Adjust Land Rover Discovery L318

1. If engine oil pressure is below figures given, check condition of oil pump and/or main and big end bearings.

Removal

1. On automatic gearbox models, remove converter drive plate. See «PLATE - DRIVE - AUTOMATIC»(ref-158799-S23955166962005013100000).
2. On manual gearbox models, remove flywheel. See «FLYWHEEL»(ref-158799-S16523719052005013100000).
3. Carefully remove oil seal from cylinder block to avoid damage to seal location or running surface on crankshaft. Discard seal. (Scheme 7)

Scheme 6

Scheme 7

1. Ensure both seal location and running surface on crankshaft are clean.
2. Lubricate replacement oil seal with engine oil.
3. Lubricate seal guide LRT-12-095 with engine oil, fit seal guide to crankshaft.
4. Fit oil seal squarely onto crankshaft and remove seal guide LRT-12-095.
5. Fit seal into location using tools LRT-12-091 and LRT-99-003. (Scheme 8)
6. On automatic gearbox models, fit converter drive plate. See «PLATE - DRIVE - AUTOMATIC»(ref-158799-S23955166962005013100000).
7. On manual gearbox models, fit flywheel. See «FLYWHEEL»(ref-158799-S16523719052005013100000).

Scheme 8

Scheme 9

1. Remove inlet manifold gasket. See «GASKET - INLET MANIFOLD»(ref-158799-S11640340422005013100000).
2. Noting their fitted order, disconnect hot leads from spark plugs.
3. Remove bolt securing engine harness to rear of cylinder head. (Scheme 9)
4. On left drive models: Remove brake servo heat shield.
5. Remove 8 bolts securing exhaust manifold to cylinder head, release manifold and collect 2 gaskets. (Scheme 10)
6. Progressively remove 4 bolts securing the rocker shaft and remove rocker shaft. (Scheme 11)
7. Remove push rods. Store push rods in their fitted order.
8. On models with Secondary Air Injection (SAI): Using a 9-mm hexagonal drive bit, remove 2 air injection adapters from cylinder head; discard adapters. Repeat this procedure until adapters are removed. (Scheme 12)
9. In the sequence shown, remove 10 bolts securing the cylinder head to block. (Scheme 13) Discard the bolts.
10. Remove cylinder head.
11. Remove cylinder head gasket. (Scheme 14)

Scheme 10

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.
2. Check head and block faces for warping and pitting. If out of specification, renew head.
3. Models with Secondary Air Injection (SAI): Using a 5/8 in x 20 TPI (threads per inch) UNF tap having a class 2A thread, remove deposits from SAI adapter tappings in cylinder head.
4. Fit cylinder head gasket with the word TOP uppermost.
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 cylinder head bolts and tighten in the sequence shown to 20 N.m (15 ft. lbs) then turn through 90°, and finally a further 90°. (Scheme 15)
8. Models with Secondary Air Injection (SAI): Fit NEW air injection adapters and using a 9-mm hexagonal drive bit, tighten to 33 N.m (24 ft. lbs).
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 N.m (30 ft. lbs).
17. Using NEW gaskets, position exhaust manifold to cylinder head, fit bolts and using sequence shown, tighten initially to 15 N.m (11 ft. lbs), then finally to 36 N.m (28 ft. lbs). (Scheme 16)
18. On left drive models: Fit brake servo heat shield.
19. Fit engine harness bolt and tighten to 22 N.m (16 ft. lbs).
20. Connect hot leads to spark plugs in their correct fitted order.
21. Fit inlet manifold gasket. See «GASKET - INLET MANIFOLD»(ref-158799-S11640340422005013100000) under OVERHAUL.

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

1. Remove inlet manifold gasket. See «GASKET - INLET MANIFOLD»(ref-158799-S11640340422005013100000) under OVERHAUL.
2. Remove bolt securing auxiliary drive belt tensioner and remove tensioner. (Scheme 17)
3. Remove 4 bolts securing alternator mounting bracket and remove bracket. (Scheme 18)
4. Noting their fitted order, disconnect hot leads from spark plugs.
5. Remove bolt securing engine earth lead.
6. On right drive models: Remove brake servo heat shield.
7. Remove 8 bolts securing exhaust manifold to cylinder head, release manifold and collect 2 gaskets. (Scheme 19)
8. Progressively remove 4 bolts securing the rocker shaft and remove rocker shaft. (Scheme 20)
9. Remove push rods. Store push rods in their fitted order.
10. Models with Secondary Air Injection (SAI): Using a 9-mm hexagonal drive bit, remove 2 air injection adapters from cylinder head; discard adapters. (Scheme 21)
11. In the sequence shown, remove 10 bolts securing the cylinder head to block. Discard the bolts. (Scheme 22)
12. Remove cylinder head.
13. Remove cylinder head gasket. (Scheme 23)

