Discovery 2. Manual — part 418

ENGINE - TD5

OVERHAUL 12-1-69

OVERHAUL

Gasket - inlet manifold

$% 30.15.08.01

Disassembly

Note: The following procedures cover engines
fitted with or without an EGR cooler. The EGR
cooler is bolted to the front of the cylinder head.

EU3 Engine in main illustration, Pre EU3 condition

shown in inset

1. Remove and discard 2 Allen screws securing

EGR pipe to exhaust manifold or EGR cooler.

2. Remove bolt securing EGR pipe to cylinder

head, (if fitted)

3. Disconnect multiplug from IAT and MAP

sensor.

4. Remove 4 bolts securing fuel cooler to inlet

manifold. and remove cooler.

5. Remove bolt securing engine dipstick tube to

camshaft carrier.

6. Release and remove engine dipstick tube.
7. Remove 'O' ring from dip stick tube.
8. Disconnect 4 leads from glow plugs.
9. Remove 2 bolts securing alternator strap

bracket, remove bracket, (if fitted)

10. Remove 2 nuts and 8 bolts and remove inlet

manifold.

11. Remove manifold gasket.

Reassembly

1. Clean inlet manifold and mating face, clean

mating faces of EGR pipe, exhaust manifold or
EGR cooler – if fitted.

2. Fit new gasket.
3. Position inlet manifold and working from the

centre outwards, fit inlet manifold nuts and
bolts and tighten to 25 Nm (18 lbf.ft) .

4. Fit alternator strap bracket and tighten bolts to

25 Nm (18 lbf.ft), (if fitted)

5. Connect glow plug leads.
6. Clean engine dipstick tube.
7. Fit new 'O' ring to dipstick tube.
8. Fit engine dipstick tube to camshaft carrier and

tighten bolt to 10 Nm (7 lbf.ft).

9. Position fuel cooler and tighten bolts to 25 Nm

(18 lbf.ft).

10. Connect multiplug to IAT and MAP sensor.
11. Position EGR pipe to exhaust manifold or EGR

cooler and using new Allen screws tighten to 10
Nm (7 lbf.ft).

12. Fit EGR pipe clamp to cylinder head, (if fitted)

and tighten bolt to 10 Nm (7 lbf.ft).

ENGINE - TD5

12-1-70 OVERHAUL

Gasket - exhaust manifold

$% 30.15.12.01

Disassembly

Note: The following procedure covers engines
fitted with or without an EGR cooler. The EGR
cooler is bolted to the front of the cylinder head.

EU3 engine illustrated

1. Remove 3 bolts securing heater pipe to

cylinder head and turbocharger heat shield.

2. Remove heater pipe.
3. Remove bolt and remove turbocharger heat

shield.

4. Remove and discard 2 Allen screws securing

EGR pipe to exhaust manifold.

5. Remove banjo bolt securing oil feed pipe to

turbocharger and discard sealing washers.

6. Loosen turbocharger drain hose union at

cylinder block.

7. Remove 10 nuts and remove exhaust manifold

and turbocharger.

8. Remove manifold gasket.

Reassembly

1. Clean exhaust manifold mating faces.
2. Position exhaust manifold to cylinder head

using new gasket and fit manifold nuts.
Working from the centre outwards, fit and
tighten nuts to 25 Nm (18 lbf.ft).

3. Clean turbocharger drain and feed hose

unions.

4. Fit turbocharger oil drain hose to cylinder block

and tighten union to 48 Nm (35 lbf.ft) .

5. Fit new sealing washers to turbocharger oil

feed pipe, fit banjo bolt and tighten to 25 Nm
(18 lbf.ft).

6. Position EGR pipe to exhaust manifold. Fit new

Allen screws and tighten to 10 Nm (7 lbf.ft).

7. Position turbocharger heat shield.
8. Position heater pipe to cylinder head and

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

9. Position exhaust manifold heatshield and

tighten M6 bolts to 9 Nm (7 lbf.ft) and M8 bolt
to 25 Nm (18 lbf.ft).

