Land Rover 2000-05

Cylinder Head

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Removal & Installation




NOTE
The cylinder head bolt torque sequence can be found in Section 1, following the Torque Specifications Chart.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Intake manifold
     
    Alternator
     
    Air conditioning compressor and position it aside leaving the hoses attached.
     
    Rocker arm cover
     
    Rocker shafts and pushrods
     
    Front exhaust pipes from the manifolds
     
    Exhaust manifolds
     
    Air cleaner and intake air duct assembly
     

  4.  
  5. On the left cylinder head, remove the ground cable attached to the left-hand cylinder head.
  6.  
  7. On the right cylinder head, remove the breather pipe from the engine lifting bracket.
  8.  
  9. Loosen the cylinder head bolts, reversing the tightening sequence.
  10.  
  11. Lift the cylinder head off the engine block.
  12.  

To install:

  1. Remove the cylinder head gaskets, then clean the gasket mating surfaces.
  2.  
  3. Clean the exhaust gasket mating faces.
  4.  
  5. Ensure that the bolt holes in cylinder block are clean and dry.
  6.  
  7. Install new cylinder head gaskets with the word TOP facing out.
  8.  
  9. Clean, then lightly oil the threads of the head bolts.
  10.  
  11. Install the cylinder heads on the block.

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-4.0L and 4.6L engines

  12.  
  13. Install the cylinder head bolts in the positions as illustrated.
    NOTE
    There are no bolts fitted in the 4 lower holes in each cylinder head.



    96mm long bolts: 2, 4, 6, 7, 8, 9, 10
     
    66mm long bolts: 1, 3, 5
     

  14.  
  15. Tighten the cylinder head bolts progressively in sequence, as shown, as follows:

    15 ft. lbs. (20 Nm)
     
    + 1 / 4 turn (90°)
     
    + 1 / 4 (90°)
     

  16.  
  17. The remaining steps are the reverse of the removal procedure.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Fill and bleed the cooling system. Run the engine and check for leaks.
  22.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Intake manifold
     
    Alternator
     
    Air conditioning compressor and position it aside leaving the hoses attached.
     
    Rocker arm cover
     
    Rocker shafts and pushrods
     
    Front exhaust pipes from the manifolds
     
    Exhaust manifolds
     
    Air cleaner and intake air duct assembly
     

  4.  
  5. On the left cylinder head, remove the ground cable attached to the left-hand cylinder head.
  6.  
  7. On the right cylinder head, remove the breather pipe from the engine lifting bracket.
  8.  
  9. Loosen the cylinder head bolts, reversing the tightening sequence.
  10.  
  11. Lift the cylinder head off the engine block.
  12.  

To install:

  1. Remove the cylinder head gaskets, then clean the gasket mating surfaces.
  2.  
  3. Clean the exhaust gasket mating faces.
  4.  
  5. Ensure that the bolt holes in cylinder block are clean and dry.
  6.  
  7. Install new cylinder head gaskets with the word -TOP- facing out.
  8.  
  9. Clean, then lightly oil the threads of the head bolts.
  10.  
  11. Install the cylinder heads on the block.

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-4.0L and 4.6L engines (2000-02)

  12.  
  13. Install the cylinder head bolts in the positions as illustrated.
    NOTE
    There are no bolts fitted in the 4 lower holes in each cylinder head.



    96mm long bolts: 2, 4, 6, 7, 8, 9, 10
     
    66mm long bolts: 1, 3, 5
     

  14.  
  15. Tighten the cylinder head bolts progressively in sequence, as shown, as follows:

    15 ft. lbs. (20 Nm)
     
    + 1 / 4 turn (90°)
     
    + 1 / 4 (90°)
     

  16.  
  17. The remaining steps are the reverse of the removal procedure.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Fill and bleed the cooling system. Run the engine and check for leaks.
  22.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the intake manifold and gasket.
  6.  
  7. For right side intake manifold, perform the following steps:
    1. Remove the auxiliary drive belt tensioner bolt. Remove the tensioner.
    2.  
    3. Remove the alternator mounting bracket.
    4.  

