Discovery 2. Manual — part 66

EMISSION CONTROL - V8

REPAIRS 17-2-59

Reservoir - vacuum - Secondary Air
Injection (SAI) - from 03MY

$% 17.25.04

Remove

1. Disconnect 2 vacuum pipes from air reservoir.
2. Remove bolt securing air reservoir to air pump

and remove the reservoir.

Refit

1. Position air reservoir to air pump, fit bolt and

tighten to 10 Nm (7 lbf.ft).

2. Connect vacuum pipes to the air reservoir.

Pump - Air - Secondary Air Injection
(SAI)

$% 17.25.07

Remove

1. Disconnect multiplug from air pump.
2. Release clip and disconnect air hose from air

pump.

3. Remove bolt securing air pump bracket to

body.

4. Remove air pump and bracket assembly.

5. Remove 3 nuts securing bracket to air pump

and collect bracket.

6. Remove 3 mountings from air pump.

Refit

1. Fit mountings to air pump and tighten to 10

Nm.

2. Fit bracket to air pump mountings and tighten

nuts to 10 Nm.

3. Position air pump assembly and tighten bolt to

20 Nm.

4. Connect air hose to SAI pump.
5. Connect multiplug to air pump.

M17 0225

2

1

3

4

M17 0226

5

5

6

EMISSION CONTROL - V8

17-2-60 REPAIRS

Air Manifold - LH - Secondary Air
Injection (SAI)

$% 17.25.17

Remove

1. Remove SAI control valve.

+

EMISSION CONTROL - V8,

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

2. Disconnect 2 air manifold unions from adapters

in cylinder head.

CAUTION: Take care that air manifold pipes
are not damaged during removal of union
nuts.

3. Remove 2 nuts securing air manifold bracket to

inlet manifold.

4. Remove air manifold.

Refit

1. Clean air manifold and cylinder head adapters.
2. Apply a small amount of engine oil to top of air

manifold union nuts and around air manifold
pipes.

3. Position air manifold and finger tighten both

union nuts.

CAUTION: Finger tighten union nuts as far
as possible, damage to air manifold pipes or
adapters may result if this is not done.

4. Tighten air manifold unions to 25 Nm (18 lbf.ft).

CAUTION: Ensure that air manifold pipes
are not distorted during tightening
operation.

5. Fit nuts securing air manifold to inlet manifold

and tighten to 25 Nm (18 lbf.ft).

6. Fit SAI control valve.

+

EMISSION CONTROL - V8,

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

M17 0234

4

3

2

2

EMISSION CONTROL - V8

REPAIRS 17-2-61

Air Manifold - RH - Secondary Air
Injection (SAI)

$% 17.25.18

Remove

1. Remove SAI control valve.

+

EMISSION CONTROL - V8,

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

2. Remove heater feed pipe.

+

HEATING AND VENTILATION,

REPAIRS, Pipe - Heater - Feed.

3. Disconnect 2 air manifold unions from adapters

in cylinder head.

CAUTION: Take care that air manifold pipes
are not damaged during removal of union
nuts.

4. Remove nut securing air manifold bracket to

inlet manifold.

5. Remove air manifold.

Refit

1. Clean air manifold and cylinder head adaptors.
2. Apply a small amount of engine oil to top of air

manifold union nuts and around air manifold
pipes.

3. Position air manifold and finger tighten both

union nuts.

CAUTION: Finger tighten union nuts as far
as possible, damage to air manifold pipes or
adapters may result if this is not done.

4. Tighten air manifold unions to 25 Nm (18 lbf.ft).

CAUTION: Ensure that air manifold pipes
are not distorted during tightening
operation.

5. Fit nut securing air manifold to inlet manifold

and tighten to 25 Nm (18 lbf.ft).

6. Fit heater feed pipe.

+

HEATING AND VENTILATION,

REPAIRS, Pipe - Heater - Feed.

7. Fit SAI control valve.

+

EMISSION CONTROL - V8,

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

M17 0223

4

3

3

5

EMISSION CONTROL - V8

17-2-62 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

1

2

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3

M17 0230