1999 LAND ROVER DISCOVERY Workshop Manual

ENGINE - V8
12-2-54 OVERHAUL
Strainer - oil pick-up
$% 12.60.20.01
Disassembly
1.Remove sump gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
engine sump.
2.Remove 2 bolts and 1 nut securing oil pick up
strainer.
3.Remove oil pick up strainer.
4.Collect spacer.
5.Remove and discard 'O' ring. Reassembly
1.Clean oil pick up strainer and 'O' ring recess.
2.Lubricate new 'O' ring with clean engine oil and
fit to recess.
3.Locate spacer on stud.
4.Position oil pick up strainer, fit bolts and tighten
to 10 Nm (7 lbf.ft). Fit nut and tighten to 22 Nm
(16 lbf.ft).
5.Fit new sump gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
engine sump.

ENGINE - V8
OVERHAUL 12-2-55
Seal - timing gear cover
$% 12.65.05.01
Disassembly
1.Secure tool LRT-12-080 to crankshaft pulley
with 2 bolts.
2.Remove crankshaft pulley bolt.
3.Remove crankshaft pulley.
4.Using tool LRT-12-088, remove oil seal from
timing gear cover and discard. Reassembly
1.Clean seal register in timing gear cover and
crankshaft pulley.
2.Ensure that bolt holes are clean and dry.
3.Apply smear of Retinax LX grease to seal
running surface on crankshaft.
CAUTION: Replacement oil seal is pre-
greased, do not apply additional lubricant.
4. Fit seal to timing gear cover using tool LRT-12-
089 .
5.Secure tool LRT-12-080 to crankshaft pulley
with 2 bolts. Fit crankshaft pulley.
6.Fit crankshaft pulley bolt and tighten to 270 Nm
(200 lbf.ft).
7.Remove tool LRT-12-080 from crankshaft
pulley.

ENGINE - V8
12-2-56 OVERHAUL
Gasket - timing gear cover
$% 12.65.04.01
Disassembly
1.Remove oil pick up strainer.

+ ENGINE - V8, OVERHAUL, Strainer
- oil pick-up.
2.Remove and discard 3 bolts securing coolant
pump pulley.
3.Remove coolant pump pulley.
4.Secure tool LRT-12-080 to crankshaft pulley
with 2 bolts.
5.Remove crankshaft pulley bolt.
6.Remove crankshaft pulley. 7.Remove oil filter and discard.
8.Noting the positions of the longer bolts, remove
9 bolts securing timing gear cover.
9.Remove timing gear cover.
10.Remove and discard timing gear cover gasket.
11.Remove seal from timing gear cover and
discard.

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:
lStage 1 - 3 Nm (2.5 lbf.ft)
lStage 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.

ENGINE - V8
OVERHAUL 12-2-61
Gasket - cylinder head
$% 12.29.02.01
Disassembly
1.Remove inlet manifold gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
inlet manifold.
2. RH cylinder head: Remove auxiliary drive belt
tensioner.
3. RH cylinder head: Remove bolts securing
alternator mounting bracket and remove
bracket.
4.Noting their fitted order, disconnect ht leads
from spark plugs.
5.Progressively remove 4 bolts securing the
rocker shaft and remove rocker shaft.
6.Remove push rods and store in their fitted
order. 7. Models with SAI: Using a 9 mm hexagonal
drive bit, remove 2 air injection adapters from
cylinder head; discard adapters.
To release the adapter thread locking agent
and prevent damage to the cylinder head,
remove the adapters by alternately loosening
then tightening slightly. Repeat this procedure
until adapters are removed.
CAUTION: Do not use air tools to remove
adapters.
8.Working in the sequence shown remove 10
bolts securing the cylinder head to block.
Discard the bolts.
9.Remove cylinder head.