Discovery 2. Manual — part 438
ENGINE - V8
OVERHAUL 12-2-45
OVERHAUL
Gasket - inlet manifold
$% 30.15.08.01
Disassembly
1. Disconnect multiplug from coolant thermistor.
2. Disconnect multiplugs from injectors; release
injector harness from fuel rail and position
aside.
3. Remove 3 bolts securing PAS pump pulley and
remove pulley.
4. Loosen bolt securing jockey pulley and remove
pulley.
5. Remove 4 bolts and one nut securing auxiliary
housing and remove housing.
6. Remove 2 nuts securing alternator cables and
release the cables.
7. Remove two bolts securing alternator and
remove alternator.
8. Remove 4 bolts securing coolant outlet elbow
and remove outlet elbow.
9. Remove and discard 'O' ring.
10. Release ht leads from rocker covers.
ENGINE - V8
12-2-46 OVERHAUL
11. Remove 4 bolts securing rocker cover and
remove cover.
12. Remove and discard rocker cover gaskets.
13. Using the sequence shown, remove 12 bolts
securing the inlet manifold.
14. Remove inlet manifold assembly.
ENGINE - V8
OVERHAUL 12-2-47
15. Remove 2 bolts securing manifold gasket and
collect gasket clamps.
16. Remove inlet manifold gasket.
17. Remove gasket seals.
Reassembly
1. Clean sealant from cylinder head and from
notches in the cylinder block.
2. Clean mating faces of cylinder block, cylinder
head and manifold.
CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.
3. Apply sealant, Part No. STC 3254 to cylinder
head and notches in cylinder block.
4. Fit new gasket seals, ensuring the ends
engage correctly in notches.
5. Apply sealant, Part No. STC 3254 to gasket
seals above the notches in the cylinder block.
6. Fit new manifold gasket, dry.
7. Position gasket clamps, fit and lightly tighten
bolts.
8. Position inlet manifold assembly to cylinder
head.
9. Fit manifold bolts and, working in the sequence
illustrated, tighten as follows:
l
Initially, tighten bolts numbered 1, 4, 9 and
12 in numerical order to 5 Nm (4 lbf.ft).
l
Inlet manifold bolts - initial tighten = 10 Nm
(8 lbf.ft).
l
Inlet manifold bolts - final tighten = 51 Nm
(38 lbf.ft).
l
Tighten inlet manifold gasket clamp bolts to
18 Nm (14 lbf.ft).
l
Tighten inlet manifold bolts to 51 Nm (38
lbf.ft)
ENGINE - V8
12-2-48 OVERHAUL
10. Clean mating faces of rocker covers and
cylinder heads.
11. Fit new rocker cover gaskets, dry, position
rocker cover, fit bolts and working in diagonal
sequence, tighten to:
l
Stage 1 - 3 Nm (2.5 lbf.ft)
l
Stage 2 - 8 Nm (6 lbf.ft)
12. Ensure that outer rim of gasket is correctly
positioned around periphery of rocker cover.
13. Secure ht leads to rocker cover.
14. Clean coolant outlet elbow mating faces.
15. Lubricate and fit new 'O' ring to outlet pipe.
16. Position coolant outlet elbow, fit bolts and
tighten to 22 Nm (17 lbf.ft).
17. Position alternator, fit mounting bolts and
tighten to 45 Nm (34 lbf.ft).
18. Position alternator cables and tighten terminal
B+ to 18 Nm (13 lbf.ft) and terminal D+ to 5 Nm
(3.5 lbf.ft).
19. Position auxiliary housing, fit bolts and tighten
to 40 Nm (30 lbf.ft). Fit nut and tighten to 22 Nm
(17 lbf.ft).
20. Clean jockey pulley mating faces.
21. Position jockey pulley and tighten bolt to 50 Nm
(37 lbf.ft).
22. Clean PAS pump pulley mating faces.
23. Position PAS pump pulley, fit bolts and tighten
to 22 Nm (17 lbf.ft).
24. Secure injector harness and connect injector
multiplugs.
25. Connect multiplug to coolant thermistor.
Gasket - exhaust manifold
$% 30.15.12.01
Disassembly
1. Remove 8 bolts securing exhaust manifold and
collect spacers. Discard the bolts.
2. Remove exhaust manifold.
3. Remove 2 manifold gaskets and discard.
Reassembly
1. Clean exhaust manifold and cylinder head
mating face.
CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.
2. Fit new gaskets, dry, fit exhaust manifold.
CAUTION: Ensure that link bar on gasket is
positioned below spark plugs.
LH bank illustrated
3. Fit spacers to new manifold bolts and, working
in the sequence illustrated, initially tighten bolts
to 15 Nm (11 lbf.ft), then finally tighten to 38 Nm
(28 lbf.ft).
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