300Tdi Discovery
12
ENGINE
20
REPAIR
CYLINDER HEAD GASKET
Service repair no - 12.29.02
Remove
1. Disconnect battery negative lead.
2. Remove bonnet [Hood].
See CHASSIS AND
BODY, Repair, Bonnet [Hood]
3. Drain coolant.
4. Remove air cleaner assembly.
See FUEL
SYSTEM, Repair, Air Cleaner
5. Detach crankcase ventilation valve and side
breather hose from rocker cover and move to
one side.
6. Remove injection pipes.
7. Disconnect spill rail from fuel injectors.
8. Remove fuel injectors and sealing washers.
Identify each injector to the location from which it
is removed.
See FUEL SYSTEM, Repair,
Injectors
9. Remove inter-connecting harness from glow
plugs.
10. Remove glow plugs.
See FUEL SYSTEM,
Repair, Glow Plugs
11. Remove top hose, radiator to thermostat.
12. Disconnect by-pass hose from thermostat.
13. Disconnect hose, thermostat to water pump.
14. Disconnect water temperature sensor lead.
15. Remove hose inter-cooler to induction manifold.
16. Remove induction manifold.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
Manifold - Tdi
17. Remove exhaust manifold and turbocharger
assembly.
See MANIFOLD AND EXHAUST
SYSTEM, Repair, Exhaust Manifold - Tdi
18. Disconnect heater hose from water pump and
move heater rail aside.
19. Disconnect heater hose from rear of cylinder
head.
20. Remove bolt securing air cleaner mounting
bracket to support strut.
21. Remove bolt securing harness bracket to
cylinder head.
22. Remove rear lifting bracket, this will also release
clips securing transmission and engine breather
pipes and multiplug. Note loose spacer under
clip securing engine breather pipe and multiplug.
