Discovery 2. Manual — part 438

ENGINE - V8

OVERHAUL 12-2-45

OVERHAUL

Gasket - inlet manifold

$% 30.15.08.01

Disassembly

1. Disconnect multiplug from coolant thermistor.
2. Disconnect multiplugs from injectors; release

injector harness from fuel rail and position
aside.

3. Remove 3 bolts securing PAS pump pulley and

remove pulley.

4. Loosen bolt securing jockey pulley and remove

pulley.

5. Remove 4 bolts and one nut securing auxiliary

housing and remove housing.

6. Remove 2 nuts securing alternator cables and

release the cables.

7. Remove two bolts securing alternator and

remove alternator.

8. Remove 4 bolts securing coolant outlet elbow

and remove outlet elbow.

9. Remove and discard 'O' ring.

10. Release ht leads from rocker covers.

ENGINE - V8

12-2-46 OVERHAUL

11. Remove 4 bolts securing rocker cover and

remove cover.

12. Remove and discard rocker cover gaskets.

13. Using the sequence shown, remove 12 bolts

securing the inlet manifold.

14. Remove inlet manifold assembly.

ENGINE - V8

OVERHAUL 12-2-47

15. Remove 2 bolts securing manifold gasket and

collect gasket clamps.

16. Remove inlet manifold gasket.
17. Remove gasket seals.

Reassembly

1. Clean sealant from cylinder head and from

notches in the cylinder block.

2. Clean mating faces of cylinder block, cylinder

head and manifold.

CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.

3. Apply sealant, Part No. STC 3254 to cylinder

head and notches in cylinder block.

4. Fit new gasket seals, ensuring the ends

engage correctly in notches.

5. Apply sealant, Part No. STC 3254 to gasket

seals above the notches in the cylinder block.

6. Fit new manifold gasket, dry.
7. Position gasket clamps, fit and lightly tighten

bolts.

8. Position inlet manifold assembly to cylinder

head.

9. Fit manifold bolts and, working in the sequence

illustrated, tighten as follows:

l

Initially, tighten bolts numbered 1, 4, 9 and
12 in numerical order to 5 Nm (4 lbf.ft).

l

Inlet manifold bolts - initial tighten = 10 Nm
(8 lbf.ft).

l

Inlet manifold bolts - final tighten = 51 Nm
(38 lbf.ft).

l

Tighten inlet manifold gasket clamp bolts to
18 Nm (14 lbf.ft).

l

Tighten inlet manifold bolts to 51 Nm (38
lbf.ft)

ENGINE - V8

12-2-48 OVERHAUL

10. Clean mating faces of rocker covers and

cylinder heads.

11. Fit new rocker cover gaskets, dry, position

rocker cover, fit bolts and working in diagonal
sequence, tighten to:

l

Stage 1 - 3 Nm (2.5 lbf.ft)

l

Stage 2 - 8 Nm (6 lbf.ft)

12. Ensure that outer rim of gasket is correctly

positioned around periphery of rocker cover.

13. Secure ht leads to rocker cover.
14. Clean coolant outlet elbow mating faces.
15. Lubricate and fit new 'O' ring to outlet pipe.
16. Position coolant outlet elbow, fit bolts and

tighten to 22 Nm (17 lbf.ft).

17. Position alternator, fit mounting bolts and

tighten to 45 Nm (34 lbf.ft).

18. Position alternator cables and tighten terminal

B+ to 18 Nm (13 lbf.ft) and terminal D+ to 5 Nm
(3.5 lbf.ft).

19. Position auxiliary housing, fit bolts and tighten

to 40 Nm (30 lbf.ft). Fit nut and tighten to 22 Nm
(17 lbf.ft).

20. Clean jockey pulley mating faces.
21. Position jockey pulley and tighten bolt to 50 Nm

(37 lbf.ft).

22. Clean PAS pump pulley mating faces.
23. Position PAS pump pulley, fit bolts and tighten

to 22 Nm (17 lbf.ft).

24. Secure injector harness and connect injector

multiplugs.

25. Connect multiplug to coolant thermistor.

Gasket - exhaust manifold

$% 30.15.12.01

Disassembly

1. Remove 8 bolts securing exhaust manifold and

collect spacers. Discard the bolts.

2. Remove exhaust manifold.
3. Remove 2 manifold gaskets and discard.

Reassembly

1. Clean exhaust manifold and cylinder head

mating face.

CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.

2. Fit new gaskets, dry, fit exhaust manifold.

CAUTION: Ensure that link bar on gasket is
positioned below spark plugs.

LH bank illustrated

3. Fit spacers to new manifold bolts and, working

in the sequence illustrated, initially tighten bolts
to 15 Nm (11 lbf.ft), then finally tighten to 38 Nm
(28 lbf.ft).