Discovery 2. Manual — part 435

ENGINE - V8

REPAIRS 12-2-33

6. Remove 4 bolts securing drive plate clamp ring

and remove ring.

7. Remove drive plate from hub.
8. Remove 6 Allen screws securing hub, remove

hub and collect spacer.

On early engines, balance weights are on
engine side of drive plate; replacement drive
plates will have balance weights on torque
converter side of drive plate.

Refit

1. Clean hub and mating face, spacer and clamp

ring.

2. Clean drive plate and ensure free from cracks

and distortion.

3. Fit spacer and hub to crankshaft, tighten Allen

screws to 78 Nm (58 lbf.ft).

4. Fit drive plate and clamp ring, tighten bolts to

45 Nm (33 lbf.ft).

5. Clean CKP sensor and mating face.
6. Fit crankshaft sensor and tighten nuts to 6 Nm

(5 lbf.ft).

7. Fit CKP sensor cover and tighten bolts to 6 Nm

(5 lbf.ft).

8. Fit CKP sensor multiplug to bracket.
9. Fit automatic gearbox.

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AUTOMATIC GEARBOX - ZF4HP22

- 24, REPAIRS, Gearbox - convertor and
transfer gearbox - V8.

Ring gear - starter

$% 12.53.19

Remove

1. Remove flywheel.

+

ENGINE - V8, REPAIRS, Flywheel.

2. Drill a 3 mm (0.12 in) diameter hole at root of 2

teeth.

3. Apply a cold chisel in root of one of ring gear

teeth, strike chisel with hammer to break ring
gear.

WARNING: SUITABLE EYE PROTECTION
MUST BE WORN.

4. Remove starter ring gear.

Refit

1. Clean flywheel and starter ring gear.
2. Heat new starter ring gear evenly to 350

°

C

(660

°

F), indicated when the ring is a light blue

colour.

3. Locate ring gear on flywheel and press ring

gear hard against flange on flywheel.

ENGINE - V8

12-2-34 REPAIRS

4. Ensure ring gear is correctly seated around the

complete circumference of flywheel and allow
to cool.

5. Fit flywheel.

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ENGINE - V8, REPAIRS, Flywheel.

Filter - oil

$% 12.60.04

Remove

1. Clean area around filter head and place a

container beneath engine.

2. Using a strap wrench, unscrew and discard

filter.

Refit

1. Clean mating face of filter head.
2. Lubricate sealing ring of new filter with clean

engine oil.

3. Fit filter and tighten by hand until it seats then

tighten a further half turn.

4. Start and run engine to check for leaks.
5. Stop engine, wait a few minutes, then check oil

level.

6. Top up engine oil.

ENGINE - V8

REPAIRS 12-2-35

Strainer - oil pick-up

$% 12.60.20

Remove

1. Remove sump gasket.

+

ENGINE - V8, REPAIRS, Gasket -

sump.

2. Remove 2 bolts and one nut securing oil pick-

up strainer.

3. Remove oil pick-up strainer.
4. Collect spacer from stud.
5. Remove and discard 'O'ring.

Refit

1. Clean oil pick up strainer and 'O' ring recess.
2. Lubricate and fit new 'O' ring.
3. Locate spacer on stud.
4. Position oil pick-up strainer, fit bolts and tighten

to 10 Nm (8 lbf.ft). Fit nut and tighten to 22 Nm
(16 lbf.ft).

5. Fit new sump gasket.

+

ENGINE - V8, REPAIRS, Gasket -

sump.

Pump - oil

$% 12.60.26

Remove

1. Remove timing gear cover gasket.

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ENGINE - V8, REPAIRS, Gasket -

timing gear cover.

2. Remove bolt securing CMP sensor, remove

clamp and sensor.

3. Remove 6 bolts securing coolant pump,

remove pump and discard gasket.

4. Remove oil pressure switch and discard

sealing washer.

5. Remove 4 bolts securing oil filter head, remove

filter head and discard 2 'O' rings.

6. Remove filter head adaptor.

Refit

1. Ensure filter head adaptor is clean and apply

Loctite 577 sealant to thread.

2. Fit filter head adaptor and tighten bolts to 13

Nm (9 lbf.ft).

3. Clean filter head and mating face.
4. Fit new 'O' rings to filter head and filter head

adaptor.

5. Fit filter head and tighten bolts to 8 Nm (6 lbf.ft).
6. Ensure oil pressure switch and mating face is

clean.

7. Fit new sealing washer and tighten switch to 15

Nm (11 lbf.ft).

ENGINE - V8

12-2-36 REPAIRS

8. Clean coolant pump and mating face.
9. Use a new gasket and fit coolant pump.

Tighten bolts securing coolant pump to 25 Nm
(19 lbf.ft).

10. Ensure CMP sensor is clean and fit sensor to

cover.

11. Fit clamp to CMP sensor and tighten bolt to 8

Nm (6 lbf.ft).

12. Fit timing gear cover gasket.

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ENGINE - V8, REPAIRS, Gasket -

timing gear cover.

Gasket - sump

$% 12.60.38

Remove

1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Remove dipstick.
4. Raise the vehicle on a ramp.
5. Drain engine oil.

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MAINTENANCE, PROCEDURES,

Engine oil - V8 engine.

6. Remove 8 bolts securing cross member and

remove cross member.

7. Raise front of vehicle under body to increase

clearance between engine and front axle.

8. Disconnect and release gearbox oil cooler pipe

and discard 'O' ring.