Range Rover. Manual — part 134
MANIFOLD AND EXHAUST SYSTEM
23
REPAIR
INLET MANIFOLD GASKETS - DIESEL - VEHICLES
WITHOUT EGR
Service repair no - 30.15.08
Remove
1. Disconnect battery negative lead.
2. Remove 4 screws securing injector covers.
Remove covers.
3. Release intake hose from ducting.
4. Release turbocharger intake hose from ducting.
5. Release breather valve from grommet in intake
ducting.
NOTE: Collect grommet. Refit to ducting.
6. Disengage 2 clips. Remove intake ducting.
7. Disconnect intake hose from manifold.
8. Disconnect multiplug from intake temperature
sensor.
9. Release fuel return hose from inlet manifold clip.
30
MANIFOLD AND EXHAUST SYSTEM
NEW RANGE ROVER
24
REPAIR
10. Remove 2 nuts and bolts securing stays to inlet
manifold.
11. Slacken 2 nuts securing manifold stays to oil
filter casing.
12. Release clip securing manifold pressure sensing
pipe to stay.
13. Remove 12 nuts securing intake manifold to
cylinder head.
14. Release gearbox breather hose bracket from
rearmost manifold stud.
15. Release manifold from studs. Ensure that
injector leak off pipes do not foul on manifold
flanges.
16. Place manifold aside. Do not strain manifold
pressure sensing hose.
MANIFOLD AND EXHAUST SYSTEM
25
REPAIR
17. Collect 6 inlet manifold gaskets.
18. Position cloth over inlet ports to prevent dirt
ingress.
Refit
19. Ensure mating faces are clean.
20. Position intake manifold with gaskets on studs.
Ensure injector leak off pipes are not fouled.
21. Position gearbox breather hose bracket on
rearmost manifold stud.
22. Secure manifold with nuts. Progressively tighten
to
22 Nm (16 lbf.ft)
23. Position manifold stays. Secure with nuts and
bolts.
24. Secure manifold pressure sensing hose to stay
with clip.
25. Connect multiplug to intake temperature sensor.
26. Engage fuel return hose into inlet manifold clip.
27. Connect intake hose. Secure with clip.
28. Position intake ducting. Engage clips.
29. Engage breather valve into ducting grommet.
30. Connect ducting to turbocharger intake hose.
Secure with clip.
31. Connect intake hose to ducting. Secure with clip.
32. Fit injector covers. Secure with screws.
33. Reconnect battery negative lead.
INTAKE MANIFOLD GASKETS - DIESEL WITH
EGR
Service repair no - 30.15.08
Remove
1. Disconnect battery negative terminal.
2. Remove air intake ducting.
See this section.
3. Disconnect vacuum hose from EGR valve.
4. Slacken clip and disconnect intercooler hose
from EGR valve.
5. Remove 2 bolts securing EGR pipe to EGR
valve.
30
MANIFOLD AND EXHAUST SYSTEM
NEW RANGE ROVER
26
REPAIR
6. Disengage clip on underside of intake manifold.
Release wiring harness and vacuum hoses.
7. Release fuel return hose and EGR vacuum pipe
from clips on underside of manifold.
8. Remove 12 nuts securing intake manifold to
cylinder head.
9. Release gearbox breather hoses from rearmost
manifold stud.
10. Release manifold from from studs. Ensure that
injector leak off pipes do not foul on manifold
flanges.
11. Position manifold aside.
CAUTION: Ensure manifold pressure
sensing hose is not strained.
12. Remove 6 seals from intake manifold ports.
CAUTION: Care must be taken when
extracting seals to ensure recesses in
intake manifold are not damaged.
13. Clean mating faces of intake manifold and
cylinder head.
14. Position cloth over inlet ports to prevent dirt
ingress.
Refit
15. Fit new seals to recesses in intake manifold.
16. Position intake manifold to studs, ensuring that
leak off pipes do not become trapped beneath
flanges.
17. Position gearbox breather hose bracket to
rearmost stud.
18. Secure manifold with nuts and progressively
tighten to
22Nm (16 lbf.in).
19. Position and secure fuel return hose, harnesses
and vacuum hoses to clips on underside of
manifold.
20. Engage EGR pipe to valve, align flange and
secure with bolts. Tighten bolts to
22 Nm
(16 lbf.in).
21. Connect intercooler hose to EGR valve and
secure with clip.
22. Connect vacuum hose to EGR valve.
23. Fit air intake ducting.
See this section.
24. Connect battery negative terminal.
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