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Discovery Series 2 BOSCH Head Gasket DIY Installation Part 2
Our Land Rover Master Technician, as he takes You step-by-step, in the replacement of the head gaskets on Our 2000 Discovery Series II with V8 BOSCH engine. We use our
kit # STC4082BKA which includes the head gasket set plus a set of head bolts. This is part 2 of 2 videos focusing on this topic. Part 1 shows the teardown and part 2 is the re-installation. We also cover replacement of the Discovery Series II short block engine. all right so you've seen us tear this down now we're gonna go over the things that we need to do before we start assembling the heads as you can see we have everything here and let's start putting it together so now we're at the point now we want to assemble the heads before we set them up on the block so just for a breakdown this is basically what you're gonna be assembling here we'll start with the head assembly itself the things you want to check obviously are for a clean straight surface for the valve cover for the exhaust and then most importantly for the head to block connection and you can see we have this all cleaned up now what we did too is we had put a straight edge on this and we can and you can actually get them out of an any automotive center someone will even loan them to you but these straight edges are accurate to within a half a thousandth of an inch and you want to do a crisscross pattern and then a straight up pattern and you want to basically look for any spots where you could see light if you hold a flashlight behind it and what that does it tells you that at that point then the head would need to be reground this one was in good shape and the bottom line is you don't want to have to have it surfaced if you don't need to reason being is if it had already been surfaced and was with inspection you have it cut again when you cut these and you cut too much off of them it because of the V pattern on the block it draws the heads closer together so what happens then is you may be able to give all the heads down but when you put the lower intake manifold on all holes aren't going to line up they're now closer together and not where they should be in regard to the manifold so keep that in mind if you like you can actually go on some of the forms that are out there you can download a program called rave Rav II and that has the overhaul manual which will give you a lot of the specs for how far you can cut the heads your torque specs for all your bolts and some some of your assembly run down beside our video so all that information makes this a little bit easier so again in this hope we we check the surface we look there surfaces are good our bracket is on now this is the driver's side head we want to make sure your ground strap is on now one thing we want to check is the oil delivery holes that run oil up to the rockers okay the way they're mounted on top and you'll see you got basically a small hole here this is a 5/32 drill bit we're just going to run that down we want to make sure that one is nice and clear that looks good and this one we can feel some drag and sure enough we've got some sticky mung in there so we're gonna do is take some break clean and blow that out on the same token the coinciding openings in the rocker arms you have your oil delivery holes feed a small chamber on the bottom of the rocker and as you can see there we get some buildup actually quite a bit and that can also cause a lowering of the oil pressure to the rockers so we want to make sure that's open and clean so we're going to clean those out we're gonna make sure those are open and then the next step would be to get the exhaust manifold bolted on so you know which manifold it is on your left side head of the two manifolds the single bolt that single bolt will always point towards the front of the engine so when you set the manifold on place if that's up front this is the correct manifold now we're going to show you something else in regard to the exhaust manifold gaskets proper positioning would be like so nope sorry like so reason being is this cross piece here that connects the two ports is below the spark plug and the head bolt now as you can see these can be mounted upside down and should you make that mistake you are now blocking off access to the head bolt and to the spark plug so when you put these gaskets on it should look like this with that cross piece laying on the bottom and then the front would be exactly the same so from there then we're gonna put the exhaust manifold bolts on don't forget that you have spacers on these bolts I've had this in this little little tray soaking and penetrating oil just to get them lubed up so these are gonna be a 12 millimeter 12-point don't forget to make sure you put your spacer so it's going to be your gasket your manifold and your spacer and then we'll lock those down good and tight and then spark plugs now we find the champions seem to run the best in these four all four six engines especially with the Bosch so you're going to set your gap which is also in the the the rave I believe these are 35 to 42 usually some at about 35 because as they where they'll stay within the specifications now is a good time to install them because it's right here in front of you you can lock them down you don't want to make them too tight because basically you've got the aluminum heads you don't want to over tighten the plugs then you're going to take a lot of torque just want to make sure you snug them in and then last but not least and I always replace the studs you'll see on the manifold that you're missing your three studs that go down through the catalytic converters reason being for that in many cases by the time you're doing an engine job on this the threads are pretty well worn off you might have even had to heat them up taking it out now these are set so that you have two different length threads the shorter end is going to go into the manifold leaving the extended area and the barrel extended out so we're going to just replace all those and it's the same thing if you have a stud puller a lock on that'll do a good job if not you can take a pair of needle nose vise grip and grab the barrel don't grab the threads spin that on and so essentially you don't see any more threads on a short and then you know it's fully seated and that's pretty much it so that at this point now once we get everything cleaned off and together we've ready to put the head on the engine all right so here's our heads completed and put together exhaust manifold spark plugs the rockers are on but loose because they're gonna come back off again e-way what do we get the heads on but they're they're they're cysts in sending the heads in place and you'll see why in a few minutes the other thing I want to mention here's your head gasket you can see that on one side they apply some red sealer and what you're gonna look for is that word top so that means that when you set this in place this is the top side this is what's going to be facing the head and again you can also recognize that by the rent sealer you see that red sealer you should be seeing that when you place it on the floor now you also have a couple locating pins on the block so you'd be able to actually set the head gasket and it'll stay in place when we lower the head on it all right so you see what I've done basically just run to rags underneath the rockers so that when they loop them under and come back up I have a good handle and threads the bolts are in you know a good 5 or 6 threads you want them in there a little bit you want to make sure this doesn't come loose second thing you want to mention always put a fennec cover on because there's a good chance you can end up popping into this you don't want to hit the fender you don't want to cause it dead just something