lock LAND ROVER DISCOVERY 1999 Repair Manual

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: Using a 9 mm hexagonal
drive bit, remove 2 air injection adapters from
cylinder head; discard adapters.
Note: 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.
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.

ENGINE - V8
12-2-18 REPAIRS
13.Remove cylinder head gasket.
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. Models with SAI: Using a 5/8 in x 20 TPI
(threads per inch) UNF tap having a class 2A
thread, remove deposits from secondary air
injection adapter tappings in cylinder head.
CAUTION: Ensure that tap used has 20 TPI.
4.Fit cylinder head gasket with the word 'TOP'
uppermost.
CAUTION: Gasket must be fitted dry.
5.Carefully fit cylinder head and locate on
dowels.
6.Lightly lubricate new cylinder head bolt threads
with clean engine oil. 7.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.
8. Models with SAI: Fit new air injection adapters
and using a 9 mm hexagonal drive bit, tighten
to 33 Nm (24 lbf.ft).
CAUTION: Do not use an air tool to tighten
adapters.
9.Clean push rods.
10.Lubricate ends of push rods with clean engine
oil.
11.Fit push rods in their removed order.
12.Clean bases of rocker pillars and mating faces
on cylinder head.
13.Clean contact surfaces on rockers, valves and
push rods.
14.Lubricate contact surfaces and rocker shaft
with clean engine oil.
15.Fit rocker shaft assembly and engage push
rods.
16.Fit rocker shaft bolts and progressively tighten
to 40 Nm (30 lbf.ft).
17.Position alternator mounting bracket, fit bolts
and tighten to 40 Nm (30 lbf.ft).
18.Position auxiliary drive belt tensioner, fit bolt
and tighten to 45 Nm (33 lbf.ft).
19.Connect ht leads to spark plugs in their fitted
order.
20. 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).
21. RH drive models: Fit brake servo heat shield.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Heat shield -
brake servo - Without Secondary Air
Injection.
22.Position engine earth lead, fit bolt and tighten to
22 Nm (16 lbf.ft).
23.Fit inlet manifold gasket.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - lower.

ENGINE - V8
12-2-22 REPAIRS
Mounting - front - LH
$% 12.45.01
Remove
1.Release turnbuckles and remove battery cover.
2.Disconnect battery earth lead.
3.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Position a jack beneath the sump, and support
the engine on the jack.
CAUTION: To prevent damage to
components, cushion the jack pad with a
block of wood or hard rubber.
6.Remove 2 nuts securing engine mountings to
chassis.
7.Remove nut securing LH mounting to cylinder
block.
8.Raise engine sufficiently to allow engine
mounting to be removed, take care not to trap
any cables, pipes or harness.
9.Remove engine mounting. Collect heat shield,
if fitted.Refit
1.Fit heat shield to engine mounting, if fitted.
2.Fit engine mounting ensuring dowel is located.
3.Lower the jack and engage engine mounting
studs in chassis.
4.Fit nuts securing LH engine mounting and
tighten to 85 Nm (63 lbf.ft).
5.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Remove stand(s) and lower vehicle.
7.Connect battery earth lead.
8.Fit battery cover and secure turnbuckles.

ENGINE - V8
REPAIRS 12-2-23
Mounting - front - RH
$% 12.45.03
Remove
1.Release turnbuckles and remove battery cover.
2.Disconnect battery earth lead.
3.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Position a jack beneath the sump, and support
the engine on the jack.
CAUTION: To prevent damage to
components, cushion the jack pad with a
block of wood or hard rubber.
6.Remove 2 nuts securing engine mountings to
chassis.
7.Remove nut securing RH mounting to cylinder
block.
8.Raise engine sufficiently to allow engine
mounting to be removed. Take care not to trap
any cables, pipes or harness.
9.Remove engine mounting.
10.Collect heat shield. Refit
1.Position heat shield.
2.Fit engine mounting ensuring dowel is located.
3.Lower the jack and engage engine mounting
studs in chassis.
4.Fit engine mounting nuts and tighten to 85 Nm
(63 lbf.ft).
5.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Remove stand(s) and lower vehicle.
7.Connect battery earth lead.
8.Fit battery cover and secure turnbuckles.