  8.  
  9. Noting the installed order, disconnect the high tension leads from the spark plugs.
  10.  
  11. For left side intake manifold, perform the following steps:
    1. Remove the bolt securing the engine harness to the read of the cylinder head.
    2.  
    3. Remove the brake vacuum servo heat shield.
    4.  

  12.  
  13. For right side intake manifold, remove the bolt holding the ground connection.
  14.  
  15. Remove 8 bolts and remove the exhaust manifold from the cylinder head. Remove the gaskets.
  16.  
  17. Progressively, remove the 4 bolts securing the rocker shaft, and remove the rocker shaft.
  18.  
  19. Remove the push rods and store them in order as removed.
  20.  
  21. If equipped with secondary air injection (SAI), remove the 2 air injection adapters from the cylinder head and discard.
  22.  
  23. In the sequence shown, remove 10 cylinder head bolts. Discard the bolts.
    NOTE
    Loosening sequence is the same for both cylinder heads. Right cylinder head shown in illustration.

  24.  
  25. Remove the cylinder head.
    CAUTION
    Carefully support both ends of the cylinder head on blocks of wood.

  26.  
  27. Remove the cylinder head gasket.

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-Discovery (2003-04)

  28.  

To install:

  1. Clean mating faces of cylinder block and head, using gasket removal spray and plastic scraper. Ensure bolt holes in block are clean and dry.
  2.  
  3. Check the head face for warping, pitting or other damage. If out of specification, repair or replace head. Maximum allowable warping is 0.002 inch (0.05mm).
    NOTE
    Not more than 0.02 inch (0.50mm) material can be removed from cylinder head surface during refacing.

  4.  
  5. Install a new cylinder head gasket (without sealant), with the word -TOP- uppermost.
  6.  
  7. Carefully install cylinder head, locating head on dowels.
  8.  
  9. Lightly lubricate the new cylinder head bolt threads with clean engine oil.
  10.  
  11. Noting that bolts 1, 3 and 5 are longer than the others, be sure bolts are installed in their proper locations.
  12.  
  13. Tighten bolts, in sequence shown, to the following specifications:
    CAUTION
    DO NOT tighten bolts 180 degrees in one operation.



    First step: 15 ft. lbs. (20 Nm)
     
    Second step: 90 degrees further
     
    Third step: 90 degrees further
     

  14.  
  15. If equipped with SAI, install new air injection adapters and tighten to 24 ft. lbs. (33 Nm).
  16.  
  17. Clean the push rods and lubricate ends with clean engine oil.
  18.  
  19. Install push rods in same order as removed.
  20.  
  21. Clean the bases of the rocker pillars and mating faces on the cylinder head.
  22.  
  23. Clean the contact surfaces on the rockers, valves and push rods.
  24.  
  25. Lubricate the contact surfaces and rocker shaft with clean engine oil.
  26.  
  27. Install the rocker shaft assembly and engage the push rods.
  28.  
  29. Install the rocker shaft bolts and progressively tighten to 30 ft. lbs. (40 Nm).
  30.  
  31. On left side cylinder head, perform the following:
    1. Install alternator mounting bracket and torque bolts to 30 ft. lbs. (40 Nm).
    2.  
    3. Install the auxiliary drive belt tensioner and torque the bolt to 33 ft. lbs. (45 Nm).
    4.  

  32.  
  33. On right side cylinder heads, connect the high tension spark plug leads to their original locations.
  34.  
  35. Install new gaskets with the exhaust manifold and tighten the bolts, in the sequence shown, to the following specifications:
    NOTE
    Bolt tightening sequence is the same for both exhaust manifolds. Illustration shows left side exhaust manifold.



