Left exhaust manifold (Discovery 3)

Removal

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

2. Remove the turbocharger. For more information, refer to Turbocharger (19.42.01)

3. Drain the coolant from the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (10/26/01)

4. Remove the battery tray. For more information, refer to Battery Shelf (76.10.30)

5. Disconnect the left EGR valve outlet pipe. For more information, refer to Exhaust Gas Recirculation (EGR) Valve Outlet Pipe (17.45.18)

6. Disconnect the coolant outlet hose from the left EGR valve. Release the clamp.



7. Disconnect the left EGR valve inlet pipe.

• Remove the 2 support bracket mounting bolts.
• Remove the support bracket.
• Remove and discard the clamp.

8. Remove the left EGR valve inlet pipe.

• Remove 2 bolts.
• Remove the gasket and discard it.

9. Disconnect the electrical connector of the left EGR valve.



10. Disconnect the coolant inlet hose from the left EGR valve. Release the clamp.



11. Remove the left EGR valve. Unscrew the 3 bolts.



12. Remove the left exhaust manifold heat shield. Remove 2 bolts.





13. Unscrew the three nuts of the exhaust gas bypass pipe.



14. Remove the left exhaust manifold. Unscrew the 6 nuts.



15. Remove and discard the left exhaust manifold gasket. Remove and discard the studs.

Installation

1. Tighten the left exhaust manifold mounting studs. (tightening torque 13 Nm). Install a new gasket.

2.

NOTE: Tighten the nuts in the order shown.

Install the left exhaust manifold. Tighten the nuts. (tightening torque 24 Nm).



3. Screw on the three exhaust gas bypass pipe nuts. Tighten the nuts. (tightening torque 24 Nm).

4. Install the left exhaust manifold heat shield. Insert and tighten the 2 bolts. (tightening torque 10 Nm).

5. Install the left EGR valve. Insert the EGR valve mounting bolts, but do not fully tighten them yet.

6.

NOTE: Do not fully tighten the clamp at this stage.

Install the left EGR valve inlet pipe.

• Install the new clamp.
• Install a new gasket.
• Loosely insert the 2 EGR valve inlet pipe mounting bolts.

7. Tighten the clamp completely.

8. Tighten the 2 EGR valve inlet pipe mounting bolts. (tightening torque 10 Nm).

9. Tighten the 3 EGR valve mounting bolts. (tightening torque 10 Nm).

10. Install the support bracket. Tighten the 2 mounting bolts. (tightening torque 10 Nm).

11. Connect the coolant inlet hose to the left EGR valve.

12. Connect the electrical connector of the left EGR valve.



13. Connect the coolant outlet hose to the left EGR valve.

14. Install the left EGR valve outlet pipe. For more information, refer to Exhaust Gas Recirculation (EGR) Valve Outlet Pipe (17.45.18)

15. Install the battery tray. For more information, refer to Battery tray (76.10.30)

16. Install the turbocharger. For more information, refer to Turbocharger (19.42.01)

17. Connect the ground cable to the battery. For more information, refer to Specifications.

18. Fill and bleed the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (10/26/01)