Discovery 2. Manual — part 414

ENGINE - TD5

REPAIRS 12-1-53

Mounting - front - LH

$% 12.45.01

Remove

1. Remove centrifuge assembly.

+

ENGINE - Td5, REPAIRS, Gasket -

centrifuge oil drain pipe.

2. Remove 3 bolts, remove oil filter adaptor

housing and discard gasket.

3. Fit suitable lifting chains to support engine.

4. With assistance remove 2 bolts securing

engine mounting to chassis.

5. Remove 4 bolts securing engine mounting

bracket to cylinder block.

6. Remove nut securing mounting to mounting

bracket.

7. Remove mounting and mounting bracket.
8. Remove mounting shield.

Refit

1. Fit shield to mounting.

2. Fit mounting and mounting bracket.
3. Fit mounting bracket to cylinder block and

tighten – bolts securing front LH engine
mounting bracket to cylinder block to 48 Nm (35
lbf.ft).

4. With assistance, fit mounting to chassis and

tighten – bolts securing front LH engine
mounting to chassis to 85 Nm (63 lbf.ft).

5. Fit mounting to mounting bracket and tighten –

nut securing front LH mounting to mounting
bracket to 85 Nm (63 lbf.ft).

6. Remove engine support chains.
7. Clean oil filter adaptor housing and mating

face.

8. Fit oil filter adaptor housing to oil cooler

housing and tighten bolts to 25 Nm (18 lbf.ft).

9. Fit centrifuge assembly.

+

ENGINE - Td5, REPAIRS, Gasket -

centrifuge oil drain pipe.

ENGINE - TD5

12-1-54 REPAIRS

Mounting - front - RH

$% 12.45.03

Remove

1. Remove fixings and remove engine acoustic

cover.

2. Release fixings and remove battery cover.
3. Disconnect battery earth lead.
4. Raise front of vehicle.

WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.

5. Remove 4 bolts and move fuel cooler to one

side.

6. Fit suitable lifting chains to support engine.

7. With assistance remove 2 bolts securing

engine mounting to chassis.

8. Remove 4 bolts securing engine mounting

bracket to cylinder block.

9. Remove nut securing mounting to mounting

bracket.

10. Remove mounting and mounting bracket.

Refit

1. Fit mounting and mounting bracket.
2. Fit front RH engine mounting bracket to

cylinder block and tighten bolts to 48 Nm (35
lbf.ft).

3. With assistance, fit front RH mounting to

chassis and tighten bolts to 85 Nm (63 lbf.ft).

4. Fit front RH mounting to mounting bracket and

tighten nut to 85 Nm (63 lbf.ft).

5. Remove engine support chains.
6. Position Fuel cooler to inlet manifold and

tighten bolts to 25 Nm (18 lbf.ft).

7. Remove stand(s) and lower vehicle.
8. Connect battery earth lead.
9. Fit battery cover and secure with fixings.

10. Fit engine acoustic cover and secure with

fixings.

ENGINE - TD5

REPAIRS 12-1-55

Mounting - engine - rear - LH

$% 12.45.07

Remove

1. Raise vehicle on ramp.
2. Position jack to support gearbox.

3. Remove 2 nuts and remove mounting.
4. Remove heat shield from mounting.

Refit

1. Clean mounting and mating faces.
2. Position heat shield to mounting.
3. Position engine rear LH mounting and tighten

nuts to 48 Nm (35 lbf.ft).

4. Lower support jack.
5. Lower vehicle.

Mounting - engine - rear - RH

$% 12.45.09

Remove

1. Raise vehicle on ramp.

2. Position jack to support gearbox.
3. Remove 2 nuts and remove mounting.

Refit

1. Clean mounting and mating faces.
2. Position engine rear RH mounting and tighten

nuts to 48 Nm (35 lbf.ft).

3. Lower support jack.
4. Lower vehicle.

ENGINE - TD5

12-1-56 REPAIRS

Flywheel

$% 12.53.07

Remove

1. Remove clutch assembly.

+

CLUTCH - Td5, REPAIRS, Clutch

assembly.

2. Remove and discard 8 bolts securing flywheel

to crankshaft and remove flywheel.

Refit

1. Clean flywheel and mating face.
2. Position flywheel to crankshaft, fit new bolts

and working in a diagonal sequence tighten to
40 Nm (30 lbf.ft), then a further 90

°

.

CAUTION: Do not carry out stages 1 and 2 in
one operation.

3. Fit clutch assembly.

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CLUTCH - Td5, REPAIRS, Clutch

assembly.

Plate - drive - automatic

$% 12.53.13

Remove

1. Remove gearbox.

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AUTOMATIC GEARBOX - ZF4HP22

- 24, REPAIRS, Gearbox - convertor and
transfer gearbox - Diesel.

2. Remove and discard 8 bolts and remove

converter drive plate, spacer and starter ring
gear.

Refit

1. Clean drive plate, spacer and starter ring gear.
2. Fit starter ring gear, spacer and drive plate to

crankshaft, fit new bolts and working in a
diagonal sequence tighten to 40 Nm (30 lbf.ft),
then a further 90

°

.

CAUTION: Do not carry out stages 1 and 2 in
one operation.

3. Refit gearbox.

+

AUTOMATIC GEARBOX - ZF4HP22

- 24, REPAIRS, Gearbox - convertor and
transfer gearbox - Diesel.