Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual

MANIFOLD AND EXHAUST SYSTEM
1
DESCRIPTION AND OPERATION MANIFOLD COMPONENT LAYOUT
1.Inlet manifold
2.Flanged nut - 2 off
3.Stud - 2 off
4.Stud - 10 off
5.Exhaust gasket6.Flanged nut - 10 off
7.Exhaust manifold
8.Inlet gasket
9.Flanged bolt - 8 off 

30MANIFOLD AND EXHAUST SYSTEM
2
DESCRIPTION AND OPERATION DESCRIPTION
General
The diesel engine has the inlet manifold attached to the right hand side of the engine and the exhaust manifold
attached to the left hand side of the engine. The inlet manifold directs cooled compressed air from the
turbocharger and intercooler into the cylinders, where it is mixed with fuel from the injectors. Exhaust gases from
the exhaust manifold can also be directed into the inlet manifold via a pipe from the exhaust...

MANIFOLD AND EXHAUST SYSTEM
3
DESCRIPTION AND OPERATION Front pipe assembly
The front pipe is of welded and fabricated tubular construction. The front pipe is connected to a flange on the
turbocharger and secured with three flanged nuts and sealed with a metal laminated gasket. The front pipe
incorporates a flexible pipe near the connection with the turbocharger and terminates in a flanged connection with
the intermediate pipe.
The flexible pipe is formed into a concertina shape with woven metal strands...

MANIFOLD AND EXHAUST SYSTEM
1
REPAIR PIPE - EXHAUST - FRONT
Service repair no - 30.10.09
Remove
1.Remove engine acoustic cover.See ENGINE ,
Repair.
2.Release clip and disconnect breather hose from
camshaft cover.
3.Release clips and disconnect air flow meter from
air filter.
4.Disconnect multiplug from air flow meter.
5.Loosen clip screw and remove air inlet hose
from turbocharger.
6.Remove 3 bolts and remove exhaust manifold
heat shield.
7.Remove 3 nuts, release front pipe from
turbocharger and discard...

30MANIFOLD AND EXHAUST SYSTEM
2
REPAIR Refit
12.Clean front pipe and mating faces.
13.Position front pipe and using new gaskets, align
to intermediate pipe and turbocharger.
14.Connect mounting rubber to front pipe.
15.Fit and tighten exhaust flange nuts to27 Nm (20
lbf.ft).
16.Fit chassis cross member, and tighten bolts to
45 Nm (33 lbf.ft)
17.Fit underbelly panel.See CHASSIS AND
BODY, Repair.
18.Position new gasket and front pipe to
turbocharger and tighten nuts to27 Nm (20
lbf.ft).
19.Position exhaust...

MANIFOLD AND EXHAUST SYSTEM
3
REPAIR EXHAUST - TAIL PIPE AND SILENCER
Service repair no - 30.10.22
Remove
1.Raise vehicle on ramp.
2.Remove 3 nuts securing silencer to tail pipe.
3.Release tail pipe from mounting and remove tail
pipe.
4.Collect silencer to tail pipe gasket.
Refit
5.Clean silencer and tail pipe mating faces.
6.Position tail pipe and secure on mounting
rubber.
7.Using a new gasket, align silencer to tail pipe.
8.Fit nuts to silencer and tighten to25 Nm (18
lbf.ft).GASKET - INLET MANIFOLD...

30MANIFOLD AND EXHAUST SYSTEM
4
REPAIR
7.Remove 4 bolts securing fuel cooler to inlet
manifold.
8.Remove 2 bolts and remove alternator support
bracket and disconnect fuel injector harness
multiplug.
9.Remove bolt securing engine dip stick tube to
camshaft carrier.
10.Remove dip stick tube and discard’O’ring.
11.Remove 2 nuts and 8 bolts securing inlet
manifold to cylinder head.
12.Disconnect multiplugs from turbocharger boost
control soleniod, ECT sensor, ambient air
pressure sensor, MAF sensor, and A/C...

MANIFOLD AND EXHAUST SYSTEM
5
REPAIR Refit
16.Clean inlet manifold and mating face.
17.Fit new gasket.
18.Fit inlet manifold, and working from the centre
outwards, tighten nuts and bolts to25 Nm (18
lbf.ft).
19.Position harness to sensors and connect
multiplugs.
20.Tighten harness clip bolts to camshaft carrier to
10 Nm (7 lbf.ft).
21.Clean dip stick tube and fit new’O’ring.
22.Fit dip stick tube and tighten bolt to10 Nm (7
lbf.ft).
23.Connect glow plug leads.
24.Fit alternator support bracket and...