Discovery 2. Manual — part 106
MANIFOLDS AND EXHAUST SYSTEMS - V8
REPAIRS 30-2-17
20. Remove 6 bolts securing upper inlet manifold
and remove upper inlet manifold.
21. Collect upper inlet 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 hose and multiplug to TP sensor.
4. Connect hose and multiplug to IACV. Secure
hose with clip.
5. Secure ht leads to upper inlet manifold.
6. Position ignition coils, fit bolts and tighten to 8
Nm (6 lbf.ft).
7. Ensure clip under ignition coils is located on
fuel pipe.
8. Secure engine harness in bulkhead clips.
9. Fit coolant rail bolt and tighten to 22 Nm (16
lbf.ft).
10. Connect breather hose to inlet plenum.
11. Connect brake servo vacuum pipe to inlet
plenum.
12. Connect EVAP pipe to inlet plenum.
13. Position coolant hoses to throttle body and
secure hose clips.
14. Fit breather hose to throttle body and secure
clip.
15. Connect multiplug to throttle body.
16. Connect throttle and cruise control cables and
secure in throttle body cams.
17. Adjust throttle and cruise control cables.
l
- V8, ADJUSTMENTS, Cable - cruise
control.
l
- V8, ADJUSTMENTS, Cable - throttle.
18. Connect air intake hose and tighten clips.
Secure harness to air intake hose.
19. Top-up cooling system
20. Fit bonnet.
21. Connect battery earth lead.
22. Fit battery cover and secure with fixings.
MANIFOLDS AND EXHAUST SYSTEMS - V8
30-2-18 REPAIRS
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.
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.
CAUTION: Take care that air manifold pipes
are not damaged during removal of union
nuts.
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
REPAIRS 30-2-19
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
30-2-20 REPAIRS
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.
V8, ADJUSTMENTS, Cable - throttle.
16. Adjust cruise control cable.
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.
24. Apply a small amount of engine oil to top of air
manifold union nuts and around air manifold
pipes.
25. Position air manifold and finger tighten both air
manifold union nuts.
CAUTION: Finger tighten union nuts as far
as possible, damage to air manifold pipes or
adaptors may result if this is not done.
26. Tighten both air manifold union nuts to 25 Nm
(18 lbf.ft).
CAUTION: Ensure that air manifold pipes
are not distorted during tightening
operation.
27. Fit nuts securing air manifold support bracket
and tighten to 25 Nm (18 lbf.ft).
28. Connect hose to air valve and tighten clip.
29. Connect vacuum hose to air valve.
30. Fit air intake hose.
31. Connect multiplug to MAF sensor.
32. Secure harness to clip.
33. Connect battery earth lead.
34. Fit battery cover and secure with fixings.
35. Top up cooling system.
36. Fit bonnet.
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