Discovery 2. Manual — part 411

ENGINE - TD5

REPAIRS 12-1-41

29. Rotate engine clockwise to align mark on

camshaft sprocket between coloured links on
timing chain.

30. Position tool LRT-12-058 through camshaft

carrier to lock camshaft.

31. Position tool LRT-12-158 through gearbox bell

housing to lock crankshaft.

32. Remove timing chain tensioner and discard

sealing washer.

33. Remove timing chain fixed guide Allen screw

from front of cylinder head.

34. Lever out camshaft sprocket blanking plug and

'O'-ring seal from front of cylinder head and
discard.

35. Remove 3 bolts and release timing sprocket

from camshaft. Discard bolts.

36. Using sequence shown, progressively loosen

then remove and discard 12 cylinder head bolts
together with their captive washers.

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

12-1-44 REPAIRS

Rocker shaft assembly

$% 12.29.29

Remove

1. Remove cooling fan.

+

COOLING SYSTEM - Td5, REPAIRS,

Fan - viscous.

2. Remove camshaft cover gasket.

+

ENGINE - Td5, REPAIRS, Gasket -

cover - camshaft.

3. Loosen lock nuts and fully retract rocker

adjusting screws to prevent damage on
reassembly.

4. Rotate engine clockwise, until camshaft

sprocket and timing chain marks are aligned
and fit tool LRT-12-058 through camshaft
carrier to lock camshaft.

5. Progressively loosen then remove and discard

6 bolts securing rocker shaft assembly.

6. Remove and discard lock nuts and rocker

adjusting screws.