Discovery 2. Manual — part 479

ENGINE MANAGEMENT SYSTEM - TD5

REPAIRS 18-1-59

Regulator - fuel pressure

$% 19.45.06

Remove

1. Release turnbuckles and remove battery cover
2. Disconnect battery earth lead.
3. Remove 3 bolts and remove engine acoustic

cover.

4. Remove 2 bolts and remove engine lifting eye.
5. Position cloth to absorb fuel spillage.

6. Release and disconnect hose from fuel cooler.

7. Release and disconnect fuel hose from

pressure regulator.

Always fit plugs to open connections to
prevent contamination.

8. Disconnect multiplug from fuel temperature

sensor.

9. Remove 3 bolts, remove pressure regulator

from cylinder head and collect gasket.

10. Remove and discard 'O' ring and fuel filter.

ENGINE MANAGEMENT SYSTEM - TD5

18-1-60 REPAIRS

11. Remove fuel temperature sensor and discard

sealing washer.

12. Remove fuel hose and fuel pipe and discard 'O'

rings.

Refit

1. Clean fuel pressure regulator and mating face.
2. Clean fuel pipe unions.
3. Using new 'O' rings, fit fuel pipe and fuel hose

to pressure regulator and tighten unions to 25
Nm (18 lbf.ft).

4. Using new sealing washer, fit fuel temperature

sensor and tighten to 14 Nm (10 lbf.ft).

5. Fit new fuel filter and 'O' ring.
6. Using a new gasket, position pressure

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

7. Connect multiplug to fuel temperature sensor.
8. Connect fuel hoses to pressure regulator and

fuel cooler.

9. Fit engine lifting eye and tighten bolts to 25 Nm

(18 lbf.ft).

10. Fit engine acoustic cover and tighten bolts to 10

Nm (6 lbf.ft).

11. Connect battery earth lead.
12. Fit battery cover and secure fixings.

Glow plugs

$% 19.60.31

Remove

1. Remove 3 bolts and remove engine acoustic

cover.

2. Release turnbuckles and remove battery cover.
3. Disconnect battery earth lead.

4. Disconnect 4 glow plug leads.
5. Loosen and remove 4 glow plugs.

Refit

1. Thoroughly clean glow plugs and seating area

in cylinder head.

2. Apply a suitable anti-sieze compound to

threads of glow plugs.

3. Fit glow plugs and tighten to 16 Nm (12 lbf. ft).
4. Connect glow plug leads.
5. Fit engine acoustic cover and secure fixings.
6. Connect battery earth lead.
7. Fit battery cover and secure fixings.

ENGINE MANAGEMENT SYSTEM - TD5

REPAIRS 18-1-61

Injectors

$% 19.60.12

Remove

1. Remove cooling fan.

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COOLING SYSTEM - Td5, REPAIRS,

Fan - viscous.

2. Remove rocker shaft.

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ENGINE - Td5, REPAIRS, Rocker

shaft assembly.

3. Position container to catch fuel spillage.

4. Disconnect quick release fuel hose connectors

from fuel connector block on cylinder head and
fuel cooler to drain fuel from cylinder head.

5. Disconnect 5 multiplugs from injectors.
6. Remove 5 Torx bolts securing injectors to

cylinder head.

7. Using LRT-12-154/1, remove injectors from

cylinder head. Collect retainers.

8. Using LRT-12-154/4, remove sealing washers

from injectors. Discard sealing washers.

9. Remove and discard 'O' rings from injectors.

10. Rotate engine manually until each cylinder

being worked on is at TDC, and remove excess
fuel from piston bowl using a syringe.

ENGINE MANAGEMENT SYSTEM - TD5

18-1-62 REPAIRS

Refit

1. Clean injector units and mating faces in

cylinder head.

2. Using LRT-12-154/2, fit a new 'O' ring to each

injector.

3. Using LRT-12-154/3, fit a new sealing washer

to each injector.

4. Fit retainer to injector. Carefully fit injector,

ensuring retainer is located on its dowel, and
tighten Torx bolt to 32 Nm (24 lbf.ft)

5. Connect multiplug to injector.
6. Repeat above operations for remaining

injectors.

7. Connect fuel hoses to connector block and fuel

cooler.

8. Programme new injectors using TestBook.
9. Fit rocker shaft.

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ENGINE - Td5, REPAIRS, Rocker

shaft assembly.

10. Fit cooling fan.

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COOLING SYSTEM - Td5, REPAIRS,

Fan - viscous.

Switch - cruise control (on/off)

$% 19.75.30

Remove

1. Carefully remove switch from instrument cowl.
2. Disconnect multiplug and remove switch.

Refit

1. Position new switch and connect multiplug.
2. Carefully push switch into instrument cowl.