engine LAND ROVER DISCOVERY 1999 Workshop Manual

ENGINE - V8
12-2-76 OVERHAUL
19.Attach a DTI to front of cylinder block, move
crankshaft rearwards, position stylus of gauge
on end of crankshaft and zero gauge.
20.Move crankshaft forwards, measure and
record end-float obtained.
l Crankshaft end-float = 0.08 to 0.26 mm
(0.003 to 0.01 in).
21.Fit connecting rod bearings.

+ ENGINE - V8, OVERHAUL, Bearings
- connecting rods.
22.Clean timing chain and gears.
23.Clean ends of crankshaft and camshaft.
24.Lubricate timing chain assembly with clean
engine oil.
25.Align timing marks and fit timing chain
assembly.
26.Fit camshaft gear bolt and tighten to 50 Nm (37
lbf.ft).
27.Fit timing gear cover gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
timing gear cover.
28.Clean crankshaft pulley.
29.Fit crankshaft pulley.
30.Fit crankshaft pulley bolt and tighten to 270 Nm
(200 lbf.ft).
31.Remove tool LRT-12-080 from crankshaft
pulley.
32.Clean oil filter and mating face.
33.Lubricate oil filter seal and fit filter to oil pump.
34.Ensure drive belt pulleys are clean and
damage free.
35.Fit auxiliary drive belt to pulleys.
36.Fit crankshaft rear oil seal.

+ ENGINE - V8, OVERHAUL, Seal -
crankshaft - rear - automatic models.

ENGINE - V8
OVERHAUL 12-2-77
Camshaft
$% 12.13.02.01
Disassembly
1.Remove inlet manifold gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
inlet manifold.
2.Progressively loosen and remove 8 bolts
securing rocker shaft assemblies.
3.Mark each rocker shaft in relation to original
head.
4.Remove rocker shaft assemblies.
5.Remove push rods and store in their fitted
order.
6.Remove tappets.
CAUTION: Store tappets upright and in their
fitted order.
7.Remove timing chain and gears.

+ ENGINE - V8, OVERHAUL, Timing
chain and gears.8.Temporarily fit camshaft gear and lightly tighten
bolt.
9. Attach a dial test indicator (DTI) to front of
cylinder block with stylus of DTI contacting
camshaft gear.
10.Push camshaft rearwards and zero the DTI.
11.Using the camshaft gear, pull camshaft
forwards and note reading on DTI. End-float
should be from 0.075 to 0.25 mm (0.003 to
0.010 in).
12.If end-float is incorrect, fit a new thrust plate. If
end-float is still incorrect, a new camshaft/gear
must be fitted.
13.Remove camshaft bolt and gear.
14.Remove 2 bolts securing camshaft thrust plate
and remove thrust plate.
15.Carefully remove the camshaft avoiding
damage to the camshaft bearings.

ENGINE - V8
12-2-78 OVERHAUL
Reassembly
1.Clean camshaft bearings in block.
2.Clean camshaft.
3.Wipe camshaft bearing faces and lobes.
4.Clean thrust plate and mating face.
5.Lubricate camshaft bearings with clean engine
oil.
6.Fit camshaft, take care not to damage camshaft
bearings.
7.Lubricate thrust plate and mating face with
clean engine oil.
8.Position thrust plate, fit and tighten bolts to 22
Nm (17 lbf.ft).
9.Fit timing chain and gears.

+ ENGINE - V8, OVERHAUL, Timing
chain and gears.
10.Immerse tappets in engine oil. Before fitting,
pump the inner sleeve of tappet several times
using a push rod to prime the tappets.
11.Clean tappet bores.
12.Lubricate tappets and tappet bores with clean
engine oil.
13.Fit tappets.
14.Clean push rods.
15.Lubricate tappet end of push rods with clean
engine oil.
16.Fit push rods.
17.Clean bases of rocker pillars and mating faces.
18.Clean contact surfaces on rockers and valves.
19.Lubricate contact surfaces on rockers and
valves with clean engine oil.
20.Fit rocker shafts and engage push rods. Ensure
rockers shafts are fitted to the correct cylinder
head.
21.Fit and progressively tighten rocker shaft bolts
to 40 Nm (30 lbf.ft).
22.Fit inlet manifold gasket.

