I bought this head gasket set from Ebay for $50 USD https://www.ebay.com/itm/127506917841. I only needed some of the gaskets, not the head gaskets.
The valley gasket end seals included in this kit are too big and don't clamp down flush at the rated torque spec. This causes the valley gasket to not sit flush and the manifold bolt holes will not align.
I bought the Felpro MS96002 kit instead after reading that it may be compatible. It fits much better. But the end seals are still a little big. So i bought another set of End Seals only - p/n ERR7283 from URO manufacturer. And finally this 3rd set fits perfect. Combined with the Felpro valley gasket, it's a near perfect fit. The Ebay valley gasket is much lesser quality than the Felpro metal one. Anyone have this much trouble with valley gaskets?
Im guessing some work was probably done on the heads previously and may have been machined down a bit. I actually think it's a junkyard motor, judging by some Paint marker markings all over the block.
With the wrong seals, i tried to "force" everything to align by starting bolts in a couple threads, and i ended up butchering those threads. Now i'm waiting on a Thread Chaser kit to try and restore them. Otherwise, helicoil. Is this what every Land Rover repair is like? LOL . this is my first one, only paid $500 USD for it, and i'm learning a lot just by working on it. I enjoy it. Was driving good even with all the leaks and Engine codes.
I learned my lesson, don't buy cheap gasket sets from Ebay, and don't try to force any bolts.

I have pics, but i read somewhere new members should not post pictures.

 

Welcome here. I'm glad you're enjoying your Disco. Thanks for letting us know what's happening with your rig. It sounds like you're on top of it. Keep us posted on how the job goes, and if you have questions this is the right place to ask.

 

If you can post a pic post it

 

I used a 3/8-16 Thread Chaser and managed to fix the threads. Afterwards, everything aligned nicely and torqued to spec.
... Except the rear clamp bolt, I could not a get a torque wrench and socket on it because it sits slightly below the fuel line port on the manifold. I should have torqued it down first, but the way I read the RAVE instructions, i torque the clamps to 5ftlbs initially and then finally 13ftlb after the manifold is installed. So i grabbed a small wrench and tried to snug it up. I hope that doesn't bite me in the end. I could take the manifold off and do it all again. Debating.

 

I couldn't get one of the bolts with a torque wrench and I was fine. You might want to get it a bit tighter than with a small wrench. You can do the two wrench method and compare tighness to an already torqued bolt. https://www.hotrod.com/news/wrenchin...-double-wrench
But don't tighten it too much, or you will strip the threads again.

 

 

We have had to carefully trim the ends of the last two sets that we have installed. They would bunch up otherwise.

 

Got everything back together and running.

Valley gasket Felpro MS96002

End seals URO ER7283

Upper intake gasket felpro MS97221

valve cover and exhaust gaskets from the ebay set.

I didn’t have a oring to match the cooling tube into the intake manifold so used the permatex gasket maker there. Hopefully it lasts but I have a oring on the way in case..

Repaired broke knock sensor wire with a coax RG174 shielded wire.

Bypassed the throttle heater plate. Mostly because I broke a bolt torquing a replacement down.

Refilled with water to leak test , bled the air bubbles , and drove it around some , temperature rises and locks in about 196F. Will do the inline thermostat mod next. And relocate the coil packs..


i wonder Does anyone recognize the Land Rover I bought? It has “Tardis” badges on the side.



it looks like it has the PCV intake mod , but it also had plastic separator baffles on the other end of the hose and one in the valve cover tube. I removed those and have a v288 PCV on hand from rockauto in case.

it also looks like it has a grease fitting already on the front u joint.

its missing the tube between the air box and the fender well.. need to find one of those

I’m noticing the carpet is pretty wet on the passenger floor after rain. Need to track that down..



Here are some pics

 

Get on top of the source of water on the floor. My D2 came at scrap price because water had leaked into a computer (ECU IIRC?) above the passengers feet, causing the vehicle to not run.