300Tdi Discovery
V8i
9
REPAIR
FRONT COVER GASKET
Service repair no - 12.65.04
1. Remove crankshaft pulley.
See Crankshaft
Pulley Assembly. Do not remove pulleys
2. Remove water pump pulley.
3. Release distributor cap clips.
4. Release plug leads from plugs and clips.
5. Place cap and leads to one side.
6. Turn engine until No. 1 piston is at T.D.C.
7. Check position of rotor arm.
8. Remove fixings securing power steering pump
bracket to water pump bracket.
9. Remove power steering pump bracket from
water pump.
10. Remove clips securing wiring to generator
tensioner.
11. Disconnect distributor feed wire.
12. Pivot power steering pump away from front
cover, tighten pivot to retain in position.
13. Disconnect vacuum pipe from distributor.
14. Remove water pump bottom hose.
15. Disconnect oil pressure switch.
16. Disconnect heater hose at water pump.
17. Remove generator tensioner from water pump,
move tensioner aside.
18. Mark distributor position to front cover.
19. Remove distributor clamp, remove distributor.
See ELECTRICAL, Repair, Distributor - V8i
20. Remove fixings sump to front cover.
21. Loosen four adjacent sump fixings.
22. Remove generator support strut from front cover,
move strut aside.
23. Loosen remaining front cover fixings and remove
front cover.
24. Remove front cover gasket.
Refit
25. Clean timing cover, clean block face.
26. Lightly grease gasket faces.
27. Fit new gasket to block face.
28. Apply hylosil to sump gasket.
29. Clean threads of cover fixing bolts, apply Loctite
372 to threads.
30. Fit timing cover, fit fixing bolts. Tighten to
28
Nm.
31. Fit generator support strut to front cover.
32. Tighten sump to timing cover fixings to
10 Nm.
33. Tighten sump fixings to
10 Nm.
34. Lubricate distributor O ring.
35. Fit distributor in position marked.
36. Align oil pump drive, if distributor does not seat
correctly.
37. Fit distributor clamp. Tighten to
20 Nm.
38. Locate generator tensioner on water pump
bracket.
39. Connect heater hose, tighten clip.
40. Connect oil pressure switch.
41. Connect bottom hose, tighten clip.
42. Connect vacuum pipe to distributor.
43. Loosen power steering pump pivot, lower pump.
44. Connect distributor feed wire.
45. Connect wire ties to generator tensioner.
46. Fit power steering pump bracket to water pump.
Tighten to
28 Nm.
47. Fit power steering pump to bracket.
48. Position distributor cap. Fit plug leads to plugs
and clips.
49. Clip distributor cap in position.
50. Fit water pump pulley. Tighten to
10 Nm.
51. Fit crankshaft pulley.
See Crankshaft Pulley
Assembly
52. Tension drive belts correctly.
53. Check ignition timing.
54. Refill cooling system.