else to work on later down the line so we're gonna do then is just simply lift up on the head I can lower it down in set it in place I only need to move it a little bit and it should pop right on you have two locating pins on the block itself one here and one in the back and it's going to hold the head gasket in place as well so everything will be lined right up and then we can put some head bolts in and get things torqued in so we got the head in place the pins will hold that it's not going to go anywhere taking the rockers back off you just back off the four bolts set that to the side because it will eventually go back on we got to put the lifters and the push rods in so you'll notice that we if you notice when you pulled it apart you had three long head bolts in the top Center and then the rest the remaining seven are the shorter bolts and there's your difference in length so we're going to put one of the long bolts in the top on the short bolt in the bottom in the center and then we'll just think we're gonna run the bus to the bolts install them and then just run them down so they're just touching when they're just touching the head and then from that point we're gonna well torque them up according to specs now specs on these we're going to be tightening them all to 15 foot-pounds and then you're going to turn each one 90 degrees with a breaker bar and then wait about 10 15 minutes and then an additional 90 degrees now being on this case we're starting with the new blocks we've got nice clean threads in the block for the head bolts they had this should this be a youth block or and you're doing just the head gaskets you want to make sure you run a thread chaser down each one of those holes you want to get it all corrosion dirt anything out of those sometimes it's even best if you have access to compress there shoot a little solvent down in each hole and blow it out with the air holding a rag over it so obviously you don't get in your face and from that point this way you won't always want to start with clean threads it's also recommended that before you run each head bolt in what we're going to do is keep a little bit of oil then we're just going to simply dip the end in those head bolts before we install them and this way you'll end up with a much better torque rating you're not fighting against any dirt or any buildup in those threads they're gonna thread in nice and easy so once we get those to win and it's essentially same procedure for the rest of the rest of the head bolts we're just going to run them in so they just touching the head so now we get the head bolts snugged in what we're gonna do that before we torque up now I want to just run this by anytime you put a head or a manifold or or even a pan like a pan gasket or a transmission pan anytime you tighten up something like that you always start from the center so you can do either top or bottom doesn't matter but you start in the center and then you simply work across and then in a outward spiral in other words so we do the bottom Center top Center then we can go to the left do top and bottom we're gonna go over to the other side bottom and then top and then around the top to bottom bottom the top and that's the best way to torque up ahead what that does is reduces Distortion you get a better lock down on it and then believe it or not make for a better job when you've done this once I'm going to wait a minute or two and then go around one more time just to make sure they're all evenly torqued all right so should have mentioned earlier the head to these bolts are 5/8 which is basically the same thing as a spark plug socket so I've used the swivel spark plug socket to run them in especially in those back corners it works very well but now that we're going to go to the 90 degree twist you're going to be getting into a much higher torque so we're going to step up to 1/2 inch drive 24-inch break a bar with a 5/8 socket on the end so we'll start in the middle and we'll go exactly 90 degrees and you can plus or minus 10 degrees it doesn't have to be absolutely perfect there are gauges out there that are available that you can actually install before you put the bolt on or socket on and it will show you at 90 degrees but 90 degrees is pretty much just a straight angle so what we'll do see like in this case really can't get a good bite on anything where it's gonna be easy to figure out 90 there we go alright so essentially here's 0 so 90 degrees is you're gonna run into where the bar should end up actually just about perpendicular to the block and we're essentially just gonna do the same thing all the way around the same thing we're gonna figure about where ninety degrees is languages right up against the farm all right then just to make it easier because the hardest ball to get ad through this whole operation is this back head bolt because we actually have to turn it to a specific torque so we've got a five base deep 1/2 inch drive socket swivel socket so this way we can get in at an angle and we'll essentially going to set it up so that it will not only drop on but set the square in an accessible point and then we can figure out 90 degrees from there so at this stage of the game this is when it gets a little tough because now we're going to do the final 90 we've waited about 10 15 minutes we let things settle in on the first torque now with the additional 90 this is gonna bring you up to over one hundred foot-pounds of torque on an average so what you may need to do when it gets real tight and a cheater bar on to this we're going to see if we can go the full 90 without having to add it in this case I think what we're going to do is because 90 is gonna put us past the firewall we're gonna go 45 and then pull this back and reset it and do the additional 45 so that's essentially the procedure for installing ahead and torquing down on their head gaskets now we're just going to do passenger's side exact same process as we did on the driver's side so next step is gonna be to install the push rods in the rockers now what he did was we cleaned up these push rods you want to put them on a nice smooth surface you want to roll them just to make sure nothing is bent you also want to check both ends kind of run your thumb nail over it if you have a if you have an error you're gonna just catch a little step at the bottom but if it feels really rough or even sharp edge you want to replace that push rod so we have all 16 all cleaned up nice and we've got the lifters in place so we're going to go back over to that engine and set things up all right first things first and I've seen guys do this these lifters come in and out of here fairly easy look at that making sure your gonna put that in facing up and not that end I've seen it done they just got to basically wiggle it'll seat in place they're all pretty well oiled because they've been soaked and you're gonna get down through the hole and you're gonna set up all your push rods make sure you go through the guides there's little holes there in the head that guide the top of the push rod all right so we're gonna set the rocker in place now remember we're gonna make sure you've got here's your rounded area where your push rods are going to seat and of course the flatlands end up on the valves so we'll just set this gently in place you want to get the bolts lined up now you got to remember that right now you're going to have there's going to be some of these push rods or in the up position because the cam they're writing directly on the cam which is going to create spring pressure on the rocker arm so when we tighten this down we just want to go a little bit at a time until we seat the rocker down on the head and then we'll put the torque wrench on it and torque specs on these are 28 foot-pounds once we have the all these bolts seated and we're just going to use a ratchet