Left exhaust manifold (Discovery 3)

Removal

All cars

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 - 4.0L (12.30.50)

Right hand drive vehicles

3. Disconnect the positive cable from the battery.

• Release the clamp.
• Release the sleeve.

Right hand drive vehicles

4. Release the wiring harness clamp. Remove the bolt.



All cars

5.

CAUTION: Never work on or under a vehicle that is supported solely by a jack. Always support the vehicle securely.

Raise and support the vehicle.

6. Remove the engine protection shield. For more information, refer to Engine Protection (76.10.50)

7. Disconnect the exhaust system from the exhaust manifold. Unscrew and discard the 2 bolts.





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8. Lower the vehicle.

9.

CAUTION: When performing this operation, it is necessary to protect the engine.

Lift the engine from the left support. Unscrew the nut.



10.

CAUTION: Before disconnecting or removing parts, make sure the area around mating surfaces and connections is clean. To prevent contamination of the system, plug all open connections.

Remove the EGR pipe. Unscrew the 2 union nuts.



11. Disconnect the high voltage (HT) electrical connectors. Move the wires aside for access.





12.

CAUTION: Before disconnecting or removing parts, make sure the area around mating surfaces and connections is clean. To prevent contamination of the system, plug all open connections.

Remove the dipstick tube.

• Remove the dipstick.
• Remove the bolt.
• Discard the O-ring.

13. Remove the exhaust manifold.

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

Installation

All cars

1.

NOTE: The exhaust manifold gasket tie rods must be located at the lower edge of the manifold.

Install the exhaust manifold.

• Install a new gasket.
• Clean the contact surfaces of the parts.
• Tighten the nuts evenly in the sequence shown. (tightening torque 25 Nm).

2. Install the dipstick tube.

• Clean the contact surfaces of the parts.
• Install a new O-ring.
• Lubricate the seal with clean engine oil.
• Tighten the bolt (tightening torque 10 Nm).
• Insert the level measuring probe.

3. Connect the high voltage electrical connectors.

4. Install the EGR pipe.

• Clean the contact surfaces of the parts.
• Tighten the nuts by hand first.
• Finally tighten the nuts to a torque of 40 Nm.

5. Lower the engine onto the support. Tighten the nut. (tightening torque 90 Nm).

6. Raise the car.

7. Install the exhaust system.

• Clean the contact surfaces of the parts.
• Screw in new bolts and tighten them. (tightening torque 40 Nm).

8. Install the engine protection screen. For more information, refer to Engine Protection (76.10.50)

9. Lower the vehicle.

Right hand drive vehicles

10.

NOTE: Apply petroleum jelly to the battery terminals.

Connect the positive battery cable.

• Clean the contact surfaces of the parts.
• Install the sealing bushing.
• Tighten the clamp nut (tightening torque 10 Nm).

Right hand drive vehicles

11. Secure the wiring harness clamp. Tighten the bolt. (tightening torque 10 Nm).

All cars

12. Install the engine cover. For more information, refer to Engine Cover - 4.0L (12.30.50)

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