Scheme 17

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.
2. Check head and block faces for warping and pitting. If out of specification, renew head.
3. On models with Secondary Air Injection (SAI): Using a 5/8 in x 20 TPI (threads per inch) UNF tap having a class 2A thread, remove deposits from SAI adapter tappings in cylinder head.
4. Fit cylinder head gasket with the word TOP uppermost.
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 N.m (15 ft. lbs) then turn through 90°, and finally a further 90°. (Scheme 24)
8. On models with SAI: Fit NEW air injection adapters and using a 9-mm hexagonal drive bit, tighten to 33 N.m (24 ft. lbs).
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 N.m (30 ft. lbs).
17. Position alternator mounting bracket, fit bolts and tighten to 40 N.m (30 ft. lbs).
18. Position auxiliary drive belt tensioner, fit bolt and tighten to 45 N.m (33 ft. lbs).
19. Connect hot 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 N.m (11 ft. lbs), then finally tighten to 36 N.m (28 ft. lbs). (Scheme 25)
21. On right drive models: Fit brake servo heat shield.
22. Position engine earth lead, fit bolt and tighten to 22 N.m (16 ft. lbs).
23. Fit inlet manifold gasket. See «GASKET - INLET MANIFOLD»(ref-158799-S11640340422005013100000) under OVERHAUL.

Scheme 18

Scheme 19

Scheme 20

1. Remove upper inlet manifold gasket. See «GASKET - INLET MANIFOLD»(ref-158799-S11640340422005013100000).
2. On models with air conditioning: Release 4 clips and remove fan cowl.
3. On models with air conditioning: Release tension on auxiliary drive belt and remove belt from air conditioning compressor. (Scheme 26) Disconnect compressor multiplug. Remove 4 bolts securing compressor and position compressor aside. (Scheme 27)
4. Release hot leads (spark plug wires) from rocker cover clips. (Scheme 28)
5. Remove screw securing dip stick tube.
6. Noting fitted position of 2 long screws or multi-hex bolts, remove and discard screws/bolts securing rocker cover; remove rocker cover. (Scheme 29)
7. Remove and discard rocker cover gasket.

Installation

1. Clean mating faces of rocker cover and cylinder head, ensure bolt holes are clean and dry.
2. Fit a NEW gasket dry, position rocker cover ensuring gasket is correctly located.
3. Fit NEW "patched" multi-hex rocker cover bolts ensuring that 2 short bolts are on side of rocker cover nearest center of engine.
4. Tighten bolts by diagonal selection to: Stage 1 3 N.m (2.5 ft. lbs) Stage 2 8 N.m (6.0 ft. lbs)
5. Ensure that outer rim of gasket is correctly positioned around periphery of rocker cover.
6. Fit and tighten screw securing dip stick tube.
7. Secure hot leads in rocker cover clips.
8. On models with air conditioning: Clean compressor dowels and dowel holes. Position compressor, fit bolts and tighten to 22 N.m (16 ft. lbs). Release auxiliary drive belt tensioner and fit belt to compressor.
9. On models with air conditioning: Position fan cowl and secure clips.
10. Fit upper inlet manifold. See «GASKET - INLET MANIFOLD»(ref-158799-S11640340422005013100000) under OVERHAUL.

Scheme 21

Scheme 22

Scheme 23

Scheme 24

1. Drain cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-139295-S42055824182004100500000).
2. Remove upper inlet manifold gasket. See «GASKET - INLET MANIFOLD»(ref-158799-S11640340422005013100000).
3. On models with Secondary Air Injection (SAI): Disconnect 2 air manifold unions from adapters in cylinder head and remove manifold. (Scheme 30)
4. Remove 2 bolts securing coolant rails to inlet manifold.
5. Release coolant rail from inlet manifold and discard "O" ring. (Scheme 31)
6. Remove nuts securing alternator cables and release cables from alternator.
7. Disconnect multiplugs from right bank of injectors and release harness from fuel rail. (Scheme 32)
8. Release hot leads from clips on rocker cover. (Scheme 33)
9. Noting fitted position of 2 long screws or multi-hex bolts, remove and discard screws/bolts securing rocker cover; remove rocker cover.
10. Remove and discard rocker cover gasket. (Scheme 34)

1. Clean mating faces of rocker cover and cylinder head, ensure bolt holes are clean and dry.
2. Fit a NEW gasket dry, position rocker cover ensuring gasket is correctly located.
3. Fit NEW "patched" multi-hex rocker cover bolts ensuring that 2 short bolts are on side of rocker cover nearest center of engine.
4. Tighten bolts by diagonal selection to: Stage 1 3 N.m (2.5 ft. lbs) Stage 2 8 N.m (6.0 ft. lbs)
5. Ensure that outer rim of gasket is correctly positioned around periphery of rocker cover.
6. Secure hot leads in rocker cover clips.
7. Secure injector harness to fuel rail and connect multiplugs to injectors.
8. Position alternator cables and tighten terminals to specification: B+ Nut Tighten to 18 N.m (13 ft. lbs) D+ Nut Tighten to 5 N.m (3 ft. lbs)
9. Clean coolant rail "O" ring recess.
10. Lubricate and fit NEW "O" ring to coolant rail, position coolant rails, fit bolts and tighten to 22 N.m (16 ft. lbs).
11. On models with SAI: Apply a small amount of engine oil to top of air manifold union nuts and around air manifold pipes.
12. On models with SAI: Position air manifold and finger tighten both air manifold union nuts.
13. On models with SAI: Tighten both union nuts to 25 N.m (18 ft. lbs).
14. Fit upper inlet manifold.
15. Refill cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-139295-S42055824182004100500000) .

