2002 LAND ROVER DISCOVERY fuel

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
12-1-84 OVERHAUL
30.Fit new fuel filter, 'O' ring, and gasket.
CAUTION: Gasket must be fitted dry.
31. If fitted: Fit fuel connector spacer block and
gasket.
32.Fit fuel connector block, fit bolts and tighten to
25 Nm (18 lbf.ft).
33.Clean glow plugs.
34.Fit glow plugs to cylinder head and tighten to
16 Nm (12 lbf.ft).
35.Fit new cylinder head gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- cylinder head.
36. Engine Serial No. Prefixes 15P to
19P:Lubricate new 'O' rings with engine oil and
fit to spill return pipe, fit pipe and tighten
connectors to 20 Nm (15 lbf.ft).
37.Before fitting the camshaft cover, the fuel
injector rockers must be adjusted following the
procedures given in Cylinder head gasket -
Refit.

+ ENGINE - Td5, OVERHAUL, Gasket
- cylinder head.
Gasket - engine sump
$% 12.60.38.01
Disassembly
1.Remove 2 bolts securing centrifuge oil drain
pipe to sump, remove and discard gasket.
2.Using sequence shown and noting their fitted
positions, remove 20 bolts securing sump to
cylinder block.
3.Release sump from locating dowels, remove
sump; remove and discard gasket.
Reassembly
1.Clean sump and mating faces, ensure bolt
holes in cylinder block are clean and dry.
2.Using suitable solvent, remove all traces of
sealant from joint faces of timing chain cover
and crankshaft rear oil seal housing.
3.Clean centrifuge oil drain pipe and mating
faces.

ENGINE - V8
REPAIRS 12-2-21
5.Release coolant rail from inlet manifold and
discard 'O' ring.
6.Remove nuts securing alternator cables and
release cables from alternator.
7.Disconnect multiplugs from RH bank of
injectors and release harness from fuel rail.
8.Release ht leads from clips on rocker cover.
9.Remove 4 bolts securing rocker cover.
10.Remove rocker cover and collect gasket. Refit
1.Clean mating faces of rocker cover and
cylinder head.
2.Using a new gasket, fitted dry, position rocker
cover ensuring gasket is correctly located.
3.Fit rocker cover bolts and working in diagonal
sequence, tighten to:
lStage 1 - 3 Nm (2.5 lbf.ft)
lStage 2 - 8 Nm (6 lbf.ft)
4.Ensure that outer rim of gasket is correctly
positioned around periphery of rocker cover.
5.Secure ht leads in rocker cover clips.
6.Secure injector harness to fuel rail and connect
multiplugs to injectors.
7.Position alternator cables, and tighten terminal
B+ nut to 18 Nm (13 lbf.ft) and terminal D+ nut
to 5 Nm (3 lbf.ft).
8.Clean coolant rail 'O' ring recess.
9.Lubricate and fit new 'O' ring to coolant rail,
position coolant rails, fit bolts and tighten to 22
Nm (16 lbf.ft).
10. Models with SAI: Clean air manifold unions,
position manifold and tighten unions nuts to 25
Nm (18 lbf.ft).
11.Fit upper inlet manifold.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
12.Refill cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.

ENGINE - V8
12-2-26 REPAIRS
Engine assembly
$% 12.41.01.99
Remove
1.Drain engine oil and remove oil filter.
2.Remove radiator.

+ COOLING SYSTEM - V8, REPAIRS,
Radiator.
3.Remove upper inlet manifold.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
4.Remove ignition coil assemblies.
5.Position absorbent material to catch spillage
and disconnect fuel pipe from fuel rail.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Release 2 hose clips and remove top hose.
7.Using a 15 mm spanner, release auxiliary drive
belt tension and remove drive belt. 8.Remove 3 bolts securing ACE pump, release
pump and tie aside.
9.Disconnect multiplug from A/C compressor.
10.Remove 4 bolts securing A/C compressor,
release compressor and tie aside.

