Brake Vacuum Pump — 2.7L Diesel (Discovery 3)

Removal

1. Disconnect the ground cable from the battery. For more information, refer to Specification

2. Remove the engine cover. For more information, refer to Engine Cover - 2.7L Diesel (12.30.50)

3.

CAUTION: To avoid contamination of the system, always plug all open connections.

Disconnect the brake booster vacuum line from the brake system vacuum pump.



4.

CAUTION: Never work on a vehicle supported only by a jack. Always support the vehicle with special stands.

Raise and support the vehicle.

5. Remove the exhaust system. For more information, refer to Exhaust System - Vehicle does not include: Diesel Fuel Filter (10/30/08)

6. Lower the rear of the transmission to provide access.

7. Remove the left exhaust bypass pipe support bracket.

• Release the wiring harness from the mount.
• Remove 3 bolts.

8. Remove the right exhaust bypass pipe support bracket. Remove 3 bolts.





9. Remove the exhaust system bypass pipe center support bracket. Remove 2 bolts.



10.

CAUTION: Use caution when handling the overflow tube to avoid damaging the insulating material.

Disconnect the bypass pipe from the turbocharger.

• Remove the turbocharger heat shield bolt.
• Unscrew and discard 3 nuts.

11. Remove the right exhaust manifold heat shield.





12. Remove the exhaust system bypass pipe.

• Unscrew and discard 3 nuts.
• Remove and discard 2 gaskets.

13. Release the high pressure fuel supply line. Remove the bolt.



14. Loosen the brake system vacuum pump nut.



15. Remove the brake vacuum pump.

• Turn out the pin.
• Remove 2 bolts.

Installation

1.

CAUTION: When assembling, be extremely careful not to smear the sealant. If the sealant smears, clean the mating surfaces and apply new sealant.

Apply sealant in the two places shown in the picture.

• Make sure the vacuum pump seal is clean and dry.
• Make sure the cams on the vacuum pump are adjusted in relation to the camshaft.
• Apply 2 sq.mm of Loctite 518 sealant in the two locations shown.
• Install the brake vacuum pump immediately after applying the sealant.
• The brake system vacuum pump should be seated on the engine in one movement, without smearing the sealant.

2. Install the brake system vacuum pump.

• Screw in 2 bolts.
• Tighten the bolts (tightening torque 23 Nm).

3. Screw in the brake system vacuum pump stud. Tighten. (tightening torque 13 Nm).



4. Screw on the brake system vacuum pump nut. Tighten. (tightening torque 13 Nm).

5. Secure the high-pressure fuel supply line. Tighten the bolt to 10 Nm.

Information obtained from the website LRman.ru

6. Install 3 new exhaust manifold studs. Tighten the 3 studs. (tightening torque 13 Nm).

7. Install 3 new turbocharger studs. Tighten 3 studs. (tightening torque 13 Nm).

8.

CAUTION: Use caution when handling the overflow tube to avoid damaging the insulating material.

Install the exhaust system bypass pipe.

• Clean the mating surfaces of the elements.
• Install 2 new gaskets.
• Screw on 6 new nuts.
• Tighten 6 nuts (tightening torque 24 Nm).

9. Install the exhaust bypass pipe center support bracket. Install the 2 bolts, but do not tighten them.

10. Install the right exhaust bypass pipe support bracket. Install the 3 bolts but do not tighten them.

11. Install the left exhaust bypass pipe support bracket. Install the 3 bolts but do not tighten them.

12. Tighten the exhaust bypass pipe support bracket bolts in the following sequence.

• Tighten the 2 bolts marked 1 (tightening torque 10 Nm).
• Loosen the 2 bolts 90 degrees.
• Tighten the 2 bolts marked 3 (tightening torque 10 Nm).
• Loosen the 2 bolts 90 degrees.
• Tighten the 4 bolts marked 2 (tightening torque 25 Nm).
• Tighten the 2 bolts marked 1 (tightening torque 25 Nm).
• Tighten the 2 bolts marked 3 (tightening torque 25 Nm).
• Secure the wiring harness.

13. Install the right exhaust manifold heat shield. Tighten the 3 bolts. (tightening torque 10 Nm).



14. Install the turbocharger heat shield. Tighten the bolt. (tightening torque 10 Nm).

15. Install the exhaust system.
For more information, please refer to Exhaust System - Vehicle does not include: Diesel Fuel Filter (10/30/08)

16.

CAUTION: To avoid contamination of the system, plug all open connections.

Connect the brake booster vacuum line to the brake system vacuum pump.

17. Install the engine cover. For more information, refer to Engine Cover - 2.7L Diesel (12.30.50)

18. Connect the ground cable to the battery. For more information, refer to Specification.