2002 LAND ROVER DISCOVERY engine

ENGINE - V8
12-2-46 OVERHAUL
11.Remove 4 bolts securing rocker cover and
remove cover.
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.Apply sealant, Part No. STC 3254 to cylinder
head and notches in cylinder block.
4.Fit new gasket seals, ensuring the ends
engage correctly in notches.
5.Apply sealant, Part No. STC 3254 to gasket
seals above the notches in the cylinder block.
6.Fit new manifold gasket, dry.
7.Position gasket clamps, fit and lightly tighten
bolts.
8.Position inlet manifold assembly to cylinder
head.
9.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)

ENGINE - V8
12-2-48 OVERHAUL
10.Clean mating faces of rocker covers and
cylinder heads.
11.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)
12.Ensure that outer rim of gasket is correctly
positioned around periphery of rocker cover.
13.Secure ht leads to rocker cover.
14.Clean coolant outlet elbow mating faces.
15.Lubricate and fit new 'O' ring to outlet pipe.
16.Position coolant outlet elbow, fit bolts and
tighten to 22 Nm (17 lbf.ft).
17.Position alternator, fit mounting bolts and
tighten to 45 Nm (34 lbf.ft).
18.Position alternator cables and tighten terminal
B+ to 18 Nm (13 lbf.ft) and terminal D+ to 5 Nm
(3.5 lbf.ft).
19.Position auxiliary housing, fit bolts and tighten
to 40 Nm (30 lbf.ft). Fit nut and tighten to 22 Nm
(17 lbf.ft).
20.Clean jockey pulley mating faces.
21.Position jockey pulley and tighten bolt to 50 Nm
(37 lbf.ft).
22.Clean PAS pump pulley mating faces.
23.Position PAS pump pulley, fit bolts and tighten
to 22 Nm (17 lbf.ft).
24.Secure injector harness and connect injector
multiplugs.
25.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).
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
12-2-50 OVERHAUL
5.Clean hub and mating face, spacer and clamp
ring.
6.Clean drive plate and ensure free from cracks
and distortion.
7.Fit spacer and hub to crankshaft, tighten Allen
screws to 78 Nm (58 lbf.ft).
8.Fit drive plate and clamp ring, tighten bolts to
45 Nm (35 lbf.ft).
9.Fit CKP sensor.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Sensor - crankshaft position
(CKP).
Seal - crankshaft - rear - manual models
$% 12.21.20.01
Disassembly
1.Restrain flywheel.
2.Working in sequence, loosen and remove 6
bolts securing clutch cover to flywheel.
3.Remove clutch cover.
4.Remove clutch plate.
5.Remove CKP sensor.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Sensor - crankshaft position
(CKP).
6.Remove 6 bolts securing flywheel.
7.Remove flywheel.

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
12-2-52 OVERHAUL
Bearing - spigot - crankshaft
$% 12.21.45.01
Disassembly
1.Remove 6 bolts securing clutch cover.
2.Remove clutch cover.
3.Tap a thread in spigot bush to accommodate a
suitable impulse extractor.
4.Fit extractor to bush.
5.Remove bush from crankshaft. Reassembly
1.Clean bush register in rear of crankshaft.
2.Using a suitable drift, fit new bush to crankshaft
so that it is flush with or up to a maximum of 1.6
mm (0.06 in) below the end of the crankshaft.
3.Ream spigot bush to 19.117 + 0.025
− 0.00 mm
(0.75 + 0.001
− 0.00 in) .
4.Remove all traces of swarf on completion.
5.Clean mating faces of flywheel and crankshaft,
dowel and dowel hole.
6.Fit clutch cover to flywheel and tighten bolts by
diagonal slection 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
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