Discovery 2. Manual — part 36

ENGINE - V8

REPAIRS 12-2-17

6. RH drive models: Remove brake servo heat

shield.

MANIFOLDS AND EXHAUST

SYSTEMS - V8, REPAIRS, Heat shield -
brake servo - Without Secondary Air
Injection.

7. Remove 8 bolts securing exhaust manifold to

cylinder head, release manifold and collect 2
gaskets.

8. Progressively remove 4 bolts securing the

rocker shaft and remove rocker shaft.

9. Remove push rods. Store push rods in their

fitted order.

10. Models with SAI: Using a 9 mm hexagonal

drive bit, remove 2 air injection adapters from
cylinder head; discard adapters.

Note: To release the adapter thread locking
agent and prevent damage to the cylinder
head, remove the adapters by alternately
loosening then tightening slightly. Repeat this
procedure until adapters are removed.

CAUTION: Do not use air tools to remove
adapters.

11. In the sequence shown, remove 10 bolts

securing the cylinder head to block. Discard the
bolts.

12. Remove cylinder head.

CAUTION: Support both ends of cylinder
head on blocks of wood.

ENGINE - V8

12-2-18 REPAIRS

13. Remove cylinder head gasket.

Refit

1. Clean mating faces of cylinder block and head

using suitable gasket removal spray and a
plastic scraper, ensure that bolt holes in block
are clean and dry. Clean mating faces of
cylinder head and exhaust manifold.

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

2. Check head and block faces for warping and

pitting. If out of specification, renew head.

3. Models with SAI: Using a 5/8 in x 20 TPI

(threads per inch) UNF tap having a class 2A
thread, remove deposits from secondary air
injection adapter tappings in cylinder head.

CAUTION: Ensure that tap used has 20 TPI.

4. Fit cylinder head gasket with the word 'TOP'

uppermost.

CAUTION: Gasket must be fitted dry.

5. Carefully fit cylinder head and locate on

dowels.

6. Lightly lubricate new cylinder head bolt threads

with clean engine oil.

7. Noting that bolts 1, 3 and 5 are longer than the

remainder, fit bolts and tighten in the sequence
shown to 20 Nm (15 lbf.ft) then 90

, and finally

a further 90

CAUTION: Do not tighten bolts 180

in one

operation.

8. Models with SAI: Fit new air injection adapters

and using a 9 mm hexagonal drive bit, tighten
to 33 Nm (24 lbf.ft).

CAUTION: Do not use an air tool to tighten
adapters.

9. Clean push rods.

10. Lubricate ends of push rods with clean engine

oil.

11. Fit push rods in their removed order.
12. Clean bases of rocker pillars and mating faces

on cylinder head.

13. Clean contact surfaces on rockers, valves and

push rods.

14. Lubricate contact surfaces and rocker shaft

with clean engine oil.

15. Fit rocker shaft assembly and engage push

rods.

16. Fit rocker shaft bolts and progressively tighten

to 40 Nm (30 lbf.ft).

17. Position alternator mounting bracket, fit bolts

and tighten to 40 Nm (30 lbf.ft).

18. Position auxiliary drive belt tensioner, fit bolt

and tighten to 45 Nm (33 lbf.ft).

19. Connect ht leads to spark plugs in their fitted

order.

20. Using new gaskets, fit exhaust manifold to

cylinder head. Fit bolts and using sequence
shown, tighten initially to 15 Nm (11 lbf.ft), then
finally tighten to 36 Nm (28 lbf.ft).

21. RH drive models: Fit brake servo heat shield.

MANIFOLDS AND EXHAUST

SYSTEMS - V8, REPAIRS, Heat shield -
brake servo - Without Secondary Air
Injection.

22. Position engine earth lead, fit bolt and tighten to

22 Nm (16 lbf.ft).

23. Fit inlet manifold gasket.

MANIFOLDS AND EXHAUST

SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - lower.

ENGINE - V8

REPAIRS 12-2-19

Gasket - rocker cover - LH

$% 12.29.40

Remove

1. Remove upper inlet manifold gasket.

MANIFOLDS AND EXHAUST

SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.

2. Models with air conditioning: Release 4

clips and remove fan cowl.

3. Models with air conditioning: Release

tension on auxiliary drive belt and remove belt
from air conditioning compressor. Disconnect
compressor multiplug. Remove 4 bolts
securing compressor and position compressor
aside.

4. Release ht leads from rocker cover clips.
5. Remove screw securing dip stick tube.

6. Noting fitted position of 2 long screws or multi-

hex bolts, remove and discard screws/bolts
securing rocker cover; remove rocker cover.

CAUTION: Screws/bolts must be replaced
with new 'patched' multi-hex bolts.

7. Remove and discard rocker cover gasket.

ENGINE - V8

12-2-20 REPAIRS

Refit

1. Clean mating faces of rocker cover and

cylinder head, ensure bolt holes are clean and
dry.

2. Fit a new gasket dry, position rocker cover

ensuring gasket is correctly located.

3. Fit new 'patched' multi-hex rocker cover bolts

ensuring that 2 short bolts are on side of rocker
cover nearest centre of engine.

4. Tighten bolts by diagonal selection to:

Stage 1 - 3 Nm (2.5 lbf.ft)

Stage 2 - 8 Nm (6 lbf.ft)

5. Ensure that outer rim of gasket is correctly

positioned around periphery of rocker cover.

6. Fit and tighten screw securing dip stick tube.
7. Secure ht leads in rocker cover clips.
8. Models with air conditioning: Clean

compressor dowels and dowel holes. Position
compressor, fit bolts and tighten to 22 Nm (16
lbf.ft). Release auxiliary drive belt tensioner
and fit belt to compressor.

9. Models with air conditioning: Position fan

cowl and secure clips.

10. Fit upper inlet manifold.

MANIFOLDS AND EXHAUST

SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.

Gasket - rocker cover - RH

$% 12.29.41

Remove

1. Drain cooling system.

COOLING SYSTEM - V8,

ADJUSTMENTS, Drain and refill.

2. Remove upper inlet manifold gasket.