Range Rover Classic. Manual — part 58
30
MANIFOLD AND EXHAUST SYSTEM
RANGE ROVER
4
REPAIR
EXHAUST MANIFOLD - Tdi
Service repair no - 30.15.10
Remove
1. Disconnect battery negative lead.
2. Remove heat shield from rear of air intake
manifold.
3. Release dip stick tube from cylinder block.
4. Disconnect the intake hose from the manifold.
5. Remove the two bolts and two nuts securing the
intake manifold to the cylinder head and
withdraw the inlet manifold.
6. Remove air filter inlet pipe to turbo unit.
7. Remove intercooler pipe from turbo to
intercooler.
8. Disconnect the EGR pipe from the inlet manifold
hose.
9. Remove the three fixings at the exhaust pipe
flange.
10. Release the turbo charger oil pipes from the
cylinder block.
11. Remove the turbo boost pipes.
12. Remove seven bolts securing the exhaust
manifold, release the heater rail and remove the
manifold gasket, complete with turbo unit.
13. Remove four bolts and disconnect diaphragm
rod from manifold, and remove turbo charger if
necessary.
Refit
14. Reverse removal procedure. 1 to 12. Use a new
manifold and exhaust flange gaskets.
15. Reconnect battery negative lead. Start engine
and check for leaks.
MANIFOLD AND EXHAUST SYSTEM
1
SPECIFICATIONS, TORQUE
TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
MANIFOLDS AND EXHAUSTS - Mpi
Inlet manifold nuts and bolts
25
. . . . . . . . . . . . . . . . . ..
Fuel pipe to fuel rail
10
. . . . . . . . . . . . . . . . . . . . .
Exhaust manifold nuts
45
. . . . . . . . . . . . . . . . . . . .
Exhaust frontpipe to manifold
10
. . . . . . . . . . . . . . . . .
Exhaust downpipe to silencer box
30
. . . . . . . . . . . . . . . .
Manifold chamber gasket
10
. . . . . . . . . . . . . . . . . . ...
CLUTCH
1
DESCRIPTION AND OPERATION
DESCRIPTION
The clutch unit fitted with the manual transmission,
comprises a single dry plate friction disc and
diaphragm spring clutch unit, secured to the engine
flywheel.
OPERATION
The unit is operated hydraulically by the clutch master
cylinder 12 and a slave cylinder 13 attached to the
transmission bell housing.
1. Crankshaft and flywheel
2. Friction plate
3. Clutch cover
4. Diaphragm spring
5. Pressure plate
6. Fulcrum posts (9) for diaphragm spring
7. Bearing rings (2) for diaphragm spring
8. Retraction links and bolts (3) for pressure plate
9. Release bearing
10. Release lever
11. Release lever pivot post
12. Master cylinder
13. Slave cylinder
14. Master cylinder pedal pushrod
15. Primary shaft and taper bearing (in gearbox)
16. Gearbox front cover
17. Primary shaft flywheel bush
18. Pedal pivot and return spring
19. Hydraulic damper (Diesel only)
33
CLUTCH
2
DESCRIPTION AND OPERATION
When the clutch pedal is depressed, hydraulic fluid
transmits the movement via the slave cylinder, release
lever 10, bearing 9, to the inner fingers of the
diaphragm spring 4.
The diaphragm spring 4 pivots on the bearing rings 7
and fulcrum posts 6 causing the pressure plate 5 to
release the clamping force on the friction plate and
linings 2.
As the the clamping force is removed from the friction
plate 2, the plate slides on the splines of the primary
shaft 15 and takes up a neutral position between the
flywheel 1 and the pressure plate 5 , thus breaking the
drive between the engine and the gearbox.
NOTE: Diesel engined vehicles have an
hydraulic damper 19 fitted into the system.
The damper contains a steel diaphragm
which absorbs slight hydraulic pulses caused by
cyclic variations of the diesel engine crankshaft at
low rpm.
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