2002 LAND ROVER DISCOVERY drain bolt

ENGINE - TD5
DESCRIPTION AND OPERATION 12-1-19
Oil Pressure switch
The oil pressure switch is located in a port on the outlet side of the oil cooler housing. It detects when a safe operating
pressure has been reached during engine starting and initiates the illumination of a warning light in the instrument
pack if the pressure drops below a given value.
Crankshaft, sump and oil pump components
The crankshaft, sump and oil pump components are described below:
Sump
The sump is a wet-type, of aluminium construction and is sealed to the engine block by means of a rubber gasket and
twenty fixing bolts. The four bolts at the gearbox end of the sump are longer than the other sixteen bolts.
The sump gasket incorporates compression limiters (integrated metal sleeves) at the bolt holes, which are included
to prevent distortion of the gasket when the sump to cylinder block bolts are being tightened.
The oil drain plug is fitted at the bottom of the oil sump reservoir. An oil return drain pipe is also attached to the oil
sump which returns oil from the centrifugal filter.
Stiffener Plate
The stiffener plate assembly provides lower engine block rigidity and utilises dowels to align it to the bottom of the
cylinder block. A rotary oil pump is integral with the stiffener plate and an oil pick-up and strainer assembly is fitted
to the underside of the stiffener plate. The stiffener and oil pump assembly is secured to the cylinder block by 22 bolts.

ENGINE - TD5
DESCRIPTION AND OPERATION 12-1-23
Fuel connector block
A = Pre EU3 models, B = EU3 models
1Fuel connector block assembly
2Outlet stub pipe
3Stub pipe – to fuel cooler
4Fuel temperature sensor
5Fuel pressure regulator
6Spill fuel return connection (EU3 models only)
A cast and machined alloy fuel connector block assembly is located at the rear RH side of the cylinder head, attached
by three flanged bolts. A metal gasket is used to seal the faces between the fuel connector block and the cylinder
head, which must be replaced every time the fuel connector block is removed.
CAUTION: The cylinder head incorporates drillings for the fuel injection system, any contamination which
enters these drillings could cause engine running problems or injector failure. It is therefore, essential that
absolute cleanliness is maintained when carrying out work on the cylinder head.
CAUTION: The valve heads, tips of the injectors and glow plugs protrude below the face of the cylinder head
and will be damaged if the cylinder head is stored face down.
Camshaft carrier
The cast aluminium alloy camshaft carrier is bolted to the cylinder head by thirteen screws. The camshaft carrier and
cylinder head assembly is attached to the cylinder block by twelve cylinder head retaining bolts which pass through
the camshaft carrier and the cylinder head to secure the assembly to the cylinder block.
The carrier is machined together with the cylinder head to form a matched pair for carrying the camshaft.
Non-return valve
A non-return valve is located at the front, bottom LH side of the cylinder head. The non-return valve prevents oil from
draining from the lash adjusters and is an integral component within the cylinder head and is non-serviceable.

ENGINE - TD5
12-1-26 DESCRIPTION AND OPERATION
Camshaft cover and engine cover components
The camshaft cover and engine cover components are described below:
Camshaft cover
The camshaft cover is cast from aluminium alloy and is fixed to the camshaft carrier/cylinder head assembly by 13
bolts. The cover has spacers and sealing washers inserted into each of the thirteen bolt holes.
A breather hose is connected to a port at the top of the camshaft cover by means of a hose clip which vents crankcase
gases back to the air intake via a breather valve in the air intake tract, located forward of the turbocharger in the
flexible air intake duct.
A rubber seal is fitted between the camshaft cover.
An oil filler aperture is included in the top of the camshaft cover, which is sealed with a plastic cap with integral rubber
seal.
Camshaft timing chain components
The timing chain cover and timing chain components are described below:
Timing chain cover
The timing chain cover is cast and machined aluminium alloy and is attached to the cylinder head by a bolt at the RH
top of the cover and by a stud and nut at the LH top of the cover. Eight screws are used to attach the timing chain
cover to the front of the engine block. The timing cover is located to the cylinder block front face by two dowels.
A viscous fan is attached to an idler pulley at the front of the engine block. The fan bearing is located on a shaft and
held in place by a circlip and a bearing flange, the inner race of the fan bearing is an interference fit on the shaft. The
fan idler pulley is attached to the bearing hub by three bolts, and the fan itself is secured to the pulley and bearing
shaft by a left hand threaded nut.

