300Tdi Defender: Upgraded Exhaust Manifold and Turbocharger
30
MANIFOLD AND EXHAUST SYSTEM
2
REPAIR
Refit
11. Fit new gasket over manifold studs.
12. Loosely fit induction manifold lower nuts to
studs.
13. Fit exhaust manifold and secure with central
upper and lower nuts.
14. Locate heater rail to its correct position and
secure with outer exhaust manifold nuts.
15. Tighten all exhaust manifold nuts to
45 Nm (33
lbf/ft).
16. Tighten exhaust front pipe to intermediate
silencer nuts to
50 Nm (37 lbf/ft).
17. Fit turbocharger outlet pipe.
18. Fit induction manifold
See Induction manifold
.
EXHAUST MANIFOLD/TURBOCHARGER
ASSEMBLY
Service repair no - 30.15.10
Remove
1. Remove induction manifold
See Induction
manifold .
2. Disconnect turbocharger inlet hose.
3. Disconnect boost pressure pipe at turbocharger.
4. Remove intercooler bottom hose.
5. Place suitable container under engine and
disconnect turbocharger oil feed and return
pipes at cylinder block.
6. Remove 3 nuts securing exhaust front pipe to
manifold flange.
7. Remove 7 nuts and lift exhaust manifold and
turbocharger assembly from cylinder head.
8. Discard manifold gasket.
Refit
9. Fit new manifold gasket.
10. Position exhaust manifold assembly onto
location studs and secure to cylinder head.
Tighten nuts to
45 Nm (33 lbf/ft).
11. Secure exhaust front pipe to manifold flange.
Tighten fixings to
50 Nm (37 lbf/ft).
12. Reconnect turbocharger oil feed and return
pipes at cylinder block.
13. Fit intercooler bottom hose.
14. Fit boost pressure pipe at turbocharger.
15. Fit turbocharger inlet hose.
16. Fit induction manifold
See Induction manifold
.