Scheme 25

1. Release turnbuckles and remove battery cover.
2. Disconnect battery earth lead.
3. Raise front of vehicle.
4. Remove underbelly panel. See «REMOVE»(ref-207934-S39396697302005120400000).
5. Position a jack beneath the sump, and support the engine on the jack.
6. Remove 2 nuts securing engine mountings to chassis. (Scheme 35)
7. Remove nut securing left 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.

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 left engine mounting and tighten to 85 N.m (63 ft. lbs).
5. Fit underbelly panel. See «REFIT»(ref-207934-S22113737512005120400000) .
6. Remove stand(s) and lower vehicle.
7. Connect battery earth lead.
8. Fit battery cover and secure turnbuckles.

Scheme 26

1. Release turnbuckles and remove battery cover.
2. Disconnect battery earth lead.
3. Raise front of vehicle.
4. Remove underbelly panel. See «REMOVE»(ref-207934-S39396697302005120400000).
5. Position a jack beneath the sump, and support the engine on the jack.
6. Remove 2 nuts securing engine mountings to chassis. (Scheme 36)
7. Remove nut securing right 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.

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 N.m (63 ft. lbs).
5. Fit underbelly panel. See «REFIT»(ref-207934-S22113737512005120400000) .
6. Remove stand(s) and lower vehicle.
7. Connect battery earth lead.
8. Fit battery cover and secure turnbuckles.

Scheme 27

Scheme 28

Scheme 29

1. Raise vehicle on lift.
2. Remove 8 bolts securing rear cross member and remove cross member. (Scheme 37)
3. Support transfer gearbox on jack.
4. Release and disconnect HO2S multiplug. (Scheme 38)
5. Remove nut securing mounting to body bracket. (Scheme 39)
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.

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 N.m (63 ft. lbs).
3. Fit nut securing mounting to body bracket and tighten to 48 N.m (35 ft. lbs).
4. Tighten nut securing mounting to gearbox bracket to 48 N.m (35 ft. lbs).
5. Connect HO2S multiplug and secure to support bracket.
6. Position rear cross member, fit bolts and tighten to 26 N.m (19 ft. lbs).
7. Lower vehicle.

Scheme 30

1. Raise vehicle on lift.
2. Remove 8 bolts securing rear cross member and remove cross member. (Scheme 37)
3. Support transfer gearbox on jack.
4. Remove nut securing mounting to body bracket. (Scheme 40)
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.

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 N.m (63 ft. lbs).
3. Fit nut securing mounting to body bracket and tighten to 48 N.m (35 ft. lbs).
4. Tighten nut securing mounting to gearbox bracket to 48 N.m (35 ft. lbs).
5. Position rear cross member, fit bolts and tighten to 26 N.m (19 ft. lbs).
6. Lower vehicle.

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

1. Drain engine oil and remove oil filter. See «REPLACE»(ref-207932-S35705178862005120400000).
2. Remove radiator.
3. Remove upper inlet manifold. See «GASKET - INLET MANIFOLD»(ref-158799-S11640340422005013100000).
4. Remove ignition coil assemblies.
5. Position absorbent material to catch spillage and disconnect fuel pipe from fuel rail.
6. Release 2 hose clips and remove top hose.
7. Using a 15-mm spanner, release auxiliary drive belt tension and remove drive belt. (Scheme 41)
8. Remove 3 bolts securing ACE pump, release pump and tie aside. (Scheme 42)
9. Disconnect multiplug from A/C compressor.
10. Remove 4 bolts securing A/C compressor, release compressor and tie aside. (Scheme 43)
11. Remove bolt securing oil cooling pipes to PAS pump housing and remove saddle clamp. (Scheme 44)
12. Release PAS pump high and low pressure pipes and position aside.
13. Release clips securing hose to coolant pump and coolant rail, release hose and position aside. (Scheme 45)
14. Release 2 harness clips from coolant rail.
15. Remove bolt securing coolant rail and position rail aside. (Scheme 46)
16. Remove bolt securing engine earth lead and position earth lead aside.
17. Remove nut securing engine harness positive lead to battery, release lead and position aside. (Scheme 47)
18. Release clips and remove fuse box cover.
19. Remove bolt securing starter lead to fuse box, release lead and position aside. (Scheme 48)
20. Disconnect 2 engine harness multiplugs from fuse box.
21. Disconnect multiplug from EVAP purge valve. (Scheme 49)
22. Remove nut securing engine harness earth to body and disconnect engine harness to main harness multiplug. (Scheme 50)
23. Remove trim fixings securing toe board and remove toe board. (Scheme 51)
24. Disconnect 5 multiplugs connecting engine harness to ECM. (Scheme 52)
25. Release engine harness, pull into engine bay and coil on top of engine.
26. Raise vehicle on ramp.
27. Remove 3 bolts securing oil cooling pipes to sump and remove saddle clamps. (Scheme 53)
28. Tie oil cooling pipes aside.
29. Remove exhaust front pipe.
30. On models with automatic gearbox: Remove access plug and remove 4 bolts securing torque converter to drive plate. (Scheme 54)
31. Rotate engine to access bolts.
32. Remove 12 bolts securing engine to gearbox. DO NOT remove the top 2 bolts at this stage. (Scheme 55)
33. Collect support brackets from bell housing bolts.
34. Attach suitable lifting equipment to engine.
35. Remove 4 nuts securing engine mountings, raise engine and remove engine mountings. (Scheme 56)
36. Lower engine, remove top bolts securing engine to gearbox and collect bracket. (Scheme 57)
37. Support gearbox on a jack.
38. Release engine from gearbox dowels.
39. With assistance remove engine from engine bay.

