2002 LAND ROVER DISCOVERY light

LIFTING AND TOWING
08-3
Rear: A pair of towing eyes at the rear of the vehicle
can be used as lashing rings and for towing another
light vehicle.
TRANSPORTING
Transporting by trailer
Front lashing eyes
Rear lashing eyes
Lashing eyes are provided on the chassis
longitudinals, at the front (behind the front wheels)
and at the rear (behind the rear wheels).

MAINTENANCE
PROCEDURES 10-5
Lamps, horns and warning indicators
Check
1.Switch on side, head and tail lamps and check
operation.
2.Check headlamp levelling operation.
3.Check turn signals and hazard warning lamps
for correct operation.
4.Press brake pedal and check operation of
brake lamps.
5.Check all exterior lamp lenses for clarity and
condition. Pay particular attention to headlamp
lenses for signs of stone chips or damage.
6.Check horn for loud, clear sound.
7.Switch on headlamps (with ignition switch at 'O'
position) and check light reminder warning
operates when door is opened.
8.Check operation of interior courtesy lights.
9.Check operation of all instrument pack warning
and indicator lights.
Wipers and washers
Check
1. Operate screen washer and switch on wipers.
Ensure washer jets are correctly aimed and
check for smooth, smear free operation of
wiper blades across screen at all speeds
including intermittent.
2.Repeat operation for rear screen washers/
wipers.

ENGINE - TD5
DESCRIPTION AND OPERATION 12-1-13
Two plastic dowels are used to locate the cylinder head to the cylinder block and must be replaced every time the
cylinder head is removed from the cylinder block.
Connecting rods
1Small-end oil holes
2Small-end bushing
3Connecting rod
4Serrated fracture
The connecting rods are machined, H-sectioned steel forgings which feature a fracture-split at the big-end between
the connecting rod and the bearing cap. The connecting rod features a serrated fracture across the big-end at right
angles to the length of the connecting rod, this forms a unique mating surface between the connecting rod and the
fractured end which is used as the big-end cap. The use of a fracture-split in the big-end of the connecting rod ensures
a perfect match for assembly on the crankshaft bearing journals and provides the connecting rod with strong
resistance to lateral movement.
The end-cap fixing bolts are offset to ensure that the cap is fitted to the connecting rod in the correct orientation. If the
end-cap is fitted incorrectly and the end-cap bolts tightened, the connecting rod must be replaced, since the matching
serrations will have been damaged.
The big-end bearing shells are plain split halves without location tags. On EU2 models the two halves of the bearing
shells are of different construction. The upper half bearing shell fitted to the connecting rod is treated using the
sputtering process. The connecting rod bearing shell can be identified by having a slightly darker colouration than the
end cap bearing shell and the back of the connecting rod bearing shell has a shinier finish than the front face.
On EU3 models both bearing shells are of the same construction as the connecting rod bearing shell.
The small-end of the connecting rod has a bushed solid eye which is free to move on the gudgeon pin, the bushing
is a hand-push interference fit. The steel bushing has two slots machined in its upper surface for providing oil
lubrication to the moving surface with the gudgeon pin. The oil slots must be correctly aligned to the oil slots provided
in the small end of the connecting rod. The small-end lubrication is supplied by squirt feed from the piston lubrication
jets.

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
12-1-42 REPAIRS
37.Using suitable lifting chains and tool LRT-12-
138 carefully remove cylinder head and place
on wooden blocks or stands.
CAUTION: Support both ends of cylinder
head on blocks of wood. With the camshaft
carrier bolted down, the injector nozzles
and some of the valves will protrude from
the face of the cylinder head.
38.Remove cylinder head gasket.
39.Note the gasket thickness indicator and ensure
the same thickness gasket is used on refitment
of cylinder head.
40.Remove and discard plastic dowels from
cylinder block.Refit
1.Clean mating faces of cylinder head and
cylinder block.
2.Check cylinder head for warping, across centre
and from corner to corner: – Maximum warp =
0.10 mm (0.0004 in)
CAUTION: Cylinder heads may not be
refaced, replace cylinder head if warping
exceeds figure given.
3.Ensure coolant and oil passages are clean.
4.Clean dowel holes and fit new plastic dowels.
5.Lightly lubricate threads and beneath heads of
cylinder head bolts with clean engine oil.
6.Fit new cylinder head gasket of the correct
thickness with the word 'TOP' uppermost.
7.Using assistance, fit cylinder head and locate
onto dowels.
8.Carefully enter cylinder head bolts, DO NOT
DROP. Lightly tighten bolts.
9.Using the sequence shown, progressively
tighten cylinder head bolts to 30 Nm (22 lbf.ft),
then to 65 Nm (48 lbf.ft), then a further 90
°, then
a further 180
° and finally a further 45°.
CAUTION: Ensure correct sequence is
followed for all 5 tightening stages. Do not
tighten bolts 315 degrees in one operation.
10.Fit nut and bolt securing cylinder head to timing
chain cover and tighten to 25 Nm (18 lbf.ft).

