Exhaust manifold (Freelander 2)

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

Removal

1. Raise the vehicle.

WARNING: Ensure that the vehicle is supported securely.

2. Remove the exhaust gas recirculation (EGR) cooler. Refer to procedure: Exhaust Gas Recirculation (EGR) Cooler (303-08B Emission Control - 2.2L Duratorq - Td4, Removal and Installation).

3. Remove the catalytic converter. Refer to the procedure: Catalytic Converter - Vehicles Not Equipped with: 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 any foreign material. 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 the gasket as unnecessary.

Installation

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

CAUTION: Clean the area around the element and remove any foreign material.

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 is required when handling this component. Carefully remove carbon deposits from both surfaces of the turbocharger and exhaust manifold before assembly.

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

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



6. Tighten the cylinder head to support bracket bolts. Tightening torque: 24 Nm

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

Clean the area around the element and remove any foreign material. Use new sealing gaskets.

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

9. Install the catalytic converter. Refer to procedure: Catalytic Converter - Vehicles Not Equipped with: Diesel Fuel Filter (309-00B Exhaust System - 2.2L Duratorq - Td4, Removal and Installation).

10. Install the EGR cooler. Refer to procedure: Exhaust Gas Recirculation (EGR) Cooler (303-08B Emission Control - 2.2L Duratorq - Td4, Removal and Installation).

11. Check the engine oil level and add oil if necessary.