TD5 Defender
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 to 25 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 to 10 Nm (7
lbf.ft).
23. Connect glow plug leads.
24. Fit alternator support bracket and tighten bolts to
45 Nm (33 lbf.ft).
25. Position fuel cooler. Apply Loctite 242 to bolts
and tighten to 18 Nm (13 lbf.ft).
26. Fit new gasket, position EGR valve and tighten
bolts to 9 Nm (7 lbf.ft).
27. Connect multiplug to MAP sensor.
28. Fit cooling fan cowl.
29. Fit engine acoustic cover.
30. Reconnect battery negative lead.
31. Fit battery cover.
GASKET - EXHAUST MANIFOLD
Service repair no - 30.15.12
Remove
1. Remove turbocharger. See FUEL SYSTEM,
Repair.
2. Models with A/C: Remove auxiliary drive belt.
See ELECTRICAL, Repair.
3. Remove 4 bolts securing compressor and move
to one side.
All Models
NOTE: EU3 Model illustrated.
4. Remove and discard 2 Allen screws securing
EGR pipe to exhaust manifold.
5. Remove 10 nuts securing exhaust manifold to
cylinder head.
6. Remove exhaust manifold and gasket.
