Land Rover Defender V8i Workshop Supplement Rover Manual

							MANIFOLD AND EXHAUST SYSTEM
1
REPAIR INTERMEDIATE PIPE
Service repair no - 30.10.11
Remove
1.Raise vehicle on ramp.
2.Release intermediate pipe from mounting
rubber.
3.Remove 2 nuts securing intermediate pipe to tail
pipe.
4.Remove 2 nuts securing intermediate pipe to
front pipe.
5.Release intermediate pipe from front and tail
pipes and remove.
Refit
6.Fit intermediate pipe to front and tail pipes.
7.Secure intermediate pipe to mounting rubber.
8.Fit nuts securing intermediate pipe to front pipe
and tighten to
30 Nm (22 lbf.ft).
9.Fit nuts securing intermediate pipe to tail pipe
and tighten to
30 Nm (22 lbf.ft).
10.Lower vehicle.TAIL PIPE
Service repair no - 30.10.22
Remove
1.Raise vehicle on a ramp.
2.Remove 2 nuts securing tail pipe to intermediate
pipe.
3.Release tail pipe from mounting rubber.
4.Release tail pipe from intermediate pipe and
feed over rear axle.
5.Remove tail pipe.
Refit
6.Feed tail pipe over rear axle and connect to
intermediate pipe.
7.Secure tail pipe to mounting rubber.
8.Fit nuts securing tail pipe to intermediate pipe
and tighten to
30 Nm (22 lbf.ft).
9.Lower vehicle. 
						

							30MANIFOLD AND EXHAUST SYSTEM
2
REPAIR INLET MANIFOLD GASKET
Service repair no - 30.15.08
Remove
1.Disconnect battery negative lead.
2.Drain cooling system.
See COOLING SYSTEM,
Adjustment, drain and refill
3.Remove fuel rail.See FUEL SYSTEM, Repair,
fuel rail
4.Remove breather hose from RH rocker cover.
5.Remove bolt securing coolant pipe brackets to
RH rocker cover and collect nut.
6.Loosen clip and disconnect coolant return hose
from inlet manifold.
7.Remove 4 bolts securing engine harness to inlet
manifold.
8.Release 8 spark plug leads from guide clips and
disconnect leads from spark plugs.
9.Remove 4 bolts securing RH rocker cover to
cylinder head.10.Remove RH rocker cover.
11.Remove and discard rocker cover gasket.
12.Remove screw securing dipstick tube to LH
rocker cover.
13.Remove 4 bolts securing LH rocker cover to
cylinder head.
14.Remove LH rocker cover.
15.Remove and discard rocker cover gasket.
16.Disconnect coolant temperature sensor
multiplug.
17.Loosen clip and disconnect coolant return hose
from inlet manifold.
18.Release coolant pipe bracket from manifold.
19.Loosen clip and remove plenum chamber
coolant hose from inlet manifold.
20.Remove 12 bolts securing inlet manifold in the
sequence shown. 
						

							MANIFOLD AND EXHAUST SYSTEM
3
REPAIR 21.With assistance, move engine harness aside
and remove inlet manifold assembly.
22.Remove 2 bolts and clamps securing inlet
manifold gasket to cylinder block.
23.Remove and discard gasket and gasket seals.
Refit
24.Ensure mating faces of inlet manifold and
cylinder head are clean.
25.Apply a thin bead of Loctite Superflex (black)
sealant to the 4 notches between the cylinder
head and block.
26.Position new gasket seals ensuring ends
engage correctly in notches.
27.Fit new inlet manifold gasket.
28.Position inlet manifold gasket clamps and fit
bolts.
NOTE: Do not fully tighten bolts at this
stage.
29.With assitance, move engine harness aside and
fit inlet manifold.
30.Fit inlet manifold bolts and initially tighten in
sequence to
10 Nm (7 lbf.ft).
NOTE: When fitting inlet manifold bolts,
tighten in reverse of removal sequence.
31.Tighten inlet manifold bolts in sequence to
51
Nm (38 lbf.ft).
32.Tighten gasket clamp bolts to18 Nm (13 lbf.ft).
33.Fit plenum chamber coolant hose to inlet
manifold and secure with clip.
34.Secure coolant pipe bracket to inlet manifold.
35.Connect coolant return hose to inlet manifold
and secure with clip.36.Connect coolant temperature sensor multiplug.
37.Clean mating faces of LH rocker cover and
cylinder head.
38.Fit new rocker cover gasket to LH rocker cover.
39.Fit rocker cover and gasket to cylinder head.
40.Fit rocker cover bolts, ensuring short bolts are
fitted inboard, and tighten by diagnonal selection
to:
Stage 1 -
4 Nm (3 lbf.ft).
Stage 2 -8 Nm (6 lbf.ft).
Stage 3 - Re-torque to8 Nm (6 lbf.ft).
NOTE: This torque tightening sequence
also applies to the RH rocker cover bolts.
41.Align dipstick tube to rocker cover and tighten
screw.
42.Clean mating faces of RH rocker cover and
cylinder head.
43.Fit new rocker cover gasket to RH rocker cover.
44.Fit rocker cover and gasket to cylinder head.
45.Tighten RH rocker cover bolts in sequence given
for LH rocker cover bolts.
46.Connect spark plug leads to spark plugs and
secure to guide clips.
47.Fit bolts securing engine harness to inlet
manifold.
48.Connect coolant return hose to inlet manifold
and secure with clip.
49.Fit nut and bolt securing coolant pipe bracket to
RH rocker cover.
50.Connect breather hose to RH rocker cover.
51.Fit fuel rail.
See FUEL SYSTEM, Repair, fuel
rail; Refit
52.Refill cooling system.See COOLING SYSTEM,
Adjustment, drain and refill
53.Reconnect battery negative lead. 
						

							MANIFOLD AND EXHAUST SYSTEM
1
SPECIFICATIONS, TORQUE TORQUE VALUES
MANIFOLDS AND EXHAUSTS - V8i
Nm lbf.ft
Inlet manifold to cylinder head 51......................................... 38
Exhaust manifold to cylinder head 20................................... 15
Exhaust front pipe to manifold 45.......................................... 33
Exhaust front pipe to intermediate pipe 30............................ 22
Exhaust intermediate pipe to tail pipe 30.............................. 22
Inlet manifold gasket clamp bolts 18..................................... 13
Rocker cover bolts 8........................................................... 6 
						

							41 - TRANSFER GEARBOX
CONTENTS
Page
REPAIR
LT230Q TRANSFER GEARBOX 1.........................................................................
NEUTRAL SWITCH 7.............................................................................................
SPECIFICATIONS, TORQUE
TORQUE VALUES 1............................................................................................... 
						

							TRANSFER GEARBOX
1
REPAIR LT230Q TRANSFER GEARBOX
Service repair no - 41.20.25/99
Remove
The transfer gearbox should be removed from
underneath the vehicle, using a hydraulic transmission
jack and adaptor plateLRT-99-010.
WARNING: Where use of a transmission
jack is necessary, it is absolutely essential
to follow the manufacturers instructions
to ensure safe and effective use of the equipment.
1.Position vehicle on a ramp.
2.Select LOW range gear and leave vehicle in
neutral.
3.Disconnect battery negative lead.
4.Remove centre console.
See CHASSIS AND
BODY, Repair, centre console
5.Remove carpet from transmission tunnel.
6.Remove high-low selector housing cover from
transmission tunnel.
7.Remove 3 trim studs securing handbrake lever
gaiter.
8.Release handbrake lever gaiter for access to
handbrake cable linkage.