and a socket to see them down then we'll torque up the specs so we got the rockers down in place the rocker shaft will actually the lands are seated on the head so now we don't have to worry about working against spring pressure the reason we did that was because you could possibly bend that rocker shaft if you could torque one end down and the other has spring pressure it actually creates a force that can bend them so now that they're seated we'll start in the middle we've got their torque wrench set at 28 foot-pounds do the two in the middle and then we go to the outside and we do it one more time just so that we know we have an even torque on all four bolts okay it's pretty much it so now we just do the same on the other side and we'll have our rockers and push rods in place so our next step is we're gonna put the lower intake manifold on to do so you're gonna grab the two end seals that come in your gasket set your Valley pan gasket and then of course the intake and basically what we've done is we clean this off so we get a nice smooth surface on both sides and you're gonna need a 3/8 drive torque wrench now you can use a long extension with a swivel end I just happen to have this tool just makes it a little bit easier this is essentially a 13 millimeter swivel on an already built onto the extension gasket scraper in case you need a final cleanup of course a ratchet extension on now this is a tool that's similar to what the factory calls for and it makes it a lot easier to get to the bolts once you get things in place to torque them up you're gonna put this on the torque wrench it's essentially a 13 millimeter 12 point with 3/8 drive can be referred to as a crow foot sometimes socket extension there's a number of different names for them but this does make the job a lot easier so what we do is start off is we're going to take some of the we'll take some of the high tack and we're going to put a little coating on both sides of the heads I don't recommend using RTV on the gasket surfaces but we are gonna use some to seal up where you've got a couple different components like where the head meets the block and where the front cover meets but mostly just the two areas that where the where the head meets the blocks you have four points so we've done that we're going to let that tack up a little bit and then essentially we're going to take some of the RTV now right here you can actually see a little valley right where the head meets the block what we want to do is we want to fill that with some RTV this will help prevent oil we Benji and we'll let that set up for a few minutes you might get a little tacky so you'll notice the end seals basically conformed to the block so one side is fairly straight the other has a curve to it and you'll see that in the gasket as well plus on the end here you have a little wedge that drops down into that area that we are TV so it's going to push some there now in the manual it tells you to reply just put one little beat of our TV but I usually do it twice down in that Valley and then I'll do it one more time over the top before we put the pan gasket on so we got the two end seals in place a little Dabba RTV again on the corners just to give a little extra missile BC just a little extra protection against an oil leak we're gonna set the pan in place or the bolt holes you can look straight down and we'll push that down into place the next are your to hold down plates now if you remember when we took this apart we put this aside so that the two bolts that hold these down they're a little different than the bolts that are in the rest of the bar so you want to make sure that you've put these aside so we're gonna very gently lower the intake sort of in place but just a little ahead so we can reach in the back and then you've got a fuel line I've got to go on then you want to make sure you hear that click once you got it on there now if you look at the ten bolts that go in this item are all the same length there are two long ones and they're gonna go in the front here and then once we get them all started we're going to torque them down now the factory calls for a sequence to start with seven foot-pounds then all the way around again in 13 foot-pounds and then a final tighten in a 38 most of your 3h drive torque wrenches are not going to get down to seven pounds so I usually set mine at ten and then I'll do 20 and then we do 38 all the way around and even then we'll let it sit for about 15-20 minutes and then go 38 one more time around just to make sure everything's torqued down nice and tight and the gaskets been compressed so just like we mentioned with the heads anytime you torque down a head or a manifold anything like that to reduce the amount of distortion we're going to start from the center and then work our way around into a spiraling outward pattern and so we've talked them all as I said we're gonna do in different come we'll do 10 20 and then 38 and then after the 38 we're going to wait about 10-15 minutes and then do 38 again just to make sure everything's down and tightened properly all right so before we put the valve covers on we have an actual bolt that goes up into the back of the head that runs through that bracket right there and what that does is holds the harness in place right about there so we need to attach that and then we also need to attach the ground strap and if you'll notice on this you'll see a green wire with a loop that's also going to go to that ground post all right so now is the point you definitely want to plug in this is for the crank sensor you're going to see the the tab right here that lot latches on to that little notch so essentially that's the wrong way that's the right way plugged this together you should hear a little click when that blocks in and then there's a bracket on the back that you're not going to be able to see this video that this hooks into to keep it from banging around in there this is a really bad connector to try to get to alright so next is gonna be your valve covers now first thing I do if you notice there's a rag sitting on top of the intake manifold we want to cover those holes you're going to be handling small bolts god forbid you drop one and it goes down they'll put one of those ports and fish it out you'll end up taking the intake back off to get at it so we put a rag over there as protection and then what we've done is we've prepped the valve covers we've shot high tech on the inside areas of both valve covers and on the areas of the gasket itself that will lay on the surface reason for that is that when it gets good and tacky we let it sit for about 15 minutes you put your gasket on the valve cover it's gonna stick and it's going to hold to it otherwise trying to hold on to that and keep it from falling in and unsettling is just a royal pain so this way gas gets stuck to the valve cover we run our bolts down we line it up so much easier now remember that these bolts are eight millimeter 12-point so you want to make sure you pull that tool out and clean the bolts up a little bit just give him a little shoot down with some brake clean or whatever it's a little cleaner before you install alright so just as a note there's a groove cut on one side of the valve cover gasket and then one side is actually relatively flat except for one raised rib that's the area that's gonna make contact with the head so the groove the area actually seats all the way around in the valve cover make sure that all four your spacers are president they didn't drop out of the gasket and then we'll get them relatively close and then essentially put the four bolts in and remember you've got the two short on the inside part of the engine and the two long on the outside closer to the exhaust manifold so your passenger side first that has your oil fill tube now remember this is a Bosch engine where