1. Clean mating faces of engine and gearbox, dowel and dowel holes.
2. Lubricate splines and bearing surface on first motion shaft with grease.
3. With assistance position engine in engine bay, align to gearbox and locate on dowels.
4. Position support brackets, fit bell housing bolts and tighten to 50 N.m (37 ft. lbs).
5. Position engine mountings, fit nuts and tighten to 85 N.m (63 ft. lbs).
6. Lower lifting equipment and remove from engine.
7. Models with automatic gearbox: Align torque converter to drive plate, fit bolts and tighten to 50 N.m (37 ft. lbs). Fit access plug.
8. Fit exhaust front pipe.
9. Position oil cooling pipe saddle clamps and tighten bolts.
10. Position engine harness into foot well.
11. Connect 5 multiplugs to ECM.
12. Fit toe board and secure with trim fixings.
13. Connect engine harness earth to body and secure with nut.
14. Connect engine harness to main harness multiplug.
15. Connect multiplug to EVAP purge valve.
16. Connect engine harness multiplugs to fuse box.
17. Connect starter lead to fuse box and secure with nut.
18. Connect engine harness positive lead to battery and tighten nut.
19. Fit fuse box cover.
20. Position engine earth lead and secure with bolt.
21. Position coolant rail and secure with bolt.
22. Connect harness clips to coolant rail.
23. Connect hose to coolant rail and coolant pump and secure with clips.
24. Connect PAS pump high and low pressure pipes and secure with clips.
25. Position oil cooling pipe saddle clamp to PAS pump housing and secure with bolt.
26. Clean A/C compressor and housing mating faces, dowels and dowel holes.
27. Position A/C compressor, fit bolts and tighten to 22 N.m (16 ft. lbs).
28. Connect multiplug to A/C compressor.
29. Clean ACE pump and housing mating faces, dowels and dowel holes.
30. Position ACE pump, fit bolts and tighten to 22 N.m (16 ft. lbs).
31. Clean all pulley VEE, fit auxiliary drive belt, using a 15-mm spanner, release belt tensioner secure belt and re-tension drive belt.
32. Ensure auxiliary drive belt is correctly located on all pulleys.
33. Fit radiator.
34. Fit top hose and secure with clips.
35. Connect fuel pipe to fuel rail.
36. Position ignition coils and connect hot leads.
37. Fit upper inlet manifold. See «GASKET - INLET MANIFOLD»(ref-158799-S11640340422005013100000) .
38. Fit NEW oil filter and refill engine with oil. See «REPLACE»(ref-207932-S35705178862005120400000) .
39. Top up gearbox oil. See «LUBRICATION»(ref-169035-S38733805962004112400000) .

Scheme 48

Scheme 49

Scheme 50

1. Remove manual gearbox.
2. Restrain flywheel.
3. Working in sequence, progressively slacken 6 bolts securing clutch cover to flywheel. Remove bolts. (Scheme 58)
4. Remove clutch cover.
5. Remove clutch plate.
6. Release Crankshaft Position (CKP) sensor multiplug from bracket. (Scheme 59)
7. Remove 2 bolts securing crankshaft sensor cover.
8. Remove crankshaft sensor cover.
9. Remove 2 nuts securing crankshaft sensor.
10. Remove crankshaft sensor.
11. Remove 6 bolts securing flywheel. (Scheme 60)
12. Remove flywheel.

Scheme 51

1. Clean mating faces of flywheel and crankshaft, dowel and dowel hole. Ensure bolt holes in crankshaft are clean and dry.
2. Fit flywheel to crankshaft and tighten bolts to 78 N.m (58 ft. lbs).
3. Clean crankshaft sensor and mating face.
4. Fit crankshaft sensor and tighten nuts to 6 N.m (4.4 ft. lbs).
5. Fit crankshaft sensor cover and tighten bolts to 6 N.m (5 ft. lbs).
6. Fit crankshaft sensor multiplug to bracket.
7. Clean clutch cover, drive plate and spigot bush in end of crankshaft. Renew worn components as necessary.
8. If refitting existing drive plate, apply Molycote FB 180 to splines.
9. Fit alignment tool LRT-12-001 to spigot bearing in crankshaft. (Scheme 61)
10. Fit drive plate onto tool LRT-12-001 ensure side marked FLYWHEEL SIDE is towards flywheel.
11. Fit clutch cover and locate on dowels.
12. Fit clutch cover bolts and tighten in diagonal sequence to 40 N.m (30 ft. lbs).
13. Fit gearbox assembly.