    First step: 11 ft. lbs. (15 Nm)
     
    Second step: 28 ft. lbs. (36 Nm)
     

  36.  
  37. On right side cylinder head, reconnect the ground strap and tighten the bolts to 16 ft. lbs. (22 Nm).
  38.  
  39. On left side cylinder head, perform the following steps:
    1. Install the brake vacuum servo heat shield.
    2.  
    3. Install the engine harness and tighten the retaining bolts to 16 ft. lbs. (22 Nm).
    4.  

  40.  
  41. On left side cylinder head, reconnect the high tension leads to the spark plugs in their original order.
  42.  
  43. Install the intake manifold gasket.
  44.  
  45. Reconnect the negative battery cable.

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-Discovery (2003-04)



    Click image to see an enlarged view

    Fig. Exhaust manifold bolt torque sequence-Discovery (2003-04)

  46.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Release fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Engine oil and oil filter
     
    Air intake hose
     
    Radiator hoses
     
    Front exhaust pipes from the manifolds
     
    Exhaust manifolds
     
    Water pump-to-coolant manifold pipes.
     
    Cooling fan cowl
     
    Engine appearance cover
     
    Valve cover grounds
     
    Ignition coil covers
     
    Ignition coil connectors
     
    Ignition coils
     
    Dipstick tube
     
    Valve covers.
     
    Spark plugs
     
    Engine lifting eyes at rear of cylinder heads
     
    20 nuts attaching 4 camshaft oil lines from each head.
     

  6.  
  7. Rotate crankshaft until cylinder no. 1 camshaft lobes are at TDC.
    NOTE
    The rear of the camshafts may appear twisted and out of alignment when cylinder no. 1 is at TDC. This is normal.

  8.  
  9. Place locking tool LRT-12-227 through timing tool access hole to lock flywheel in position.
  10.  
  11. On each cylinder head, remove the Variable Camshaft Control (VCC) solenoid connector.
  12.  
  13. Remove 2 bolts securing each VCC seal and remove seals.
  14.  
  15. Using socket LRT-12-226, remove the VCC solenoids.
  16.  
  17. Disconnect coolant hose from alternator.
  18.  
  19. On the right cylinder head, disconnect the engine wiring harness from the upper timing cover and remove the harness bracket.
  20.  
  21. Remove the Camshaft Position Sensor (CMP) harness ties and connector.
  22.  
  23. Remove Secondary Air Intake (SAI) pipes from each cylinder head and position aside.
  24.  
  25. Remove upper timing gear covers.
  26.  
  27. Remove CMP sensor rings.
    NOTE
    Sensor ring attaching bolt is a left hand thread.

  28.  
  29. Loosen both VCC units and exhaust camshaft sprocket bolts 1 / 2 turn.

    Click image to see an enlarged view

    Fig. VCC unit and exhaust camshaft bolt locations-Range Rover (2003-04) left side shown; right side similar

  30.  
  31. Position camshaft locking tools LRT-12-223/3 and 223/4 to rear of camshafts and tighten in position.
  32.  
  33. Position tools LRT-12-223/5 and 223/6 over locking tools and tighten into spark plug threads.
  34.  
  35. Compress exhaust timing chain tensioner and install tool LRT-12-220 to chain tensioner.
  36.  
  37. Remove VCC unit and exhaust camshaft sprocket bolts.
  38.  
  39. Remove exhaust camshaft sprockets, chain and VCC units.
    NOTE
    Secure exhaust timing chain the cylinder head to prevent it from falling into lower timing cover.



    Click image to see an enlarged view

    Fig. Installing locking tools to rear of camshafts-Range Rover (2003-04) left side shown; right side similar



    Click image to see an enlarged view

    Fig. Installing locking tool to cylinder head-Range Rover (2003-04) left side shown; right side similar



    Click image to see an enlarged view

    Fig. Installing tool to exhaust timing chain tensioner-Range Rover (2003-04) left side shown; right side similar

  40.  
  41. Remove locking tool from timing tool access hole.
  42.  
  43. Rotate crankshaft pulley counterclockwise to align the 45 degree BTDC mark.
    NOTE
    Hold the exhaust timing chain tight and under tension when rotating crankshaft.

