Discovery 2. Manual — part 463

EMISSION CONTROL - V8

REPAIRS 17-2-51

Air Manifold - LH - Secondary Air
Injection (SAI)

$% 17.25.17

Remove

1. Remove SAI control valve.

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EMISSION CONTROL - V8,

REPAIRS, Control Valve - Secondary Air
Injection (SAI).

2. Loosen 2 union nuts securing air manifold to

cylinder head adaptors.

3. Remove 2 nuts securing air manifold bracket to

inlet manifold.

4. Remove air manifold.

Refit

1. Clean air manifold and cylinder head adaptors.
2. Fit air manifold and start union nuts.
3. Fit nuts securing air manifold to inlet manifold.
4. Tighten air manifold unions to 25 Nm.
5. Fit SAI control valve.

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EMISSION CONTROL - V8,

REPAIRS, Control Valve - Secondary Air
Injection (SAI).

Air Manifold - RH - Secondary Air
Injection (SAI)

$% 17.25.18

Remove

1. Remove SAI control valve.

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EMISSION CONTROL - V8,

REPAIRS, Control Valve - Secondary Air
Injection (SAI).

2. Remove heater feed pipe.

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HEATING AND VENTILATION,

REPAIRS, Pipe - Heater - Feed.

3. Loosen 2 union nuts securing air manifold to

cylinder head adaptors.

4. Remove nut securing air manifold bracket to

inlet manifold.

5. Remove air manifold.

Refit

1. Clean air manifold and cylinder head adaptors.
2. Fit air manifold and start union nuts.
3. Fit nut securing air manifold to inlet manifold.
4. Tighten air manifold unions to 25 Nm.
5. Fit heater feed pipe.

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HEATING AND VENTILATION,

REPAIRS, Pipe - Heater - Feed.

6. Fit SAI control valve.

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EMISSION CONTROL - V8,

REPAIRS, Control Valve - Secondary Air
Injection (SAI).

M17 0234

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M17 0223

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5

EMISSION CONTROL - V8

17-2-52 REPAIRS

Solenoid - Vacuum - Secondary Air
Injection (SAI)

$% 17.25.47

Remove

1. Release multiplug from solenoid.
2. Disconnect 2 vacuum hoses from solenoid.
3. Release solenoid from mounting bracket and

remove.

Refit

1. Secure solenoid to mounting bracket.
2. Connect vacuum hoses and multiplug to

solenoid.

Pipe - Secondary Air Injection (SAI)

$% 17.25.59

Remove

1. Loosen clip securing RH SAI control valve hose

to air injection pipe.

2. Release hose from air injection pipe.
3. Loosen clip securing SAI pump hose to air

injection pipe.

4. Release hose from air injection pipe.

5. Loosen clip securing LH SAI control valve hose

to air injection pipe.

6. Release hose from air injection pipe.
7. Disconnect multiplug from SAI vacuum

solenoid.

M17 0236

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M17 0230

EMISSION CONTROL - V8

REPAIRS 17-2-53

8. Remove 2 nuts securing air injection pipe to air

intake plenum.

9. Release pipe from clip on rear of air intake

plenum.

10. Release 3 clips securing harness to engine bay

bulkhead.

11. Position container to collect any coolant

spillage.

12. Release clips securing heater hoses to heater.
13. Release hoses from heater.
14. With assistance, manoeuvre air injection pipe

from engine bay.

Refit

1. With assistance, manoeuvre air injection pipe

into engine bay and secure onto clip at rear of
air intake plenum.

2. Connect heater hoses to heater and secure

with clips.

3. Reposition harness along engine bay bulkhead

and secure with clips.

4. Fit and tighten nuts securing air injection pipe to

air intake plenum.

5. Connect multiplug to SAI vacuum solenoid.
6. Connect air pump hose to air injection pipe and

secure with clip.

7. Connect LH and RH SAI control valve hoses to

air injection pipe and secure with clips.

8. Remove container.
9. Top up engine coolant.

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MAINTENANCE, PROCEDURES,

Cooling system.

M17 0231

M17 0232

M17 0233

EMISSION CONTROL - V8

17-2-54 REPAIRS

Pump - Fuel Leak Detection - up to 03MY

$% 17.45.41

Remove

1. Raise the vehicle on lift.

2. Disconnect multiplug from fuel leak detection

pump.

3. Release leak detection air filter hose from top of

pump.

4. Remove 3 Torx screws securing pump to

mounting bracket.

5. Remove clip securing EVAP canister hose to

pump.

6. Release EVAP canister hose from pump.
7. Remove pump.

Refit

1. Connect EVAP canister hose to pump and

secure with clip.

2. Position pump to mounting bracket and secure

with Torx screws.

3. Connect leak detection air filter hose to top of

leak detection pump.

4. Connect multiplug to pump.
5. Lower vehicle.

Pump - fuel leak detection - from 03MY

$% 17.45.41

Remove

1. Raise the vehicle on lift.

2. Disconnect multiplug from the fuel leak

detection pump.

3. Remove 3 screws securing the fuel leak

detection pump to the chassis mounting
bracket.

4. Position absorbent cloth around fuel hoses to

collect any fuel spillage.

5. Disconnect the fuel leak detection filter pipe

from the fuel leak detection pump.

CAUTION: Always fit plugs to open
connections to prevent contamination.

6. Remove and discard clip securing EVAP pipe

to the fuel leak detection pump and disconnect
the pipe.

7. Remove the fuel leak detection pump.

Refit

1. Connect the EVAP pipe to the fuel leak

detection pump and secure with a new clip.

2. Connect the fuel leak detection filter pipe to the

fuel leak detection pump.

3. Remove absorbent cloth.
4. Fit and tighten 3 screws securing the fuel leak

detection pump to the chassis mounting
bracket.

5. Connect multiplug to the fuel leak detection

pump.

6. Lower the vehicle lift.

M17 0235

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