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.

Scheme 52

Scheme 53

1. Remove automatic gearbox. See «REMOVAL & INSTALLATION - AUTOMATIC TRANSMISSION»(ref-170706).
2. Remove 2 bolts securing CKP sensor cover.
3. Remove Crankshaft Position (CKP) sensor cover. (Scheme 59)
4. Remove 2 nuts securing CKP sensor.
5. Remove CKP sensor.
6. Early engines: Remove 4 bolts securing drive plate clamp ring and remove ring. (Scheme 62)
7. Early engines: Remove drive plate from hub.
8. Early engines: Remove 6 Allen bolts securing hub and starter ring gear, remove hub, starter ring gear and collect spacer. 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.
9. Later engines: Remove 4 bolts securing drive plate clamp ring and remove ring. (Scheme 63)
10. Later engines: Remove drive plate.
11. Later engines: Remove 6 Allen bolts securing starter ring gear to crankshaft; remove starter ring gear.

1. All engines: Ensure bolt holes in crankshaft are clean and dry.
2. All engines: Clean all component.
3. All engines: Check that drive plate is free from cracks and distortion.
4. Early engines: Fit hub, starter ring gear and spacer to crankshaft, fit Allen bolts and tighten to 78 N.m (58 ft. lbs).
5. Early engines: Fit drive plate and clamp ring, fit bolts and tighten to 45 N.m (33 ft. lbs).
6. Later engines: Fit starter ring gear, fit Allen bolts and tighten to 85 N.m (63 ft. lbs).
7. Later engines: Fit drive plate and clamp ring, fit bolts and tighten to 45 N.m (33 ft. lbs).
8. Clean CKP sensor and mating face.
9. Fit crankshaft sensor and tighten nuts to 6 N.m (5 ft. lbs).
10. Fit CKP sensor cover and tighten bolts to 6 N.m (5 ft. lbs).
11. Fit CKP sensor multiplug to bracket.
12. Fit automatic gearbox. See «REMOVAL & INSTALLATION - AUTOMATIC TRANSMISSION»(ref-170706) .

Scheme 54

1. Remove flywheel. See «FLYWHEEL»(ref-158799-S16523719052005013100000).
2. Drill a 3 mm (0.12 in) diameter hole at root of 2 teeth. (Scheme 64)
3. Apply a cold chisel in root of one of ring gear teeth, strike chisel with hammer to break ring gear.
4. Remove starter ring gear.

Scheme 55

1. Clean flywheel and starter ring gear.
2. Heat NEW starter ring gear evenly to 350°C (660°F), indicated when the ring is a Light Blue color. (Scheme 65)
3. Locate ring gear on flywheel and press ring gear hard against flange on flywheel.
4. Ensure ring gear is correctly seated around the complete circumference of flywheel and allow to cool.
5. Fit flywheel. See «FLYWHEEL»(ref-158799-S16523719052005013100000).

Scheme 56

1. Clean area around filter head and place a container beneath engine.
2. Using a strap wrench, unscrew and discard filter. (Scheme 66)

1. Clean mating face of filter head.
2. Lubricate sealing ring of NEW filter with clean engine oil.
3. Fit filter and tighten by hand until it seats then tighten a further half turn.
4. Start and run engine to check for leaks.
5. Stop engine, wait a few minutes, then check oil level.
6. Top up engine oil.

Scheme 57

1. Remove sump gasket. See «GASKET - SUMP»(ref-158799-S39265238712005020200000).
2. Remove 2 bolts and one nut securing oil pick- up strainer. (Scheme 67)
3. Remove oil pick-up strainer.
4. Collect spacer from stud.
5. Remove and discard "O" ring.

1. Clean oil pick up strainer and "O" ring recess.
2. Lubricate and fit NEW "O" ring.
3. Locate spacer on stud.
4. Position oil pick-up strainer, fit bolts and tighten to 10 N.m (8 ft. lbs). Fit nut and tighten to 22 N.m (16 ft. lbs).
5. Fit NEW sump gasket. See «GASKET - SUMP»(ref-158799-S39265238712005020200000) .

Scheme 58

1. Remove timing gear cover gasket. See «GASKET - TIMING GEAR COVER»(ref-158799-S30584393282005013100000).
2. Remove bolt securing CMP sensor, remove clamp and sensor. (Scheme 68)
3. Remove 6 bolts securing coolant pump, remove pump and discard gasket.
4. Remove oil pressure switch and discard sealing washer.
5. Remove 4 bolts securing oil filter head, remove filter head and discard 2 "O" rings.
6. Remove filter head adaptor.