your fill tube is on the passenger side of course on a Jemez engine you're gonna find it on the driver's side no all we did was just basically hold up the wiring hard-ass sneak that in and then visually give a look at where the bolts line up and you can kind of wiggle it back and forth and you'll feel one of the little bolts kind of drop down in there what we're going to do is and we'll get them all started now the book says to torque to two and a half foot pounds you're gonna need a very small almost like a dial type quarter inch drive torque wrench if you want to torque it up it's two and a half pounds to do all four and then you go up to six pounds is the final torque on on all four bolts so one sides torqued in place and then simply we're just gonna do the exact same on the other side and before you started tightening bolts down because of all is wiring in one eye you just want to make sure you don't have a wire pinched between the valve cover and the head anywhere in the front or the back will lead the problems later on down the line so same thing with this side we've got some wires hanging around so we want to make sure that we don't get them we don't get them caught up in the valve cover and it's pretty much to it on those alright so they would have the valve covers in place we got the lower intake in place at this point we can grab the main harnesses we can kind of set them in place now in most cases when you when you first took this apart you had basically tie straps that went into these these four locations so of course they get brittle they fall apart you try to open them up they break so you can do it one of two ways you can actually wire tie it directly just loop under and wire tie it or I know a lot of automotive centers have the wire ties with what they call a little Christmas tree attached to them and that Christmas tree will pop right into those holes and wire tie the harness in place and that's what we're going to do with this but this way at least pull the harness out you'll also notice that there is one more green wire on this now if you have like a 2001 and later you probably aren't going to find these green wires this isn't this was a I think this was also this was a 2000 but you've seen this on the early disco twos don't see it so much on the later so if you don't see the green wires don't panic it's not that they're missing that just on that particularly design they're not used so don't worry about that rest of it this harness will get down the side of the bracket what we're really thinking about right now is we're going to put the main harness back in this place and then we're gonna plug in all the injectors and then this small bolt right here on the fuel rail is going to be the bolt we're gonna run out and then we're gonna attach that green wire right here for that round idle air control the one wire you want to be concerned with this wires for the knock sensor this is going to run all the way down and underneath you just want to make sure we get that down there because once we get the bracket and the alternator in place or I'm sorry the power steering pump in place we don't want to pinch that wire we want to make sure we put that in a good spot all right bingo okay that's good for now and then as we go along we'll be plugging everything else in all right so at this point now we're back underneath the vehicle we've got to get a few things connected yet now that one harness that has the lead for the starter the starter wire and for the knock sensor on the right hand side we got to sneak that through a hall that is on the upper back side of the mount so that it comes through to just above the starter so you got here's the end of your started connection this is going to go on to this nut here there's a small Spade pushing right on that right over the top of this stud and nut that's your for your s wire that'll be this lead right here and then you also have your connector that you're going to push in you're going to click into your knock sensor right here then once we've done that then we can sneak the heatshield in there and get that popped in place before we put the exhaust on so getting the shield back up in there sort of a bit of a magic trick this bracket tucked up into the all right you know we work on trying to get there's a tab on the end of this that drops into a hole which will help line up just kind of working back and forth until we find it there we go all right and that puts that in place so if you have a mirror what you can do is actually look up inside the mount the see if the holes lined up or not once we determine it isn't it or it isn't turn it the way we need to turn it to get it to line up all right so this is what the finished product should look like this clip is locked around the solenoid your wiring is protected from the heat from the heat shield and then the front bolt is in and locked in place so this is good and solid not going anywhere so now we just quickly we're gonna look through the other side and here we have the other knock sensor we've plugged that in and you'll notice that this loop lines right up with this hole right here and so what we're going to do is go find a bolt put the bolt in there and then that will lock that one piece of wire right there in place so keep it secure and then we can put the exhaust back up in place so now we're ready to put the exhaust up in place we've got to get your to hold gasket up in there and usually can push it up in place I always like to start on the driver's side and leaves me some flexibility on the passenger side we're not gonna run the nuts up tight initially we just want to get them up in place and then the front part is essentially getting up in there to get the gasket on this is actually sometimes a little easier from up top it says we're just gonna lay the gasket right over the opening we'll line up the holes all right so we're gonna hook the exhaust stop we find it's a lot easier to get to this passenger side setup then from underneath because you got the driveshaft and everything else in a way so we're just gonna sneak down in there then we're gonna slide the gasket up over the studs so we can raise that up and it's gonna take a little take a little doing but it will go and we got one two and three and then you can just raise the exhaust up you have to reach down in pull up on the exhaust and slide the studs over with one arm hold it up and the other we're gonna just put one nut on to help support it all right so we've got that side hooked up basically just got the three bolts and I just want to make note don't forget now's a good time to plug in that o2 sensor and then tuck the wire in back behind the right side head and it'll keep it out of the way the exhaust well it's just to give you a shot what we've done on the passenger's side you're going to leave the nuts loose you got allow for some slack and now we're going to pop the driver's side on all right so basically at this point now we've got the six nuts in on the exhaust we're going to run them up we got them completely tight as far as torque specs because of the long extension you need to get up there a torque wrench isn't going to be accurate anyway so you just want to essentially just get them good and tight and then don't forget to plug in your o2 sensor connector on the driver's side and we're going to tuck that back in behind the bracket so next what we're going to do is we'll get these transmission coolant lines back up in place gonna have to do a little don't be a little pushing in pollen but we essentially need to twist it get this one up into this upper clip the lower one into the lower clip and then we'll show you where the other one goes alright so we're gonna install the bracket now that supports the AC compressor and the steering pump you want to make sure if you have an oil cooler equipped