Discovery 2. Manual — part 445
ENGINE - V8
OVERHAUL 12-2-73
6. Reference mark main bearing caps to aid
assembly.
7. Remove 10 side bolts securing main bearing
caps to block.
8. Collect 'Dowty' washers from side bolts. Rear
side bolts have Allen heads.
9. Starting at the centre main bearing cap,
progressively loosen, then remove 2 bolts
securing each main bearing cap.
10. Release and remove main bearing caps.
CAUTION: Keep bearing caps, bearings and
bolts in their fitted order.
11. Remove crankshaft.
12. Remove main bearings from cylinder block and
main bearing caps.
13. Remove key from keyway.
14. Remove rear main sealing washers.
Inspect
1. Clean crankshaft journals and bearing
locations in cylinder block.
2. Inspect main bearings for wear and renew if
necessary. Main bearings are available in two
oversizes. If 2nd oversize bearing is being
fitted, it may be necessary to grind thrust
face of centre main bearing to achieve
correct end-float.
l
Main bearing 1st oversize = 0.254 mm (0.01
in).
l
Main bearing 2nd oversize = 0.508 mm
(0.02 in).
3. Check main bearing journals for wear and
scoring. Measure for ovality; taking 3
measurements at 120
°
intervals at each end
and at centre of journals.
l
Journal diameter - standard = 63.487 to
63.500 mm (2.499 to 2.520 in).
l
1st undersize journal = 63.223 to 63.246
mm (2.511 to 2.512 in).
l
2nd undersize journal = 62.979 to 62.992
mm (2.509 to 2.510 in).
l
Journal width - standard = 26.975 to 27.026
mm (1.061 to 1.064 in).
l
Maximum ovality = 0.040 mm (0.002 in)
ENGINE - V8
12-2-74 OVERHAUL
Reassembly
1. Clean main bearing locations in cylinder block
and bearing caps.
2. Clean sealant from rear main bearing cap and
mating faces.
3. Fit key to keyway.
4. Check threads of main bearing cap bolts for
damage, renew bolts in pairs.
5. Lubricate grooved main bearing shells with
clean engine oil and fit to their locations in
cylinder block.
NOTE: Ensure that the flanged bearing is fitted
to the centre position.
6. Lubricate crankshaft journals with clean engine
oil.
7. Position crankshaft in cylinder block.
8. Attach a DTI to front of cylinder block, move
crankshaft rearwards, position stylus of gauge
on end of crankshaft and zero gauge.
9. Move crankshaft forwards, measure and
record end-float obtained.
l
Crankshaft end-float = 0.08 to 0.26 mm
(0.003 to 0.01 in).
10. Lubricate plain bearing shells with clean
engine oil and fit to main bearing caps.
11. Fit main bearing caps 1 to 4 only at this stage,
ensuring that they are the correct way round
and in their fitted order.
12. Lightly lubricate threads of main bearing cap
bolts with clean engine oil.
13. Fit main bearing cap bolts but do not tighten at
this stage. Do not fit side bolts at this stage.
14. Fit side seals to rear main bearing cap,
ensuring that seals do not protrude above
bearing cap face.
15. Apply a 3 mm (0.12 in) wide bead of sealant,
Part No. STC 50550 to bearing cap rear mating
faces on cylinder block.
CAUTION: Ensure sealant does not enter
bolt holes.
16. Carefully fit rear main bearing cap assembly, fit
but do not tighten bolts.
CAUTION: Ensure engine oil does not enter
the side bolt holes in the bearing cap.
17. Lubricate 'Dowty' washers with engine oil and
fit to side bolts.
18. Fit but do not tighten side bolts. Rear side
bolts are Allen headed.
ENGINE - V8
OVERHAUL 12-2-75
19. Using the sequence shown, tighten main
bearing cap bolts as follows:
l
Initial torque - all main bearing cap bolts and
side bolts - 13.5 Nm (10 lbf.ft).
l
Final torque - main bearing cap side bolts 11
to 15 - 45 Nm (34 lbf.ft).
l
Final torque - main bearing cap bolts 1 to 8
- 72 Nm (54 lbf.ft).
l
Final torque - main bearing cap bolts 9 and
10 - 92 Nm (68 lbf.ft).
l
Final torque - main bearing cap side bolts 16
to 20 - 45 Nm (34 lbf.ft).
20. Fit connecting rod bearings.
ENGINE - V8, OVERHAUL, Bearings
21. Clean timing chain and gears.
22. Clean ends of crankshaft and camshaft.
23. Lubricate timing chain assembly with clean
engine oil.
24. Align timing marks and fit timing chain
assembly.
25. Fit camshaft gear bolt and tighten to 50 Nm (37
lbf.ft).
26. Fit timing gear cover gasket.
ENGINE - V8, OVERHAUL, Gasket -
27. Clean crankshaft pulley.
28. Fit crankshaft pulley.
29. Fit crankshaft pulley bolt and tighten to 270 Nm
(200 lbf.ft).
30. Remove tool LRT-12-080 from crankshaft
pulley.
31. Clean oil filter and mating face.
32. Lubricate oil filter seal and fit filter to oil pump.
33. Ensure coolant pump and pulley mating faces
are clean.
34. Fit coolant pump pulley and tighten bolts to 22
Nm (16 lbf.ft).
35. Ensure drive belt pulleys are clean and
damage free.
36. Fit auxiliary drive belt to pulleys.
37. Fit crankshaft rear oil seal.
ENGINE - V8
12-2-76 OVERHAUL
Camshaft
$% 12.13.02.01
Disassembly
1. Remove inlet manifold gasket.
ENGINE - V8, OVERHAUL, Gasket -
2. Progressively loosen and remove 8 bolts
securing rocker shaft assemblies.
3. Mark each rocker shaft in relation to original
head.
4. Remove rocker shaft assemblies.
5. Remove push rods and store in their fitted
order.
6. Remove tappets.
7. Remove timing chain and gears.
8. Temporarily fit camshaft gear and lightly tighten
bolt.
9. Attach a dial test indicator (DTI) to front of
cylinder block with stylus of DTI contacting
camshaft gear.
10. Push camshaft rearwards and zero the DTI.
11. Using the camshaft gear, pull camshaft
forwards and note reading on DTI. End-float
should be from 0.075 to 0.25 mm (0.003 to
0.010 in).
12. If end-float is incorrect, fit a new thrust plate. If
end-float is still incorrect, a new camshaft/gear
must be fitted.
13. Remove camshaft bolt and gear.
14. Remove 2 bolts securing camshaft thrust plate
and remove thrust plate.
15. Carefully remove the camshaft avoiding
damage to the camshaft bearings.
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