1. Ensure filter head adaptor is clean.
2. Fit filter head adaptor and tighten bolts to 13 N.m (9 ft. lbs).
3. Clean filter head and mating face.
4. Fit NEW "O" rings to filter head and filter head adaptor.
5. Fit filter head and tighten bolts to 8 N.m (6 ft. lbs).
6. Ensure oil pressure switch and mating face is clean.
7. Fit NEW sealing washer and tighten switch to 15 N.m (11 ft. lbs).
8. Clean coolant pump and mating face.
9. Use a NEW gasket and fit coolant pump. Tighten bolts securing coolant pump to 25 N.m (19 ft. lbs).
10. Ensure CMP sensor is clean and fit sensor to cover.
11. Fit clamp to CMP sensor and tighten bolt to 8 N.m (6 ft. lbs).
12. Fit timing gear cover gasket. See «GASKET - TIMING GEAR COVER»(ref-158799-S30584393282005013100000) .

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Remove dipstick.
4. Raise the vehicle on a ramp.
5. Drain engine oil. See «REPLACE»(ref-207932-S35705178862005120400000).
6. Remove 8 bolts securing cross member and remove cross member. (Scheme 69)
7. Raise front of vehicle under body to increase clearance between engine and front axle.
8. Disconnect and release gearbox oil cooler pipe and discard "O" ring. (Scheme 70)
9. Remove 2 clips securing oil cooler pipes at front of sump. (Scheme 71)
10. Remove clip securing oil cooler pipes to side of sump. (Scheme 72)
11. Remove clip bracket.
12. Remove 2 forward facing bolts securing sump to bell housing. (Scheme 73)
13. Remove 4 rear facing bolts securing sump to bell housing.
14. Remove 2 bolts in sump recess.
15. Remove 3 nuts securing front of sump.
16. Remove 12 bolts securing sump flange to engine.
17. Maneuver sump over front axle and remove sump.
18. Discard sump gasket.

Scheme 64

Scheme 65

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. (Scheme 74)
4. Fit NEW gasket, dry, to sump, ensuring that locating tags are correctly positioned.
5. Maneuver 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 N.m (16 ft. lbs). (Scheme 75)
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 N.m (18 ft. lbs).
14. Refill engine oil and fit dipstick.
15. Connect battery earth lead.
16. Fit battery cover and retain with fixings.

Scheme 66

1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Raise front of vehicle.
4. Remove fixings and remove underbelly panel.
5. Disconnect multiplug from oil pressure switch. (Scheme 76)
6. Position container below switch to catch oil spillage.
7. Remove oil pressure switch and discard sealing washer.

1. Clean oil pressure switch threads.
2. Fit NEW sealing washer to switch.
3. Fit oil pressure switch and tighten to 15 N.m (11 ft. lbs).
4. Connect multiplug to oil pressure switch.
5. Fit underbelly panel and secure with fixings.
6. Remove stand(s) and lower vehicle.
7. Connect battery earth lead.
8. Fit battery cover and retain with fixings.
9. Top up engine oil.

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

1. Release fixings and remove battery cover.
2. Release fixings and remove cooling fan cowl.
3. Remove front grille. See «REMOVE»(ref-207934-S31877035392005120400000).
4. Remove 6 scrivets and remove left and right air deflectors from front panel. (Scheme 77)
5. Remove nut and move left horn aside. (Scheme 78)
6. Remove 2 bolts securing radiator left and right upper mounting brackets to body panel and remove brackets. (Scheme 79)
7. Remove 4 screws securing air conditioning condenser left and right upper mounting brackets to condenser.
8. Remove condenser upper mounting brackets with rubber mounts from radiator extension brackets.
9. Remove 2 bolts securing left and right extension brackets to radiator and remove brackets. (Scheme 80)
10. Position absorbent cloth under each oil cooler hose connection to collect oil spillage. (Scheme 81)
11. Push against coupling release rings and disconnect both hoses from oil cooler.
12. Remove screw securing oil cooler to radiator.
13. Release cooler from its location on radiator.
14. Release radiator lower mountings from location in chassis and carefully move radiator towards engine sufficiently only to release engine oil cooler from radiator. (Scheme 82)
15. Remove engine oil cooler.

1. Fit engine oil cooler to radiator, engage in location and secure with screw.
2. Fit radiator to location in chassis.
3. Ensure connections are clean, then secure hoses to oil cooler.
4. Fit extension brackets to radiator and secure with bolts.
5. Fit brackets with rubber mounts to extension brackets and secure to air conditioning condenser with screws.
6. Fit radiator upper mounting brackets and secure to body with bolts.
7. Fit left horn and secure with nut.
8. Fit left and right air deflectors to front panel and secure with scrivets.
9. Fit front grille. See «REFIT»(ref-207934-S11530763662005120400000) .
10. Fit cooling fan cowl and secure with fixings.
11. Fit battery cover and secure with fixings.
12. Top up engine oil.