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

EMISSION CONTROL - V8
DESCRIPTION AND OPERATION 17-2-3
Evaporative emission system
component layout
1Purge valve
2Service port
3Snorkel tube (UK / ROW only)
4CVS unit (NAS vehicles with vacuum type leak
detection only)
5EVAP canister breather tube
6Vent pipe – fuel tank to EVAP canister
7Relief valve regulated flow
8Relief valve (UK / ROW only)
9Relief valve free flow
10Fuel filler cap
11Liquid vapour separator #
(UK / ROW type shown)12Fuel filler hose (UK / ROW type shown)
13Tank breather hose (UK / ROW only)
14Vent hose
15Roll over valves (ROV's) –
(4 off, UK / ROW spec. shown)
16Fuel tank and breather assembly
17EVAP canister
18Purge line connection to engine manifold
19Tank EVAP system pressure sensor (NAS
vehicles with vacuum type leak detection only)
M17 0209
4
3
1
6
5
16
10
8
13
17
9
7
11
12
15
14
18
2
19

EMISSION CONTROL - V8
17-2-4 DESCRIPTION AND OPERATION
Evaporative emission system (with
positive pressure leak detection)
component layout (NAS only)
1Purge valve
2Service port
3Air filter canister
4EVAP canister breather tube
5Leak detection pump
6EVAP canister
7Vent pipe – fuel tank to EVAP canister
8Liquid vapour separator (metal)9Fuel filler cap
10Fuel filler
11Fuel tank breather assembly
12Vent hose
13Roll over valves (inside fuel tank)
14Fuel tank
15Purge line connection to engine manifold
M17 0208
3
1
7
4
14
11
6
8
10
13
12
15
2
5
9

EMISSION CONTROL - V8
DESCRIPTION AND OPERATION 17-2-5
Evaporative emission system control
diagram
1Battery
2Fuse 13 (engine compartment fusebox)
3Inertia switch
4Main relay (engine compartment fusebox)
5Engine Control Module (ECM)
6Purge Valve (black harness connector)
7Canister vent solenoid (CVS) valve – NAS
vehicles with vacuum type EVAP system leak
detection capability only8Leak detection pump – NAS vehicles with
positive pressure type EVAP system leak
detection capability only
9Fuel tank pressure sensor – NAS vehicles with
vacuum type EVAP system leak detection
capability only
10Instrument pack (MIL warning light)
M17 0210
12
3
4
5
6
7
9
8
10

EMISSION CONTROL - V8
DESCRIPTION AND OPERATION 17-2-7
1Engine Control Module (ECM)
2SAI vacuum solenoid valve
3Purge valve
4Vacuum reservoir (up to 2003 model year
location shown)
5SAI control valve (2 off)
6SAI pump
7SAI pump relay
8Main relay

EMISSION CONTROL - V8
17-2-8 DESCRIPTION AND OPERATION
Secondary air injection system control
diagram
1Fuselink 2 (engine compartment fusebox)
2SAI pump relay
3SAI pump
4SAI vacuum solenoid valve
(grey harness connector)5Engine Control Module (ECM)
6Battery
7Fuse 13 (engine compartment fusebox)
8Inertia switch
9Main relay
9
M17 0207
1
2
3
4
5
7
6
8

