300Tdi Defender
MANIFOLD AND EXHAUST SYSTEM
1
REPAIR
INDUCTION MANIFOLD
Service repair no - 30.15.02
Remove
1. Disconnect battery.
2. Remove oil filler cap and remove rocker cover
insulation.
3. Remove hose intercooler to induction manifold. If
fitted, remove EGR valve.
See FUEL SYSTEM,
Repair, EGR valve
4. Remove 2 screws and release heat shield from
induction manifold.
5. Slacken induction manifold lower securing nuts,
located below exhaust manifold.
6. Remove induction manifold upper securing bolts.
7. Remove induction manifold. Plug apertures in
cylinder head with clean rag to prevent any items
falling into engine.
8. Check gasket is satisfactory for further use.
Refit
9. Clean induction manifold mating face.
10. Position induction manifold and secure with
upper and lower fixings.
11. Tighten securing nuts and bolts to
25 Nm (18
lbf/ft).
12. Fit manifold heat shield.
13. Fit hose intercooler to induction manifold.
14. Fit rocker cover insulation.
15. Reconnect battery.
INDUCTION/EXHAUST MANIFOLD GASKET
Service repair no - 30.15.15
Remove
1. Remove induction manifold
See Induction
manifold .
2. Remove turbocharger outlet hose.
3. Raise vehicle and slacken exhaust front pipe to
intermediate silencer flange nuts. Ensure pipe is
free to turn.
NOTE: If removing exhaust manifold and
turbocharger assembly from vehicle,
remove manifold to exhaust front pipe
nuts while working under vehicle.
4. Remove exhaust manifold securing nuts,
removing centre lower nut first.
5. Move heater rail clear of exhaust manifold.
6. With exhaust manifold and turbocharger still
attached to exhaust front pipe, withdraw from
head by turning front pipe until sufficient access
is gained to remove gasket.
7. Suitably support exhaust manifold and
turbocharger assembly to prevent damage.
8. Remove induction manifold lower nuts.
9. Remove gasket.
10. Clean mating faces.
