2002 LAND ROVER DISCOVERY lock

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).
2.Remove 4 bolts securing drive plate clamp ring
and remove ring.
3.Remove drive plate from hub.
4.Remove 6 Allen screws securing hub, remove
hub and collect spacer. 5.Carefully remove oil seal from cylinder block to
avoid damage to seal location or running
surface on crankshaft.
Reassembly
1.Ensure both seal location and running surface
on crankshaft are clean.
2.Fit seal guide LRT-12-095 to crankshaft.
3.Fit new seal squarely onto crankshaft and
remove guide.
CAUTION: Oil seal must be fitted dry.
4.Fit seal into location using tools LRT-12-091
and LRT-99-003.

ENGINE - V8
OVERHAUL 12-2-51
8.Carefully remove oil seal from cylinder block to
avoid damage to seal location or running
surface on crankshaft.
Reassembly
1.Ensure both seal location and running surface
on crankshaft are clean.
2.Fit tool LRT-12-095 to crankshaft.
3.Fit new seal squarely onto crankshaft and
guide.
CAUTION: Oil seal must be fitted dry.4.Fit seal into location using tools LRT-12-091
and LRT-99-003.
5.Clean mating faces of flywheel and crankshaft,
dowel and dowel hole.
6.Fit flywheel to crankshaft and, working in a
diagonal sequence, tighten bolts to 78 Nm (58
lbf.ft).
7.Fit CKP sensor.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Sensor - crankshaft position
(CKP).
8.Clean clutch cover, drive plate and spigot bush
in end of crankshaft.
9.Renew worn components as necessary.
10.If refitting existing drive plate, apply Molycote
FB 108 to splines.
11.Fit LRT-12-001 alignment tool to spigot bearing
in crankshaft.
12.Fit drive plate onto alignment tool, ensure side
marked 'flywheel side' is against flywheel.
13.Fit clutch cover and locate on dowels.
14.Fit clutch cover bolts and tighten in diagonal
sequence to 40 Nm (30 lbf.ft).

ENGINE - V8
OVERHAUL 12-2-53
Gasket - engine sump
$% 12.60.38.01
Disassembly
1.Remove 3 nuts and 14 bolts securing sump to
cylinder block.
2.Remove sump.
3.Remove and discard gasket.
Reassembly
1.Clean all traces of sealant from the sump and
sump mating faces, using a solvent cleaner or
plastic scraper.
2.Apply a 5 mm (0.2 in) wide bead of sealant, Part
No. STC 50550 across the cylinder block to
front cover joint and across the cylinder block to
rear main bearing joint. Apply a globule of
sealant to cover the end of the cruciform seal,
(see illustration above).
3.Fit new sump gasket, dry, ensure location tags
are correctly positioned.
4.Fit the sump to the cylinder block.5. Noting that the two parts of the tool are
handed, fit tool LRT- 12-183 to the engine
back plate using bell housing nuts and bolts.
6.Secure the tool to the sump using the bolts
which are part of the tool. The holes in the tool
are larger than the diameter of the bolts,
allowing the tool and the sump to move as
the sump bolts are tightened.
7.Fit the sump nuts and bolts, and working in the
sequence shown, tighten to 22 Nm (16 lbf.ft).
8.Remove tool LRT-12-183.
M12 5741
M12 5713
14106248
12
16
17
15
117315913

ENGINE - V8
OVERHAUL 12-2-57
6.Apply smear of Retinax LX grease to oil seal
running surface on crankshaft.
7. Fit seal to timing gear cover using tool LRT-12-
089.
8.Clean and fit crankshaft pulley.
9.Fit crankshaft pulley bolt and tighten to 270 Nm
(200 lbf.ft).
10.Remove tool LRT-12-080 from crankshaft
pulley.
11.Clean oil filter mating face.
12.Lubricate new oil filter seal with clean engine oil
and fit filter.
13.Ensure coolant pump and pulley mating faces
are clean.
14.Remove all traces of thread locking material
from coolant pump pulley drive flange bolt
holes using an M8 tap.
15.Fit coolant pump pulley and tighten new
Patchlok bolts to 22 Nm (16 lbf.ft).
16.Fit oil pick up strainer.

