1996 LAND ROVER DEFENDER exhaust

FUEL SYSTEM
17
REPAIR EGR VALVE
Service repair no - 17.45.01
Remove
1.Disconnect multi-plug from EGR valve.
2.Disconnect vacuum pipe from EGR valve.
3.Remove 2 Allen screws securing EGR valve to
exhaust manifold.
4.Remove 2 bolts securing air inlet delivery tube to
EGR valve.
5.Remove EGR valve and discard gaskets.
Refit
6.Clean mating faces of EGR valve and exhaust
manifold.
7.Position new gaskets and fit EGR valve to
delivery tube and exhaust manifold. Tighten
bolts to
25 Nm (18 lbf/ft).
8.Fit vacuum pipe and multi-plug to EGR valve.EGR VALVE MODULATOR
Service repair no - 17.45.04
Remove
1.Disconnect multi-plug from modulator.
2.Disconnect spill pipe (green), modulator to air
cleaner hose.
3.Disconnect vacuum pipe (blue), modulator to
EGR valve.
4.Disconnect vacuum pipe (white), modulator to
brake servo pipe.
5.Unscrew 2 nuts securing modulator to flexible
mountings.
6.Remove modulator.
Refit
7.Fit modulator to flexible mountings and tighten
nuts to
8 Nm (6 lbf/ft).
8.Fit modulator pipes, ensuring they are connected
to correct ports.
9.Connect modulator multi-plug.

COOLING SYSTEM
1
DESCRIPTION AND OPERATION ENGINE COOLING SYSTEM
Description
The complete cooling system of the 300Tdi engine
incorporates three independent functions:- Engine
(coolant) cooling; Turbo (charge air) intercooling;
Engine oil cooling.The intercooler is a separate aluminium unit, located
on the LH side of the engine compartment adjacent to
the radiator, sharing the same upper and lower
mountings. For details of turbo intercooling
See
FUEL SYSTEM, Description and operation,
Operation
. The oil cooler matrix is an integral part of
the radiator. Pre-formed pipes/hoses are used to link
the components within the separate systems as
shown below.
Engine cooling system
1.Radiator
2.Thermostat housing
3.Radiator bottom hose
4.Viscous fan
5.Water pump
6.Radiator top hose
7.Heater return hose
8.Coolant supply hose
9.By-pass hose
10.Radiator bleed (purge) hose
11.Bleed (purge) hose, thermostat housing
12.'Y' piece ejector
13.Expansion tank14.Heater rail
15.Heater unit
16.Heater feed hose
17.Intercooler
18.Air cleaner
19.Air feed hose
20.Turbocharger
21.Charge air supply pipe/hose
22.Cooled charge air supply hose
23.Exhaust manifold
24.Engine oil cooler
25.Feed pipe, engine oil cooler
26.Return pipe, engine oil cooler
27.Oil filter

MANIFOLD AND EXHAUST SYSTEM
1
DESCRIPTION AND OPERATION MANIFOLDS AND EXHAUST SYSTEM
Description
The exhaust systems fitted on all models with the
300Tdi engine comprise three sections; front pipe
assembly, intermediate silencer assembly, and tail
pipe and silencer assembly. All sections, including
silencers, are manufactured from luminised steel to
give the system a durable working life under all
conditions. Special clamps are provided to ensureleak proof jointing between the various sections,
which are supported by flexible rubber mountings.
Catalytic convertor
When fitted, the catalytic converter is integral with the
front pipe assembly, which also incorporates a flexible
joint. The catalyst forms part of the engine emission
control that can also include an EGR valve system
See FUEL SYSTEM, Repair, EGR valve
Exhaust system - 90
1.Gasket
2.Front pipe
3.Front pipe with catalytic converter
4.Front mounting bracket
5.Intermediate silencer6.Intermediate mounting brackets
7.Tail pipe silencer*
8.Tail pipe silencer mounting
9.Tail pipe mounting
* Deleted on later models

30MANIFOLD AND EXHAUST SYSTEM
2
DESCRIPTION AND OPERATION The catalyst comprises platinum coated ceramic
elements. The Hydrocarbons (HC), Oxides of nitrogen
(NOx) and Carbon monoxide (CO) emitted by the
engine react with the catalytic element and exhaust
temperature to convert the toxic gas into Nitrogen
(N
2), Carbon dioxide (CO2) and water vapour.
Exhaust system - 110/130
1.Gasket
2.Front pipe
3.Front pipe with catalytic converter
4.Front mounting bracket
5.Intermediate silencer6.Intermediate mounting brackets
7.Tail pipe silencer
8.Tail pipe silencer mounting
9.Tail pipe mounting

MANIFOLD AND EXHAUST SYSTEM
1
REPAIR INDUCTION MANIFOLD
Service repair no - 30.15.02
Remove
1.Disconnect battery.
2.Remove oil filler cap and remove rocker cover
insulation.
3.Remove hose intercooler to induction manifold. If
fitted, remove EGR valve.
See FUEL SYSTEM,
Repair, EGR valve
4.Remove 2 screws and release heat shield from
induction manifold.
5.Slacken induction manifold lower securing nuts,
located below exhaust manifold.
6.Remove induction manifold upper securing bolts.
7.Remove induction manifold. Plug apertures in
cylinder head with clean rag to prevent any items
falling into engine.
8.Check gasket is satisfactory for further use.
Refit
9.Clean induction manifold mating face.
10.Position induction manifold and secure with
upper and lower fixings.
11.Tighten securing nuts and bolts to
25 Nm (18
lbf/ft).
12.Fit manifold heat shield.
13.Fit hose intercooler to induction manifold.
14.Fit rocker cover insulation.
15.Reconnect battery.INDUCTION/EXHAUST MANIFOLD GASKET
Service repair no - 30.15.15
Remove
1.Remove induction manifold
See Induction
manifold
.
2.Remove turbocharger outlet hose.
3.Raise vehicle and slacken exhaust front pipe to
intermediate silencer flange nuts. Ensure pipe is
free to turn.
NOTE: If removing exhaust manifold and
turbocharger assembly from vehicle,
remove manifold to exhaust front pipe
nuts while working under vehicle.
4.Remove exhaust manifold securing nuts,
removing centre lower nut first.
5.Move heater rail clear of exhaust manifold.
6.With exhaust manifold and turbocharger still
attached to exhaust front pipe, withdraw from
head by turning front pipe until sufficient access
is gained to remove gasket.
7.Suitably support exhaust manifold and
turbocharger assembly to prevent damage.
8.Remove induction manifold lower nuts.
9.Remove gasket.
10.Clean mating faces.

