300Tdi Discovery
MFI
15
REPAIR
11. Loosen clip and disconnect top hose from
thermostat housing.
12. Disconnect multiplug from distributor amplifier
module.
13. Loosen clip and disconnect hose from heater
valve.
14. Remove injector harnesses from behind fuel rail
and lay to one side.
15. Loosen union and disconnect fuel return hose
from fuel rail.
NOTE: The intake manifold can be
removed from the cylinder block without
removing the fuel rail and injectors.
16. Using the sequence shown, remove 12 bolts
securing the intake manifold to cylinder block.
17. Remove the intake manifold.
18. Noting their fitted position, remove bolts and
clamps securing intake manifold gasket to
cylinder block.
19. Remove and discard gasket.
20. Remove and discard gasket seals.
Do not carry out further dismantling if component
is removed for access only.
21. Remove 5 nuts securing fuel rail support
brackets to intake manifold.
22. Remove fuel rail and injectors.
23. Remove 2 bolts securing thermostat housing to
intake manifold.
24. Remove thermostat housing.
25. Remove bolt securing coolant pipe to intake
manifold. Loosen union and remove coolant
pipe. Remove and discard ’O’ ring.
26. Fit new ’O’ ring to coolant pipe. Position coolant
pipe to intake manifold. Fit bolt securing coolant
pipe support bracket to intake manifold and
tighten pipe union.
27. Clean mating faces of thermostat housing and
intake manifold.
28. Fit thermostat housing to intake manifold using a
new gasket, fit and tighten bolts.
29. Position fuel rail to intake manifold, fit and
tighten retaining bolts.