+ ENGINE - V8, OVERHAUL, Strainer
- oil pick-up.
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.

ENGINE - V8
12-2-58 OVERHAUL
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. 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.

ENGINE - V8
12-2-60 OVERHAUL
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.Position rocker shaft assembly to cylinder
head ensuring push rods are engaged in
rocker arms.
4.Fit rocker shaft bolts and progressively tighten
to 40 Nm (30 lbf.ft).
5.Clean mating faces of rocker covers and
cylinder heads.
6.Fit new rocker cover gaskets, dry, position
rocker cover, fit bolts and working in diagonal
sequence, tighten to:
lStage 1 - 3 Nm (2.5 lbf.ft)
lStage 2 - 8 Nm (6 lbf.ft)
7.Ensure that gasket is correctly positioned
around periphery of rocker cover.
8.Secure ht leads to rocker cover.
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.Working in the sequence shown remove 10
bolts securing the cylinder head to block.
Discard the bolts.
8.Remove cylinder head.

ENGINE - V8
OVERHAUL 12-2-61
9.Remove cylinder head gasket.
CAUTION: Support both ends of cylinder
head on blocks of wood.
Inspect
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.
CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.
2.Check head and block faces for warping and
pitting.
lMaximum cylinder head warp = 0.05 mm
(0.002 in).
Note: Cylinder head can be refaced to 0.50
mm (0.02 in) maximum below head height –
See cylinder head overhaul.Reassembly
1.Fit cylinder head gasket with the word TOP
uppermost.
CAUTION: Gaskets must be fitted dry.
2.Carefully fit cylinder head and locate on
dowels.
3.Lightly lubricate new cylinder head bolt threads
with clean engine oil.
4.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 turn through 90
°, then a further 90 °. CAUTION: Do not
tighten bolts 180
° in one operation.
5.Clean the push rods, Lubricate ends of push
rods with clean engine oil, and fit in their
removed order.
6.Clean bases of rocker pillars and mating faces
on cylinder head.
7.Clean contact surfaces on rockers, valves and
push rods.
8.Lubricate contact surfaces and rocker shaft
with clean engine oil.
9.Fit rocker shaft assembly and engage push
rods.
10.Fit rocker shaft bolts and progressively tighten
to 40 Nm (30 lbf.ft).
11.Connect ht leads to spark plugs in their correct
fitted order.
12. RH cylinder head: Position alternator
mounting bracket, fit bolts and tighten to 40 Nm
(30 lbf.ft).
13. RH cylinder head: Fit auxiliary drive belt
tensioner.
14.Fit inlet manifold gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
inlet manifold.

ENGINE - V8
12-2-62 OVERHAUL
Cylinder head - overhaul
$% 12.29.19.01
Disassembly
1.Remove cylinder head gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
cylinder head.
2.Loosen screw on tool LRT-12-034.
3.Fit tool LRT-12-034 to valve and tighten screw
to compress valve spring sufficiently to release
collets from valve spring cap.
4.Remove 2 collets and release valve spring
compressor.
5.Remove valve spring cap and valve spring.
6.Remove valve from cylinder head.
7.Remove and discard valve stem oil seal.
8.Repeat above operations for remaining valves.
9.Keep valves, springs, caps and collets in their
fitted order. Inspect
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.
CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.
2.Clean cylinder head, valve springs, valves and
inlet valve guide bores. Ensure all loose
particles of carbon are removed on completion.
3.Check head and block faces for warping and
pitting. Maximum warp = 0.05 mm (0.002 in).
4.Check cylinder head height at each end of
head. Renew a head which is outside limits.
a22.94 mm (0.903 in) - New
b62.56 mm (2.463 in) - New
5.Cylinder head can be refaced to 0.50 mm (0.02
in) max. below head height.