Land Rover 2000-05

Exhaust Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front exhaust pipes from the exhaust manifolds
     

  4.  
  5. Lower the vehicle.
  6.  
  7. For the left manifold, perform the following:
    1. Release the intake hose from the plenum chamber.
    2.  
    3. Release the harness from the intake hose clip.
    4.  
    5. Remove the air flow meter.
    6.  
    7. Disconnect the purge valve (11) and position the valve aside.

      Click image to see an enlarged view

      Fig. Purge valve mounting bolt location-Range Rover

    8.  

  8.  
  9. For the right manifold, perform the following:
    1. Disconnect the spark plug wires and position them out of the way.
    2.  
    3. Unscrew the right shock absorber top mounting bolt to provide additional clearance for the removal of the heat shield.
    4.  

  10.  
  11. Remove or disconnect the following:

    The 8 bolts (for the right manifold) or 7 bolts (for the left manifold) securing the outer heat shield to the manifold.
     
    The 8 exhaust manifold-to-cylinder head mounting bolts, then remove manifolds.
     

  12.  

To install:

  1. Ensure all gasket mating surfaces are clean.
  2.  
  3. Install or connect the following:

    Manifolds using new gaskets. Tighten the bolts 40 ft. lbs. (55 Nm), in the sequence as shown.

    Click image to see an enlarged view

    Fig. Exhaust manifold torque sequence-Range Rover model

     
    Heat shields and tighten the mounting bolts to 72 inch lbs. (8 Nm).
     
    Purge valve on the shock absorber turret
     
    Air flow meter
     
    Right shock absorber top mounting bolt to 63 ft. lbs. (85 Nm).
     
    Spark plug wires
     
    Front exhaust pipes to the manifolds and tighten the mounting nuts to 37 ft. lbs. (50 Nm).
     
    Negative battery cable
     

  4.  


NOTE
This procedure is the same for both exhaust manifolds.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise vehicle on a 4-post lift or raise front of vehicle and support on safety stands.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the exhaust manifold-to-exhaust pipe retaining nuts.
  8.  
  9. Remove the 8 manifold bolts. Remove the exhaust manifold and discard the 2 gaskets.
  10.  

To install:

  1. Clean all mating surfaces.
  2.  
  3. Place the exhaust manifold in position on the cylinder head along with new gaskets.
  4.  
  5. Install spacers and the exhaust manifold bolts. Working from the center outward, tighten bolts to 28 ft. lbs. (38 Nm).
  6.  
  7. Install the exhaust pipe to the exhaust manifold. With a new gasket in place, tighten the exhaust pipe retaining nuts to 22 ft. lbs. (30 Nm).
  8.  
  9. Lower the vehicle.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Start the engine and check for exhaust leaks.
  14.  
  15. Road test the vehicle and check for proper engine operation.
  16.  

  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    The following procedure applies to either side exhaust manifold

  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Oxygen sensor connectors from ahead and behind the catalytic converter
     
    Support exhaust system with a suitable jack
     
    4 nuts attaching the front exhaust rubber mountings to body
     
    Front exhaust pipes from the exhaust manifolds
     
    Lower the exhaust system with the jack
     
    8 nuts attaching the exhaust manifold
     
    Exhaust manifold and discard the gaskets
     

  4.  

To install:

  1. Ensure all gasket mating surfaces are clean.
  2.  
  3. Install or connect the following:

    Apply copper grease to exhaust manifold mounting studs
     
    Manifolds using new gaskets and nuts. Tighten the nuts 17 ft. lbs. (23 Nm).
     
    Raise exhaust system with the jack
     
    Exhaust pipes using new mounting nuts. Tighten the nuts to 33 ft. lbs. (45 Nm).
     
    Exhaust rubber mounting nuts and tighten to 18 ft. lbs. (25 Nm)
     
    Lower the jack
     
    Connect oxygen sensor connectors
     
    Negative battery cable
     

  4.  

Left Rear
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Position vehicle on 4 post ramp.
  4.  
  5. Disconnect battery ground lead.
  6.  
  7. Remove engine acoustic cover.
  8.  
  9. Remove underbelly panel.
  10.  
  11. Using a 3 / 8 in. socket bar raise auxiliary drive belt tensioner and release drive belt from alternator and PAS pump pulleys.
  12.  
  13. Remove 3 bolts securing A/C compressor to fixing brackets and position compressor aside.
  14.  
  15. Remove compressor heat shield.
  16.  
  17. Release and disconnect HO 2 S connector.
  18.  
  19. Release HO 2 S harness from clip.
  20.  
  21. Release and disconnect post catalyst HO 2 S connector.
  22.  
  23. Release HO 2 S harness from clips.
  24.  
  25. Remove 2 nuts securing exhaust front pipe to exhaust manifold.
  26.  
  27. Remove 4 nuts securing manifold and remove exhaust manifold.
  28.  
  29. Remove and discard manifold and down pipe gaskets.
  30.  

To install:

  1. Clean exhaust manifold and mating faces.
  2.  
  3. Using new gaskets, fit exhaust manifold and tighten nuts to cylinder head to 33 ft. lbs. (45 Nm) and nuts to front pipe to 37 ft. lbs. (50 Nm).
  4.  
  5. Connect H0 2 S connectors, secure connectors to brackets and harness to clips.
  6.  
  7. Clean compressor and mounting bracket mating faces.
  8.  
  9. Fit compressor heat shield.
  10.  
  11. Position compressor to mounting and align heat shield. Fit and tighten bolts to 18 ft. lbs. (25 Nm).
  12.  
  13. Using a 3 / 8 in. square drive socket bar, raise auxiliary drive belt tensioner and fit drive belt to pulleys.
  14.  
  15. Fit underbelly panel.
  16.  
  17. Fit engine acoustic cover.
  18.  
  19. Connect the negative battery cable.
  20.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery ground lead.
  4.  
  5. Remove right side catalytic converter.
  6.  
  7. Remove 4 nuts securing exhaust manifold to cylinder head, remove manifold and discard gasket.
  8.  

To install:

  1. Clean exhaust manifold and mating face.
  2.  
  3. Using new gasket, fit exhaust manifold and tighten nuts to 45 Nm (33 ft. lbs.).
  4.  
  5. Fit right side catalytic converter.
  6.  
  7. Connect the negative battery cable.
  8.