Exhaust manifold — removal and installation (Defender 2007+)

Removing

1. Disconnect the wire "masses" from the battery.

For more information, see the chapter: Disconnecting and connecting the battery (414-01 Battery, Battery Mount and Wires, General Procedures).

2. Remove the turbocharger.

For more information, see chapter: Turbocharger (303-04B Fuel supply and controls - turbocharger - ID4 2.4L diesel engine, Removal - Refitting).

3. Remove the turbocharger heat shield bracket. Turn out a bolt.



4. Turn out two bolts of fastening of a final collector to the heat exchanger of recirculation of the fulfilled gases (EGR).



5.

CAUTION: Plug all openings. Use new caps.

Remove the oil level indicator tube and the indicator itself. Remove the O-ring and send it for recycling.




6.

CAUTION: Plug all openings. Use new caps.

Remove the exhaust manifold.

• Remove 6 bolts and remove 2 nuts.
• Remove the exhaust manifold gasket and discard it.

7. Turn out two hairpins of a final collector and reject them.

Installation

1. Install new exhaust manifold studs. Tighten (tightening torque 20 Nm).




2.

NOTE: Remove and discard plugs.

NOTE: Clean the contact surfaces of the elements.

Install the exhaust manifold.

• Install a new exhaust manifold gasket.
• Tighten (tightening torque 40 Nm).

3.

NOTE: Remove and discard plugs.

Insert the oil dipstick and install the oil level indicator tube.

• Install the sealing ring.
• Tighten (tightening torque 23 Nm).

4. Install the bolts securing the EGR heat exchanger to the exhaust manifold. Tighten (tightening torque 23 Nm).




5. Install the turbocharger heat shield bracket. Tighten (tightening torque 10 Nm).



6. Install the turbocharger.

For more information, see chapter: Turbocharger (303-04B Fuel supply and controls - turbocharger - ID4 2.4L diesel engine, Removal - Refitting).

7. Connect the wire "masses" to the battery.

For more information, see the chapter: Connecting the Battery (414-01 Battery, Battery Mount and Wires, General Procedures).