Discovery 2. Manual — part 430

ENGINE - V8

REPAIRS 12-2-13

REPAIRS

Seal - crankshaft - rear

$% 12.21.20

Remove

1. Automatic gearbox models:Remove

converter drive plate.

+

ENGINE - V8, REPAIRS, Plate - drive

- automatic.

2. Manual gearbox models:Remove flywheel.

+

ENGINE - V8, REPAIRS, Flywheel.

3. Carefully remove oil seal from cylinder block to

avoid damage to seal location or running
surface on crankshaft. Discard seal.

Refit

1. Ensure both seal location and running surface

on crankshaft are clean.

2. Fit seal guide LRT-12-095 to crankshaft.

CAUTION: Oil seal must be fitted dry.

3. Fit new oil seal squarely onto crankshaft and

remove guide.

4. Fit seal into location using tools LRT-12-091

and LRT-99-003.

5. Automatic gearbox models:Fit converter

drive plate.

+

ENGINE - V8, REPAIRS, Plate - drive

- automatic.

6. Manual gearbox models:Fit flywheel.

+

ENGINE - V8, REPAIRS, Flywheel.

ENGINE - V8

12-2-14 REPAIRS

Gasket - cylinder head - LH

$% 12.29.02

Remove

1. Remove inlet manifold gasket.

+

MANIFOLDS AND EXHAUST

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

2. Noting their fitted order, disconnect ht leads

from spark plugs.

3. Remove bolt securing engine harness to rear

of cylinder head.

4. LH drive models: Remove brake servo heat

shield.

+

MANIFOLDS AND EXHAUST

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

5. Remove 8 bolts securing exhaust manifold to

cylinder head, release manifold and collect 2
gaskets.

6. Progressively remove 4 bolts securing the

rocker shaft and remove rocker shaft.

7. Remove push rods. Store push rods in their

fitted order.

8. Models with SAI: Remove 2 air injection

adapters from cylinder head and discard.

9. In the sequence shown, remove 10 bolts

securing the cylinder head to block. Discard the
bolts.

ENGINE - V8

REPAIRS 12-2-15

10. Remove cylinder head.

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

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

uppermost.

CAUTION: Gaskets must be fitted dry.

4. Carefully fit cylinder head and locate on

dowels.

5. Lightly lubricate new cylinder head bolt threads

with clean engine oil.

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

remainder, fit cylinder head 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.

7. Models with SAI: Fit new air injection adapters

and tighten to 33 Nm (24 lbf.ft).

8. Clean push rods.
9. Lubricate ends of push rods with clean engine

oil.

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

on cylinder head.

12. Clean contact surfaces on rockers, valves and

push rods.

13. Lubricate contact surfaces and rocker shaft

with clean engine oil.

14. Fit rocker shaft assembly and engage push

rods.

15. Fit rocker shaft bolts and progressively tighten

to 40 Nm (30 lbf.ft).

16. Using new gaskets, position exhaust manifold

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

ENGINE - V8

12-2-16 REPAIRS

17. LH drive models: Fit brake servo heat shield.

+

MANIFOLDS AND EXHAUST

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

18. Fit engine harness bolt and tighten to 22 Nm

(16 lbf.ft).

19. Connect ht leads to spark plugs in their correct

fitted order.

20. Fit inlet manifold gasket.

+

MANIFOLDS AND EXHAUST

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

Gasket - cylinder head - RH

$% 12.29.03

Remove

1. Remove inlet manifold gasket.

+

MANIFOLDS AND EXHAUST

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

2. Remove bolt securing auxiliary drive belt

tensioner and remove tensioner.

3. Remove 4 bolts securing alternator mounting

bracket and remove bracket.

4. Noting their fitted order, disconnect ht leads

from spark plugs.

5. Remove bolt securing engine earth lead.