TD5 Defender
12
ENGINE
2
OVERHAUL
GASKET - EXHAUST MANIFOLD
Service repair no - 30.15.12.01
Remove
NOTE: The following procedure covers
both EU3 and non EU3 engines
NOTE: EU3 engine illustrated.
1. Remove 3 bolts securing heater pipe to cylinder
head and turbocharger heat shield.
2. Remove heater pipe.
3. Remove bolt and remove turbocharger heat
shield.
4. Remove and discard 2 Allen screws securing
EGR pipe to exhaust manifold.
5. Remove banjo bolt securing oil feed pipe to
turbocharger and discard sealing washers.
6. Loosen turbocharger drain hose union at
cylinder block.
7. Remove 10 nuts and remove exhaust manifold
and turbocharger.
8. Remove manifold gasket.
Refit
1. Clean exhaust manifold mating faces.
2. Position exhaust manifold to cylinder head using
new gasket and fit manifold nuts.
3. Working from the centre outwards, fit and tighten
nuts to 25 Nm (18 lbf.ft) .
4. Clean turbocharger drain and feed hose unions.
5. Fit turbocharger oil drain hose to cylinder block
and tighten union to 48 Nm (35 lbf.ft) .
6. Fit new sealing washers to turbocharger oil feed
pipe, fit banjo bolt and tighten to 25 Nm (18
lbf.ft) .
7. Position EGR pipe to exhaust manifold. Fit new
Allen screws and tighten to 10 Nm (7 lbf.ft) .
8. Position turbocharger heat shield.
9. Position heater pipe to cylinder head and tighten
bolts to 25 Nm (18 lbf.ft) .
10. Position exhaust manifold heatshield and tighten
M6 bolts to 9 Nm (7 lbf.ft) and M8 bolt to 25
Nm (18 lbf.ft).