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
12-1-52 REPAIRS
5.Fit 2 upper bolts securing engine oil cooler pipe
and gearbox housing to engine and tighten to
50 Nm (37 lbf.ft) .
6.Lower engine onto mountings, and tighten nuts
to 85 Nm (63 lbf.ft) .
7.Remove tool LRT-12-138 from engine.
8.Fit and tighten bolt securing engine closing
panel to gearbox.
9.Raise vehicle on ramp.
10.Fit nuts and bolts securing engine LH and RH
mountings to chassis and tighten to 85 Nm (63
lbf.ft).
11.Fit remaining bolts securing gearbox housing to
engine and tighten to 50 Nm (37 lbf.ft).
12.Rotate crankshaft and align drive plate to
torque converter.
13.Using a magnetic socket, fit and tighten new
torque converter drive plate bolts to 50 Nm (37
lbf.ft) .
14.Fit front cross member and tighten bolts to 26
Nm (19 lbf.ft).
15.Align gearbox oil cooler pipes.
16.Fit oil cooler pipe clip and tighten bolts to 9 Nm
(7 lbf.ft).
17.Position gearbox oil cooler pipe clamps and
tighten nuts.
18.Position coolant rail and secure support bracket
in engine LH and RH mounting brackets.
19.Fit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
20.Lower ramp.
21.Position coolant rail to front chassis member, fit
and tighten bolt to 10 Nm (7 lbf.ft).
22.Connect heater hose to coolant rail and secure
with clip.
23.Connect hose to coolant pump and secure with
clip.
24.Position PAS pump and tighten bolts to 25 Nm
(18 lbf.ft).
25.Position PAS pump pulley and lightly tighten
bolts.
26.Position ACE pump, fit bolts and tighten to 25
Nm (18 lbf.ft).
27.Position A/C compressor, fit bolts and tighten
to 25 Nm (18 lbf.ft).
28.Position ancillary drive belt, rotate tensioner
anti-clockwise and locate belt to pulleys.
29.Tighten PAS pump pulley bolts to 10 Nm (7
lbf.ft).
30.Position air intake hose to air cleaner and
secure clips.
31.Position engine harness and connect
multiplugs to compressor, MAF sensor,
turbocharger boost solenoid, AAP & IAT
sensor.
32.Position air inlet hose to turbocharger and
tighten clip. 33.Connect hoses to turbocharger boost solenoid
and secure clips.
34.Clean CKP sensor and mating face.
CAUTION: If originally fitted: Fit spacer to
CKP sensor.
35.Using new 'O' ring, fit CKP sensor, tighten CKP
sensor bolt to 9 Nm (7 lbf.ft) and connect
multiplug.
36.Connect multiplug to EGR modulator.
37.Connect engine earth lead to battery earth lead
and tighten bolt.
38.Connect engine harness multiplug to ECM and
main harness.
39.Connect engine harness multiplugs to fuse
box.
40.Position glow plug lead to fusebox and secure
with bolt.
41.Position battery and alternator leads to fusebox
and secure with bolts.
42.Fit engine compartment fuse box cover.
43.Connect vacuum hose to EGR valve.
44.Connect hose to vacuum pump and secure
vacuum pipe to fuel cooler.
45.Disconnect fuel hose from connector block and
connect to fuel cooler.
46.Connect fuel hoses to fuel cooler and
connector block on cylinder head.
47.Position expansion tank, connect hose and
secure with clip. Secure tank to body mounting.
48.Connect coolant hoses to fuel cooler and
coolant rail and secure clips.
49.Fit turbocharger.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Turbocharger.
50. Fit radiator.

+ COOLING SYSTEM - Td5, REPAIRS,
Radiator.
51.Fill engine with oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - diesel engine.
52.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
53.Fit bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.

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.