LAND ROVER DISCOVERY 1999 Workshop Manual

EMISSION CONTROL - V8
17-2-58 REPAIRS
Control Valve - Secondary Air Injection
(SAI)
$% 17.25.02
Remove
1.Release clip and disconnect air hose from
valve.
2.Disconnect vacuum hose from valve.
3.Remove 2 bolts securing valve to air manifold.
4.Remove valve and discard gasket.
Do not allow dirt or debis to enter the air
manifold.
Refit
1.Clean SAI control valve and mating face on
manifold.
2.Fit new gasket and fit valve. Tighten bolts to 10
Nm (7 lbf.ft).
3.Connect vacuum hose.
4.Connect air hose and secure with clip.
Reservoir - Vacuum - Secondary Air
Injection (SAI) - up to 03MY
$% 17.25.04
Remove
1.Disconnect 2 vacuum hoses from reservoir.
2.Remove bolt securing reservoir to mounting
bracket and collect reservoir.
Refit
1.Position reservoir to mounting bracket and
tighten bolt to 10 Nm.
2.Connect vacuum hoses to reservoir.
M17 0222
1
2
3
4
M17 02272
1
1

EMISSION CONTROL - V8
REPAIRS 17-2-59
Reservoir - vacuum - Secondary Air
Injection (SAI) - from 03MY
$% 17.25.04
Remove
1.Disconnect 2 vacuum pipes from air reservoir.
2.Remove bolt securing air reservoir to air pump
and remove the reservoir.
Refit
1.Position air reservoir to air pump, fit bolt and
tighten to 10 Nm (7 lbf.ft).
2.Connect vacuum pipes to the air reservoir.
Pump - Air - Secondary Air Injection
(SAI)
$% 17.25.07
Remove
1.Disconnect multiplug from air pump.
2.Release clip and disconnect air hose from air
pump.
3.Remove bolt securing air pump bracket to
body.
4.Remove air pump and bracket assembly.
5.Remove 3 nuts securing bracket to air pump
and collect bracket.
6.Remove 3 mountings from air pump.
Refit
1.Fit mountings to air pump and tighten to 10
Nm.
2.Fit bracket to air pump mountings and tighten
nuts to 10 Nm.
3.Position air pump assembly and tighten bolt to
20 Nm.
4.Connect air hose to SAI pump.
5.Connect multiplug to air pump.
M17 0225
2
1
3
4
M17 0226
5
5
6

EMISSION CONTROL - V8
17-2-60 REPAIRS
Air Manifold - LH - Secondary Air
Injection (SAI)
$% 17.25.17
Remove
1.Remove SAI control valve.

+ EMISSION CONTROL - V8,
REPAIRS, Control Valve - Secondary Air
Injection (SAI).
2.Disconnect 2 air manifold unions from adapters
in cylinder head.
CAUTION: Take care that air manifold pipes
are not damaged during removal of union
nuts.
3.Remove 2 nuts securing air manifold bracket to
inlet manifold.
4.Remove air manifold.Refit
1.Clean air manifold and cylinder head adapters.
2.Apply a small amount of engine oil to top of air
manifold union nuts and around air manifold
pipes.
3.Position air manifold and finger tighten both
union nuts.
CAUTION: Finger tighten union nuts as far
as possible, damage to air manifold pipes or
adapters may result if this is not done.
4.Tighten air manifold unions to 25 Nm (18 lbf.ft).
CAUTION: Ensure that air manifold pipes
are not distorted during tightening
operation.
5.Fit nuts securing air manifold to inlet manifold
and tighten to 25 Nm (18 lbf.ft).
6.Fit SAI control valve.

+ EMISSION CONTROL - V8,
REPAIRS, Control Valve - Secondary Air
Injection (SAI).
M17 0234
4
3
2
2

EMISSION CONTROL - V8
REPAIRS 17-2-61
Air Manifold - RH - Secondary Air
Injection (SAI)
$% 17.25.18
Remove
1.Remove SAI control valve.

+ EMISSION CONTROL - V8,
REPAIRS, Control Valve - Secondary Air
Injection (SAI).
2.Remove heater feed pipe.

+ HEATING AND VENTILATION,
REPAIRS, Pipe - Heater - Feed.
3.Disconnect 2 air manifold unions from adapters
in cylinder head.
CAUTION: Take care that air manifold pipes
are not damaged during removal of union
nuts.
4.Remove nut securing air manifold bracket to
inlet manifold.
5.Remove air manifold.Refit
1.Clean air manifold and cylinder head adaptors.
2.Apply a small amount of engine oil to top of air
manifold union nuts and around air manifold
pipes.
3.Position air manifold and finger tighten both
union nuts.
CAUTION: Finger tighten union nuts as far
as possible, damage to air manifold pipes or
adapters may result if this is not done.
4.Tighten air manifold unions to 25 Nm (18 lbf.ft).
CAUTION: Ensure that air manifold pipes
are not distorted during tightening
operation.
5.Fit nut securing air manifold to inlet manifold
and tighten to 25 Nm (18 lbf.ft).
6.Fit heater feed pipe.

+ HEATING AND VENTILATION,
REPAIRS, Pipe - Heater - Feed.
7.Fit SAI control valve.

