An exhaust manifold (Freelander 2)

WARNING: Use caution when working near hot exhaust system components.

Removing

1. Raise the vehicle.

WARNING: Place secure stands under the vehicle.

2. Remove the EGR heat exchanger (EGR). Refer to Procedure: EGR Cooler (EGR) (303-08B Emission reduction - 2.2L Duratorq - Td4, Removal and installation).

3. Remove the catalytic converter. Refer to Procedure: Catalytic Converter - Vehicle Not Included: Diesel Fuel Filter (309-00B Exhaust system - 2.2L Duratorq - Td4, Removal and installation).

4.

NOTE: Plug all openings.

5.

Clean the area around the element and remove foreign material from it. Plug all openings. Use new caps.

6. Disconnect the turbocharger.

CAUTION: Plug all openings. Use new caps.

7. Remove the EGR cooler from the exhaust manifold elbow.



8.

CAUTION: Plug all openings. Use new caps.

NOTE: Discard gasket as useless.

Installation

• Install a new gasket.
• Install the exhaust manifold.
• Tighten the bolts evenly and progressively in the sequence shown. Tightening torque: 25 Nm

CAUTION: Clean area around element and remove foreign material from area.

2. Install the EGR cooler to the exhaust manifold. Tightening torque: 10 Nm

3. Install the turbocharger. Tightening torque: 24 Nm

Use new bolts. Extreme cleanliness must be observed when handling this element. Carefully remove carbon deposits from both surfaces of the turbocharger and exhaust manifold before reassembly.

4. Install the turbocharger support bracket, but do not fully tighten the bolts at this stage.

5. Tighten the bolt securing the turbocharger to the support bracket. Tightening torque: 24 Nm

6. Tighten bolts of fastening of a head of cylinders to a basic arm. Tightening torque: 24 Nm

7. Connect the turbocharger oil line. Tightening torque: 24 Nm

Clean the area around the element and remove foreign material from it. Use new seals.

8. Install the turbocharger exhaust pipe. Tightening torque: 25 Nm

9. Install the catalytic converter. Refer to Procedure: Catalytic Converter - Vehicle Not Included: Diesel Fuel Filter (309-00B Exhaust system - 2.2L Duratorq - Td4, Removal and installation).

10. Install the EGR cooler. Refer to Procedure: EGR Cooler (EGR) (303-08B Emission reduction - 2.2L Duratorq - Td4, Removal and installation).

11. Check the engine oil level and top up if necessary.