  44.  
  45. Remove tools from camshaft sprockets and cylinder head.
  46.  
  47. Remove bolt attaching timing chain guide rail to cylinder head.
  48.  
  49. Remove cylinder heads bolts in reverse of tightening sequence.
  50.  
  51. Remove cylinder head.
  52.  
  53. Remove o-ring from top of cylinder block.

    Click image to see an enlarged view

    Fig. Crankshaft pulley timing marks-Range Rover (2003-04)

  54.  

To install:

  1. Clean mating faces of cylinder block and head, using gasket removal spray and plastic scraper. Ensure bolt holes in block are clean and dry.
  2.  
  3. Check the head face for warping, pitting or other damage. If out of specification, repair or replace head. Maximum allowable warping is 0.002 inch (0.05mm).
    NOTE
    Not more than 0.02 inch (0.50mm) material can be removed from cylinder head surface during refacing.

  4.  
  5. Install a new o-ring into the cylinder block.
  6.  
  7. Apply sealant to cylinder block as shown.

    Click image to see an enlarged view

    Fig. Applying sealant to cylinder block-Range Rover (2003-04) left side shown; right side similar

  8.  
  9. Install a new cylinder head gasket to locating dowels on cylinder block.
  10.  
  11. Place cylinder head on block.
  12.  
  13. Install washers and the new cylinder head bolts.
  14.  
  15. Tighten bolts, in sequence shown, to the following specifications:

    First step: 22 ft. lbs. (30 Nm)
     
    Second step: 80 degrees further
     
    Third step: 80 degrees further

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-Range Rover (2003-04)

     

  16.  
  17. Install bolt attaching timing chain guide rail to cylinder head.
  18.  
  19. Carefully rotate the camshafts until the letter and cylinder number markings on the rear of the camshafts are in an upright position.
  20.  
  21. Install the camshaft locking tools to the rear of the camshafts.
  22.  
  23. Install the locking plate over locking tools and tighten into spark plug threads.
  24.  
  25. Rotate crankshaft pulley clockwise to align the 45 degree BTDC mark.
    NOTE
    Hold the exhaust timing chain tight and under tension when rotating crankshaft.

  26.  
  27. Place locking tool LRT-12-227 through timing tool access hole to lock flywheel in position.
  28.  
  29. Position exhaust timing chains on VCC and exhaust camshaft sprockets.
  30.  
  31. Install VCC unit and exhaust camshaft sprocket bolts and hand tighten.
  32.  
  33. Compress exhaust timing chain tensioners and remove tool LRT-12-220 from chain tensioners.
  34.  
  35. Install Special tools LRT-12-221 and 222 to the right side cylinder head and hand tighten the bolt.

    Click image to see an enlarged view

    Fig. Installing special tools to cylinder head-Range Rover (2003-04) right side shown; left side similar

