Engine Valley Cover Gasket - Revised Part
11/03/9412/04/94/US
SUBJECT
Valley Cover Gasket V8 Petrol Engine - New Part
Introduction
AFFECTED VEHICLES
All V8 petrol derivatives from VIN LH 644747 - LJ 071711
and LD 936297
MODEL
Range Rover
Discovery Defender
DETAIL
To improve the sealing integrity of the inlet manifold to cylinder heed joint a new valley gasket has been introduced together with a revised fitting process. The new material construction is a steel inner plate with a black/grey rubberised facing.
The new part is directly interchangeable with the previous part and should be used in instances of gasket sealing integrity is in question on the previous part.
PARTS INFORMATION
New Inlet Manifold Gasket ERR 4923 Loctite Superflex 593 or 596 (See bulletin G92-004 for supplier details)
PROCEDURE
NOTE: Refer to section 12 Of the Workshop Manual for repair and removal instructions.
1) Ensure all surfaces are free from dirt and degrease the area shown in 2.
2) Apply a small amount of Loctite Superflex Sealant to the four notches created by the cylinder heed to block joint. (Refer to Bulletin G92-004 for supplier details). Ensure that the sealant is confined to the area of application and should not be allowed to enter the tappet chamber.
WARRANTY
Normal warranty policy and procedure supplies.
COMP. CODE
2U1N
SRO
Refer to individual Service Operation Times identified in the appropriate manual to suit the derivative or model.
3) Install the manifold gasket end seals. ensuring that the seal ends fit securely in the notches created by the cylinder head to block joint.
4) Apply a globule of Loctite Superflex sealant on the top of the seal where it fits in the notches.
5) Place the valley gasket in position.
6) Fit the valley gasket clamps and tighten to 0.50-1.0 Nm (0.5-0.7 lbf ft). Do not fully tighten at this stage.
7) Place the inlet manifold on top of the gasket and fit the respective bolts to their locations as shown in the illustration opposite. Bolts with a length of 1-3/8 inches (35 mm) are fitted to inlet manifold holes numbered 1,2,3,4,5,6,7,8,9 and 12. Bolts with a length of 1-7/8 inches (48 mm) are fitted to inlet manifold holes numbered 10 and 11.
8) Check that the valley gasket, clamps and inlet manifold are correctly positioned and start each bolt into the cylinder heads.
NOTE:
The bolts do not align at right angles to the manifold/head faces and this may give the illusion of misalignment.
9) When tightening the inlet manifold bolts they should be tightened using the sequence shown in the illustration above.
10) Initially tighten all manifold bolts in the sequence shown to 10 Nm (7 lbf ft).
11) Secondly tighten all the manifold bolts in the sequence shown to 48-54 Nm (35-40 lbf ft)
12) Finally tighten the damp bolts at the front and rear of the valley gasket to 14-20 Nm (10-15 lbf ft).
NOTE:
Ensure that the damps do not move during the tightening operation
13) Complete the reassembly following the instructions in the Workshop Manual.
14) Start the engine. check for fluid/air leaks and correct throttle operation.