Discovery 2. Manual — part 527
MANIFOLDS AND EXHAUST SYSTEMS - V8
REPAIRS 30-2-15
Refit
1. Clean old RTV sealant from cylinder head and
cylinder block notches.
2. Clean mating faces of cylinder block, cylinder
head and inlet manifold.
3. Apply RTV sealant to cylinder head and
cylinder block notches.
4. Fit new gasket seals, ensuring ends engage
correctly in notches.
5. Fit new inlet manifold gasket.
6. Position gasket clamps and fit bolts, but do not
tighten at this stage.
7. Position inlet manifold to engine. Fit manifold
bolts and, working in the sequence shown,
tighten bolts initially to 10 Nm (7 lbf.ft) then to
51 Nm (38 lbf.ft).
8. Tighten gasket clamp bolts to 18 Nm (13 lbf.ft).
9. Connect fuel pipe.
10. Clean top hose outlet pipe mating faces.
11. Fit new 'O' ring to outlet pipe.
12. Position outlet pipe, fit bolts and tighten to 22
Nm (16 lbf.ft).
13. Position alternator, fit bolts and tighten to 45
Nm (33 lbf.ft).
14. Position PAS pump to auxiliary housing and
locate housing on engine. Fit bolts and tighten
to 40 Nm (30 lbf.ft).
15. Fit and tighten auxiliary housing nut to 10 Nm (7
lbf.ft).
16. Fit bolts securing PAS pump and tighten to 22
Nm (16 lbf.ft).
17. Position oil cooling pipe bracket fit bolt and
tighten to 22 Nm (16 lbf.ft).
18. Fit and tighten PAS pump high pressure pipe.
19. Position jockey pulley and tighten bolt to 50 Nm
(37 lbf.ft).
20. Clean PAS pump pulley mating faces.
21. Position PAS pump pulley, fit bolts and tighten
to 22 Nm (16 lbf.ft).
22. Clean ACE pump dowels and dowel holes.
23. Position ACE pump, fit bolts and tighten to 22
Nm (16 lbf.ft).
24. Fit auxiliary drive belt.
REPAIRS, Belt - auxiliary drive.
25. Secure injector harness and connect injector
multiplugs.
26. Position top hose and secure clips.
27. Fit rocker covers.
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28. Check and top up PAS fluid
MANIFOLDS AND EXHAUST SYSTEMS - V8
30-2-16 REPAIRS
Gasket - exhaust manifold
$% 30.15.12
This procedure is the same for both exhaust manifold
gaskets.
Remove
1. Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2. Remove 3 nuts securing front pipe to exhaust
manifold, release front pipe and collect gasket.
3. Remove 8 bolts and spacers securing exhaust
manifold.
4. Remove exhaust manifold.
5. Remove 2 manifold gaskets.
Refit
1. Clean exhaust manifold and cylinder head
mating face.
2. Position exhaust manifold and new gaskets on
cylinder head.
3. Fit spacers and exhaust manifold securing
bolts and, working from the centre outwards,
tighten bolts to 38 Nm. (28 lbf.ft).
4. Clean front pipe and manifold mating faces.
5. Using a new gasket, position front pipe, fit nuts
and tighten to 30 Nm. (22 lbf.ft).
6. Remove stand(s) and lower vehicle.
MANIFOLDS AND EXHAUST SYSTEMS - V8
REPAIRS 30-2-17
Gasket - inlet manifold - upper - Without
Secondary Air Injection
$% 30.15.24
Remove
1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Remove bonnet.
4. Release MAF sensor harness from clip.
5. Loosen clips securing air intake hose. Release
and remove air intake hose.
Note: Pre 03 MY air intake hose illustrated.
6. Disconnect throttle and cruise control cables.
Release cables from abutment bracket and
position aside.
7. Disconnect EVAP pipe from inlet plenum.
8. Disconnect multiplug from throttle body.
9. Remove clip securing breather hose to throttle
body and release breather hose.
10. Position a drain tray beneath the engine to
collect coolant.
11. Release clips securing coolant hoses to
throttle body and disconnect hoses.
12. Disconnect brake servo vacuum pipe from inlet
plenum.
MANIFOLDS AND EXHAUST SYSTEMS - V8
30-2-18 REPAIRS
13. Disconnect breather hose from inlet plenum.
14. Remove bolt securing coolant rails.
15. Release engine harness from bulkhead clips
and position aside.
16. Remove 4 bolts securing ignition coils and
position ignition coils aside.
17. Release plug leads from upper manifold clips.
18. Disconnect multiplug from IACV.
19. Release and disconnect IACV hose.
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.
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- V8, ADJUSTMENTS, Cable - cruise
control.
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- 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.
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