  36.  
  37. Install special nut LRT-12-224 to the left side VCC unit.
  38.  
  39. Connect a multimeter set to the ohms scale between the pin of the left side VCC unit and the stud on the oil line.
  40.  
  41. Rotate the VCC unit using a wrench on the special nut and 30 ft. lbs (40 Nm) of torque, to remove the oil cushion and ensure the VCC is at the full stop position. When the unit reaches the full stop position, continuity should be present.
  42.  
  43. Tighten the left side VCC unit and exhaust camshaft sprockets bolts to 11 ft. lbs. (15 Nm). Loosen the bolts 1 / 4 turn.
  44.  
  45. Repeat this procedure on the right side VCC unit and exhaust camshafts.
  46.  
  47. Tighten the bolt on tool LRT-12-222 to 6.3 inch lbs. (0.7 Nm) to set the chain tension.
  48.  
  49. Rotate the left side VCC unit using a wrench on the special nut and 30 ft. lbs (40 Nm) of torque, to remove the oil cushion and ensure the VCC is at the full stop position. When the unit reaches the full stop position, continuity should be present.
  50.  
  51. Tighten the left side VCC unit bolt to 81 ft. lbs. (110 Nm). Tighten the exhaust camshaft sprockets bolts to 92 ft. lbs. (125 Nm).
  52.  
  53. Rotate the right side VCC unit using a wrench on the special nut and 30 ft. lbs (40 Nm) of torque, to remove the oil cushion and ensure the VCC is at the full stop position. When the unit reaches the full stop position, continuity should be present.
  54.  
  55. Tighten the right side VCC unit bolt to 81 ft. lbs. (110 Nm). Tighten the exhaust camshaft sprockets bolts to 92 ft. lbs. (125 Nm).
  56.  
  57. Install the CMP sensor ring on the right side and hand tighten the nut.
  58.  
  59. Install special tool LRT-12-228/1 to the locating dowel on the CMP ring and tighten the tool to the cylinder head.
    NOTE
    To ensure correct CMP alignment, make sure the tool is aligned flush with the cylinder head and lower timing gear cover before tightening the bolts.



    Click image to see an enlarged view

    Fig. Installing special tool to VCC unit-Range Rover (2003-04) right side shown; left side similar

  60.  
  61. Tighten the right side CMP bolt to 30 ft. lbs. 40 Nm).
  62.  
  63. Repeat the procedure on the left side CMP sensor ring, except use tool LRT-12-228/2.
  64.  
  65. Remove all special tools from all locations.
  66.  
  67. Clean upper timing gear covers and install new gaskets.
  68.  
  69. Install new chain tensioner o-ring and apply sealant to areas shown.

    Click image to see an enlarged view

    Fig. Applying sealant to upper timing cover surface-Range Rover (2003-04) right side shown; left side similar

  70.  
  71. Install new gaskets to upper timing belt gear covers and install the covers and bolts. Tighten the bolts hand tight.
  72.  
  73. Install new valve cover gaskets and hand tighten 4 bolts.
  74.  
  75. Tighten upper timing gear cover bolts to 11 ft. lbs. (15 Nm).
  76.  
  77. Remove valve covers.
  78.  
  79. Install new sealing washer and install timing chain tensioner and tighten plug to 30 ft. lbs. (40 Nm).
  80.  
  81. Install the VCC solenoids and tighten to 18 ft. lbs. (25 Nm).
  82.  
  83. Install VCC seal and tighten the bolts. Remove seals.
  84.  
  85. Install Secondary Air Intake (SAI) pipes to each cylinder head.
  86.  
  87. Install the CMP harness ties and connectors.
  88.  
  89. On the right cylinder head, install the engine wiring harness bracket and harness to the upper timing cover.
  90.  
  91. Connect coolant hose to alternator.
  92.  
  93. Install 20 nuts securing 4 camshaft oil lines to each head.
  94.  
  95. Install engine lifting eyes at rear of cylinder heads.
  96.  
  97. Apply sealant to cylinder head as shown.
  98.  
  99. Install new gaskets and sealing washers to valve covers and tighten nuts and bolts in sequence to 7 ft. lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Applying sealant to valve cover surface-Range Rover (2003-04) right side shown; left side similar



    Click image to see an enlarged view

    Fig. Valve cover bolt tightening sequence-Range Rover (2003-04)

  100.  
  101. Install or connect the following:

    Spark plugs
     
    Dipstick tube
     
    Ignition coils
     
    Ignition coil connectors
     
    Ignition coil covers
     
    Valve cover grounds
     
    Engine appearance cover
     
    Cooling fan cowl
     
    Water pump-to-coolant manifold pipes.
     