EMISSION CONTROL - V8
DESCRIPTION AND OPERATION 17-2-9
Emission Control Systems
Engine design has evolved in order to minimise the emission of harmful by-products. Emission control systems are
fitted to Land Rover vehicles which are designed to maintain the emission levels within the legal limits pertaining for
the specified market.
Despite the utilisation of specialised emission control equipment, it is still necessary to ensure that the engine is
correctly maintained and is in good mechanical order so that it operates at its optimal condition. In particular, ignition
timing has an effect on the production of HC and NO
x emissions, with the harmful emissions rising as the ignition
timing is advanced.
CAUTION: In many countries it is against the law for a vehicle owner or an unauthorised dealer to modify or
tamper with emission control equipment. In some cases, the vehicle owner and/or the dealer may even be
liable for prosecution.
The engine management ECM is fundamental for controlling the emission control systems. In addition to controlling
normal operation, the system complies with On Board Diagnostic (OBD) system strategies. The system monitors and
reports on faults detected with ignition, fuelling and exhaust systems which cause an excessive increase in tailpipe
emissions. This includes component failures, engine misfire, catalyst damage, catalyst efficiency, fuel evaporative
loss and exhaust leaks.
When an emission relevant fault is determined, the fault condition is stored in the ECM memory. For NAS vehicles,
the MIL warning light on the instrument pack will be illuminated when the fault is confirmed. Confirmation of a fault
condition occurs if the fault is still found to be present during the driving cycle subsequent to the one when the fault
was first detected.

+ ENGINE MANAGEMENT SYSTEM - V8, DESCRIPTION AND OPERATION, Description - engine
management.
The following types of supplementary control system are used to reduce harmful emissions released into the
atmosphere from the vehicle:
1Crankcase emission control – also known as blow-by gas emissions from the engine crankcase.
2Exhaust emission control – to limit the undesirable by-products of combustion.
3Fuel vapour evaporative loss control – to restrict the emission of fuel through evaporation from the fuel
system.
4Fuel leak detection system (NAS only) – there are two types of system which may be used to check the
evaporative emission system for the presence of leaks from the fuel tank to purge valve.
aVacuum leak detection test – checks for leaks down to 1 mm (0.04 in.) in diameter.
bPositive pressure leak detection test – utilises a leak detection pump to check for leaks down to 0.5 mm (0.02
in.) in diameter.
5Secondary air injection system (Where fitted) – to reduce emissions experienced during cold starting.

EMISSION CONTROL - V8
17-2-10 DESCRIPTION AND OPERATION
Crankcase Emission Control System
The concentration of hydrocarbons in the crankcase of an engine is much greater than that in the vehicle's exhaust
system. In order to prevent the emission of these hydrocarbons into the atmosphere, crankcase emission control
systems are employed and are a standard legal requirement.
The crankcase ventilation system is an integral part of the air supply to the engine combustion chambers and it is
often overlooked when diagnosing problems associated with engine performance. A blocked ventilation pipe or filter
or excessive air leak into the inlet system through a damaged pipe or a leaking gasket can affect the air:fuel mixture,
performance and efficiency of the engine. Periodically check the ventilation hoses are not cracked and that they are
securely fitted to form airtight connections at their relevant ports.
The purpose of the crankcase ventilation system is to ensure that any noxious gas generated in the engine crankcase
is rendered harmless by complete burning of the fuel in the combustion chamber. Burning the crankcase vapours in
a controlled manner decreases the HC pollutants that could be emitted and helps to prevent the development of
sludge in the engine oil as well as increasing fuel economy.
A spiral oil separator is located in the stub pipe to the ventilation hose on the right hand cylinder head rocker cover,
where oil is separated and returned to the cylinder head. The rubber ventilation hose from the right hand rocker cover
is routed to a port on the right hand side of the inlet manifold plenum chamber where the returned gases mix with the
fresh inlet air passing through the throttle butterfly valve. The stub pipe on the left hand rocker cover does not contain
an oil separator, and the ventilation hose is routed to the throttle body housing at the air inlet side of the butterfly valve.
The ventilation hoses are attached to the stub pipe by metal band clamps.