Discovery 2. Manual — part 105

MANIFOLDS AND EXHAUST SYSTEMS - V8

REPAIRS 30-2-13

20. Remove inlet manifold gasket.
21. Remove gasket seals.

Refit

1. Clean all traces of sealant from cylinder head

and cylinder block notches.

2. Clean mating faces of cylinder block, cylinder

head and inlet manifold.

3. Apply sealant, Part No. STC 50550 to cylinder

head and cylinder block notches.

4. Fit new gasket seals, ensuring ends engage

correctly in notches.

5. Fit new inlet manifold gasket.
6. Position gasket clamps and fit bolts, but do not

tighten at this stage.

7. Position inlet manifold to engine. Fit manifold

bolts and, working in the sequence shown,
tighten bolts initially to 10 Nm (7 lbf.ft) then to
51 Nm (38 lbf.ft).

8. Tighten gasket clamp bolts to 18 Nm (13 lbf.ft).
9. Connect fuel pipe.

10. Clean top hose outlet pipe mating faces.
11. Fit new 'O' ring to outlet pipe.
12. Position outlet pipe, fit bolts and tighten to 22

Nm (16 lbf.ft).

13. Position alternator, fit bolts and tighten to 45

Nm (33 lbf.ft).

14. Position PAS pump to auxiliary housing and

locate housing on engine. Fit bolts and tighten
to 40 Nm (30 lbf.ft).

15. Fit and tighten auxiliary housing nut to 10 Nm (7

lbf.ft).

16. Fit bolts securing PAS pump and tighten to 22

Nm (16 lbf.ft).

17. Position oil cooling pipe bracket fit bolt and

tighten to 22 Nm (16 lbf.ft).

18. Fit and tighten PAS pump high pressure pipe.
19. Position jockey pulley and tighten bolt to 50 Nm

(37 lbf.ft).

20. Clean PAS pump pulley mating faces.
21. Position PAS pump pulley, fit bolts and tighten

to 22 Nm (16 lbf.ft).

22. Clean ACE pump dowels and dowel holes.
23. Position ACE pump, fit bolts and tighten to 22

Nm (16 lbf.ft).

24. Fit auxiliary drive belt.

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CHARGING AND STARTING,

REPAIRS, Belt - auxiliary drive.

25. Secure injector harness and connect injector

multiplugs.

26. Position top hose and secure clips.
27. Fit rocker covers.

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+

ENGINE - V8, REPAIRS, Gasket

- rocker cover - LH.

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ENGINE - V8, REPAIRS, Gasket

- rocker cover - RH.

28. Check and top up PAS fluid

MANIFOLDS AND EXHAUST SYSTEMS - V8

30-2-14 REPAIRS

Gasket - exhaust manifold

$% 30.15.12

This procedure is the same for both exhaust manifold
gaskets.

Remove

1. Raise front of vehicle.

WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.

2. Remove 3 nuts securing front pipe to exhaust

manifold, release front pipe and collect gasket.

3. Remove 8 bolts and spacers securing exhaust

manifold.

4. Remove exhaust manifold.
5. Remove 2 manifold gaskets.

Refit

1. Clean exhaust manifold and cylinder head

mating face.

2. Position exhaust manifold and new gaskets on

cylinder head.

3. Fit spacers and exhaust manifold securing

bolts and, working from the centre outwards,
tighten bolts to 38 Nm. (28 lbf.ft).

4. Clean front pipe and manifold mating faces.
5. Using a new gasket, position front pipe, fit nuts

and tighten to 30 Nm. (22 lbf.ft).

6. Remove stand(s) and lower vehicle.

MANIFOLDS AND EXHAUST SYSTEMS - V8

REPAIRS 30-2-15

Gasket - inlet manifold - upper - Without
Secondary Air Injection

$% 30.15.24

Remove

1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Remove bonnet.

+

EXTERIOR FITTINGS, REPAIRS,

Bonnet.

4. Release MAF sensor harness from clip.
5. Loosen clips securing air intake hose. Release

and remove air intake hose.

Note: Pre 03 MY air intake hose illustrated.

6. Disconnect throttle and cruise control cables.

Release cables from abutment bracket and
position aside.

7. Disconnect EVAP pipe from inlet plenum.
8. Disconnect multiplug from throttle body.
9. Remove clip securing breather hose to throttle

body and release breather hose.

10. Position a drain tray beneath the engine to

collect coolant.

11. Release clips securing coolant hoses to

throttle body and disconnect hoses.

MANIFOLDS AND EXHAUST SYSTEMS - V8

30-2-16 REPAIRS

12. Disconnect brake servo vacuum pipe from inlet

plenum.

13. Disconnect breather hose from inlet plenum.
14. Remove bolt securing coolant rails.
15. Release engine harness from bulkhead clips

and position aside.

16. Remove 4 bolts securing ignition coils and

position ignition coils aside.

17. Release plug leads from upper manifold clips.
18. Disconnect multiplug from IACV.
19. Release and disconnect IACV hose.