    Exhaust manifolds
     
    Front exhaust pipes from the manifolds
     
    Air intake hose
     
    Radiator hoses
     
    Engine oil and oil filter
     
    Coolant
     

  102.  
  103. Reconnect the negative battery cable.
  104.  
  105. Start the engine and check for leaks.
  106.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery ground lead.
  4.  
  5. Drain cooling system.
  6.  
  7. Remove intake manifold chamber.
  8.  
  9. Remove right side exhaust manifold gasket.
  10.  
  11. Remove camshaft timing belt.
  12.  
  13. Remove 4 bolts securing right side front timing belt cover backplate to cylinder head and remove the backplate.
  14.  
  15. Depress the locking collar and release the breather hose from right side intake manifold.
  16.  
  17. For 2003-04 models, remove the right side camshaft cover gasket.
  18.  
  19. Release the 3 locking clips and disconnect 3 connectors from plug top coils.
  20.  
  21. Remove the bolt securing ground lead to right side camshaft cover and release ground lead.
  22.  
  23. Remove 6 bolts securing plug top coils to camshaft cover and remove coils.
  24.  
  25. Remove 3 nuts and 3 bolts securing ignition coils to left side intake manifold and release coil ground lead.
  26.  
  27. Remove ignition coils and position aside.
  28.  
  29. Release clip and disconnect coolant bleed hose from right side intake manifold. Position the hose aside.
  30.  
  31. Release the injector harness clips from injector protection cover or from the bosses on the fuel rail.
  32.  
  33. If so equipped, remove 2 bolts securing the injector protection cover and the right side fuel rail to right side intake manifold. Remove the cover.
  34.  
  35. Remove 2 bolts securing fuel rail to left side intake manifold.
  36.  
  37. Release the injectors from the manifolds and carefully position the fuel rail and injectors aside.
    CAUTION
    Always plug all open connections to prevent contamination.

  38.  
  39. For 2000-02 models, remove the 14 bolts and remove right side camshaft cover and gasket.
  40.  
  41. Progressively loosen and remove 8 cylinder head bolts, using the sequence shown.
  42.  
  43. With assistance, remove cylinder head assembly.
    CAUTION
    Carefully support both ends of the cylinder head on blocks of wood.

  44.  
  45. Remove and discard the right cylinder head gasket.
    CAUTION
    DO NOT rotate the crankshaft with one cylinder head installed.

  46.  
  47. For 2003-04 models, remove and discard both cylinder head locating dowels.
  48.  
  49. Install cylinder liner clamps LRT-12-144 and secure with bolts. Ensure that feet of clamps do not protrude over the bores.
  50.  

To install:

  1. Clean the cylinder head face, using gasket removal spray and a plastic scraper.
  2.  
  3. Remove bolts securing cylinder liner clamps LRT-12-144 to cylinder block and remove clamps, without rotating the crankshaft.
  4.  
  5. Clean the cylinder block face, dowels and dowel holes.
  6.  
  7. Clean cylinder head bolts and wipe dry.
  8.  
  9. Lightly lubricate threads and beneath heads of cylinder head bolts with clean engine oil.
  10.  
  11. For 2000-02 models, ensure the locating dowels are secured in the cylinder block.
  12.  
  13. For 2003-04 models, install new dowels supplied with the cylinder head gasket kit. Ensure dowels are installed so 0.40-0.43 inch (10-11mm) of the dowel is above the cylinder block top face.
  14.  
  15. Install the new cylinder head gasket onto the cylinder block with the word 'TOP' uppermost.
  16.  
  17. With assistance, fit cylinder head and carefully position right side inlet to left side intake manifold and to the cylinder head dowels.
  18.  
  19. Carefully install cylinder head bolts. DO NOT DROP. Screw bolts into place by hand.
  20.  
  21. Tighten cylinder head bolts progressively in the sequence illustrated to:

    Step 1: 18 ft. lbs. (25 Nm)
     
    Step 2: Tighten in the same sequence to 18 ft. lbs. (25 Nm)
     
    Step 3: Tighten in the same sequence to 18 ft. lbs. (25 Nm)
     
    Step 4: In the same sequence to plus 180 degrees.
     

