Front cover gasket (Discovery 1)

Removal

Editor's note: Drain the coolant.

1. Remove the crankshaft pulley.

2. Remove the water pump pulley.

3. Remove the distributor cap.

4. Remove the high-voltage wires from the spark plugs and disconnect them from the clips.

5. Remove the distributor cap along with the wires.

6. Bring the piston of the first cylinder to the TDC compression position, check the position of the distributor rotor.

7. Unscrew the power steering pump bracket fasteners from the water pump.

8. Remove the power steering pump bracket.

9. Disconnect the generator wiring clips.

10. Disconnect the distributor power wire.

11. Rotate the power steering pump away from the front cover and secure it in this position.

12. Disconnect the vacuum hose from the distributor.

13. Remove the lower water pump hose.

14. Disconnect the oil pressure sensor wire.

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15. Disconnect the heater hose from the water pump.

16. Remove the generator tension bar from the water pump and move it to the side.

17. Mark the position of the distributor relative to the front cover.

18. Remove the distributor (see "Electrical equipment").

19. Unscrew the tray fastening to the front cover.

20. Loosen the four adjacent pan mounting bolts.

21. Remove the generator support stand from the front cover.

22. Unscrew the remaining cover mounting bolts and remove the cover.

23. Remove the gasket.

Installation

24. Clean the mating surfaces of the block and front cover.

25. Lightly lubricate the gasket with grease and install it on the block.



26. Apply sealant to the pan gasket.

27. Clean the threads of the cover mounting bolts and apply Loctite 372 sealing adhesive to the threads.

28. Install the front cover, tighten the mounting bolts to 28 N·m.

29. Install the generator support stand.

30. Tighten the oil pan mounting bolts to 10 Nm.

31. Lubricate the distributor sealing ring and install the distributor into the cover. Align the relative position marks made earlier.

32. If the marks do not align, check the oil pump drive.

33. Secure the distributor with a bracket and tighten the bracket bolt to a torque of 20 Nm.

34. Install:

• generator bar;
• heater hose;
• oil pressure sensor;
• lower water pump hose;
• distributor vacuum hose;
• distributor supply wire.

35. Install the power steering pump and its bracket. Tighten the bracket fasteners to 28 Nm.

36. Install the distributor cap, connect the high-voltage wires.

37. Install the water pump pulley. Tighten the mounting bolts to 10 Nm.

38. Install the crankshaft pulley.

39. Install the accessory drive belt.

40. Check the ignition timing.

41. Fill the cooling system.