300Tdi Discovery
30
MANIFOLD AND EXHAUST SYSTEM
4
REPAIR
EXHAUST MANIFOLD - Tdi
Service repair no - 30.15.10
Remove
1. Disconnect battery negative lead.
2. Remove heat shield from rear of air intake
manifold.
3. Release dip stick tube from cylinder block.
4. Disconnect the intake hose from the manifold.
5. Remove the two bolts and two nuts securing the
intake manifold to the cylinder head and
withdraw the inlet manifold.
6. Remove air filter inlet pipe to turbo unit.
7. Remove intercooler pipe from turbo to
intercooler.
8. Disconnect the EGR pipe from the inlet manifold
hose.
9. Remove the three fixings at the exhaust pipe
flange.
10. Release the turbo charger oil pipes from the
cylinder block.
11. Remove the turbo boost pipes.
12. Remove seven bolts securing the exhaust
manifold, release the heater rail and remove the
manifold gasket, complete with turbo unit.
13. Remove four bolts and disconnect diaphragm
rod from manifold, and remove turbo charger if
necessary.
Refit
14. Reverse removal procedure. 1 to 12. Use a new
manifold and exhaust flange gaskets.
15. Reconnect battery negative lead. Start engine
and check for leaks.