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

1. Remove oil pick-up strainer. See «STRAINER - OIL PICK-UP»(ref-158799-S25127749082005013100000).
2. Remove timing gear cover oil seal. See «SEAL - COVER - TIMING GEARS»(ref-158799-S09133079372005013100000).
3. Remove engine oil filter. See «FILTER - OIL»(ref-158799-S35247622872005013100000).
4. Remove and discard 3 bolts securing coolant pump pulley and remove pulley. (Scheme 83)
5. Remove 3 bolts securing PAS pump pulley and remove pulley. (Scheme 84)
6. Drain cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-139295-S42055824182004100500000).
7. Release clip and disconnect coolant hose from coolant pump. (Scheme 85)
8. Disconnect multiplug from oil pressure switch. (Scheme 86)
9. Disconnect multiplug from CMP sensor.
10. If fitted: Loosen union and disconnect oil cooler pipe from timing gear cover. Remove and discard "O" ring.
11. Remove 9 bolts securing timing gear cover and remove cover. Remove and discard gasket. (Scheme 87)

Scheme 78

Scheme 79

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. (Scheme 88)
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 N.m (17 ft. lbs). Ensure CMP sensor multiplug bracket is secured by bolt. (Scheme 89)
7. If fitted: Fit NEW "O" ring to oil cooler pipe, connect pipe to timing gear cover and tighten union to 15 N.m (11 ft. lbs).
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 N.m (16 ft. lbs).
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 N.m (16 ft. lbs).
14. Ensure mating faces of oil filter and adaptor are clean, smear clean engine oil onto seal and fit filter. See «FILTER - OIL»(ref-158799-S35247622872005013100000).
15. Fit timing gear cover oil seal. See «SEAL - COVER - TIMING GEARS»(ref-158799-S09133079372005013100000).
16. Fit oil pick-up strainer. See «STRAINER - OIL PICK-UP»(ref-158799-S25127749082005013100000).
17. Refill cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-139295-S42055824182004100500000)

Scheme 80

Scheme 81

1. Remove auxiliary drive belt. See «GENERATORS & REGULATORS»(ref-26433).
2. Secure tool LRT-12-080 to crankshaft pulley with 2 bolts. (Scheme 90)
3. Remove crankshaft pulley bolt.
4. Remove crankshaft pulley.
5. Use tool LRT-12-088, to remove oil seal from timing gear cover. (Scheme 91)

Scheme 82

1. Clean seal register in timing gear cover and crankshaft pulley.
2. Apply smear of Retinax LX grease to seal running surface on crankshaft.
3. Fit seal to timing gear cover using tool LRT-12- 089. (Scheme 92)
4. Fit crankshaft pulley bolt and tighten to 270 N.m (200 ft. lbs).
5. Remove tool LRT-12-080 from crankshaft pulley.
6. Fit auxiliary drive belt. See «GENERATORS & REGULATORS»(ref-26433).

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

1. Disconnect multiplug from coolant thermistor. (Scheme 93)
2. Disconnect multiplugs from injectors; release injector harness from fuel rail and position aside.
3. Remove 3 bolts securing PAS pump pulley and remove pulley. (Scheme 94)
4. Loosen bolt securing jockey pulley and remove pulley.
5. Remove 4 bolts and one nut securing auxiliary housing and remove housing. (Scheme 95)
6. Remove 2 nuts securing alternator cables and release the cables.
7. Remove two bolts securing alternator and remove alternator. (Scheme 96)
8. Remove 4 bolts securing coolant outlet elbow and remove outlet elbow. (Scheme 96)
9. Remove and discard "O" ring.
10. Release hot leads from rocker covers.
11. Noting fitted position of 4 long screws or multi-hex bolts, remove and discard 8 screws/bolts securing rocker covers; remove rocker covers. (Scheme 97)
12. Remove and discard rocker cover gaskets.
13. Using the sequence shown, remove 12 bolts securing the inlet manifold. (Scheme 98)
14. Remove inlet manifold assembly.
15. Remove 2 bolts securing manifold gasket and collect gasket clamps. (Scheme 99)
16. Remove inlet manifold gasket.
17. Remove gasket seals.

Scheme 89

1. Clean sealant from cylinder head and from notches in the cylinder block.
2. Clean mating faces of cylinder block, cylinder head and manifold.
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: Initially, tighten bolts numbered 1, 4, 9 and 12 in numerical order to 5 N.m (4 ft. lbs). (Scheme 100) Inlet manifold bolts - initial tighten = 10 N.m (8 ft. lbs). Inlet manifold bolts - final tighten = 51 N.m (38 ft. lbs). Tighten inlet manifold gasket clamp bolts to = 18 N.m (14 ft. lbs). Tighten inlet manifold bolts to = 51 N.m (38 ft. lbs).
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 covers nearest center of engine.
14. Tighten bolts by diagonal selection to: Stage 1 3 N.m (2.5 ft. lbs). Stage 2 8 N.m (6.0 ft. lbs).
15. Ensure that outer rim of each gasket is correctly positioned around periphery of rocker cover.
16. Secure hot 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 N.m (17 ft. lbs).
20. Position alternator, fit mounting bolts and tighten to 45 N.m (34 ft. lbs).
21. Position alternator cables and tighten terminals: B+ Tighten to 18 N.m (13.0 ft. lbs) D+ Tighten to 5 N.m (3.5 ft. lbs)
22. Position auxiliary housing, fit bolts and tighten to 40 N.m (30 ft. lbs). Fit nut and tighten to 22 N.m (17 ft. lbs).
23. Clean jockey pulley mating faces.
24. Position jockey pulley and tighten bolt to 50 N.m (37 ft. lbs).
25. Clean PAS pump pulley mating faces.
26. Position PAS pump pulley, fit bolts and tighten to 22 N.m (17 ft. lbs).
27. Secure injector harness and connect injector multiplugs.
28. Connect multiplug to coolant thermistor.

