner is to be
replaced, ensure tensioner is correct for
engine. Tensioner bodies are colour coded
as follows: Engine Serial No. Prefixes 10P to
14P – BLACK with, additionally on later
engines, YELLOW on tensioner hex. head.
Serial No. Prefixes 15P to 19P – body is
colour coded YELLOW. Later tensioners
may be fitted to early engines provided that
the modified adjustable guide is also fitted.
2.Remove 3 bolts securing damper to crankshaft
pulley, remove damper.
3.Fit LRT-51-003 to crankshaft pulley.
4.Secure tool using 2 bolts.
5.Using assistance, restrain engine and remove
crankshaft pulley bolt; discard bolt.
WARNING: CRANKSHAFT BOLT IS
TIGHTENED TO 460 Nm (340 lbf.ft), ENSURE
ENGINE IS ADEQUATELY RESTRAINED.
6.Remove crankshaft pulley.7.Remove sump gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- engine sump.
8.Noting their fitted position, remove 8 bolts
securing timing chain cover.
9.Release timing chain cover from locating
dowels, remove cover.
10.Remove bolt securing oil pump drive sprocket.
11.Remove oil pump drive sprocket.
12.Remove camshaft and crankshaft sprockets
together with timing and oil pump drive chains.
13.Remove Woodruff key from crankshaft.
14.Remove 2 bolts and remove timing chain fixed
guide.