Discovery 2. Manual — part 528

MANIFOLDS AND EXHAUST SYSTEMS - V8

REPAIRS 30-2-19

Gasket - inlet manifold - upper - With
Secondary Air Injection

$% 30.15.24

Remove

1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Remove bonnet.

EXTERIOR FITTINGS, REPAIRS,

Bonnet.

4. Disconnect multiplug from MAF sensor.
5. Release clip on intake hose and release

harness.

Note: Pre 03 MY air intake hose illustrated.

6. Release and disconnect IACV hose.
7. Loosen clip securing air intake hose to throttle

body.

8. Release 2 clips securing MAF sensor.
9. Release and remove air intake hose.

10. Disconnect vacuum hose from air valve.
11. Loosen clip securing air valve hose to air valve.
12. Remove 2 nuts securing air manifold support

bracket to upper inlet manifold.

13. Disconnect 2 air manifold unions from adapters

in cylinder head.

14. Remove LH air manifold.

15. Disconnect purge valve hose from inlet

manifold.

16. Release purge valve from clips and air control

valve from bracket and lay aside.

17. Disconnect multiplug from IACV.
18. Release clip and disconnect breather hose

from throttle housing.

19. Disconnect multiplug from TP sensor.

MANIFOLDS AND EXHAUST SYSTEMS - V8

30-2-20 REPAIRS

20. Position container to collect spillage.
21. Release clips and disconnect 2 coolant hoses

from throttle housing.

22. Loosen outer cable locknuts and release

throttle and cruise control cables from
abutment.

23. Release throttle and cruise control cables from

clips and throttle cams and position aside.

24. Depress plastic collar and disconnect brake

servo hose from inlet manifold.

25. Release clip and disconnect breather hose

from manifold.

26. Disconnect vacuum hose from manifold.
27. Release engine harness from bulkhead clips

and position aside.

28. Release and remove bonnet seal from rear of

engine bay.

29. Remove 2 bolts securing air pipe and coil

bracket to manifold.

30. Loosen 2 lower bolts securing coil bracket

sufficiently to allow bracket to clear manifold.

31. Release plug leads from upper manifold clips.

32. Loosen clip and disconnect air hose from air

valve.

33. Remove 2 nuts securing RH air manifold

support bracket to upper inlet manifold.

MANIFOLDS AND EXHAUST SYSTEMS - V8

REPAIRS 30-2-21

34. Release clip and disconnect IACV hose.
35. Remove 6 bolts securing upper manifold and

remove manifold.

36. Collect upper manifold gasket.

Refit

1. Clean upper and lower inlet manifold mating

faces, dowels and dowel holes.

2. Using a new gasket, position upper inlet

manifold. Fit bolts and, working in a diagonal
sequence, tighten to 22 Nm (16 lbf.ft).

3. Connect IACV hose and secure clip.
4. Connect hose to air valve and tighten clip.
5. Secure plug leads to clips.
6. Fit and tighten nuts securing RH air manifold

support bracket.

7. Align air pipe and coil bracket, fit bolts and

tighten to 8 Nm (6 lbf.ft).

8. Tighten 2 lower bolts securing coil bracket to 8

Nm (6 lbf.ft).

9. Fit bonnet seal.

10. Secure engine harness in bulkhead clips.

11. Connect breather hose to manifold and secure

clip.

12. Connect vacuum hose to inlet manifold.
13. Connect brake servo hose to inlet manifold.
14. Connect throttle and cruise control cables.
15. Adjust throttle cable.

ENGINE MANAGEMENT SYSTEM -

V8, ADJUSTMENTS, Cable - throttle.

16. Adjust cruise control cable.

ENGINE MANAGEMENT SYSTEM -

V8, ADJUSTMENTS, Cable - cruise control.

17. Connect coolant hoses to throttle housing and

secure clips.

18. Connect multiplug to TP sensor.
19. Connect breather hose to throttle housing and

secure with clip.

20. Connect multiplug to IACV.
21. Secure purge valve and air control valve to clips

and bracket.

22. Connect purge hose to manifold.
23. Clean air manifold unions, position manifold

and start union nuts.

24. Fit and tighten nuts securing air manifold

support bracket.

25. Tighten air manifold union nuts to 25 Nm (18

lbf.ft)

26. Connect hose to air valve and tighten clip.
27. Connect vacuum hose to air valve.
28. Fit air intake hose.
29. Connect multiplug to MAF sensor.
30. Secure harness to clip.
31. Connect battery earth lead.
32. Fit battery cover and secure with fixings.
33. Top up cooling system.