vehicle you want to make sure that the one line for the oil cooler underneath is back in behind the bracket also your wire going down to your your knock sensor you want to make sure that's clear and then basically you're going to set it up on that stud that's on the front of the head and that's going to come through this hole right in top of the power steering pump and we just slide that again double-check your wire make sure it's not pinched in there and we'll put the put the top bolt on you'll feel the thread they line right up alright so we'll put the other two bolts on and then we have the nut that goes on the sword and the single bolt up top and then we're just gonna run those in tight just quickly before I run them in just to show you where the bolts out where the locations are the nut and the single bolt up top this is a ten millimeter head these are all going to be thirteen and just going to set them up good and tight okay one thing I'm going to mention about this oil cooler the one line that we snuck in behind the bracket obviously attaches down underneath and gets locked down but to put it in the right position what we're going to need to do is we've we don't want to set it up on this bracket right away we're gonna leave this off we got to get underneath we're gonna essentially put the other end of the tube up into its location by the filter leave that nut loose then get back up in here set the bolt up in this so now the hose is in its proper position there's no tension on any of the parts and then we go back down torque the the nut that secures it to the oil filter housing and then back up to tighten this one alright so what we're going to do next is we're gonna hook up the upper this is the lines for the heater hoses for your heating system I'm gonna move that out of the way and then put a little replace this whole ring and then put a little Vaseline on there so it slips in this way it won't pinch it as we go in it's kind of a tight fit alright so next I'm gonna show it's already connected but just to remind you we're gonna connect you got this you got a black connector here and that's going to go to the cam sensor don't forget it because it's kind of out of sight so underneath the water pump and you don't see it so you don't want to forget connecting that you're going to need that so you can start the vehicle then you also got your oil pressure center right here we've connected those and now what we're going to do is put the other line on for the oil cooler don't forget gotta make sure you put your you put your new o-ring on make sure that can spin all right so now I'll show you we put the lower hose in place you have the one down tube goes into the small opening the long neck is what attaches to the water pump and then the short loop this goes to the angled upward outlet of the thermostat okay just so you have a note top of the thermostat has two outlets you have one that goes up at an angle and one that comes straight up the one at an angle is what's going to get down to the lower hose this one's going to go to the upper hose we'll show you that when we get to that point so now we're just going to squeeze the clamp sign get those into place you can see we got our electrical connections in place and we have this hose in and now the upper hose this has got a short bolt that goes into the bottom and that's been installed and tightened up so then we're going to be ready to put that last bracket in alright so let's get that bracket down in place you can see we've got one two three four bolts that run through so here's the lower on the inside it's the easy one to see this way we can line that up and get that started and that'll make lining up the other three that much easier okay next is gonna be the cooling tube you can see we've got this torqued in place does this say hoses on we got some stuff here that eventually is going to get bolted to this bracket right now we just need to get these on so the tube essentially is tucked in right in the front of the intake manifold you've got an old ring on the back you want to make sure you put a new oil ring there we're going to put a little Vaseline on that and then just to get things started we'll put one bolt in there we'll need about a six or eight inch extension and a ten millimeter socket the reason we put this on after the brackets because there's a support bracket right here that bolts to the alternator support so you need that in place before you can put this tube in so now it's just a matter of we put that one bolt in there and then we're going to put one in the support bracket to support it alright so we put a bolt here in the support bracket so now this will just hold it in place and we can sneak in underneath and install these other bolts all right and now for the fun part in their infinite wisdom Land Rover puts the ignition coils buried back behind the upper plenum so in other words if we put the plan of mine you'd be almost impossible to put this on first off you can't even get to the bottom bolts once the plenum is in place and you can't really tighten them until you put the upper bolts in so what we normally do is we will lay this in place we'll put the two bottom bolts in and we're just gonna just snug them and then back them off just a little bit enough to give a little bit of movement the reason being is when we put the upper plenum on that has to slide underneath these holes so we've got to have some movement in there so that we can line them up and you were going to use the top bolts to secure this in place all right so we're gonna do we're going to drop this into place but before we go trying to put the bolts in place we have the two electrical connectors there's one and there's the other and each one of these gets plugged into each side this powers this side coil this powers this side and then basically one coil will power four cylinders and each coil pack has actually two individual coils built into it the other thing what we're gonna do is before we even grab those little bolts we're gonna put a rag over the top here because god forbid we dropped one down in the hole it will not be fun fishing it out all right so we got both the holes lined up we've got one started on one side now you can see these are hard to get at so if you put a little dab of our TV or you can even use grease and we're gonna do is put that on that socket and that's gonna hold that bolt so we can sneak it down in there location so we can get it started and then we're gonna do the same we did with the other one we'll run it down Snug it in and then just basically back it off about a half a turn just to allow enough slack so it'll wiggle so we can get those top bolts set alright so now we're gonna put the plug wires in now you'll notice most of the plug wire sets even after market for these are numbered you can see here's number one number three number five number seven so there's one three five seven two four six eight same thing on the other side so we're gonna just start plugging these in and what I do is I like to give a little shot a silicon in each one four one makes it go on easier adds a little extra protection to the boot and this way you feel the distinct set in when you put the boot on the plug you should actually kind of feel it click in just put that in your hold it right there and so that's seven threes number five it's gonna go in the middle right here I should hear that click then we'll just do the same thing to the other side alright so now we've got that all set up in the back we're gonna put the upper plenum on don't forget your steel gasket you've cleaned off the top surface of the lower manifold you have to raise dowels on here that are gonna basically give you the right location that's going to hold the gasket in place and then the manifold we self is gonna click on to those as well now if