Right exhaust manifold (Discovery 3)

Removal

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

2.

CAUTION: Never work on a vehicle supported only by a jack. Always support the vehicle securely.

Raise and support the vehicle.

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

4. Remove the additional battery tray. For more information, refer to Additional Battery Shelf (76.10.31)

5. Remove the exhaust pipe of the right exhaust gas recirculation (EGR) valve. For more information, refer to the exhaust pipe of the Exhaust Gas Recirculation Valve (EGR) (17.45.18)

6. Remove the fuel line retaining bracket.

• Disconnect the fuel lines.
• Remove the bolt.

7. Disconnect the EGR valve plug connector.



8. Disconnect the coolant inlet hose from the EGR valve. Loosen the clamp.





9. Disconnect the coolant outlet hose from the EGR valve.

• Remove the bolt.
• Release the clamp.

10. Remove the EGR valve inlet pipe.

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

11. Remove the right front wheel assembly with the tire.

12. To gain access, remove the upper control arm and brake line heat shields.





13. Remove the right EGR valve assembly with the heat exchanger. Unscrew the 3 bolts.



14. Remove the right exhaust manifold heat shield. Remove 3 bolts.



15. Unscrew the 2 nuts of the exhaust gas bypass pipe.



16. Unscrew the remaining nut of the exhaust gas bypass pipe.





17. Remove the right exhaust manifold.

• Unscrew 6 nuts.
• Remove the gasket and discard it.
• Remove and discard the studs.

Installation

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

2.

NOTE: Tighten the nuts in the order shown.

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



3. Tighten the exhaust gas bypass pipe nut. (tightening torque 24 Nm).



4. Tighten the 2 exhaust gas bypass pipe nuts. (tightening torque 24 Nm).

5. Install the right exhaust manifold heat shield. Install the bolts and tighten them to 10 Nm.

(The original was published on the portal: «www.lrman.ru»)

6. Install the EGR valve assembly with the right bank heat exchanger. Install the EGR valve bolts, but do not fully tighten them at this stage.

7.

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

Install the EGR valve inlet pipe.

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

8. Close the clamp completely.

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

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

11. Install the upper control arm and brake line heat shields.

12. Install the wheel and tire assembly.

13. Tighten the EGR valve bolt. (tightening torque 10 Nm).

14. Connect the coolant outlet hose to the EGR valve.

15. Connect the coolant inlet hose to the EGR valve.

16. Connect the EGR valve electrical connector.

17. Install the fuel line bracket.

• Insert the fuel line support bracket bolt and tighten. (tightening torque 10 Nm).
• Secure the fuel lines.

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

19. Install the extra battery tray. For more information, refer to Extra Battery Shelf (76.10.31)

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

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