2002 LAND ROVER DISCOVERY air filter

MAINTENANCE
PROCEDURES 10-11
Air cleaner - V8 engine
Replace
1.Replace air cleaner element.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Element - air filter.
Clean
1.Clean the drain hole in filter casing.
Air cleaner and dump valve - diesel
engine
Replace/clean
1.Replace air cleaner element.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Element - air filter.
2.Remove all dirt from dump valve.
Auxiliary drive belt
Check
TD5 auxiliary belt
V8 auxiliary belt
1Tensioner pulley
2Alternator
3A/C compressor
4ACE pump
5Idler pulley - V8 only
6PAS pump
7Viscous fan pulley
8Crankshaft pulley
9Idler pulley - V8 only
1.Check auxiliary drive belt for signs of splits,
fraying, oil contamination and wear.

MAINTENANCE
PROCEDURES 10-15
Centrifuge rotor – diesel engine
Replace
1.Replace centrifuge rotor.

+ ENGINE - Td5, REPAIRS, Rotor -
centrifuge.
Engine oil filter - diesel engine
Replace
1.Replace oil filter.

+ ENGINE - Td5, REPAIRS, Filter - oil.
Engine oil filter – V8 engine
WARNING: Avoid excessive skin contact with
used engine oil. Used engine oil contains
potentially harmful contaminants which may
cause skin cancer or other serious skin
disorders.
Replace
1.Disconnect battery.
2.Position suitable container beneath oil filter.
3.Using a strap type filter wrench, remove filter
element, discard element.
4.Smear sealing ring of replacement filter
element with engine oil.
5.Fit filter element, tighten two thirds of a turn by
hand or to 17 Nm (13 lbf.ft).
6.Top-up engine with recommended grade of oil
to correct mark on dipstick.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
7.Connect battery.
8.Run engine and check for oil leaks from filter.
9.Stop engine, wait for oil to return to sump.
10.Re-check oil level and top-up if necessary.

MAINTENANCE
PROCEDURES 10-17
Automatic gearbox
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Replace oil filter
1.Replace oil filter.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Filter - oil.
Replace oil
1. Ensure that gearbox is cool. Apply
handbrake and securely chock front and rear
wheels.
2.Place a suitable container beneath gearbox.
3.Clean area around oil filler/level and drain
plugs.
4.Remove oil drain plug, remove and discard
sealing washer.
5.Allow oil to drain.
6.Fit new sealing washer to oil drain plug.
7.Fit automatic gearbox drain plug and tighten to
15 Nm (11 lbf.ft).
8.Remove oil filler/level plug, remove and discard
sealing washer.9.Fill gearbox with recommended oil to bottom of
oil level/filler plug hole.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
10.Select 'P' (Park).
11.Ensure handbrake is applied.
12.Start engine and allow it to idle.
13.Apply footbrake.
14.Move selector lever through all gear positions,
while continuing to fill the gearbox. Select 'P'
(Park).
15.With engine idling, continue filling gearbox until
a 2 mm bead of oil runs from oil filler/level plug
hole.
16.Fit new sealing washer to automatic gearbox
filler/level plug, fit plug and tighten to 30 Nm (22
l b f . f t ) .
17.Stop engine.
18.Remove all traces of oil from gearbox casing.

MAINTENANCE
PROCEDURES 10-21
ACE actuators
Check
Actuator boots
1.Check ACE actuator gaiters for splits, damage
and clips for security.
ACE filter
Replace
1.Replace ACE filter.

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.

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
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
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
REPAIRS 12-1-63
Refit
1.Clean oil pressure switch threads.
2.Fit oil pressure switch and tighten to 15 Nm (11
lbf.ft).
3.Connect multiplug to oil pressure switch.
4.Position exhaust manifold heatshield and
tighten M6 bolts to 9 Nm (7 lbf.ft) and M8 bolts
to 25 Nm (18 lbf.ft).
5.Fit and secure engine acoustic cover.
6.Top up engine oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - diesel engine.
Cooler - engine oil
$% 12.60.68
Remove
1.Drain cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
2.Remove centrifuge assembly.

+ ENGINE - Td5, REPAIRS, Gasket -
centrifuge oil drain pipe.
3.Remove clutch housing bolt and release
coolant pipe from rear of engine.
4.Release clip and coolant hose from oil cooler.
5.Disconnect multiplug from oil pressure switch.
6.Remove full-flow oil filter element using a
suitable strap wrench.
7.Remove 3 bolts, remove oil filter adaptor
housing and discard gasket.
8.Remove 7 bolts, remove oil cooler and discard
gasket.
9.Remove oil pressure switch.