Discovery 2. Manual — part 41

ENGINE - V8

REPAIRS 12-2-37

Gasket - sump

$% 12.60.38

Remove

1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Remove dipstick.
4. Raise the vehicle on a ramp.
5. Drain engine oil.

+

MAINTENANCE, PROCEDURES,

Engine oil - V8 engine.

6. Remove 8 bolts securing cross member and

remove cross member.

7. Raise front of vehicle under body to increase

clearance between engine and front axle.

8. Disconnect and release gearbox oil cooler pipe

and discard 'O' ring.

9. Remove 2 clips securing oil cooler pipes at

front of sump.

10. Remove clip securing oil cooler pipes to side of

sump.

11. Remove clip bracket.

12. Remove 2 forward facing bolts securing sump

to bell housing.

13. Remove 4 rear facing bolts securing sump to

bell housing.

14. Remove 2 bolts in sump recess.
15. Remove 3 nuts securing front of sump.

ENGINE - V8

12-2-38 REPAIRS

16. Remove 12 bolts securing sump flange to

engine.

17. Manoeuvre sump over front axle and remove

sump.

18. Discard sump gasket.

Refit

1. Clean all traces of sealant from the sump and

sump mating faces using a plastic scraper or
solvent.

2. Ensure bolt holes in cylinder block are clean

and dry.

3. Apply a 5 mm (0.2 in) wide bead of sealant, Part

No. STC 50550, across the cylinder block to
front cover joint and across the cylinder block to
rear main bearing joint. Apply a globule of
sealant to cover the ends of the cruciform
seals, (see illustration).

4. Fit new gasket, dry, to sump, ensuring that

locating tags are correctly positioned.

5. Manoeuvre sump into position, fit and lightly

tighten 2 bolts to retain sump in place, then fit
and lightly tighten remainder of bolts.

6. Working in the sequence illustrated, tighten the

sump bolts to 22 Nm (16 lbf.ft).

7. Position side clip bracket, fit and tighten bolt.

8. Position oil cooler pipe clips, fit and tighten

nuts.

9. Clean gearbox oil cooler pipe 'O' ring recess

and mating face.

10. Lubricate and fit new 'O' ring to gearbox oil

cooler pipe.

11. Position pipe and tighten nut.
12. Lower front of vehicle.
13. Position cross member to chassis, fit bolts and

tighten to 25 Nm (18 lbf.ft).

14. Refill engine oil and fit dipstick.
15. Connect battery earth lead.
16. Fit battery cover and retain with fixings.

ENGINE - V8

REPAIRS 12-2-39

Switch - oil pressure

$% 12.60.50

Remove

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

4. Remove fixings and remove underbelly panel.

5. Disconnect multiplug from oil pressure switch.
6. Position container below switch to catch oil

spillage.

7. Remove oil pressure switch and discard

sealing washer.

Refit

1. Clean oil pressure switch threads.
2. Fit new sealing washer to switch.
3. Fit oil pressure switch and tighten to 15 Nm (11

lbf.ft) .

4. Connect multiplug to oil pressure switch.
5. Fit underbelly panel and secure with fixings.
6. Remove stand(s) and lower vehicle.
7. Connect battery earth lead.
8. Fit battery cover and retain with fixings.
9. Top up engine oil.

Cooler - engine oil

$% 12.60.68

Remove

1. Release fixings and remove battery cover.
2. Release fixings and remove cooling fan cowl.
3. Remove front grille.

+

EXTERIOR FITTINGS, REPAIRS,

Grille - front - up to 03MY.

4. Remove 6 scrivets and remove LH and RH air

deflectors from front panel.

5. Remove nut and move LH horn aside.

ENGINE - V8

12-2-40 REPAIRS

6. Remove 2 bolts securing radiator LH and RH

upper mounting brackets to body panel and
remove brackets.

7. Remove 4 screws securing air conditioning

condenser LH and RH upper mounting
brackets to condenser.

8. Remove condenser upper mounting brackets

with rubber mounts from radiator extension
brackets.

9. Remove 2 bolts securing LH and RH extension

brackets to radiator and remove brackets.

10. Position absorbent cloth under each oil cooler

hose connection to collect oil spillage.

11. Push against coupling release rings and

disconnect both hoses from oil cooler.

CAUTION: Always fit plugs to open
connections to prevent contamination.

12. Remove screw securing oil cooler to radiator.
13. Release cooler from its location on radiator.
14. Release radiator lower mountings from

location in chassis and carefully move radiator
towards engine sufficiently only to release
engine oil cooler from radiator.

15. Remove engine oil cooler.

Refit

1. Fit engine oil cooler to radiator, engage in

location and secure with screw.

2. Fit radiator to location in chassis.
3. Ensure connections are clean, then secure

hoses to oil cooler.

4. Fit extension brackets to radiator and secure

with bolts.

5. Fit brackets with rubber mounts to extension

brackets and secure to air conditioning
condenser with screws.

6. Fit radiator upper mounting brackets and

secure to body with bolts.

7. Fit LH horn and secure with nut.
8. Fit LH and RH air deflectors to front panel and

secure with scrivets.

9. Fit front grille.

+

EXTERIOR FITTINGS, REPAIRS,

Grille - front - up to 03MY..

10. Fit cooling fan cowl and secure with fixings.
11. Fit battery cover and secure with fixings.
12. Top up engine oil.