Land Rover Defender Workshop Rover Manual

MANIFOLDANDEXHAUST SYSTEM
1
DESCRIPTION
ANDOPERATION
MANIFOLDS
ANDEXHAUST SYSTEM
Description The exhaust systems fittedonallmodels withthe
300Tdi enginecomprise threesections; frontpipe
assembly, intermediate silencerassembly, andtail
pipe andsilencer assembly. Allsections, including
silencers, aremanufactured fromluminised steelto
give thesystem adurable working lifeunder all
conditions. Specialclampsareprovided toensure leak
proof jointing between thevarious sections,
which aresupported byflexible...

30MANIFOLD
ANDEXHAUST SYSTEM
2 DESCRIPTION
ANDOPERATION
The
catalyst comprises platinumcoatedceramic
elements. TheHydrocarbons (HC),Oxides ofnitrogen
(NOx) andCarbon monoxide (CO)emitted bythe
engine reactwiththecatalytic elementandexhaust
temperature toconvert thetoxic gasintoNitrogen
(N 2),
Carbon dioxide(CO
2)
and water vapour.
Exhaust system-110/130
1. Gasket
2. Front pipe
3. Front pipewithcatalytic converter
4. Front mounting bracket
5. Intermediate silencer 6.
Intermediate mountingbrackets
7. Tail...

MANIFOLDANDEXHAUST SYSTEM
1
REPAIR
INDUCTION
MANIFOLD
Service repairno-30.15.02
Remove 1. Disconnect battery.
2. Remove oilfiller capand remove rockercover
insulation.
3. Remove hoseintercooler toinduction manifold. If
fitted, remove EGRvalve.
SeeFUEL SYSTEM,
Repair, EGRvalve
4.Remove 2screws andrelease heatshield from
induction manifold.
5. Slacken induction manifoldlowersecuring nuts,
located belowexhaust manifold.
6.Remove induction manifolduppersecuring bolts.
7. Remove induction manifold....

30MANIFOLD
ANDEXHAUST SYSTEM
2 REPAIR
Refit
11. Fitnew gasket overmanifold studs.
12. Loosely fitinduction manifoldlowernutsto
studs.
13. Fitexhaust manifold andsecure withcentral
upper andlower nuts.
14. Locate heaterrailtoits correct position and
secure withouter exhaust manifold nuts.
15. Tighten allexhaust manifold nutsto
45Nm (33
lbf/ft).
16. Tighten exhaust frontpipetointermediate
silencer nutsto
50Nm (37lbf/ft).
17. Fitturbocharger outletpipe.
18. Fitinduction manifold
SeeInduction manifold
....

MANIFOLDANDEXHAUST SYSTEM
3
REPAIR
EXHAUST
FRONTPIPE
Service repairno-30.10.09
Remove 1. Disconnect battery.
2. Raise vehicle onramp.
3. Remove 3securing nutsatexhaust manifold
flange.
4. Remove throughboltsecuring frontpipe
mounting brackettochassis.
5. Remove bracketandrubber mounting from
exhaust pipe.
NOTE:Achassis undertray maybefitted
on some vehicle derivatives toconform to
legal requirements. Whenunder chassis
remove andrefit procedures arerequired, itmay
be necessary toremove theundertray
See...

30MANIFOLD
ANDEXHAUST SYSTEM
4 REPAIR
INTERMEDIATE
PIPE-90
Service repairno-30.10.11
Remove 1. Raise vehicle onramp.
2. Release intermediate pipefrom frontmounting
rubber, seeJ6243.
3. Remove 2flange nutssecuring intermediate
pipe totail pipe.
4. Release intermediate pipefrom rearmounting
rubber.
5. Remove 2flange nutssecuring intermediate
pipe tofront pipe.
6. Release intermediate pipefrom frontandtail
pipe andremove.
Refit 7. Fitintermediate pipetofront andtailpipes.
8. Secure intermediate pipetofront...

MANIFOLDANDEXHAUST SYSTEM
5
REPAIR
TAILPIPE
-90
Service repairno-30.10.22
Remove 1. Raise vehicle onramp.
2. Remove 2flange nutssecuring tailpipe to
intermediate pipe,seeJ6243.
3. Release tailpipe from inboard mounting rubber.
4. Release tailpipe from outboard mounting rubber
and remove.
Refit 5. Fittail pipe tointermediate pipe.
6. Secure tailpipe tomounting rubbers.
7. Secure tailpipe tointermediate pipe.Tighten
nuts to
30Nm (22lbf/ft).
8.Lower vehicle. TAILPIPE
-110/130
Service repairno-30.10.22...

CLUTCH1
DESCRIPTION
ANDOPERATION
DESCRIPTION The
clutch unitcomprises asingle dryplate friction
disc anddiaphragm springclutchunit,secured tothe
engine flywheel. OPERATIONThe
unitisoperated hydraulically bythe clutch master
cylinder (12)andaslave cylinder (13)attached tothe
transmission bellhousing.
Clutch components
1. Crankshaft andflywheel
2. Friction plate
3. Clutch cover
4. Diaphragm spring
5. Pressure plate
6. Fulcrum posts(9)fordiaphragm spring
7. Bearing rings(2)fordiaphragm spring
8. Retraction...

33CLUTCH
2 DESCRIPTION
ANDOPERATION
When theclutch pedalisdepressed, hydraulicfluid
transmits themovement viathe slave cylinder, release
lever (10),bearing (9),tothe inner fingers ofthe
diaphragm spring(4).
The diaphragm spring(4)pivots onthe bearing rings
(7) and fulcrum posts(6)causing thepressure plate
(5) torelease theclamping forceonthe friction plate
and linings (2). As
the theclamping forceisremoved fromthefriction
plate (2),theplate slides onthe splines ofthe primary
shaft (15)andtakes upaneutral...

CLUTCH1
FAULT
DIAGNOSIS
CLUTCH
ASSEMBLY CONDITIONS
For theclutch tooperate correctly itis important the
following conditions aresatisfied:-
The primary shaft(15)must befree inthe
crankshaft spigotbush(17).
Thefriction plate(2)must beable toslide easily on
the splines onthe primary shaft(15),toaposition
where itdoes notcontact eithertheflywheel orthe
pressure plate.
Thefriction platemustnotbedistorted orthe
linings contaminated withoil,which maycause itto
stick orcontinue torun incontact withtheflywheel...