1999 LAND ROVER DISCOVERY engine

ENGINE - V8
REPAIRS 12-2-41
Gasket - timing gear cover
$% 12.65.04
Remove
1.Remove oil pick-up strainer.

+ ENGINE - V8, REPAIRS, Strainer -
oil pick-up.
2.Remove timing gear cover oil seal.

+ ENGINE - V8, REPAIRS, Seal - cover
- timing gears.
3.Remove engine oil filter.

+ ENGINE - V8, REPAIRS, Filter - oil.
4.Remove and discard 3 bolts securing coolant
pump pulley and remove pulley.
5.Remove 3 bolts securing PAS pump pulley and
remove pulley.
6.Drain cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.7.Release clip and disconnect coolant hose from
coolant pump.
8.Disconnect multiplug from oil pressure switch.
9.Disconnect multiplug from CMP sensor.
10. If fitted: Loosen union and disconnect oil
cooler pipe from timing gear cover. Remove
and discard 'O' ring.
CAUTION: Always fit plugs to open
connections to prevent contamination.
11.Remove 9 bolts securing timing gear cover and
remove cover. Remove and discard gasket.

ENGINE - V8
12-2-42 REPAIRS
Refit
1.Clean mating faces of timing gear cover and
cylinder block. Clean dowels and dowel holes.
Ensure bolt holes are clean and dry, remove all
traces of sealant from bolt threads.
2.Fit new gasket, dry, to dowels in cylinder block.
3.Locate tool LRT-12-090 on timing cover and oil
pump drive gear.
4.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.
5.Remove tool LRT-12-090.
6.Apply sealant, Part Number STC 50552 to
threads of timing cover bolts, fit bolts and
working in the sequence illustrated, tighten to
22 Nm (17 lbf.ft) . Ensure CMP sensor multiplug
bracket is secured by bolt.
7. If fitted: Fit new 'O' ring to oil cooler pipe,
connect pipe to timing gear cover and tighten
union to 15 Nm (11 lbf.ft).
8.Connect multiplug to oil pressure switch.
9.Connect multiplug to CMP sensor. 10.Connect coolant hose to coolant pump and
secure with clip.
11.Ensure mating faces of PAS pump pulley and
drive flange are clean, fit pulley and tighten
bolts to 22 Nm (16 lbf.ft).
12.Remove all traces of thread locking material
from coolant pump pulley drive flange bolt
holes using an M8 tap.
13.Ensure mating faces of coolant pump pulley
and drive flange are clean, fit pulley and tighten
new Patchlok bolts to 22 Nm (16 lbf.ft).
14.Ensure mating faces of oil filter and adaptor are
clean, smear clean engine oil onto seal and fit
filter.
15.Fit timing gear cover oil seal.

+ ENGINE - V8, REPAIRS, Seal - cover
- timing gears.
16.Fit oil pick-up strainer.

+ ENGINE - V8, REPAIRS, Strainer -
oil pick-up.
17.Refill cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.

ENGINE - V8
REPAIRS 12-2-43
Seal - cover - timing gears
$% 12.65.05
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Secure tool LRT-12-080 to crankshaft pulley
with 2 bolts.
3.Remove crankshaft pulley bolt.
4.Remove crankshaft pulley.
5.Use tool LRT-12-088, to remove oil seal from
timing gear cover. Refit
1.Clean seal register in timing gear cover and
crankshaft pulley.
CAUTION: Seal is pre-greased, do not apply
additional lubricant.
2.Apply smear of Retinax LX grease to seal
running surface on crankshaft.
3.Fit seal to timing gear cover using tool LRT-12-
089 .
4.Fit crankshaft pulley bolt and tighten to 270 Nm
(200 lbf.ft).
5.Remove tool LRT-12-080 from crankshaft
pulley.
6.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.

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.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.
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.Ensure bolt holes are clean and dry.
4.Apply sealant, Part No. STC 50550 to cylinder
head and notches in cylinder block.
5.Fit new gasket seals, ensuring the ends
engage correctly in notches.
6.Apply sealant, Part No. STC 50550 to gasket
seals above the notches in the cylinder block.
7.Fit new manifold gasket, dry.
8.Position gasket clamps, fit and lightly tighten
bolts.
9.Position inlet manifold assembly to cylinder
head. 10.Fit manifold bolts and, working in the sequence
illustrated, tighten as follows:
lInitially, tighten bolts numbered 1, 4, 9 and
12 in numerical order to 5 Nm (4 lbf.ft).
lInlet manifold bolts - initial tighten = 10 Nm
(8 lbf.ft).
lInlet manifold bolts - final tighten = 51 Nm
(38 lbf.ft).
lTighten inlet manifold gasket clamp bolts to
18 Nm (14 lbf.ft).
lTighten inlet manifold bolts to 51 Nm (38
lbf.ft)
11.Clean mating faces of rocker cover and cylinder
head, ensure that bolt holes are clean and dry.
12.Fit new rocker cover gaskets, dry, position
rocker covers, ensuring gaskets are correctly
located.
13.Fit new 'patched' multi-hex rocker cover bolts
ensuring that short bolts are on sides of rocker
coves nearest centre of engine.
14.Tighten bolts by diagonal selection to:
lStage 1 - 3 Nm (2.5 lbf.ft)
lStage 2 - 8 Nm (6 lbf.ft)
15.Ensure that outer rim of each gasket is correctly
positioned around periphery of rocker cover.
16.Secure ht leads to rocker cover.
17.Clean coolant outlet elbow mating faces.
18.Lubricate and fit new 'O' ring to outlet pipe.
19.Position coolant outlet elbow, fit bolts and
tighten to 22 Nm (17 lbf.ft).
20.Position alternator, fit mounting bolts and
tighten to 45 Nm (34 lbf.ft).

ENGINE - V8
12-2-48 OVERHAUL
21.Position alternator cables and tighten terminal
B+ to 18 Nm (13 lbf.ft) and terminal D+ to 5 Nm
(3.5 lbf.ft).
22.Position auxiliary housing, fit bolts and tighten
to 40 Nm (30 lbf.ft). Fit nut and tighten to 22 Nm
(17 lbf.ft).
23.Clean jockey pulley mating faces.
24.Position jockey pulley and tighten bolt to 50 Nm
(37 lbf.ft).
25.Clean PAS pump pulley mating faces.
26.Position PAS pump pulley, fit bolts and tighten
to 22 Nm (17 lbf.ft).
27.Secure injector harness and connect injector
multiplugs.
28.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).

ENGINE - V8
OVERHAUL 12-2-49
Seal - crankshaft - rear - automatic
models
$% 12.21.20.01
Disassembly
1.Remove CKP sensor.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Sensor - crankshaft position
(CKP).
Note: Later engines are fitted with a modified
starter ring gear which incorporates the reluctor
plate, spacer and hub. The modified ring gear
may be fitted as a replacement to early
engines.
2. Early engines: Remove 4 bolts securing drive
plate clamp ring and remove ring.
3. Early engines: Remove drive plate from hub.
4. Early engines: Remove 6 Allen bolts securing
hub and starter ring gear, remove hub, starter
ring gear and collect spacer.
Note: On early engines, balance weights are on
engine side of drive plate, replacement drive
plates will have balance weights on torque
converter side of drive plate.5. Later engines: Remove 4 bolts securing drive
plate clamp ring and remove ring.
6. Later engines: Remove drive plate.
7. Later engines: Remove 6 Allen bolts securing
starter ring gear to crankshaft, remove starter
ring gear.
8.Carefully remove oil seal from cylinder block to
avoid damage to seal location or running
surface on crankshaft.