you get one it's a little stubborn we just put a socket over it now what we're gonna do is we're gonna set the manifold in place let's pull this up because we're gonna need this this will go on your idle air control motor because of the way this is set up when we put the plenum on we're gonna need to lift the front it's going to drop in we line it up with the front dowel lower it down and then lock it on to that dowel and then from there once we lock once we put the bolts in and lock down the upper plenum then we have to reach in the back and line up these two holes and run two bolts down through and this will actually bolt to the back of the upper plenum alright so now we're ready to put the upper plenum on we've taken the studs out of the sides and you can either put the studs back in after you put this in place or you can just get some six millimeter bolts three-quarters of an inch long and they'll work just as well so by doing that though it gives us a little more freedom to move this around and get it in place essentially what you're going to be doing is on the back the manifold you have these two bosses that come out these are the two bolt holes for the bolts that hold the top of the coil that goes over the top of this so what we're gonna do is go in in an angle and then drop it down and then move it so that we it drops on to the two locating dowels and once that's in place then it's just put the bolts in and lock them down and what I've done to is to save a little time you can bend this back out of the way here's the single bolt that we left in the manifold when we took this apart so we can just leave it in there and then of course it's going to go in in this position so I remember you've got a sink also a single bolt in the back and a single bolt in the front beside the three long ones that you're going to torque down so now it's just a matter of set this in place you may need a flashlight when you can see what you're doing is simply gonna walk this back slowly you can actually see how everything lines up all right so we've got our hardware right here take our three bolts drop those in and if you can't quite get your fingers in these front and back bolts what I've used is a tool and I'll show you in a second is a tool that called expanding fingers and it will grab around the head bolt and you can actually run it down spin it in and then come in with a socket extension a ratchet to torque it down all right so you can see what the tool does it'll actually hold the bolt on the end it gives you access to do a deeper area right here and you just run your finger down through the feel for the hole and by grabbing the head of the bolt you can actually use the tool to spin it in until you feel it seat down and we'll just do the rest with the socket and we'll do the same with the front bolt sleep in there yeah all right all right so we'll get a 10-millimeter socket extension ratchet and we'll torque those down all right so there is no torque spec listening and Land Rover's overhaul manual specifically for these bolts they have a general a general chart eight millimeter bolts they recommended torque to 13 foot-pounds I think that's a little bit on the loose side I don't have an exact torque spec to recommend but you see what I essentially do is run them until they're snug and then just give them just a little twist just to add some tension let them sit for a couple seconds and then go back and start from the middle and just will go around twice just to make sure everything is tight and even all right so now at this point we have this torque down now's a good time what we're gonna do is we're gonna connect the throttle body heater hoses remember we have this long one over here this is gonna go across because once you put your alternator and your AC compressor back in it's kind of tough to get them in there so I'll do those then you also have your PCV breather hose right here that's gonna go onto this spigot you want to check this black this black spigot or nipple on those because these have a tendency to loosen up so you want to make sure you snug that in you don't want any vacuum leaks there and of course plug in this is the vacuum line over to your brake booster you're gonna plug that in and then what you have right here is the one heater hose that has the hole for a bolt or where the stud was through the side you want to reattach that and then your other heater hose tube or lay up over the top we're gonna put a new bolt in there so that's essentially we're just gonna hook up all the in celery's we've also got for your emission controls you have your your control solenoid here this is going to plug into the throttle body and then your connector for your idle air motor so all that gets connected to this upper plenum and then we can go on to the next step the first one and the fun part is getting those two bolts for the coil to the manifold lined up because you're essentially going to do that by feel what you can do is you can move this big harness a little more out of the way so you can get your hand down in there and the rest is pretty much done by feel and this is why we leave the bottom bolts a little loose on that coil mount so that we can rock this back and forth and eventually get the hole lined up and get the bolt started yeah take a little patience a little time but you'll get it all right so here's a good example you find yourself having a hard time getting that ball lined up if you can get up like I have an expanding mirror that I can use in the back any mural work but what you can do that is angle it down so you can get a look at why you're not able to line up and you'll see like on this one what we've got to do is be able to move that bracket forward and we don't I didn't quite leave it loose enough on the bottom to do that so what we do is we take a little pry bar and then we just just gently move it back a little bit and now we know we can see the holes are lined up put a bolt in there get that lock down all right and then what we're gonna do next is put the throttle and the cruise control cable hook up on here because these two bolts at least one of them is sort of covered by the AC compressor so we're gonna put that off this way the whole upper plenum is all together by the time we're ready to put our two-inch hilary's on and our idler pulleys so you got two eight millimeter head bolts here I'll hook up that bracket we just sort of snug it and what you'll need to do is go to full open throttle you'll see a little slot in the top there slide the barrel in and then line up the slot to pop it fully in place just to make sure it's in there completely you know so you should be able to swivel that little barrel in there so then you know you're in properly and then the same thing with the cruise control slide that over so it lines up with the groove all right you should just have some slight tension on it should have just a little bit of free play on that not much and I will just get up millimeter socket tighten that up and we'll have everything together on the plane all right so just a quick review on the upper plenum because we want to make sure so we've tightened down the four bolts up top one in the back one one in the front for a total of six you have your connection here for your idle air motor you have your connection here for your admission control this is for the evap system this is the OP the purge valve so you have your electrical connection and then you have your hose connection right here this is just a pop in your breather hose and your throttle position sensor you've got your connector up in here so we're we're good there your two heater hoses to the throttle body heater and they're on nice and snug and they're in the back and then of course your two bolts and then we just showed you how to put the throttle cables on and we'll go around