2002 LAND ROVER DISCOVERY wheel bolts

ENGINE - TD5
12-1-12 DESCRIPTION AND OPERATION
Description
General
The Td5 diesel engine is a 2.5 litre, 5 cylinder, in-line direct injection unit having 2 valves per cylinder, operated by a
single overhead camshaft. The engine emissions, on pre EU3 models, comply with ECD2 (European Commission
Directive) and on EU3 models, comply with ECD3 legislative requirements. Both models employ electronic engine
management control, positive crankcase ventilation and exhaust gas recirculation to limit the emission of pollutants.
The unit is water cooled and turbo-charged and is controlled by an electronic engine management system.
The engine is a monobloc cast iron construction with an aluminium stiffening plate fitted to the bottom of the cylinder
block to improve lower structure rigidity. The cylinder head and sump are cast aluminium. An acoustic cover is fitted
over the upper engine to reduce engine generated noise.
The engine utilises the following features:
lElectronic Unit Injectors (EUI's) controlled by an Engine Management System for precise fuel delivery under
all prevailing operating conditions.
lTurbocharging which delivers compressed air to the combustion chambers via an intercooler for improved
power output.
lFuel Cooler
lOil Cooler
lCentrifuge Oil Filter
lHydraulic Lash Adjusters with independent finger followers
Cylinder block components
The cylinder block components are described below:
Cylinder Block
The cylinders and crankcase are contained in a single cast iron construction. The cylinders are direct bored and
plateau honed with lubrication oil supplied via lubrication jets for piston and gudgeon pin lubrication and cooling. It is
not possible to rebore the cylinder block if the cylinders become worn or damaged. Three metal core plugs are fitted
to the three centre cylinders on the right hand side of the cylinder block.
Lubrication oil is distributed throughout the block via the main oil gallery to critical moving parts through channels
bored in the block which divert oil to the main and big-end bearings via oil holes machined into the crankshaft. Oil is
also supplied from the cylinder block main gallery to the five lubrication jets which cool and lubricate the piston and
gudgeon pins. Plugs are used to seal both ends of the main oil gallery at front and rear of the engine block. An oil
cooler is fitted to the LH side of the engine block; ports in the oil cooler assembly mate with ports in the cylinder block
to facilitate coolant flow. Oil is diverted through the oil cooler, centrifuge filter and full-flow filter before supplying the
main oil gallery. A tapping in the oil filter housing provides a lubrication source for the turbocharger bearings and an
oil pressure switch is included in a tapping in the oil cooler housing which determines whether sufficient oil pressure
is available to provide engine lubrication and cooling.
Cylinder cooling is achieved by water circulating through chambers in the engine block casting. A threaded coolant
jacket plug is located at the front RH side of the cylinder block.
Cast mounting brackets are bolted to both sides of the engine block for mounting the engine to the chassis on the LH
and RH hydramount studs.
The gearbox bolts directly to the engine block; a gearbox shim plate is located between the adjoining faces of the
gearbox and the flywheel side of the engine block and is fixed to the rear of the engine block by two bolts. Two hollow
metal dowels locate the rear of the cylinder block to the gearbox shim plate. The gearbox casing provides the
mounting for the starter motor.
A port is included at the rear left hand side of the cylinder block which connects to the turbocharger oil drain pipe to
return lubrication oil to the sump.
A plug sealing the lubrication cross-drilling gallery is located at the front right hand side of the cylinder block and plugs
for the main lubrication gallery is included at the front and rear of the cylinder block.

ENGINE - TD5
DESCRIPTION AND OPERATION 12-1-21
Crankshaft
1Front end to crankshaft sprocket
2Oil supply cross-drillings
3Main journals
4Big-end journals
5Rear end to flywheel
The crankshaft is constructed from cast iron and is surface-hardened. The areas between the crankshaft journals and
the adjoining webs and balance weights are compressed using the cold roll process to form journal fillets.
Cross-drillings in the crankshaft between adjoining main and big-end bearings are used to divert lubrication oil to the
big-end bearings.
A torsional vibration damper is attached to the crankshaft pulley by three bolts.
The crankshaft is carried in six main bearings, with end-float being controlled by thrust washers positioned on both
sides of No. 3 main bearing.
Main bearings
There are six main bearings used to carry the crankshaft. Each of the bearing caps are of cast iron construction and
are attached to the cylinder block by two bolts.
The bearing shells are of the split cylindrical type. The upper half bearing shells are grooved to facilitate the supply of
lubrication oil to the bearings and fit into a recess in the underside of the cylinder block. The lower half bearing shells
are smooth and fit into the bearing caps.
Steel-backed thrust washers are included at each side of No. 3 main bearing to control crankshaft end-float. One side
of each of the thrust washers is grooved, the grooved side of each of the thrust washers is fitted facing outward from
No. 3 main bearing.
Cylinder head components
The cylinder head components are described below:
Cylinder head
The cylinder head is of aluminium construction. It is not possible to reface the cylinder head if it becomes worn or
damaged. An alloy camshaft carrier is bolted directly to the upper surface of the cylinder head. Two dowels are
included in the cylinder head upper face for correct location of the camshaft carrier.
The EU3 cylinder head has a single internal fuel rail for delivering fuel to the injectors and an external fuel pipe for
returning spill fuel back to the fuel connector block. Therefore, pre EU3 and EU3 model cylinder heads are not
interchangeable.
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.

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
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
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
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 - V8
REPAIRS 12-2-31
Flywheel
$% 12.53.07
Remove
1.Remove gearbox

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
2.Restrain flywheel.
3.Working in sequence, progressively slacken 6
bolts securing clutch cover to flywheel.
Remove bolts.
4.Remove clutch cover.
5.Remove clutch plate.
6.Release crankshaft sensor multiplug from
bracket.
7.Remove 2 bolts securing crankshaft sensor
cover. 8.Remove crankshaft sensor cover.
9.Remove 2 nuts securing crankshaft sensor.
10.Remove crankshaft sensor.
11.Remove 6 bolts securing flywheel.
12.Remove flywheel.
On early engines, balance weights are on
engine side of flywheel; replacement flywheels
will have balance weights on clutch side of
flywheel.
Refit
1.Clean mating faces of flywheel and crankshaft,
dowel and dowel hole.
2.Fit flywheel to crankshaft and tighten bolts to
78 Nm (58 lbf.ft).
3.Clean crankshaft sensor and mating face.
4.Fit crankshaft sensor and tighten nuts to 6 Nm
(4.4 lbf.ft).
5.Fit crankshaft sensor cover and tighten bolts to
6 Nm (5 lbf.ft).
6.Fit crankshaft sensor multiplug to bracket.
7.Clean clutch cover, drive plate and spigot bush
in end of crankshaft. Renew worn components
as necessary.
8.If refitting existing drive plate, apply 'Molycote
FB 180' to splines.