Discovery 2. Manual — part 430
ENGINE - V8
REPAIRS 12-2-13
REPAIRS
Seal - crankshaft - rear
$% 12.21.20
Remove
1. Automatic gearbox models:Remove
ENGINE - V8, REPAIRS, Plate - drive
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
ENGINE - V8, REPAIRS, Plate - drive
6. Manual gearbox models:Fit flywheel.
ENGINE - V8
12-2-14 REPAIRS
Gasket - cylinder head - LH
$% 12.29.02
Remove
1. Remove inlet manifold gasket.
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
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.
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.
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - lower.
Gasket - cylinder head - RH
$% 12.29.03
Remove
1. Remove inlet manifold gasket.
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.
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