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Discovery 2. Manual - part 413

ENGINE - TD5

REPAIRS 12-1-49

20. Disconnect multiplug from CKP sensor.
21. Remove bolt securing CKP sensor to gearbox

housing and discard 'O' ring.

CAUTION: If fitted: Retain CKP sensor.

22. Loosen clip securing air inlet hose to

turbocharger and remove hose.

23. Disconnect multiplugs from compressor, MAF

sensor, turbocharger boost solenoid valve,
AAP & IAT sensor.

24. Release clip and disconnect hose from

turbocharger boost solenoid valve.

25. Loosen bolts securing PAS pulley.
26. Rotate ancillary drive belt tensioner anti-

clockwise, release and remove drive belt.

27. Release clips and remove air intake hose from

air cleaner.

28. Remove 4 bolts and move compressor aside.
29. Remove 3 bolts and move ACE pump aside.

30. Remove 3 bolts and remove PAS pump pulley.
31. Remove 4 bolts and move PAS pump aside.

ENGINE - TD5

12-1-50 REPAIRS

32. Release clip and disconnect hose from coolant

pump.

33. Release clip and disconnect heater hose from

coolant rail.

34. Remove bolt securing coolant rail to front

chassis member.

35. Raise vehicle on ramp.
36. Release coolant rail support brackets from

engine LH and RH mounting brackets.

37. Remove coolant rail.
38. Remove starter motor.

CHARGING AND STARTING,

REPAIRS, Starter motor - diesel.

39. Remove and discard 3 bolts securing torque

converter to drive plate.

40. Remove 2 bolts securing gearbox oil cooler

pipe clips from sump and alternator mounting
bracket.

41. Mark position of gearbox oil cooler pipe

clamps.

42. Remove 3 nuts and remove oil cooler pipe

clamps.

43. Loosen RH oil cooler pipe union.
44. Move pipes aside and tighten RH pipe union.

ENGINE - TD5

REPAIRS 12-1-51

45. Remove 8 bolts and remove front cross

member.

46. Remove 6 bolts securing gearbox housing to

engine.

47. Remove 4 bolts and nuts securing RH and LH

front engine mountings to chassis.

48. Lower vehicle ramp.

49. Remove 2 upper bolts securing gearbox

housing and oil cooler coolant pipe to engine.

50. Release clip, disconnect hose from engine oil

cooler and move aside.

51. Remove bolt securing engine closing panel to

gearbox.

52. Fit tool LRT-12-138 to lifting chains and

connect to lifting eyes on engine.

53. Remove 2 nuts from RH and LH front engine

mountings.

54. Position trolley jack to support gearbox.
55. With assistance, raise chains, remove engine

from vehicle and lower onto bench.

Refit

1. With assistance, raise engine from bench and

position in vehicle.

2. With assistance, align engine to gearbox and

torque converter.

3. Position engine RH and LH mountings to

brackets and fit nuts.

4. Position engine oil cooler pipe, connect hose to

oil cooler and secure with clip.

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.

Content .. 411 412 413 414 ..