2002 LAND ROVER DISCOVERY light

ENGINE - TD5
12-1-62 REPAIRS
Valve - relief - oil pressure
$% 12.60.56
Remove
1.Remove sump gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
sump.
2.Remove and discard plug from oil pump
housing.
3.Remove spring and valve.
Refit
1.Clean valve, spring and plug.
2.Clean valve seating inside oil pump housing.
3.Check valve and bore for scoring and
corrosion. Light scoring may be removed using
grade 600 emery cloth soaked in oil.
4.Check spring for distortion, check free length of
spring: Spring free length = 42.00 mm (1.65 in).
CAUTION: Renew relief valve as an
assembly.
5.Lubricate valve and seating.
6.Fit valve and spring to pump.
7.Apply Loctite 243 sealant to threads of new
plug.
CAUTION: Do not attempt to fit original
plug.
8.Fit oil pump pressure relief valve plug and
tighten to 23 Nm (17 lbf.ft).
9.Fit sump gasket.

+ ENGINE - Td5, REPAIRS, Gasket -
sump.
10.Check engine oil level, top-up if necessary.
Switch - oil pressure
$% 12.60.50
Remove
1.Remove fixings and remove engine acoustic
cover.
2.Remove 3 bolts and remove exhaust manifold
heat shield.
3.Disconnect multiplug from oil pressure switch.
4.Position container below switch to catch oil
spillage.
5.Remove oil pressure switch from oil cooler
housing.

ENGINE - TD5
12-1-72 OVERHAUL
16.Remove bolt and nut securing front of cylinder
head to timing chain cover.
17.Using sequence shown, progressively loosen
then remove 12 cylinder head bolts; discard
bolts together with their captive washers.
18.Using assistance, remove cylinder head and
support each end of cylinder head on 2 wooden
blocks.
19.Remove the cylinder head gasket.
20.Note the gasket thickness indicator and ensure
the same thickness gasket is used on refitment
of the cylinder head.
CAUTION: If new pistons, connecting rods
or crankshaft are to be fitted, it will be
necessary to measure piston stand proud in
order to determine thickness of gasket
required – See Pistons, Connecting Rods
and Cylinder Bores – Cylinder head gasket
selection.
21.Remove and discard 2 plastic locating dowels
from cylinder block.
22.Carry out cylinder head overhaul procedures.

+ ENGINE - Td5, OVERHAUL, Cylinder
head - overhaul.Reassembly
1.Thoroughly clean cylinder block and cylinder
head mating faces.
2.Ensure coolant and oil passageways are clear
and bolt holes are clean and dry.
3.Ensure locating dowel holes in cylinder block
are clean and dry.
4.Fit new plastic locating dowels in cylinder block.
5.Fit new cylinder head gasket of the correct
thickness with the word 'TOP' uppermost.
CAUTION: Gasket must be fitted dry.
6.Ensure that timing pin LRT-12-058 is still fitted
and using assistance, fit cylinder head.
7.Carefully enter new cylinder head bolts
together with their captive washers. DO NOT
DROP. Lightly tighten bolts.
8.Using sequence shown tighten cylinder head
bolts to:
lStage 1 - 30 Nm (23 lbf.ft)
lStage 2 - 65 Nm (48 lbf.ft)
lStage 3 - 90
°
lStage 4 - Further 180
°
lStage 5 - Further 45°
CAUTION: Ensure correct tightening
sequence is followed for all 5 tightening
stages, do not tighten bolts 315
° in one
operation.
9.Fit cylinder head to timing chain cover nut and
bolt and tighten to 25 Nm (18 lbf.ft).
10.Clean camshaft sprocket and mating face on
camshaft.

