Workshop Manuals Factory service & repair Rover
Rover 800 Workshop Manual (1996-1999)13 · Manifold & exhaust systems
13 · Engine

Exhaust manifold gaskets - KV6

Make
Rover
Model
800 Workshop Manual
Year
1996–1999
Section
Repairs › Exhaust manifold gaskets - KV6
Manifold & exhaust systemsExhaust manifold gaskets - KV6 · page 1 of 4

Refit

  1. Clean exhaust manifold and cylinder head mating faces and fit NEW gaskets.
  2. Fit manifold and turbocharger assembly.
  3. Position support bracket spacers and fit but DO NOT tighten bolts.
  4. Fit nuts securing manifold and tighten progressively in a diagonal sequence to 30 Nm.
  5. Tighten support bracket bolts.
  6. Clean coolant pump inlet adapter mating faces and fit NEW gasket.
  7. Position adapter and fit and tighten Allen screws.
  8. Connect hose to adapter housing and tighten hose clip.
  9. Align coolant pipe bracket to turbocharger support bracket and fit but DO NOT tighten Allen screw.
  10. Fit and tighten bolt securing coolant pipe bracket to backplate.
  11. Tighten Allen screw securing coolant pipe.
  12. Connect connecting pipe hose to coolant pump and tighten hose clips
  13. Clean inlet elbow mating faces and fit NEW gasket.
  14. Position elbow and fit and tighten Allen screws.
  15. Remove plug from turbocharger, connect intercooler hose and tighten hose clip.
  16. Using NEW sealing washers, connect turbocharger oil feed union and tighten banjo bolt.
  17. Clean turbocharger oil return hose union.
  18. Connect and tighten union. Remove cloth.
  19. Clean turbocharger and outlet elbow mating faces and fit NEW gasket.
  20. Fit outlet elbow and heat shield bracket. Fit and tighten nuts.
  21. Align engine steady bar bracket. Fit and tighten upper bolts to 80 Nm.
  22. Tighten lower bolt to 80 Nm.
  23. Fit bolt securing steady bar to bracket, position special nut and tighten bolt to 45 Nm.
  24. Position turbocharger heatshield, position plate. Fit and tighten bolts.
  25. Fit exhaust front pipe. See this section.
  26. Fit manifold heat shield. See this section.
  27. Fit air cleaner assembly. See ENGINE MANAGEMENT SYSTEM - EDC, Repairs.
  28. Refill cooling system. See COOLING SYSTEM - DIESEL, Adjustments.

EXHAUST MANIFOLD GASKETS - KV6

Service repair no - 30.15.12

Remove

  1. Disconnect battery earth lead.
  2. Remove engine acoustic cover, See BODY, Repairs.
Exhaust manifold gaskets - kv6 – Remove engine acoustic cover, See BODY, Repairs.
  1. Remove 2 bolts securing spark plug cover to LH camshaft. Remove cover.

Parts & tools for this job For 1996 Rover 800

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