Scheme 90

1. Remove 8 bolts securing exhaust manifold and collect spacers. Discard the bolts.
2. Remove exhaust manifold. (Scheme 101)
3. Remove 2 manifold gaskets and discard.

Scheme 91

1. Clean exhaust manifold and cylinder head mating face.
2. Fit NEW gaskets, dry, fit exhaust manifold.
3. Fit spacers to NEW manifold bolts and, working in the sequence illustrated, initially tighten bolts to 15 N.m (11 ft. lbs), then finally tighten to 38 N.m (28 ft. lbs). see scheme 102

Scheme 92

Scheme 93

Scheme 94

1. Remove CKP sensor. See «REMOVAL»(ref-174122-S01059551712005032900000).
2. Early Engines Remove 4 bolts securing drive plate clamp ring and remove ring. see scheme 103
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.
5. Later Engines Remove 4 bolts securing drive plate clamp ring and remove ring. see scheme 104
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. see scheme 105

Scheme 95

1. Ensure both seal location and running surface on crankshaft are clean. Ensure that bolt holes in crankshaft are clean and dry.
2. Lubricate replacement oil seal with engine oil.
3. Lubricate seal guide LRT-12-095 with engine oil and position guide to crankshaft. see scheme 106
4. Fit NEW seal squarely onto crankshaft and remove guide LRT-12-095.
5. Fit seal into location using tools LRT-12-091 and LRT-99-003.
6. All Engines Ensure bolt holes in crankshaft are clean and dry.
7. All Engines Clean all components.
8. All Engines Check that drive plate is free from cracks and distortion.
9. Early Engines Fit hub, starter ring gear and spacer to crankshaft, tighten Allen bolts to 78 N.m (58 ft. lbs).
10. Early Engines Fit drive plate and clamp ring, tighten bolts to 45 N.m (35 ft. lbs).
11. Later Engines Fit starter ring gear, fit Allen bolts and tighten to 85 N.m (63 ft. lbs).
12. Later Engines Fit drive plate and clamp ring, fit bolts and tighten to 45 N.m (33 ft. lbs).
13. Fit CKP sensor. See «INSTALLATION»(ref-174122-S31500708762005032900000).

Scheme 96

Scheme 97

Scheme 98

1. Restrain flywheel.
2. Working in sequence, loosen and remove 6 bolts securing clutch cover to flywheel. see scheme 107
3. Remove clutch cover.
4. Remove clutch plate.
5. Remove CKP sensor. See «REMOVAL»(ref-174122-S01059551712005032900000).
6. Remove 6 bolts securing flywheel. see scheme 108
7. Remove flywheel.
8. Carefully remove oil seal from cylinder block to avoid damage to seal location or running surface on crankshaft. see scheme 109

Scheme 99

1. Ensure both seal location and running surface on crankshaft are clean. Ensure that bolt holes are clean and dry.
2. Lubricate replacement oil seal with engine oil.
3. Lubricate seal guide LRT-12-095 with engine oil and position to crankshaft.
4. Fit NEW seal squarely onto crankshaft and remove guide LRT-12-095.
5. Fit seal into location using tools LRT-12-091 and LRT-99-003. see scheme 110
6. Clean mating faces of flywheel and crankshaft, dowel and dowel hole.
7. Fit flywheel to crankshaft and, working in a diagonal sequence, tighten bolts to 78 N.m (58 ft. lbs).
8. Fit CKP sensor. See «INSTALLATION»(ref-174122-S31500708762005032900000).
9. Clean clutch cover, drive plate and spigot bush in end of crankshaft.
10. Renew worn components as necessary.
11. If refitting existing drive plate, apply Molycote FB 108 to splines.
12. Fit LRT-12-001 alignment tool to spigot bearing in crankshaft.
13. Fit drive plate onto alignment tool, ensure side marked FLYWHEEL SIDE is against flywheel.
14. Fit clutch cover and locate on dowels.
15. Fit clutch cover bolts and tighten in diagonal sequence to 40 N.m (30 ft. lbs).

Scheme 100

Scheme 101

1. Remove 6 bolts securing clutch cover. see scheme 111
2. Remove clutch cover.
3. Tap a thread in spigot bush to accommodate a suitable impulse extractor.
4. Fit extractor to bush (spigot bearing).
5. Remove pilot bush (spigot bearing) from crankshaft. see scheme 112