ENGINE - TD5
OVERHAUL 12-1-73
11.Ensure engine is set to TDC firing - No.1
cylinder.
12.Check that mark on camshaft sprocket is
positioned between the 2 coloured links on
timing chain.
13.Position sprocket to camshaft, fit and lightly
tighten 3 new bolts then loosen bolts half a
turn.
14.Clean fixed guide Allen screw and apply
Loctite 242 to screw threads.
15.Fit fixed timing chain guide Allen screw 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
(33 lbf.ft).
18.Tighten camshaft sprocket bolts to 37 Nm (27
lbf.ft).
19.Remove tool LRT-12-058 from camshaft.
20.Lubricate a new 'O' ring with engine oil and fit to
camshaft sprocket access plug.21.Fit camshaft sprocket access plug.
22.Clean alternator/vacuum pump oil hose union.
23.Lubricate a new 'O' ring with engine oil and fit to
alternator/vacuum pump oil hose union.
24.Fit and tighten alternator/vacuum pump oil
hose union to 10 Nm (7 lbf.ft).
25.Fit bolt securing alternator strap bracket to
cylinder head and tighten to 25 Nm (18 lbf.ft).
26.Connect multiplugs to ECT sensor and EUI's.
CAUTION: Following cylinder head
overhaul, it will be necessary, before fitting
the camshaft cover to adjust the fuel
injector rockers using the following
procedures:
27.Rotate engine clockwise until No.1 EUI lobe is
at full lift.
28.Tighten No.1 rocker adjusting screw until the
EUI plunger is felt to 'bottom out'.
29.Loosen rocker adjusting screw 1 complete turn
to give EUI plunger the required bump
clearance and tighten rocker adjusting screw
to 16 Nm (12 lbf.ft).
CAUTION: Ensure screw does not turn as
locknut is tightened.
30.Carry out the above procedures for the
remaining 4 rocker arms.
31.After completion of rocker adjustment, slowly
rotate engine clockwise 2 complete turns by
hand to ensure that no EUI's are bottoming out
on their plungers.
32.Clean camshaft cover and mating face.
33.Fit new sealing washers and isolators as
necessary to camshaft cover.
34.Fit new camshaft cover gasket to cover.
CAUTION: Gasket must be fitted dry.

ENGINE - TD5
12-1-82 OVERHAUL
Reassembly
1.Lubricate new valve stem oil seals with engine
oil.
2.Using tool LRT-12-071 fit valve stem oil seals.
3.Lubricate valve guides, valve stems, valve
spring caps and springs with engine oil. 4.Assemble valves, springs and spring caps
ensuring they are in their original fitted order.
5.Compress valve springs using tool LRT-12-
034 , fit collets.
6.Using a wooden dowel and mallet, tap each
spring cap lightly to seat collets.
7.Lubricate new injector 'O' rings with engine oil.
8.Using tool LRT-12-154/2, fit new 'O' ring to
each injector.

ENGINE - TD5
OVERHAUL 12-1-83
9.Using tool LRT-12-154/3, fit new sealing
washer to each injector.
10.Support each end of cylinder head on blocks of
wood ensuring blocks are clear of valves.
11.Position reaction posts in their original fitted
order.
12.Carefully fit EUI's, ensuring they are in their
original fitted order and that each retainer is
located on its dowel.
CAUTION: If new EUI's are fitted, ensure
replacements are correct. Engine Serial No.
Prefixes 10P to 14P – Push rod bushes are
coloured BLACK or BLUE. Serial No.
Prefixes 15P to 19P – Push rod bushes are
coloured GREEN.
13.Fit new retainer bolts and tighten to 32 Nm (24
lbf.ft).
If new injectors are fitted they must be
programmed for use with the ECM using
TestBook.
14.Lubricate lash adjusters and bores with engine
oil.
15.Fit lash adjusters ensuring they are in their
original fitted order.
16.Lubricate finger followers with engine oil.
17.Fit finger followers ensuring they are in their
original fitted order.
18.Lubricate cams and bearing journals on
camshaft, cylinder head and camshaft carrier
with engine oil.
19.Position camshaft in cylinder head with the
timing pin hole in the vertical position.20.Apply an even film of sealant, Part No. STC
4600 to camshaft carrier face and spread to an
even film using a roller.
CAUTION: Ensure sealant does not block
oilways (arrowed) or contaminate camshaft
bearings. Assembly and bolt tightening
must be completed within 20 minutes of
applying sealant.
21.Fit camshaft carrier ensuring it is correctly
located on dowels.
22.Fit and lightly tighten new camshaft carrier
bolts.
23.Using sequence shown, progressively tighten
bolts to 25 Nm (18 lbf.ft).
24.Lubricate a new camshaft rear oil seal with
engine oil, fit seal using a suitable mandrel.
25.Position rocker shaft on camshaft carrier
ensuring rocker shaft is located on dowel.
26.Fit new rocker shaft retaining bolts and working
from the centre outwards, tighten rocker shaft
bolts to 32 Nm (24 lbf.ft).
27.Fit injector harness and connect multiplugs.
28.Clean fuel connector block and mating face.
29.Lubricate a new fuel filter 'O' ring with engine
oil.

ENGINE - TD5
OVERHAUL 12-1-85
4.Apply a bead of 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.
5.Position new sump gasket.
CAUTION: Gasket must be fitted dry.
6.Position sump, fit and lightly tighten bolts
ensuring they are in their original fitted
positions.
7.Using sequence shown, tighten sump bolts to
25 Nm (18 lbf.ft).8.Fit new centrifuge oil drain pipe gasket.
CAUTION: Gasket must be fitted dry.
9.Fit centrifuge oil drain pipe, fit bolts and tighten
to 10 Nm (7 lbf.ft).

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
12-1-92 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.