ENGINE - V8
12-2-24 REPAIRS
Mounting - rear - LH
$% 12.45.07
Remove
1.Raise vehicle on lift.
2.Remove 8 bolts securing rear cross member
and remove cross member.
3.Support transfer gearbox on jack.
CAUTION: To prevent damage to
components, cushion the jack pad with a
block of wood or hard rubber.
4.Release and disconnect HO2S multiplug.5.Remove nut securing mounting to body
bracket.
6.Remove nut securing mounting to mounting
bracket.
7.Remove 4 bolts securing mounting bracket to
gearbox.
8.Remove mounting and mounting bracket
assembly.
9.Remove mounting rubber.
10.Remove heat shield, if fitted.
Refit
1.If fitted position heatshield, fit mounting rubber
to mounting bracket, fit nut but do not tighten.
2.Position mounting bracket assembly, fit bolts
securing mounting bracket to gearbox and
tighten to 85 Nm (63 lbf.ft).
3.Fit nut securing mounting to body bracket and
tighten to 48 Nm (35 lbf.ft).
4.Tighten nut securing mounting to gearbox
bracket to 48 Nm (35 lbf.ft).
5.Connect HO2S multiplug and secure to support
bracket.
6.Position rear cross member, fit bolts and
tighten to 26 Nm (19 lbf.ft).
7.Lower vehicle.

ENGINE - V8
REPAIRS 12-2-25
Mounting - rear - RH
$% 12.45.09
Remove
1.Raise vehicle on lift.
2.Remove 8 bolts securing rear cross member
and remove cross member.
3.Support transfer gearbox on jack.
CAUTION: To prevent damage to
components, cushion the jack pad with a
block of wood or hard rubber.
4.Remove nut securing mounting to body
bracket.
5.Remove nut securing mounting to mounting
bracket.
6.Remove 4 bolts securing mounting bracket to
gearbox.
7.Remove mounting and mounting bracket
assembly.
8.Remove mounting rubber.
9.Remove heat shield, if fitted.Refit
1.If fitted, position heatshield, fit mounting rubber
to mounting bracket, fit nut but do not tighten.
2.Position mounting bracket assembly, fit bolts
securing mounting bracket to gearbox and
tighten to 85 Nm (63 lbf.ft).
3.Fit nut securing mounting to body bracket and
tighten to 48 Nm (35 lbf.ft).
4.Tighten nut securing mounting to gearbox
bracket to 48 Nm (35 lbf.ft).
5.Position rear cross member, fit bolts and
tighten to 26 Nm (19 lbf.ft).
6.Lower vehicle.

ENGINE - V8
12-2-38 REPAIRS
16.Remove 12 bolts securing sump flange to
engine.
17.Manoeuvre sump over front axle and remove
sump.
18.Discard sump gasket.
Refit
1.Clean all traces of sealant from the sump and
sump mating faces using a plastic scraper or
solvent.
2.Ensure bolt holes in cylinder block are clean
and dry.
3.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 ends of the cruciform
seals, (see illustration).
4.Fit new gasket, dry, to sump, ensuring that
locating tags are correctly positioned.
5.Manoeuvre sump into position, fit and lightly
tighten 2 bolts to retain sump in place, then fit
and lightly tighten remainder of bolts.
6.Working in the sequence illustrated, tighten the
sump bolts to 22 Nm (16 lbf.ft).
7.Position side clip bracket, fit and tighten bolt. 8.Position oil cooler pipe clips, fit and tighten
nuts.
9.Clean gearbox oil cooler pipe 'O' ring recess
and mating face.
10.Lubricate and fit new 'O' ring to gearbox oil
cooler pipe.
11.Position pipe and tighten nut.
12.Lower front of vehicle.
13.Position cross member to chassis, fit bolts and
tighten to 25 Nm (18 lbf.ft).
14.Refill engine oil and fit dipstick.
15.Connect battery earth lead.
16.Fit battery cover and retain with fixings.

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
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
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.