2002 LAND ROVER DISCOVERY battery

ENGINE MANAGEMENT SYSTEM - TD5
18-1-48 REPAIRS
Sensor - crankshaft (CKP)
$% 18.30.12
Remove
1.Disconnect multiplug from CKP sensor.
2.Remove bolt securing CKP sensor. Remove
CKP sensor from gearbox housing and discard
'O' ring.
3. If fitted:Remove and discard spacer.
Refit
1.Clean gearbox housing and CKP sensor.
2. If fitted:Fit new spacer.
3.Fit new 'O' ring, position CKP sensor to
gearbox housing and tighten bolt to 9 Nm (7
lbf.ft).
4.Connect multiplug to CKP sensor.
Air filter assembly
$% 19.10.01
Remove
1.Release turnbuckles and remove battery
cover.
2.Disconnect battery earth lead.
3.Remove 2 nuts and remove air intake duct.
4.Release 2 clips securing MAF sensor.
5.Release MAF sensor from air filter cover and
position aside.

ENGINE MANAGEMENT SYSTEM - TD5
REPAIRS 18-1-49
6.Release air filter from 3 grommets, remove
assembly and discard 'O' ring.
7.Remove 2 screws, remove AAP sensor and
discard 'O' ring.
Refit
1.Clean MAF sensor and air filter mating faces.
2.Fit new 'O' ring to air filter.
3.Clean AAP sensor.
4.Using new 'O' ring, fit AAP sensor and tighten
screws.
5.Position air filter assembly and secure in
grommets.
6.Position MAF sensor and secure clips.
7.Position intake duct to air filter and tighten nuts.
8.Connect battery earth lead.
9.Fit battery cover and secure with fixings.
Element - air filter
$% 19.10.10
Remove
1.Release 2 clips and disconnect MAF sensor
from air filter cover.

ENGINE MANAGEMENT SYSTEM - TD5
18-1-50 REPAIRS
2.Disconnect multiplug from AAP sensor.
3.Release 2 clips and remove cover from air
filter.
4.Remove air filter element.
Refit
1.Clean air filter body and cover.
2.Fit new air filter element.
3.Position air cleaner cover and secure clips.
4.Position MAF sensor and secure clips.
5.Connect multiplug to AAP sensor.
Sensor - fuel temperature
$% 19.22.08
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Release fixings and remove battery cover.
3.Disconnect battery earth lead.
4.Disconnect multiplug from fuel temperature
sensor.
5. Thoroughly clean area around fuel
temperature sensor before removal.
6.Remove fuel temperature sensor and discard
sealing washer.
Refit
1.Clean fuel temperature sensor mating faces.
2.Fit new sealing washer and tighten fuel
temperature sensor to 13 Nm (10 lbf.ft) .
3.Connect multiplug to fuel temperature sensor.
4.Connect battery earth lead.
5.Fit battery cover and secure fixings.
6.Fit engine acoustic cover, and secure with
fixings.

ENGINE MANAGEMENT SYSTEM - TD5
REPAIRS 18-1-53
Element - fuel filter
$% 19.25.07
Remove
1.Release turnbuckles and remove battery cover.
2.Disconnect battery earth lead.
3.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
4.Clean area around fuel filter.
5.Disconnect multiplug from filter element.
6.Remove fuel filter element.
Refit
1.Clean fuel filter and mating face.
2.Fit new fuel filter element and connect
multiplug.
3.Remove stand(s) and lower vehicle.
4.Connect battery earth lead.
5.Fit battery cover and secure the fixings.
Cooler - fuel
$% 19.25.30
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Remove battery cover.
3.Disconnect battery earth lead.
4.Drain cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
5.Release 3 clips and disconnect 3 coolant hoses
from fuel cooler.
6.Release 2 fuel hoses from fuel cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
7.Release vacuum pipe clip from fuel cooler.
8.Noting which bolts are removed from the upper
fixing holes, remove 4 bolts securing fuel cooler
to inlet manifold. Remove cooler.
Refit
1.Clean fuel hose connections.
2.Apply Loctite 242 to the two upper bolts.
3.Position fuel cooler to inlet manifold, fit bolts
and tighten the upper bolts to 18 Nm (13 lbf.ft)
and the lower bolts to 25 Nm (18 lbf.ft).
4.Connect fuel hoses to fuel cooler.
5.Connect coolant hoses to fuel cooler, secure
with clips.
6.Secure vacuum hose to fuel cooler.
7.Refill cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
8.Fit engine acoustic cover and secure with
fixings.
9.Connect battery earth lead.
10.Fit battery cover.