ENGINE - V8
12-2-30 REPAIRS
Refit
1.Clean mating faces of engine and gearbox,
dowel and dowel holes.
2.Lubricate splines and bearing surface on first
motion shaft with grease.
3.With assistance position engine in engine bay,
align to gearbox and locate on dowels.
4.Position support brackets, fit bell housing bolts
and tighten to 50 Nm (37 lbf.ft).
5.Position engine mountings, fit nuts and tighten
to 85 Nm (63 lbf.ft).
6.Lower lifting equipment and remove from
engine.
7. Models with automatic gearbox: Align torque
converter to drive plate, fit bolts and tighten to
50 Nm (37 lbf.ft). Fit access plug.
8.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
9.Position oil cooling pipe saddle clamps and
tighten bolts.
10.Position engine harness into foot well.
11.Connect 5 multiplugs to ECM.
12.Fit toe board and secure with trim fixings.
13.Connect engine harness earth to body and
secure with nut.
14.Connect engine harness to main harness
multiplug.
15.Connect multiplug to EVAP purge valve.
16.Connect engine harness multiplugs to fuse
box.
17.Connect starter lead to fuse box and secure
with nut.
18.Connect engine harness positive lead to
battery and tighten nut.
19.Fit fuse box cover.
20.Position engine earth lead and secure with
bolt.
21.Position coolant rail and secure with bolt.
22.Connect harness clips to coolant rail.
23.Connect hose to coolant rail and coolant pump
and secure with clips.
24.Connect PAS pump high and low pressure
pipes and secure with clips.
25.Position oil cooling pipe saddle clamp to PAS
pump housing and secure with bolt.
26.Clean A/C compressor and housing mating
faces, dowels and dowel holes. 27.Position A/C compressor, fit bolts and tighten
to 22 Nm (16 lbf.ft).
28.Connect multiplug to A/C compressor.
29.Clean ACE pump and housing mating faces,
dowels and dowel holes.
30.Position ACE pump, fit bolts and tighten to 22
Nm (16 lbf.ft).
31.Clean all pulley 'V's, fit auxiliary drive belt,
using a 15mm spanner, release belt tensioner
secure belt and re-tension drive belt .
32.Ensure auxiliary drive belt is correctly located
on all pulleys.
33.Fit radiator.

+ COOLING SYSTEM - V8, REPAIRS,
Radiator.
34.Fit top hose and secure with clips.
35.Connect fuel pipe to fuel rail.
36.Position ignition coils and connect ht leads.
37.Fit upper inlet manifold.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
38.Fit new oil filter and refill engine with oil.

+ ENGINE - V8, REPAIRS, Filter - oil.

+ MAINTENANCE, PROCEDURES,
Engine oil - V8 engine.
39.Top up gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.

ENGINE - V8
OVERHAUL 12-2-45
OVERHAUL
Gasket - inlet manifold
$% 30.15.08.01
Disassembly
1.Disconnect multiplug from coolant thermistor.
2.Disconnect multiplugs from injectors; release
injector harness from fuel rail and position
aside.
3.Remove 3 bolts securing PAS pump pulley and
remove pulley.
4.Loosen bolt securing jockey pulley and remove
pulley. 5.Remove 4 bolts and one nut securing auxiliary
housing and remove housing.
6.Remove 2 nuts securing alternator cables and
release the cables.
7.Remove two bolts securing alternator and
remove alternator.
8.Remove 4 bolts securing coolant outlet elbow
and remove outlet elbow.
9.Remove and discard 'O' ring.
10.Release ht leads from rocker covers.

