Discovery 2. Manual — part 523

MANIFOLDS AND EXHAUST SYSTEMS - TD5

REPAIRS

30-1-7

11. Remove 2 nuts and 8 bolts securing inlet

manifold to cylinder head.

12. Disconnect multiplugs from turbocharger

pressure sensor, ECT sensor, AAP sensor,
MAF sensor, A/C compressor and fuel injector
harness.

13. Remove 2 bolts securing harness to camshaft

carrier.

Note: Engine with EGR cooler illustrated.

14. Release harness from engine and inlet

manifold.

15. Remove inlet manifold and gasket.

Refit

1. Clean inlet manifold and mating faces.
2. Fit new gasket.
3. Fitinlet manifold and, working from the centre

outwards, tighten nuts and bolts to 25 Nm (18
lbf.ft).

4. Position harness to sensors and connect

multiplugs.

5. Tighten bolts securing harness clip to camshaft

carrier to 9 Nm (7 lbf.ft).

6. Clean dip stick tube and fit new 'O' ring.
7. Fit dip stick tube and tighten bolt to 9 Nm (7

lbf.ft).

8. Connect leads to glow plugs.
9. Fit alternator support bracket and tighten bolts

to 45 Nm (33 lbf.ft).

10. Position fuel cooler and tighten bolts to 25 Nm

(18 lbf.ft).

11. Fit new gasket, position EGR valve and tighten

bolts to 9 Nm (7 lbf.ft).

12. Connect multiplug to MAP sensor.
13. Fit upper fan cowl.
14. Fit engine acoustic cover.
15. Connect battery earth lead.
16. Fit battery cover.

MANIFOLDS AND EXHAUST SYSTEMS - TD5

30-1-8

REPAIRS

Gasket - exhaust manifold

$% 30.15.12

Remove

Note: The following procedure covers engines
fitted with or without an EGR cooler. The EGR
cooler is bolted to the front of the cylinder head.

1. Remove turbocharger.

+

ENGINE MANAGEMENT SYSTEM -

Td5, REPAIRS, Turbocharger.

2. Models with air conditioning: Remove

auxiliary drive belt.

+

CHARGING AND STARTING,

REPAIRS, Belt - auxiliary drive.

3. Models with air conditioning: Remove 4 bolts

securing compressor and move to one side.

4. Remove and discard 2 Allen screws securing

EGR pipe to exhaust manifold.

Note: Engine with EGR cooler illustrated.

5. Remove 10 nuts securing exhaust manifold to

cylinder head.

6. Remove exhaust manifold and gasket.

Refit

1. Clean exhaust manifold and mating faces.
2. Fit new gasket.Fit exhaust manifold and,

working from the centre outwards, tighten nuts
to 25 Nm (18 lbf.ft) .

3. Models with air conditioning:

Positioncompressor and tighten bolts to 25 Nm
(18 lbf.ft).

4. Position EGR valve pipe, fit new Allen screws

and tighten to 9 Nm (7 lbf.ft).

5. Fit turbocharger.

+

ENGINE MANAGEMENT SYSTEM -

Td5, REPAIRS, Turbocharger.

6. Models with air conditioning: Fit auxiliary

drive belt.

+

CHARGING AND STARTING,

REPAIRS, Belt - auxiliary drive.

MANIFOLDS AND EXHAUST SYSTEMS - V8

DESCRIPTION AND OPERATION

30-2-1

MANIFOLDS AND EXHAUST SYSTEMS - V8

DESCRIPTION AND OPERATION

Exhaust manifold component layout

1 Exhaust manifold RH
2 Spacer 16 off
3 Torx bolt 16 off
4 Exhaust manifold LH
5 Gasket 4 off

MANIFOLDS AND EXHAUST SYSTEMS - V8

30-2-2

DESCRIPTION AND OPERATION

Inlet manifold component layout