Discovery 2. Manual — part 412

ENGINE - TD5

REPAIRS 12-1-45

Refit

1. Clean rocker shaft and mating faces.

CAUTION: If rockers or rocker shaft are to
be replaced, ensure replacements are
correct. Engine Serial No. Prefixes 10P to
14P are fitted with type A rocker arms and
shaft. Engine Serial No. Prefixes 15P to 19P
are fitted with type B rocker arms and shaft.
Type B rocker arms and shaft may be fitted
to Engine Serial No. Prefixes 10P to 14P as
an assembly.

2. Fit new rocker adjusting screws fully into rocker

arm. Fit new lock nuts to screws but do not
tighten.

CAUTION: Ensure screws are correct for
type of rocker arms fitted. Replacement
screws for Engine Serial No. Prefixes 15P to
19P have a centre punch mark adjacent to
the adjusting slot. These screws are not
interchangeable with those fitted to Engine
Serial No. Prefixes 10P to 14P.

3. Fit rocker shaft ensuring it is located on dowel.
4. Fit and progressively tighten new rocker shaft

bolts to 33 Nm (24 lbf.ft).

5. Before refitting the camshaft cover the

electronic injection unit (EUI) rockers must be
adjusted.

6. Remove tool LRT-12-058 from camshaft.
7. Rotate engine clockwise until No 1 injector lobe

is at full lift.

8. Rotate rocker adjusting screw clockwise until

the injector plunger is felt to bottom out.

9. Rotate rocker adjusting screw anti-clockwise

one complete turn to give plunger the required
bump clearance and tighten rocker arm
adjusting screw locknut to 16 Nm (12 lbf.ft) .

CAUTION: Ensure screw does not turn as
locknut is tightened.

10. Carry out above procedure for the remaining 4

rocker arms.

11. After completion of rocker arm adjustment,

slowly rotate engine clockwise 2 complete
turns by hand to ensure that no injectors are
bottoming out on their plungers.

12. Fit camshaft cover gasket.

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ENGINE - Td5, REPAIRS, Gasket -

cover - camshaft.

13. Fit cooling fan coupling.

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COOLING SYSTEM - Td5, REPAIRS,

Fan - viscous.

ENGINE - TD5

12-1-46 REPAIRS

Gasket - cover - camshaft

$% 12.29.40

Remove

1. Remove 3 bolts and remove engine acoustic

cover.

2. Release clip and disconnect breather hose

from camshaft cover.

3. Remove 13 bolts securing camshaft cover.
4. Collect sealing washers and spacers.
5. Remove camshaft cover and gasket.

Refit

1. Clean camshaft cover and mating face.
2. Renew sealing washers and spacers as

necessary.

3. Not EU3 model:- Apply two 3 mm diameter

beads of sealant, STC 5433, to areas 'A' shown
on illustration.

Excessive use of sealant could result in
blockage of oil drain hole, arrowed 'B' on
illustration.

4. Fit new gasket, fit camshaft cover to camshaft

carrier and tighten – camshaft cover bolts to 9
Nm (7 lbf.ft).

5. Position breather hose to camshaft cover and

secure with clip.

6. Fit engine acoustic cover and secure with

fixings.

M12 7538

A

B

A

ENGINE - TD5

REPAIRS 12-1-47

Engine and ancillaries

$% 12.41.01

Remove

1. Remove bonnet.

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EXTERIOR FITTINGS, REPAIRS,

Bonnet.

2. Remove underbelly panel.

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EXTERIOR FITTINGS, REPAIRS,

Panel - underbelly.

3. Drain engine oil.

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MAINTENANCE, PROCEDURES,

Engine oil - diesel engine.

4. Remove radiator.

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COOLING SYSTEM - Td5, REPAIRS,

Radiator.

5. Remove turbocharger.

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ENGINE MANAGEMENT SYSTEM -

Td5, REPAIRS, Turbocharger.

6. Release clips and disconnect heater hoses

from fuel cooler and coolant rail.

7. Release clip and disconnect expansion tank

coolant hose from fuel cooler.

8. Disconnect fuel hoses, tank to fuel cooler and

connector block on cylinder head.

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

9. Disconnect fuel hose from fuel cooler and

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

10. Release servo vacuum pipe from clip on fuel

cooler and release hose from vacuum pump.

11. Release expansion tank from body mounting,

release clip, disconnect hose and remove tank.

ENGINE - TD5

12-1-48 REPAIRS

12. Disconnect vacuum hose from EGR valve.

13. Remove engine compartment fuse box cover.
14. Remove bolts securing battery and alternator

leads to fuse box.

15. Remove bolt securing glow plug lead to fuse

box.

16. Disconnect 2 engine harness multiplugs from

fuse box.

17. Disconnect 2 engine harness multiplugs from

ECM and main harness.

18. Remove bolt securing engine earth lead to

battery earth lead.

19. Disconnect multiplug from EGR modulator.