Discovery 2. Manual — part 478

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.

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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.

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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

REPAIRS 18-1-57

9. Loosen clip and disconnect inlet hose from

intercooler.

10. Loosen clip and disconnect outlet hose from

intercooler.

11. Remove nut securing horn and move horn

aside.

12. Remove 2 bolts securing radiator LH and RH

upper mounting brackets to body panel and
remove brackets.

13. Remove 4 screws securing LH and RH upper

mounting brackets to condenser.

14. Remove brackets with rubber mounts from

intercooler.

15. Remove 2 bolts securing intercooler to radiator.
16. Release radiator lower mountings from location

in chassis and carefully move radiator towards
engine sufficiently only to release intercooler
from radiator.

17. Remove intercooler.

Refit

1. Fit intercooler to radiator, and fit and tighten

bolts.

2. Engage radiator lower mountings in chassis.

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.

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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.