EMISSION CONTROL - TD5
17-1-4 DESCRIPTION AND OPERATION
Emission Control Systems
Engine design has evolved in order to minimise the emission of harmful by-products. Emission control systems fitted
to Land Rover vehicles are designed to maintain the emission levels within the legal limits pertaining for the specified
market.
Despite the utilisation of specialised emission control equipment, it is still necessary to ensure that the engine is
correctly maintained and is in good mechanical order, so that it operates at its optimum condition.
In addition to emissions improvements through engine design and the application of electronic engine management
systems, special emission control systems are used to limit the pollutant levels developed under certain conditions.
Two main types of additional emission control system are utilised with the Td5 engine to reduce the levels of harmful
emissions released into the atmosphere. These are as follows:
1Crankcase emission control – also known as blow-by gas emissions from the engine crankcase.
2Exhaust gas recirculation – to reduce NO
2 emissions.
Crankcase emission control
All internal combustion engines generate oil vapour and smoke in the crankcase as a result of high crankcase
temperatures and piston ring and valve stem blow-by, a closed crankcase ventilation system is used to vent
crankcase gases back to the air induction system and so reduce the emission of hydrocarbons.
Gases from the crankcase are drawn into the inlet manifold to be burnt in the combustion chambers with the fresh air/
fuel mixture. The system provides effective emission control under all engine operating conditions.
Crankcase gases are drawn through the breather port in the top of the camshaft cover and routed through the breather
hose and breather valve on the flexible air intake duct to be drawn into the turbocharger intake for delivery to the air
inlet manifold via an intercooler.
An oil separator plate is included in the camshaft cover which removes the heavy particles of oil before the crankcase
gas leaves via the camshaft cover port. The rocker cover features circular chambers which promote swirl in the oil
mist emanating from the cylinder head and camshaft carrier. As the mist passes through the series of chambers
between the rocker cover and oil separator plate, oil particles are thrown against the separator walls where they
condense and fall back into the cylinder head via two air inlet holes located at each end of the rocker cover.
The breather valve is a depression limiting valve which progressively closes as engine speed increases, thereby
limiting the depression in the crankcase. The valve is of moulded plastic construction and has a port on the underside
which plugs into a port in the flexible air intake duct. A port on the side of the breather valve connects to the camshaft
cover port by means of a breather hose which is constructed from a heavy-duty braided rubber hose which is held in
place by hose clips. A corrugated plastic sleeve is used to give further protection to the breather hose. The breather
valve is orientation sensitive, and “TOP” is marked on the upper surface to ensure it is mounted correctly.
It is important that the system is airtight so hose connections to ports should be checked and the condition of the
breather hose should be periodically inspected to ensure it is in good condition.

EMISSION CONTROL - TD5
DESCRIPTION AND OPERATION 17-1-5
Exhaust gas recirculation
The exhaust gas recirculation (EGR) valve permits a controlled amount of exhaust gas to combine with the fresh air
entering the engine. The exhaust gas reduces the combustion temperature by delaying the fuel burning rate, which
assists in reducing the quantity of oxides of nitrogen.
On EU3 models, an EGR cooler is employed to further reduce the combustion temperature. By passing the exhaust
gas through a bundle of pipes flooded by coolant, the density of the exhaust gas going into the engine is increased.
This process further reduces the amount of oxygen, which in turn, further reduces the amount of NO
2 in the exhaust.
Recirculating too much exhaust gas can result in higher emissions of soot, HC and CO due to insufficient air. The
recirculated exhaust gas must be limited so that there is sufficient oxygen available for combustion of the injected fuel
in the combustion chamber, to do this the Engine Control Module (ECM) is used to control the precise quantity of
exhaust gas to be recirculated in accordance with the prevailing operating conditions. Influencing factors include:
lthe mass of air flow detected by the mass air flow sensor.

+ ENGINE MANAGEMENT SYSTEM - Td5, DESCRIPTION AND OPERATION, Description.
lthe ambient air pressure, determined by the ambient air pressure sensor which is used to initiate adjustments
to reduce the amount of smoke produced at high altitudes.

+ ENGINE MANAGEMENT SYSTEM - Td5, DESCRIPTION AND OPERATION, Description.
Other factors which are taken into consideration by the engine management system for determining the optimum
operating condition include:
lManifold inlet air temperature
lCoolant temperature
lEngine speed
lFuel delivered
The main components of the EGR system are as follows.
EGR Modulator
1Port to vacuum source (white band)
2Port to EGR valve (blue band)
3Port to atmosphere via in-line filter (green
band)4Harness connector (black)