Discovery 2. Manual — part 46

ENGINE - V8

OVERHAUL 12-2-57

Reassembly

1. Clean timing gear cover and mating face.
2. Clean oil seal register in timing gear cover.
3. Ensure bolt holes in cylinder block are clean

and dry, remove all traces of sealant from
threads of timing cover bolts.

4. Fit a new timing gear cover gasket, dry, to

timing cover locating dowels.

5. Locate tool LRT-12-090. on timing cover and

oil pump drive gear.

6. Position timing cover to cylinder block and at

the same time rotate tool LRT-12-090. until
drive gear keyway is aligned with Woodruff key.

7. Remove tool LRT-12-090..
8. Apply sealant, Part Number STC 50552 to

threads of timing cover bolts.

9. Align 2 camshaft sensor harness clips to timing

gear cover bolt holes. Noting positions of the
longer bolts and, working in the sequence
shown, tighten timing gear cover bolts to 22
Nm (16 lbf.ft).

10. Apply smear of Retinax LX grease to oil seal

running surface on crankshaft.

CAUTION: Replacement oil seal is pre-
greased, do not apply any additional
lubricant.

11. Fit seal to timing gear cover using tool LRT-12-

089.

12. Clean and fit crankshaft pulley.
13. Fit crankshaft pulley bolt and tighten to 270 Nm

(200 lbf.ft).

14. Remove tool LRT-12-080 from crankshaft

pulley.

15. Clean oil filter mating face.
16. Lubricate new oil filter seal with clean engine oil

and fit filter.

17. Ensure coolant pump and pulley mating faces

are clean.

18. Remove all traces of thread locking material

from coolant pump pulley drive flange bolt
holes using an M8 tap.

19. Fit coolant pump pulley and tighten new

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

20. Fit oil pick up strainer.

+

ENGINE - V8, OVERHAUL, Strainer

- oil pick-up.

ENGINE - V8

12-2-58 OVERHAUL

Timing chain and gears

$% 12.65.12.01

Disassembly

1. Remove timing gear cover gasket.

+

ENGINE - V8, OVERHAUL, Gasket -

timing gear cover.

2. Fit crankshaft pulley bolt and rotate engine to

align timing marks. Remove crankshaft pulley
bolt.

3. Restrain camshaft gear and remove gear

retaining bolt.

4. Remove timing chain and gears as an

assembly.

5. Remove gears from timing chain.
6. Remove key from crankshaft.

ENGINE - V8

OVERHAUL 12-2-59

Reassembly

1. Clean timing chain and gears and gear

locations.

2. Fit key to crankshaft.

3. Temporarily fit gears to camshaft and

crankshaft. If necessary, rotate shafts to align
timing marks. When aligned correctly, the
timing marks will face each other; crankshaft
gear timing mark at twelve o'clock position and
camshaft gear timing mark at six o'clock
position.

4. Remove gears from shafts and fit to timing

chain.

5. With timing marks aligned, fit timing chain and

gears as an assembly.

6. Restrain the camshaft gear and tighten

retaining bolt to 50 Nm (37 lbf.ft).

7. Fit timing gear cover gasket.

+

ENGINE - V8, OVERHAUL, Gasket -

timing gear cover.

Rocker shaft - overhaul

$% 12.29.49

If both rocker shafts are to be removed, identify
each assembly to ensure refitment to original
cylinder head.

Disassembly

1. Release ht leads from rocker covers.

2. Noting fitted position of 4 long screws or multi-

hex bolts, remove and discard 8 screws/bolts
securing rocker covers; remove rocker covers.

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

ENGINE - V8

12-2-60 OVERHAUL

3. Remove and discard rocker cover gaskets.

4. Progressively remove 4 bolts securing rocker

shaft assembly to cylinder head, release
rocker shaft from push rods and remove rocker
shaft.

5. Ensure push rods remain located in tappets

when rocker shaft is removed. Retain all
components in their removed sequence for
re-assembly.

6. Remove and discard split pin from one end of

rocker shaft.

7. Collect plain and wave washers.
8. Remove the rocker arms, rocker pillars and

springs.

9. Remove and discard remaining split pin and

collect plain and wave washers.

Inspect

1. Clean all components.
2. Inspect rocker shaft and rocker arms for wear

and scoring. Replace as required.

3. Replace weak or broken springs.
4. Lubricate moving parts with clean engine oil.

Reassembly

1. Reassemble rocker shafts, ensuring that

components are returned to their original
positions, secure plain washers with new split
pins.

2. Ensure shaft identification groove is positioned

at one o'clock, with push rod locations of rocker
arms to the right. Oil feed restriction will
result if rocker shafts are incorrectly
assembled.

3. Ensure that rocker shaft bolt holes are clean

and dry.

4. Position rocker shaft assembly to cylinder

head ensuring push rods are engaged in
rocker arms.

5. Fit rocker shaft bolts and progressively tighten

to 40 Nm (30 lbf.ft).

6. Clean mating faces of rocker cover and cylinder

head, ensure that bolt holes are clean and dry.

7. Fit new rocker cover gasket, dry, position

rocker cover, ensuring that gasket is correctly
located.

8. Fit new, 'patched' multi-hex bolts ensuring that

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

9. Tighten bolts by diagonal selection to:

l

Stage 1 - 3 Nm (2.5 lbf.ft)

l

Stage 2 - 8 Nm (6 lbf.ft)

10. Ensure that gasket is correctly positioned

around periphery of rocker cover.

11. Secure ht leads to rocker cover.