Discovery 2. Manual — part 410

ENGINE - TD5

REPAIRS 12-1-37

REPAIRS

Pulley - crankshaft

$% 12.21.01

Remove

1. Remove fixings and underbelly panel.
2. Remove radiator.

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COOLING SYSTEM - Td5, REPAIRS,

Radiator.

3. Using a 15 mm ring spanner, release the

auxiliary drive belt tensioner.

4. Remove auxiliary drive belt.
5. Remove 3 bolts and remove crankshaft TV

damper.

6. Position tool LRT-51-003 to crankshaft pulley

and secure with 2 bolts.

7. Remove and discard crankshaft pulley bolt.

Remove crankshaft pulley.

8. Remove 2 bolts and remove tool LRT-51-003

Refit

1. Position new crankshaft pulley to vice.
2. Remove 3 bolts and remove TV damper from

new crankshaft pulley.

3. Using a lint free cloth, thoroughly clean oil seal

recess and the running surface on crankshaft
pulley.

4. Fit crankshaft pulley.

5. Fit tool LRT-51-003 to crankshaft pulley and

secure with 2 bolts.

6. Fit new crankshaft pulley bolt and tighten to

460 Nm (340 lbf.ft), using a torque multiplier.

7. Remove 2 bolts and remove tool LRT-51-003

from crankshaft pulley.

8. Fit TV damper to crankshaft pulley and tighten

– TV damper bolts to 80 Nm (59 lbf.ft) .

9. Fit auxiliary drive belt to pulleys.

10. Fit radiator.

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COOLING SYSTEM - Td5, REPAIRS,

Radiator.

11. Fit underbelly panel and secure with fixings.

ENGINE - TD5

12-1-38 REPAIRS

Seal - crankshaft - rear

$% 12.21.20

Remove

1. Automatic models: Remove drive plate

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ENGINE - Td5, REPAIRS, Plate -

drive - automatic.

2. Manual models: Remove flywheel.

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ENGINE - Td5, REPAIRS, Flywheel.

3. Remove sump gasket.

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ENGINE - Td5, REPAIRS, Gasket -

sump.

4. Remove 5 bolts securing crankshaft oil seal

housing to cylinder block.

5. Remove crankshaft oil seal housing.

Refit

1. Clean interface between crankshaft oil seal

housing and cylinder block.

2. Position seal protector, LRT-12-061 over

crankshaft boss. Fit new seal and remove tool
LRT-12-061 .

CAUTION: Oil seal must be fitted dry.

3. Fit crankshaft rear oil seal housing bolts and

using sequence shown, tighten to 9 Nm (7
lbf.ft).

4. Fit new sump gasket.

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ENGINE - Td5, REPAIRS, Gasket -

sump.

5. Automatic models: Fit drive plate

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ENGINE - Td5, REPAIRS, Plate -

drive - automatic.

6. Manual models: Fit flywheel.

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ENGINE - Td5, REPAIRS, Flywheel.

ENGINE - TD5

REPAIRS 12-1-39

Gasket - cylinder head

$% 12.29.02

Remove

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 bonnet.

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EXTERIOR FITTINGS, REPAIRS,

Bonnet.

2. Release turnbuckles and remove battery cover.
3. Disconnect battery earth lead.
4. Drain cooling system.

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COOLING SYSTEM - Td5,

ADJUSTMENTS, Drain and refill.

5. Remove camshaft cover gasket.

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ENGINE - Td5, REPAIRS, Gasket -

cover - camshaft.

6. Remove cooling fan coupling.

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COOLING SYSTEM - Td5, REPAIRS,

Fan - viscous.

7. Remove 3 bolts and remove exhaust manifold

heat shield.

8. Remove turbocharger oil feed banjo bolt and

discard sealing washers.

9. Remove 3 nuts, release turbocharger from

exhaust manifold, discard gasket and tie
turbocharger aside.

10. Disconnect multiplugs from compressor, MAF

sensor, turbocharger wastegate modulator,
and AAP & IAT sensor.

11. Remove 2 bolts securing engine harness to

camshaft carrier.

12. Disconnect multiplug from EUI's and coolant

temperature sensor.

ENGINE - TD5

12-1-40 REPAIRS

13. Disconnect 4 glow plug connectors.
14. Disconnect MAP sensor multiplug from inlet

manifold.

15. Position engine harness clear of inlet manifold.
16. Disconnect vacuum hose from EGR valve.

17. Release 3 clips and disconnect coolant hoses

from fuel cooler.

18. Disconnect fuel hoses, tank to fuel cooler and

connector block on cylinder head.

CAUTION: Always fit plugs to open
connections to prevent contamination.

19. Disconnect fuel hose from connector block on

cylinder head.

20. Disconnect fuel hose from fuel cooler and

secure to connector block on cylinder head.
This is to prevent contamination of the fuel
injection system.

Pre EU3 model shown

21. Loosen clip screw and disconnect air intake

hose from EGR valve.

22. Loosen vacuum pump oil feed pipe union from

cylinder head and discard 'O' ring.

23. Loosen 2 bolts and release alternator support

bracket from cylinder head.

24. Pre EU3 model: Remove bolt securing EGR

valve pipe clamp to cylinder head.

25. EU3 model: Release the clips and disconnect

the coolant hoses from the EGR cooler.

26. Remove nut and bolt securing cylinder head to

timing chain cover.

27. Release clips and disconnect top hose, heater

hose and heater feed hose.

28. 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.