+ EMISSION CONTROL - V8,
REPAIRS, Control Valve - Secondary Air
Injection (SAI).
M17 0223
43
3
5

EMISSION CONTROL - V8
17-2-62 REPAIRS
Solenoid - Vacuum - Secondary Air
Injection (SAI)
$% 17.25.47
Remove
1.Release multiplug from solenoid.
2.Disconnect 2 vacuum hoses from solenoid.
3.Release solenoid from mounting bracket and
remove.
Refit
1.Secure solenoid to mounting bracket.
2.Connect vacuum hoses and multiplug to
solenoid.
Pipe - Secondary Air Injection (SAI)
$% 17.25.59
Remove
1.Loosen clip securing RH SAI control valve hose
to air injection pipe.
2.Release hose from air injection pipe.
3.Loosen clip securing SAI pump hose to air
injection pipe.
4.Release hose from air injection pipe.
5.Loosen clip securing LH SAI control valve hose
to air injection pipe.
6.Release hose from air injection pipe.
7.Disconnect multiplug from SAI vacuum
solenoid.
M17 0236
1
2
2
3
M17 0230

EMISSION CONTROL - V8
REPAIRS 17-2-63
8.Remove 2 nuts securing air injection pipe to air
intake plenum.
9.Release pipe from clip on rear of air intake
plenum.
10.Release 3 clips securing harness to engine bay
bulkhead.
11.Position container to collect any coolant
spillage.
12.Release clips securing heater hoses to heater.
13.Release hoses from heater.
14.With assistance, manoeuvre air injection pipe
from engine bay.Refit
1.With assistance, manoeuvre air injection pipe
into engine bay and secure onto clip at rear of
air intake plenum.
2.Connect heater hoses to heater and secure
with clips.
3.Reposition harness along engine bay bulkhead
and secure with clips.
4.Fit and tighten nuts securing air injection pipe to
air intake plenum.
5.Connect multiplug to SAI vacuum solenoid.
6.Connect air pump hose to air injection pipe and
secure with clip.
7.Connect LH and RH SAI control valve hoses to
air injection pipe and secure with clips.
8.Remove container.
9.Top up engine coolant.

+ MAINTENANCE, PROCEDURES,
Cooling system.
M17 0231
M17 0232
M17 0233

EMISSION CONTROL - V8
17-2-64 REPAIRS
Pump - Fuel Leak Detection - up to 03MY
$% 17.45.41
Remove
1.Raise the vehicle on lift.
2.Disconnect multiplug from fuel leak detection
pump.
3.Release leak detection air filter hose from top of
pump.
4.Remove 3 Torx screws securing pump to
mounting bracket.
5.Remove clip securing EVAP canister hose to
pump.
6.Release EVAP canister hose from pump.
7.Remove pump.
Refit
1.Connect EVAP canister hose to pump and
secure with clip.
2.Position pump to mounting bracket and secure
with Torx screws.
3.Connect leak detection air filter hose to top of
leak detection pump.
4.Connect multiplug to pump.
5.Lower vehicle.
Pump - fuel leak detection - from 03MY
$% 17.45.41
Remove
1.Raise the vehicle on lift.
2.Disconnect multiplug from the fuel leak
detection pump.
3.Remove 3 screws securing the fuel leak
detection pump to the chassis mounting
bracket.
4.Position absorbent cloth around fuel hoses to
collect any fuel spillage.
5.Disconnect the fuel leak detection filter pipe
from the fuel leak detection pump.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Remove and discard clip securing EVAP pipe
to the fuel leak detection pump and disconnect
the pipe.
7.Remove the fuel leak detection pump.
Refit
1.Connect the EVAP pipe to the fuel leak
detection pump and secure with a new clip.
2.Connect the fuel leak detection filter pipe to the
fuel leak detection pump.
3.Remove absorbent cloth.
4.Fit and tighten 3 screws securing the fuel leak
detection pump to the chassis mounting
bracket.
5.Connect multiplug to the fuel leak detection
pump.
6.Lower the vehicle lift.
M17 0235
2
3
4
57

EMISSION CONTROL - V8
REPAIRS 17-2-65
Filter - fuel leak detection pump - up to
03MY
$% 17.45.42
Remove
1.Remove bolt securing air filter to mounting
bracket and collect nut.
2.Remove clip securing hose to air filter.
3.Release hose from air filter.
4.Remove air filter.
Refit
1.Connect hose to air filter and secure with clip.
2.Position air filter to mounting bracket and
secure with nut and bolt.
Filter - fuel leak detection pump - from
03MY
$% 17.45.42
Remove
1.Remove Allen bolt securing fuel leak detection
pump filter to the mounting bracket.
2.Remove and discard clip securing fuel pipe to
the fuel leak detection pump filter and
disconnect the pipe.
CAUTION: Always fit plugs to open
connections to prevent contamination.
3.Remove the fuel leak detection pump filter.
Refit
1.Connect fuel pipe to the fuel leak detection
pump and secure with a new clip.
2.Position fuel leak detection pump filter to
mounting bracket, fit Allen bolt and tighten to 3
Nm (2.2 lbf.ft).
17M 0224

ENGINE MANAGEMENT SYSTEM - V8
DESCRIPTION AND OPERATION 18-2-1
ENGIN E MANAGEMENT SY STEM - V8 DESCRIPTION AND OPERAT ION
Engine management component
location - Passenger compartment
LHD illustrated
1Engine control module
2Diagnostic connector3Malfunction indication lamp