30MANIFOLD AND EXHAUST SYSTEM
2
REPAIR Refit
11.Fit new gasket over manifold studs.
12.Loosely fit induction manifold lower nuts to
studs.
13.Fit exhaust manifold and secure with central
upper and lower nuts.
14.Locate heater rail to its correct position and
secure with outer exhaust manifold nuts.
15.Tighten all exhaust manifold nuts to
45 Nm (33
lbf/ft).
16.Tighten exhaust front pipe to intermediate
silencer nuts to
50 Nm (37 lbf/ft).
17.Fit turbocharger outlet pipe.
18.Fit induction manifold
See Induction manifold
.EXHAUST MANIFOLD/TURBOCHARGER
ASSEMBLY
Service repair no - 30.15.10
Remove
1.Remove induction manifold
See Induction
manifold
.
2.Disconnect turbocharger inlet hose.
3.Disconnect boost pressure pipe at turbocharger.
4.Remove intercooler bottom hose.
5.Place suitable container under engine and
disconnect turbocharger oil feed and return
pipes at cylinder block.
6.Remove 3 nuts securing exhaust front pipe to
manifold flange.
7.Remove 7 nuts and lift exhaust manifold and
turbocharger assembly from cylinder head.
8.Discard manifold gasket.
Refit
9.Fit new manifold gasket.
10.Position exhaust manifold assembly onto
location studs and secure to cylinder head.
Tighten nuts to
45 Nm (33 lbf/ft).
11.Secure exhaust front pipe to manifold flange.
Tighten fixings to
50 Nm (37 lbf/ft).
12.Reconnect turbocharger oil feed and return
pipes at cylinder block.
13.Fit intercooler bottom hose.
14.Fit boost pressure pipe at turbocharger.
15.Fit turbocharger inlet hose.
16.Fit induction manifold
See Induction manifold
.

MANIFOLD AND EXHAUST SYSTEM
3
REPAIR EXHAUST FRONT PIPE
Service repair no - 30.10.09
Remove
1.Disconnect battery.
2.Raise vehicle on ramp.
3.Remove 3 securing nuts at exhaust manifold
flange.
4.Remove through bolt securing front pipe
mounting bracket to chassis.
5.Remove bracket and rubber mounting from
exhaust pipe.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray
See
CHASSIS AND BODY, Repair, Front undertray or
See CHASSIS AND BODY, Repair, Rear undertray
.
6.Remove flange nuts securing front pipe to
intermediate silencer assembly and separate
flanges.
7.Release front pipe at manifold and remove
gasket.
8.Move front pipe rearwards, lower front end and
at the same time twist toward propeller shaft.
Move pipe forward and withdraw from under
vehicle.
Refit
9.Manouvre front pipe into position and secure to
intermediate silencer flange. Do not fully tighten
fixings at this stage.
10.Fit new gasket and secure front pipe to exhaust
manifold. Tighten fixings to
50 Nm (37 lbf/ft).
11.Fit front pipe bracket and mounting rubber to
chassis.
12.Fully tighten front pipe to intermediate silencer
flange nuts to
30 Nm (22 lbf/ft).
13.Lower vehicle ramp and reconnect battery.

30MANIFOLD AND EXHAUST SYSTEM
4
REPAIR INTERMEDIATE PIPE - 90
Service repair no - 30.10.11
Remove
1.Raise vehicle on ramp.
2.Release intermediate pipe from front mounting
rubber, see J6243.
3.Remove 2 flange nuts securing intermediate
pipe to tail pipe.
4.Release intermediate pipe from rear mounting
rubber.
5.Remove 2 flange nuts securing intermediate
pipe to front pipe.
6.Release intermediate pipe from front and tail
pipe and remove.
Refit
7.Fit intermediate pipe to front and tail pipes.
8.Secure intermediate pipe to front and rear
mounting rubbers.
9.Secure intermediate pipe to front pipe. Tighten
nuts to
30 Nm (22 lbf/ft).
10.Secure intermediate pipe to tail pipe. Tighten
nuts to
30 Nm (22 lbf/ft).
11.Lower vehicle.INTERMEDIATE PIPE - 110/130
Service repair no - 30.10.11
Remove
1.Raise vehicle on ramp.
2.Release intermediate pipe from mounting
rubber, see J6244.
3.Remove 2 flange nuts securing intermediate
pipe to tail pipe.
4.Remove 2 flange nuts securing intermediate
pipe to front pipe.
5.Release intermediate pipe from front and tail
pipe and remove.
Refit
6.Fit intermediate pipe to front and tail pipes.
7.Secure intermediate pipe to mounting rubbers.
8.Secure intermediate pipe to front pipe. Tighten
nuts to
30 Nm (22 lbf/ft).
9.Secure intermediate pipe to tail pipe. Tighten
nuts to
30 Nm (22 lbf/ft).
10.Lower vehicle.