+ COOLING SYSTEM - Td5, DESCRIPTION AND OPERATION, Description.
The front of the crankshaft passes through a hole in the lower part of the timing cover. An oil seal is pressed into a
recess in the front of the timing cover to seal the interface between the front of the crankshaft and the timing cover.
A stub pipe is fitted to the front RH side of the timing cover which is used to attach the oil drain pipe from the vacuum
pump by means of a hose and spring clip.
Timing chains
The timing chain between the camshaft and crankshaft sprockets is a duplex type, each chain having 56 links. The
timing chain is contained between a fixed plastic guide and an hydraulically adjustable plastic tensioner arm which
are attached to the front of the engine block.
To cope with higher injection loads of the EU3 engine, the timing drive between the camshaft and crankshaft has been
upgraded. This requires thicker chain links to be used, therefore, the individual pre EU3 and EU3 components are not
interchangeable.
To distinguish between the two timing chains the links are different colours. A pre EU3 chain has blue links and a EU3
chain has bronze links.
The oil pump timing chain is a single type and traverses the oil pump sprocket and the rear crankshaft sprocket.
The timing chains are oil lubricated, with oil being provided by a chain lubrication jet and from oil flow returning back
to the sump from the cylinder head. An oil hole is included at the front left hand side of the cylinder head which supplies
oil from the cylinder head oil galleries.

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
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
12-1-46 REPAIRS
Gasket - cover - camshaft
$% 12.29.40
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Release clip and disconnect breather hose
from camshaft cover.
3.Remove 13 bolts securing camshaft cover.
4.Collect sealing washers and spacers.
5.Remove camshaft cover and gasket.
Refit
1.Clean camshaft cover and mating face.
2.Renew sealing washers and spacers as
necessary. 3. Not EU3 model:- Apply two 3 mm diameter
beads of sealant, STC 5433, to areas 'A' shown
on illustration.
Excessive use of sealant could result in
blockage of oil drain hole, arrowed 'B' on
illustration.
4.Fit new gasket, fit camshaft cover to camshaft
carrier and tighten – camshaft cover bolts to 9
Nm (7 lbf.ft).
5.Position breather hose to camshaft cover and
secure with clip.
6.Fit engine acoustic cover and secure with
fixings.
M12 7538
A
B
A

ENGINE - TD5
REPAIRS 12-1-53
Mounting - front - LH
$% 12.45.01
Remove
1.Remove centrifuge assembly.

+ ENGINE - Td5, REPAIRS, Gasket -
centrifuge oil drain pipe.
2.Remove 3 bolts, remove oil filter adaptor
housing and discard gasket.
3.Fit suitable lifting chains to support engine.
4.With assistance remove 2 bolts securing
engine mounting to chassis.
5.Remove 4 bolts securing engine mounting
bracket to cylinder block.
6.Remove nut securing mounting to mounting
bracket.
7.Remove mounting and mounting bracket.
8.Remove mounting shield.
Refit
1.Fit shield to mounting. 2.Fit mounting and mounting bracket.
3.Fit mounting bracket to cylinder block and
tighten – bolts securing front LH engine
mounting bracket to cylinder block to 48 Nm (35
lbf.ft).
4.With assistance, fit mounting to chassis and
tighten – bolts securing front LH engine
mounting to chassis to 85 Nm (63 lbf.ft).
5.Fit mounting to mounting bracket and tighten –
nut securing front LH mounting to mounting
bracket to 85 Nm (63 lbf.ft).
6.Remove engine support chains.
7.Clean oil filter adaptor housing and mating
face.
8.Fit oil filter adaptor housing to oil cooler
housing and tighten bolts to 25 Nm (18 lbf.ft).
9.Fit centrifuge assembly.

+ ENGINE - Td5, REPAIRS, Gasket -
centrifuge oil drain pipe.

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.