Exhaust manifold — removal and installation (Defender 2007+)

Removal

1. Disconnect the ground wire from the battery.

For more information, refer to the chapter: Disconnecting and connecting the battery (414-01 Battery, Battery Mounting and Cables, General Procedures).

2. Remove the turbocharger.

For more information, see the chapter: Turbocharger (303-04B Fuel Delivery and Controls - Turbocharger - ID4 2.4L Diesel Engine, Removal and Installation).

3. Remove the turbocharger heat shield bracket. Remove the bolt.



4. Remove the two bolts securing the exhaust manifold to the exhaust gas recirculation (EGR) heat exchanger.



5.

CAUTION: Plug all openings. Use new caps.

Remove the oil level indicator tube and the indicator itself. Remove the sealing ring and send it for disposal.





6.

CAUTION: Plug all openings. Use new caps.

Remove the exhaust manifold.

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

7. Remove the two exhaust manifold studs and discard them.

Installation

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

[The article was copied from this resource: lrman.ru]





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 it up (tightening torque 40 Nm).

3.

NOTE: Remove and discard plugs.

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

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

4. Install the EGR heat exchanger mounting bolts 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 the chapter: Turbocharger (303-04B Fuel Delivery and Controls - Turbocharger - ID4 2.4L Diesel Engine, Removal and Installation).

7. Connect the ground wire to the battery.

For more information, refer to the chapter: Connecting the Battery (414-01 Battery, Battery Mounting and Cables, General Procedures).