Left valve mechanism cover (Discovery 3)

Removing

WARNING: Wait at least 30 seconds after stopping the engine before attempting any repair to the high pressure fuel injection system. Failure to follow this instruction may result in injury.

WARNING: Do not carry or use a cell phone while working on or near any fuel related parts. There is a danger of ignition of flammable vapours. Failure to follow these instructions may result in injury.

WARNING: Do not smoke or walk with a lit cigarette or open flame of any type while working on or near fuel related items. There is a danger of ignition of flammable vapours. Failure to follow these instructions may result in injury.

CAUTION: This procedure is related to fuel handling. Always be aware of the possibility of fuel splashing and observe fuel handling precautions. Failure to follow these instructions may result in injury.

CAUTION: Do not make any repairs to the fuel injection system while the engine is running. Fuel pressure in the system can reach 1650 bar (23.931 psi inch). Failure to follow this instruction may result in injury.

WARNING: Make sure that the workshop area where the vehicle is being worked on is as clean and dust free as possible. Dirt and dust from working on the clutch, brakes, or from machining or welding operations can contaminate the fuel system and cause performance problems.

CAUTION: Always perform the cleaning procedure before making any repairs to the fuel injection system components. Failure to follow this instruction may result in dirt entering the fuel injection system.

WARNING: Diesel fuel injection equipment is manufactured to very precise tolerances and with very close clearances. Therefore, it is especially important to observe absolute cleanliness when working with these elements. Open holes or lines should always be plugged with appropriate plugs. Failure to follow this instruction may result in dirt entering the fuel injection system.

1. Disconnect the wire "masses" from the battery. For more information refer to Specification.

2. Remove the air intake throttle. For more information refer to Air Intake Damper (19.70.32)

3. Remove the accessory drive belt. For more information refer to Drive Belt Accessories (86.10.03)

4. Remove the accessory drive belt idler pulley. Turn out a bolt.



5. Disconnect the knock sensor wiring harness from the cylinder head cover.

6. Disunite an electric socket of the gauge of a detonation.



7. Disconnect the glow plug harness from the cylinder head cover.




8. Disconnect the engine oil pressure sensor electrical connector (EOP).



9. Disconnect the breather from the cylinder head cover.



10. Remove the fuel injector. For more information refer to Fuel Injector (19.60.10)

11. Remove the 2 remaining fuel injectors.

12. Loosen the fastening of the high pressure fuel supply line. Turn out a bolt.


13.

CAUTION: Make sure the high pressure fuel supply line remains in contact with the fuel pump and fuel manifold until both connections are disconnected and cleaned. Failure to follow this instruction may result in dirt entering the fuel injection system.

Remove the high pressure fuel supply line and discard it. Plug open connections.



14. Remove the fuel manifold. Remove the two remaining bolts.



15. Remove the fuel manifold support bracket.

• Loosen the dipstick tube.
• Remove the three remaining bolts.

16. Remove the engine cover guide pins.




17. Release the fastening of the timing belt cover.

• Replace the timing belt cover to access the two front cylinder head cover bolts.
• Completely loosen the seven specified timing belt cover screws.

18. Remove the left cylinder head cover. Loosen the 13 cylinder head cover screws.

Installation

1. Establish a cover of the left head of cylinders. Tighten 13 screws (tightening torque 10 Nm).

2. Install the timing belt cover. Tighten 7 screws (tightening torque 10 Nm).

3. Install engine cover guide pins.

4. Install the high pressure fuel line support bracket.

• Install two bolts.
• Tighten the bolts (tightening torque 23 Nm).
• Attach the dipstick tube.

5. Install the fuel manifold. Screw in the two bolts, but don't tighten them all the way yet.

6. Install a new high pressure fuel supply line.

• Open the holes closed with plugs.
• Install the new high pressure fuel feed line, but do not tighten the connections yet.
• Tighten the screws securing the fuel manifold support bracket (tightening torque 23 Nm).
• Tightening the connections of the new high-pressure fuel supply line is carried out in four stages in the following sequence:
• Step 1: Tighten the connection of the high pressure fuel supply line to the bypass manifold (tightening torque 15 Nm).
• Step 2: Tighten high pressure fuel supply line to fuel rail (tightening torque 15 Nm).
• Step 3: Tighten the connection of the high pressure fuel supply line to the bypass manifold (tightening torque 30 Nm).
• Step 4: Tighten the connection of the high pressure fuel supply line to the fuel manifold (tightening torque 30 Nm).

7. Attach the high pressure fuel supply line. Tighten the remaining bolt (tightening torque 10 Nm).

8. Install the fuel injector. For more information refer to Fuel Injector (19.60.10)

9. Install the 2 remaining fuel injectors.

10. Attach the breather to the cylinder head cover.

11. Dock the electrical connector of the engine oil pressure sensor (EOP).

12. Dock an electric socket of the gauge of a detonation.

13. Connect the glow plug harness to the cylinder head cover.

14. Install the accessory drive belt pulley. Insert the bolt and tighten it (tightening torque 47 Nm).

15. Put on the accessory drive belt. For more information refer to Drive Belt Accessories (86.10.03)

16. Install the air intake throttle. For more information refer to Air Intake Damper (19.70.32)

17. Connect the wire "masses" to the battery. For more information refer to Specification.