ENGINE - TD5

OVERHAUL 12-1-71

Gasket - cylinder head

$% 12.29.02.01

Disassembly

Note: The following procedures cover engines
fitted with or without an EGR cooler. The EGR
cooler is bolted to the front of the cylinder head.

1. Remove exhaust manifold gasket.

+

ENGINE - Td5, OVERHAUL, Gasket

- exhaust manifold.

2. Remove inlet manifold gasket.

+

ENGINE - Td5, OVERHAUL, Gasket

- inlet manifold.

3. EGR cooler fitted: Remove and discard 2

Allen screws securing EGR pipe to cooler.

4. Progressively loosen then remove 13 bolts

securing camshaft cover, remove cover;
remove and discard gasket.

5. Remove isolators and sealing washers from

cover.

6. Disconnect injector multiplug from camshaft

carrier.

7. Disconnect multiplug from ECT sensor.
8. Remove bolt securing alternator strap bracket

to cylinder head.

9. Using crankshaft pulley bolt, rotate crankshaft

and set engine to TDC No.1 cylinder firing -
coloured links on timing chain must be aligned
with timing mark on camshaft sprocket.

10. Fit timing pin LRT-12-058 into slot in camshaft.

11. Disconnect alternator/vacuum pump oil feed

pipe union from cylinder head, remove and
discard 'O' ring.

12. Remove camshaft sprocket access plug from

front of cylinder head, remove and discard 'O'
ring.

13. Remove timing chain fixed guide Allen screw.
14. Remove timing chain tensioner, remove and

discard sealing washer.

15. Remove and discard 3 bolts securing camshaft

sprocket to camshaft; release sprocket from
camshaft.

ENGINE - TD5

12-1-72 OVERHAUL

16. Remove bolt and nut securing front of cylinder

head to timing chain cover.

17. Using sequence shown, progressively loosen

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

18. Using assistance, remove cylinder head and

support each end of cylinder head on 2 wooden
blocks.

19. Remove the cylinder head gasket.
20. Note the gasket thickness indicator and ensure

the same thickness gasket is used on refitment
of the cylinder head.

CAUTION: If new pistons, connecting rods
or crankshaft are to be fitted, it will be
necessary to measure piston stand proud in
order to determine thickness of gasket
required – See Pistons, Connecting Rods
and Cylinder Bores – Cylinder head gasket
selection.

21. Remove and discard 2 plastic locating dowels

from cylinder block.

22. Carry out cylinder head overhaul procedures.

+

ENGINE - Td5, OVERHAUL, Cylinder

head - overhaul.

Reassembly

1. Thoroughly clean cylinder block and cylinder

head mating faces.

2. Ensure coolant and oil passageways are clear

and bolt holes are clean and dry.

3. Ensure locating dowel holes in cylinder block

are clean and dry.

4. Fit new plastic locating dowels in cylinder block.
5. Fit new cylinder head gasket of the correct

thickness with the word 'TOP' uppermost.

CAUTION: Gasket must be fitted dry.

6. Ensure that timing pin LRT-12-058 is still fitted

and using assistance, fit cylinder head.

7. Carefully enter new cylinder head bolts

together with their captive washers. DO NOT
DROP. Lightly tighten bolts.

8. Using sequence shown tighten cylinder head

bolts to:

l

Stage 1 - 30 Nm (23 lbf.ft)

l

Stage 2 - 65 Nm (48 lbf.ft)

l

Stage 3 - 90

°

l

Stage 4 - Further 180

°

l

Stage 5 - Further 45

°

CAUTION: Ensure correct tightening
sequence is followed for all 5 tightening
stages, do not tighten bolts 315

°

in one

operation.

9. Fit cylinder head to timing chain cover nut and

bolt and tighten to 25 Nm (18 lbf.ft).

10. Clean camshaft sprocket and mating face on

camshaft.