  22.  
  23. Clean mating surfaces of camshaft cover and carrier.
  24.  
  25. Clean inside of camshaft cover. If necessary, wash oil separator gauze and blow dry.
  26.  
  27. Install new gasket and position camshaft cover to carrier.
    CAUTION
    When fitting camshaft cover gasket, ensure arrows on gasket point towards intake manifold.

  28.  
  29. Install bolts and tighten in sequence illustrated to 7 ft. lbs. (9 Nm).
  30.  
  31. Remove and discard lower O-rings from injectors.
  32.  
  33. Clean injectors and injector locations in fuel rail.
  34.  
  35. Lubricate new O-rings with castor oil and install them on the injectors.
  36.  
  37. Position fuel rail assembly and secure injectors to intake manifolds.
  38.  
  39. If so equipped, position injector protection cover to right side fuel rail and secure injector harness to protection cover with clips.
  40.  
  41. Install bolts securing fuel rail to intake manifolds and tighten to 7 ft. lbs. (9 Nm).
  42.  
  43. Connect coolant bleed hose to intake manifold and secure with clip.
  44.  
  45. Connect the breather hoses to the right side camshaft cover and intake manifold.
  46.  
  47. Position ignition coils to left side intake manifold.
  48.  
  49. Position ground lead, fit nuts and bolts securing ignition coils to left side intake manifold and tighten to 7 ft. lbs. (9 Nm).
  50.  
  51. Position plug top coils to spark plugs and right side camshaft cover, fit and tighten bolts to 7 ft. lbs. (9 Nm).
  52.  
  53. If so equipped, position the ground lead to the right side camshaft cover. Install the bolt and tighten to 7 ft. lbs. (9 Nm).
  54.  
  55. Connect connectors to the plug top coils and secure with locking clips.
  56.  
  57. Clean camshaft timing belt cover backplate bolts and apply Loctite 242 to the first 3 threads.
  58.  
  59. Position the backplate, fit and tighten bolts to 7 ft. lbs. (9 Nm).
  60.  
  61. Install the camshaft timing belt.
  62.  
  63. Install right side exhaust manifold gasket.
  64.  
  65. Install the intake manifold chamber.
  66.  
  67. Fill the cooling system.
  68.  

Left Side
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the battery ground lead.
  4.  
  5. Drain cooling system.
  6.  
  7. Remove the intake manifold chamber.
  8.  
  9. Remove left side exhaust manifold gasket.
  10.  
  11. Remove the camshaft timing belt.
  12.  
  13. Remove 4 bolts securing left side front camshaft timing belt cover backplate to cylinder head and then remove the backplate.
  14.  
  15. Remove the left camshaft cover gasket
  16.  
  17. Disconnect the ignition coils from the left intake manifold, and disconnect the coil ground lead.
  18.  
  19. Remove the ignition coils and position them aside.
  20.  
  21. Disconnect the coolant bleed hose from the intake manifold and move it aside.
  22.  
  23. Disconnect the PCV breather hose from the left intake manifold.
  24.  
  25. Remove special bolt securing high tension lead guide bracket to left side camshaft cover and remove bracket.
  26.  
  27. Disconnect camshaft position (CMP) sensor multiplug and release male multiplug from mounting bracket.
  28.  
  29. Remove the bolt securing the multiplug bracket, remove bracket.
  30.  
  31. Disconnect clips securing right side injector harness to injector protection cover.
    NOTE
    Protection covers are NOT fitted to vehicles.

  32.  
  33. Remove 2 bolts securing protection cover and fuel rail to right side intake manifold, remove cover.
  34.  
  35. Remove 2 bolts securing fuel rail to left side intake manifold.
  36.  
  37. Release the injectors from the manifolds and carefully position the fuel rail and injectors aside.
    CAUTION
    Always fit plugs to open connections to prevent contamination.

  38.  
  39. Remove 14 bolts and remove left side camshaft cover and gasket.
  40.  
  41. Progressively loosen and remove 8 cylinder head bolts.

