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Discovery 2. Manual - part 431

ENGINE - V8

REPAIRS 12-2-17

6. RH drive models: Remove brake servo heat

shield.

MANIFOLDS AND EXHAUST

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

7. Remove 8 bolts securing exhaust manifold to

cylinder head, release manifold and collect 2
gaskets.

8. Progressively remove 4 bolts securing the

rocker shaft and remove rocker shaft.

9. Remove push rods. Store push rods in their

fitted order.

10. Models with SAI: Remove 2 air injection

adapters and discard.

11. In the sequence shown, remove 10 bolts

securing the cylinder head to block. Discard the
bolts.

12. Remove cylinder head.

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

13. Remove cylinder head gasket.

ENGINE - V8

12-2-18 REPAIRS

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 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. Position alternator mounting bracket, fit bolts

and tighten to 40 Nm (30 lbf.ft).

17. Position auxiliary drive belt tensioner, fit bolt

and tighten to 45 Nm (33 lbf.ft).

18. Connect ht leads to spark plugs in their fitted

order.

19. Using new gaskets, fit exhaust manifold to

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

20. RH drive models: Fit brake servo heat shield.

MANIFOLDS AND EXHAUST

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

21. Position engine earth lead, fit bolt and tighten to

22 Nm (16 lbf.ft).

22. Fit inlet manifold gasket.

MANIFOLDS AND EXHAUST

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

ENGINE - V8

REPAIRS 12-2-19

Gasket - rocker cover - LH

$% 12.29.40

Remove

1. Remove upper inlet manifold gasket.

MANIFOLDS AND EXHAUST

SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.

2. Models with air conditioning: Release 4

clips and remove fan cowl.

3. Models with air conditioning: Release

tension on auxiliary drive belt  and remove belt
from air conditioning compressor. Disconnect
compressor multiplug.   Remove 4 bolts
securing compressor and position compressor
aside.

4. Release ht leads from rocker cover clips.
5. Remove screw securing dip stick tube.

6. Remove 4 bolts securing rocker cover.
7. Remove rocker cover and collect gasket.

Refit

1. Clean mating faces of rocker cover and

cylinder head.

2. Using a new gasket, fitted dry, position rocker

cover ensuring gasket is correctly located.

3. Fit rocker cover bolts and working in diagonal

sequence, tighten to:

Stage 1 - 3 Nm (2.5 lbf.ft)

Stage 2 - 8 Nm (6 lbf.ft)

4. Ensure that outer rim of gasket is correctly

positioned around periphery of rocker cover.

5. Fit and tighten screw securing dip stick tube.
6. Secure ht leads in rocker cover clips.
7. Models with air conditioning: Clean

compressor dowels and dowel holes. Position
compressor, fit bolts and tighten to 22 Nm (16
lbf.ft). Release auxiliary drive belt tensioner
and fit belt to compressor.