to the other side and we'll do a quick review on that all right and then on the passenger side course we have our the breather hoses connected and this clamp is on we've plugged in our vacuum line that feeds our brake vacuum booster our two heater hoses we have the Bolton on top that locks the two brackets so the hoses the metal hoses together along with the single bolt down now I'm going to make a note on this that on these engines without secondary air there's a spacer that goes between this hose bracket and the upper plenum and you would have found that when you took it off sometimes after these vehicles that they've been worked on once before somebody didn't put that spacer back in just a couple flat washers works just fine so that's in place and then of course everything else lines up here now you'll see two and this is kind of a neat trick you can actually take a razor knife and cut this rubber connector for these two hoses though you don't need to all right but just a note and then what we're gonna do then is you can see we have some exposed wire down here that I really don't like we're gonna get some plastic convolute to go over the top of that before we attach everything to this bracket and then we're ready to put the AC compressor and the alternator on alright so next step was what we're gonna do we're gonna tie in the heater hose you have there's actually a threaded hole behind this opening that's going to bolt and support this line up against the alternator mounting bracket and then you see you got two little brackets right here what you're going to want to use is this is a tie strap with what they call a Christmas tree on the end of it so you can wrap it around the wiring here and then plug the Christmas tree into that and that'll basically hold this up in here now as you just can see the old cover has starting to fall is falling off on this leaving the wire insulation exposed you see this piece right here I've installed just to cover up the wiring there we're gonna do the same with this we're gonna replace that convolute like I said you can buy that in any automotive center and then you've got your ground wire right here and that's going to be bolted right in this position from the front there's a threaded hole on the front of the bracket so then that'll get this all set so then the next step will be both the alternator and the AC compressor so just to give you a little overall look what we have is so you're our ground line is attached here our bracket that comes off of this hose is attached here we replaced convolute over the exposed wiring and then we've taken the wire ties with the Christmas trees and put them in place so that everything is essentially in its place so now we're ready to put the alternator on so alternator mounts on this bracket and what you have are these sliding shoes basically that are used to install the alternator and what they do is they actually slide within the bracket most cases once you've taken the alternator out and pried it out this one's already back in place this one you can I'll show you see how it hangs out leaves and area there you take your hammer and open up the space so the alternator will just drop in when you tighten it up it pulls those shoes in and locks everything in place and the only two wires that you need to attach are going to be your battery feed cable and then your field wire and you can see essentially just on the back of the alternator you've only got two positions so it's kind of hard to get it wrong and the alternator obviously is going to set in this position so we're gonna hook our wiring up first and then we're gonna set the alternator in there and then just as a tip there's a lot of hardware put aside on this and there's a lot of bigger bolts as we get towards the end as far as the hanging brackets the plainer why not you'll notice that the two alternator bolts have this goldish tone they're an anodized bolt so if you're not quite sure what bolts go on the alternator look for this gold-tone on the shaft and the size of the bolt and then those will be the correct ones for the alternator so next is gonna be the AC compressor and as you can see basically you just have four bolts up top there is a locating dial here which will help you to get it set up and located now as you remember we didn't have to disconnect the AC lines this is just been sitting here waiting for us to put it back together and what I normally do is before you slide the sign you got this back left-hand corner bolt always put that on first cuz what's gonna happen is when you get the compressor here in line you're not going to be able to install this bolt because the throttle linkage is going to be in a way so before you set it in grab one your alternator bolts and it'll actually help you line up a little better because that will locate in the back hole and then you've got your dowel in the front and now we'll just drop our three remaining bolts in this one will obviously have to put in tighten up with a wrench the other three if you have compressed air you can run it in with that or just do all them with a socket and a ratchet all right so now we're gonna start putting the pulleys on so we can get the belt on now one thing we did notice when we got into it this the original tensioner was binding up the to bet the two idlers one of them felt kind of rough so we actually offered this kit we can get both the idler pulleys and the tensioner if you're gonna put a new motor in you don't need any future problems for the low-cost that you can get this kit for it's well worth putting in you don't have to deal with the belt problem so what we're going to do then is we're going to install these and then we've got to put the water pump pulley on and the power steering pump which is just a matter of flying up the pulleys put your bolts in and tighten them up but just so you know you'll see that the two idlers are of different sizes the smaller pulley is going to be mounted here so you're going to want to put the tensioner on first and then the small pulley and then your large pulley is going to be located right here and then at that point we'll put the other two on alright so here's what the pulleys look like installed like I said small and on the bottom big one up top and then you want to give a little test spin just to make sure they're seated properly ok so spins got a little bit of resistance which is good that's a nice tight bearing and then the tensioner and then you always want to look in the back and make sure that the back of this is seated flat there's a locating pin that drops in so you're gonna slide that pin in to the hole in the back side of the bracket and then just move this up until your bolt drops in tighten it up and you're good alright so next is going to be water pump pulley and power steering pulley alright before you put the power steering pulley on and I've seen it done because it can be mounted in either direction so what you're going to do is basically look at the pulley and you're going to see the imprint of the I guess I would call the triangle of the pyramid which is the surface that's going to ride on the pond the pump itself you'll see the imprint on one side on the other you won't so obviously then this is the proper side to install against the power steering pump there is a difference in the offset so if you do install it backwards the belts not gonna line up right so you want to make sure you see that imprint and then on the water pump pulley you will see where there are marks on the ball holes where the original bolts went so you just want to reuse those because this way you know everything's gonna line up right so on the water pump pulley what I like to do is I'll turn this so that I've got one threaded hole straight up so I have an orientation because once I go to slide the pulley over I can't see