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-Freelander

  42.  
  43. With assistance, remove cylinder head assembly.
    CAUTION
    Support both ends of cylinder head on blocks of wood.

  44.  
  45. Remove and discard cylinder head gasket and the cylinder head locating dowels.
  46.  
  47. Install cylinder liner clamps LRT-12-144 and secure with bolts. Ensure that feet of clamps do not protrude over bores.
  48.  

To install:

  1. Clean cylinder head face.
  2.  
  3. Remove bolts securing cylinder liner clamps LRT-12-144 to cylinder block and remove clamps.
  4.  
  5. Clean cylinder block face, dowels and dowel holes.
  6.  
  7. Clean cylinder head bolts and wipe dry.
  8.  
  9. Lightly lubricate threads and beneath heads of cylinder head bolts with clean engine oil.
  10.  
  11. Install 2 new locating dowels, supplied with the cylinder head gasket.
  12.  
  13. Check that the installed height of the dowels is 0.40-0.43 inch (10-11mm) above the cylinder block top face.
  14.  
  15. Install new cylinder head gasket onto cylinder block with the word 'TOP' uppermost.
  16.  
  17. With assistance, fit cylinder head and carefully position left side inlet to right side intake manifold, cylinder head to dowels.

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-Freelander

  18.  
  19. Carefully place bolts into the cylinder head. DO NOT DROP. Screw bolts into place by hand.
  20.  
  21. Tighten cylinder head bolts progressively in the sequence illustrated to:

    Step 1: 18 ft. lbs. (25 Nm)
     
    Step 2: Tighten in the same sequence to 18 ft. lbs. (25 Nm)
     
    Step 3: Tighten in the same sequence to 18 ft. lbs. (25 Nm)
     
    Step 4: In the same sequence to plus 180 degrees.
     

  22.  
  23. Clean mating surfaces of camshaft cover and carrier.
  24.  
  25. Clean inside of camshaft cover. If necessary, wash oil separator gauze and blow dry.
  26.  
  27. Install gasket and position camshaft cover to carrier.
    CAUTION
    When fitting camshaft cover gasket, ensure arrows on gasket point towards intake manifold.

  28.  
  29. Install bolts and tighten in sequence illustrated to 7 ft. lbs. (9 Nm).
  30.  
  31. Remove and discard O-rings from injectors.
  32.  
  33. Clean injectors and injector locations in fuel rail.
  34.  
  35. Lubricate new O-rings with castor oil and fit to injectors.
  36.  
  37. Position fuel rail assembly and secure injectors to intake manifolds.
  38.  
  39. Position injector protection cover to right side fuel rail and secure injector harness to protection cover with clips.
  40.  
  41. Install bolts securing fuel rail to intake manifolds and tighten to 7 ft. lbs. (9 Nm).
  42.  
  43. Position CMP sensor bracket, fit and tighten bolt to 7 ft. lbs. (9 Nm).
  44.  
  45. Connect CMP sensor multiplug and secure to bracket.
  46.  
  47. Connect breather hose to left side intake manifold.
  48.  
  49. Connect coolant bleed hose to intake manifold and secure with clip.
  50.  
  51. Position ignition coils to left side intake manifold.
  52.  
  53. Position ground lead, fit nuts and bolts securing ignition coils to left side intake manifold and tighten to 7 ft. lbs. (9 Nm).
  54.  
  55. Position high tension lead guide bracket, fit and tighten special bolt.
  56.  
  57. Connect high tension leads to spark plugs and secure high tension leads in guide clips.
  58.  
  59. Clean camshaft timing belt cover backplate bolts and apply Loctite 242 to the first 3 threads.
  60.  
  61. Position backplate, fit and tighten bolts to 7 ft. lbs. (9 Nm).
  62.  
  63. Install camshaft timing belt.
  64.  
  65. Install left side exhaust manifold gasket.
  66.  
  67. Install intake manifold chamber.
  68.  
  69. Fill cooling system.
  70.  

 
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