Defender 300Tdi (1996+). Manual — part 33
30
MANIFOLD AND EXHAUST SYSTEM
2
DESCRIPTION AND OPERATION
The catalyst comprises platinum coated ceramic
elements. The Hydrocarbons (HC), Oxides of nitrogen
(NOx) and Carbon monoxide (CO) emitted by the
engine react with the catalytic element and exhaust
temperature to convert the toxic gas into Nitrogen
(N
2
), Carbon dioxide (CO
2
) and water vapour.
Exhaust system - 110/130
1. Gasket
2. Front pipe
3. Front pipe with catalytic converter
4. Front mounting bracket
5. Intermediate silencer
6. Intermediate mounting brackets
7. Tail pipe silencer
8. Tail pipe silencer mounting
9. Tail pipe mounting
MANIFOLD AND EXHAUST SYSTEM
1
REPAIR
INDUCTION MANIFOLD
Service repair no - 30.15.02
Remove
1. Disconnect battery.
2. Remove oil filler cap and remove rocker cover
insulation.
3. Remove hose intercooler to induction manifold. If
fitted, remove EGR valve.
See FUEL SYSTEM,
Repair, EGR valve
4. Remove 2 screws and release heat shield from
induction manifold.
5. Slacken induction manifold lower securing nuts,
located below exhaust manifold.
6. Remove induction manifold upper securing bolts.
7. Remove induction manifold. Plug apertures in
cylinder head with clean rag to prevent any items
falling into engine.
8. Check gasket is satisfactory for further use.
Refit
9. Clean induction manifold mating face.
10. Position induction manifold and secure with
upper and lower fixings.
11. Tighten securing nuts and bolts to
25 Nm (18
lbf/ft).
12. Fit manifold heat shield.
13. Fit hose intercooler to induction manifold.
14. Fit rocker cover insulation.
15. Reconnect battery.
INDUCTION/EXHAUST MANIFOLD GASKET
Service repair no - 30.15.15
Remove
1. Remove induction manifold
See Induction
manifold .
2. Remove turbocharger outlet hose.
3. Raise vehicle and slacken exhaust front pipe to
intermediate silencer flange nuts. Ensure pipe is
free to turn.
NOTE: If removing exhaust manifold and
turbocharger assembly from vehicle,
remove manifold to exhaust front pipe
nuts while working under vehicle.
4. Remove exhaust manifold securing nuts,
removing centre lower nut first.
5. Move heater rail clear of exhaust manifold.
6. With exhaust manifold and turbocharger still
attached to exhaust front pipe, withdraw from
head by turning front pipe until sufficient access
is gained to remove gasket.
7. Suitably support exhaust manifold and
turbocharger assembly to prevent damage.
8. Remove induction manifold lower nuts.
9. Remove gasket.
10. Clean mating faces.
30
MANIFOLD AND EXHAUST SYSTEM
2
REPAIR
Refit
11. Fit new gasket over manifold studs.
12. Loosely fit induction manifold lower nuts to
studs.
13. Fit exhaust manifold and secure with central
upper and lower nuts.
14. Locate heater rail to its correct position and
secure with outer exhaust manifold nuts.
15. Tighten all exhaust manifold nuts to
45 Nm (33
lbf/ft).
16. Tighten exhaust front pipe to intermediate
silencer nuts to
50 Nm (37 lbf/ft).
17. Fit turbocharger outlet pipe.
18. Fit induction manifold
See Induction manifold
.
EXHAUST MANIFOLD/TURBOCHARGER
ASSEMBLY
Service repair no - 30.15.10
Remove
1. Remove induction manifold
See Induction
manifold .
2. Disconnect turbocharger inlet hose.
3. Disconnect boost pressure pipe at turbocharger.
4. Remove intercooler bottom hose.
5. Place suitable container under engine and
disconnect turbocharger oil feed and return
pipes at cylinder block.
6. Remove 3 nuts securing exhaust front pipe to
manifold flange.
7. Remove 7 nuts and lift exhaust manifold and
turbocharger assembly from cylinder head.
8. Discard manifold gasket.
Refit
9. Fit new manifold gasket.
10. Position exhaust manifold assembly onto
location studs and secure to cylinder head.
Tighten nuts to
45 Nm (33 lbf/ft).
11. Secure exhaust front pipe to manifold flange.
Tighten fixings to
50 Nm (37 lbf/ft).
12. Reconnect turbocharger oil feed and return
pipes at cylinder block.
13. Fit intercooler bottom hose.
14. Fit boost pressure pipe at turbocharger.
15. Fit turbocharger inlet hose.
16. Fit induction manifold
See Induction manifold
.
MANIFOLD AND EXHAUST SYSTEM
3
REPAIR
EXHAUST FRONT PIPE
Service repair no - 30.10.09
Remove
1. Disconnect battery.
2. Raise vehicle on ramp.
3. Remove 3 securing nuts at exhaust manifold
flange.
4. Remove through bolt securing front pipe
mounting bracket to chassis.
5. Remove bracket and rubber mounting from
exhaust pipe.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray
See
CHASSIS AND BODY, Repair, Front undertray or
See CHASSIS AND BODY, Repair, Rear undertray
.
6. Remove flange nuts securing front pipe to
intermediate silencer assembly and separate
flanges.
7. Release front pipe at manifold and remove
gasket.
8. Move front pipe rearwards, lower front end and
at the same time twist toward propeller shaft.
Move pipe forward and withdraw from under
vehicle.
Refit
9. Manouvre front pipe into position and secure to
intermediate silencer flange. Do not fully tighten
fixings at this stage.
10. Fit new gasket and secure front pipe to exhaust
manifold. Tighten fixings to
50 Nm (37 lbf/ft).
11. Fit front pipe bracket and mounting rubber to
chassis.
12. Fully tighten front pipe to intermediate silencer
flange nuts to
30 Nm (22 lbf/ft).
13. Lower vehicle ramp and reconnect battery.
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