those we'll set that bolt right in place and it's sort of lining up and you just roll it around a little bit to let bolt lines right up slight this up over the hub put the other two on now these don't require a great amount of torque and you can actually when you go to tighten these you can actually get your hand wrapped around that pulley and be able to tighten it again look for the tripod point that straight up it aligns itself right up alright so then we just put the last remaining two bolts in and then we get everything tightened up all right so now comes the fun part we're gonna put the belt on if you didn't take a picture before he took it apart to give you an idea of how its routed this is the best way to go about it we're gonna phone basically the belt like so and we've done a sag or a loop in the center and that loop is going to go around the power steering pulley okay then we're gonna go up and over the AC compressor and we're gonna go up and over the alternator around the tensioner and at this point we're not gonna worry about that little pulley and you'll see why in a minute then we're going under that made the steering too damp the crankshaft pulley up and over power steering pulley and around this larger idler yeah some things you got a slight go to get up so what that essentially does gets everything in place now of course rib side of the belt will always be on the ribs pulleys so you have alternator AC compressor power steering pump lower deeper and tension or old ribs so you should have rib sight on there now what we do is we take our wrench now this is a different size than the original with this kit they originally you'd have a 15 millimeter here but they have stepped up to a 16 millimeter put that up and won't push it down we're simply gonna just give us enough room to slide that belt up and over the little pulley and then before you take all let allow all the tension on there just a quick feel to make sure that the belt is fully seated and all the other pulleys wet up and there you are belts in place so next step then is going to be putting the fan shroud and the fan on and your upper radiator hose alright so very important we don't want to forget the dipstick now these use a very high vacuum PCV system as well as the emission control is also incorporated on there so literally any vacuum leak can create a drivability issue on these so when I put the dipstick in we're gonna actually run a bead of black RTV right around the base of this neural this is what seats down on the block where when we insert this and this way by the time we actually get to the point where we're ready to start it this will be pretty well be setup so we know we got a good seal so that's really all we're gonna do is throw a little little black RTV on that take our finger and just run around about the thickness of that raised area tick-tick-tick to and then we're just gonna basically slide it right down the hole see your hole right there now slide right in and then you have a threaded hole right here on the side of the valve cover and you flip this up this is going to line right up with it there and then once we run that screw in there let that our TV set up we'll be all set and then we can actually put our dipstick right inside the tube all right and of course you want to plug in your AC compressor and that's your great plug connector right here you push that into you hear the click and just put this down where it's really not rubbing against anything too severely and then we just have the one wire here for the mass air flow sensor we'll put that to the side all right so now what we're going to do is we're going to put the lower shroud in for the fan there are just bay there's two clips that attach on the bottom and then two Phillips screws on each side here then they're gonna hold that lock that down and then the fan and then the upper shroud and then the actually it's going to be the lower shroud the fan and we're going to do the radiator hose one thing I want to mention on these lay the thermostat if you taking a good look right here top of the thermostat has two outlets one goes off at about a forty degree angle one points straight up they're both the same size and I have seen where somebody could actually install it with this reversed which will actually cause an overheating problem so you want to make sure that the angled outlet goes to the lower hose which goes down to the water pump and the straight up is going to go to the upper radiator hose which also attaches here and here but just keep that note so the angle to the water pump straight up to the upper radiator all right so we put our Stroud we got two Phillips screws grab the bottom we pull out make sure that those tabs on the bottom if holding it in place and we just slide the fan in and we try to get it as square as possible you do I do it just the back of my hand up against the front of the fan clutch and if you just work it real slow eventually you'll hit a spot where it'll feel like the threads will catch and then from there you can just spin it on all right so I've put the upper hose in place but I want to show you basically how it looks should look when it's installed your so you have your bleeder cap right here your joined here at that front tube upper radiator and then of course down on the thermostat clamps are in place and you want to make sure you can feel that bulb that little bulge at the end of the nipples that you attach these to and they're there so that with the clamp behind it there's no chance of it coming off it's just a little security measure they built into these so you would just want to make sure the clamp is below or behind that bulge so that you know you've got it in a proper position all right so essentially we're ready at this point we've gotta just put the top cover on which is four screws that only turn the eternal 90 degrees in there in and then we'll put the air filter in the hose in and then we can put on our final colon line which is the overflow or the vent line that goes across into the expansion tank okay actually we're gonna do is we're going to put this the vent blind on now because this cover actually goes over the top of it you see these two raised areas right here actually is the channel that this is gonna rest in kind of acts as a sort of a support we just push that on there what I would suggest is if this host feels brittle at all nodes if you can't take it and flex it like that it feels like it's gonna crack and split replace it because more unlikely it's exactly what it's going to do very soon and you certainly don't want to risk your your new engine and all your work on a relatively inexpensive hose same thing were there anything else wearable on the engine if you're gonna put the time and money put a new engine on if the old hoses feel dried out put new hoses on it I've done that with every engine I've put in new hoses new belt anything basically rubber and flexible it's not worth the risk it's worth a little extra money for the security of knowing you've got a good system in there so it around a little bit so it lines up you see the cutout on the side there's for that hose you got one hop and just turn 90 degrees and you'll actually feel the screw come to a stop when it seats in there we go and just squeeze that upper hose a little bit and pop that right in place we're pretty much assembled there and now we just need to hook up the intake tube and the air filter assembly right just to make it easier now Chris the air filter you pulled it out so you get the idea it's basically a pop in I like to do is I shoot a little silicone spray on those rubber rubber sets that that goes into it just
Applies To These Models:
Discovery Series II | '99-'04
Range Rover 4.0 (P38) | '95-'02
Range Rover 4.6 (P38) | '95-'02
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