Range Rover. Manual — part 130
MANIFOLD AND EXHAUST SYSTEM
7
REPAIR
6. Remove exhaust manifold. Collect gaskets and
discard.
NOTE: The gasket fitted to No. 1 & 2
exhaust ports acts as a turbocharger heat
shield.
Refit
7. Ensure mating faces are clean.
8. Position new gaskets and turbocharger heat
shield to cylinder head studs. Ensure tabs face
outwards.
9. Position exhaust manifold. Secure with nuts and
flat washers. Working from centre outwards,
progressively tighten to
22 Nm (16 lbf.ft).
10.
Vehicles with EGR: Secure EGR pipe flange to
manifold with bolts. Tighten to
22 Nm
(16 lbf.ft).
11. Position turbocharger with new gasket to
exhaust manifold. Secure with bolts. Tighten to
45 Nm (33 lbf.ft).
12. Fit heat shield.
See this section.
13. Remove safety stands. Lower vehicle.
14. Reconnect battery negative lead.
EXHAUST MANIFOLD HEAT SHIELD - DIESEL
Service repair no - 30.15.09
Remove
1. Disconnect battery negative lead.
2. Raise the vehicle.
WARNING: Support on safety stands.
3. Remove cooling fan cowl.
See COOLING
SYSTEM, Repair.
4. Release intake hose from ducting.
5. Release turbocharger intake hose from ducting.
6. Release breather valve from intake ducting
grommet.
30
MANIFOLD AND EXHAUST SYSTEM
NEW RANGE ROVER
8
REPAIR
NOTE: Collect grommet. Refit to ducting.
7. Disengage 2 clips securing intake ducting.
Remove ducting.
8. Remove 3 bolts securing intake ducting bracket
and exhaust manifold heat shield to camshaft
cover. Collect bracket.
9. Disconnect heater hose from coolant connecting
pipe.
10. Remove bolt securing coolant connecting pipe to
engine front cover.
11. Remove coolant pipe. Remove ’O’ ring and
discard.
12. Slacken clips securing turbocharger outlet hose
to turbocharger and intercooler.
13. Remove turbocharger outlet hose assembly.
14. Release harness from 2 heat shield clips.
15. Remove heat shield.
Refit
16. Position heat shield.
17. Secure harness to heat shield clips.
18. Position outlet hose to turbocharger and
intercooler. Secure with clips.
19. Using a new ’O’ ring, position coolant pipe.
Engage to engine front cover.
20. Secure connecting pipe to front cover with bolt.
Tighten to
10 Nm (7 lbf.ft)
21. Connect heater hose. Secure with clip.
22. Align exhaust manifold heat shield. Position
intake ducting bracket.
23. Secure ducting bracket and heat shield with
bolts.
24. Position intake ducting. Engage clips.
25. Engage breather valve into ducting grommet.
26. Connect ducting to turbocharger intake hose.
Secure with clip.
27. Connect intake hose to ducting. Secure with clip.
28. Fit cooling fan cowl.
See COOLING SYSTEM,
Repair.
29. Remove safety stands. Lower vehicle.
30. Reconnect battery negative lead.
MANIFOLD AND EXHAUST SYSTEM
9
REPAIR
EXHAUST FRONT PIPE - V8
Service repair no - 30.10.09
Remove
1. Raise vehicle on four post lift.
2. Support transmission with a suitable stand.
3. Remove 6 nuts securing transmission mount to
crossmember. Remove snubber bar. Discard
nuts.
4. Remove 3 of 4 nuts and bolts securing each side
of crossmember to chassis.
5. With assistance, remove remaining bolt securing
crossmember. Remove crossmember.
6. Disconnect heated oxygen sensor (HO2S)
harnesses. Release multiplugs from sump
brackets.
7. Remove cable tie securing L.H. HO2S harness
to gearbox bracket.
8. Remove 2 nuts securing front pipe to
intermediate pipe flanges.
9. Remove 6 nuts securing front pipe to exhaust
manifold flanges.
10. Remove front pipe. Collect front pipe to manifold
gaskets.
11. If necessary, remove HO2S.
See FUEL
SYSTEM, Repair.
Refit
12. Ensure mating faces are clean.
13. If removed, fit HO2S.
See FUEL SYSTEM,
Repair.
14. Position front pipe assembly with gaskets to
manifolds. Secure with nuts. Tighten to
50 Nm
(37 lbf.ft)
15. Secure front pipe to intermediate pipe flange
with nuts. Tighten to
25 Nm (18 lbf.ft)
16. Secure LH HO2S harness to gearbox bracket
with cable tie.
17. Connect HO2S harnesses. Secure multiplugs to
sump brackets.
18. With assistance, position transmission
crossmember on chassis. Secure with nuts and
bolts. Tighten to
45 Nm (33 lbf.ft)
19. Fit snubber bar. Secure transmission mount to
crossmember with new flange nuts. Tighten to
45 Nm (33 lbf.ft)
20. Remove support from transmission.
21. Lower vehicle.
30
MANIFOLD AND EXHAUST SYSTEM
NEW RANGE ROVER
10
REPAIR
EXHAUST FRONT PIPE - V8 - FROM 97MY UP TO
99MY
Service repair no - 30.10.09
Remove
1. Raise vehicle on 4 post ramp.
2. Support transmission using a suitable stand.
3. Remove 4 nuts and 2 bolts securing
transmission mount to crossmember and discard
nuts.
4. Remove transmission snubber bar.
5. Remove 2 bolts securing rear of side acoustic
covers to crossmember.
6. Remove 3 of 4 nuts and bolts securing each side
of crossmember to chassis.
7. With assistance, remove remaining bolt securing
crossmember and remove crossmember.
8. Disconnect 2 oxygen sensor harness multiplugs
from oxygen sensor flylead.
9. Release 2 oxygen sensor flylead multiplugs from
brackets.
10. Release flyleads from 2 clips.
11. Remove 2 nuts securing front pipe to
intermediate pipe flange.
12. Remove 6 nuts securing front pipe to exhaust
manifold down pipe flanges
13. Using assistance, remove front pipe and collect
2 front pipe to manifold gaskets.
Do not carry out further dismantling if
component is removed for access only.
14. Remove 2 heated oxygen sensors from front
pipe and discard sealing washers.
15. Fit NEW sealing washers to heated oxygen
sensors.
16. Fit heated oxygen sensors to front pipe and
tighten to
20 Nm (15 lbf.ft)
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