ENGINE MANAGEMENT SYSTEM - TD5
REPAIRS 18-1-55
Turbocharger
$% 19.42.01
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Release fixings and remove battery cover.
3.Disconnect battery earth lead.
4.Remove cooling fan cover.
5.Remove 3 bolts and remove exhaust manifold
heat shield.
6.Release clip and disconnect breather hose
from camshaft cover.
7.Release clip and disconnect vacuum hose from
turbocharger wastegate.
8.Loosen clips and release air intake and outlet
hoses from turbocharger. 9.Remove turbocharger oil feed banjo bolt and
discard sealing washers.
10.Remove 2 bolts and release turbocharger oil
drain pipe and discard gasket.
11.Remove 3 nuts and release exhaust front pipe
from turbocharger and discard gasket.
12.Remove 3 nuts securing turbocharger to
exhaust manifold.
13. Remove turbocharger and discard gasket.
Refit
1.Clean turbocharger and exhaust manifold
mating faces.
2.Using a new gasket, fit turbocharger to exhaust
manifold and tighten nuts to 30 Nm (22 lbf.ft).
3.Using new gasket, align exhaust front pipe and
tighten nuts to 30 Nm (22 lbf.ft).
4.Using new gasket, align turbocharger drain
pipe and tighten bolts to 9 Nm (7 lbf.ft).
5.Fit banjo bolt to oil feed pipe using new sealing
washers and tighten to 25 Nm (18 lbf.ft)..
6.Position air hoses to turbocharger and tighten
clips.
7.Position and secure breather hose to camshaft
cover.
8.Position and secure vacuum hose to
turbocharger wastegate.
9.Position exhaust manifold heat shield and
tighten M6 bolts to 9 Nm (7 lbf.ft) and M8 bolt to
25 Nm (18 lbf.ft).
10.Fit fan cowl and secure fixings.
11.Fit acoustic cover and secure the fixings.
12.Connect battery earth lead.
13.Fit battery cover and secure fixings.

ENGINE MANAGEMENT SYSTEM - TD5
18-1-56 REPAIRS
Intercooler
$% 19.42.15
Remove
1.Remove cooling fan and coupling.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
2.Remove battery.
3.Remove vehicle jack from battery carrier.
4.Remove screw and release engine control
module (ECM) from battery carrier.
5.Remove 7 bolts and remove battery carrier. 6.Remove 2 screws and remove lower half of fan
cowl.
7.Remove front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.
8.Remove 6 scrivets and remove LH and RH air
deflectors from front panel.

ENGINE MANAGEMENT SYSTEM - TD5
18-1-58 REPAIRS
3.Fit brackets with rubber mountings to
intercooler and fit and tighten screws securing
brackets to condenser.
4.Fit radiator upper mounting brackets and
tighten bolts.
5.Fit LH horn and secure with nut.
6.Connect inlet and outlet hoses to intercooler
and tighten clips.
7.Fit lower half of fan cowl and secure with
screws.
8.Fit LH and RH air deflectors to front panel and
secure with scrivets.
9.Fit front grille.
10.Fit battery carrier and secure with bolts.
11.Fit ECM and secure with screw.
12.Fit jack to battery carrier.
13.Fit battery.
14.Fit cooling fan and coupling.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
Valve - solenoid boost control
$% 19.42.30
Remove
1.Loosen clip and release air intake hose from
MAF sensor.
2.Release clips and disconnect vacuum hoses
from solenoid valve.
3.Disconnect multiplug from solenoid valve.
4.Remove 2 bolts and remove solenoid valve.
Refit
1.Position solenoid valve and tighten bolts.
2.Connect multiplug to solenoid valve.
3.Connect vacuum hoses and secure with clips.
4.Position air intake hose to MAF sensor and
secure clip.

ENGINE MANAGEMENT SYSTEM - TD5
REPAIRS 18-1-59
Regulator - fuel pressure
$% 19.45.06
Remove
1.Release turnbuckles and remove battery cover
2.Disconnect battery earth lead.
3.Remove 3 bolts and remove engine acoustic
cover.
4.Remove 2 bolts and remove engine lifting eye.
5.Position cloth to absorb fuel spillage.
6.Release and disconnect hose from fuel cooler. 7.Release and disconnect fuel hose from
pressure regulator.
Always fit plugs to open connections to
prevent contamination.
8.Disconnect multiplug from fuel temperature
sensor.
9.Remove 3 bolts, remove pressure regulator
from cylinder head and collect gasket.
10.Remove and discard 'O' ring and fuel filter.