Range-Rover-Manual-Exhaust.pdf

PO;;; 1987

MANIFOLD AND EXHAUST SYSTEM [30 1

EXHAUST SYSTEM COMPLETE

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EXHAUST SYSTEM COMPLETE

WARNING: To prevent personal injury occurring

from a hot exh‘aust system, DO NOT attempt to

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NOTE: Ensure that no exhaust leaks are evident

disconnect any of the components until ample

in either a new or an old exhaust system, as this

time has elapsed to allow the exhaust system to

will affect vehicle performance, and contravene

cool.

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Federal emission regulations.

Continued

REVISED: DEC. 87

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MANIFOLD AND EXHAUST SYSTEM

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Remove and refit

EXHAUST MANIFOLD

Removing

Remove and refit

1. Raise the vehicle on a suitable hoist and apply

the parking brake.

Left hand

2. Remove the four fixings securing the grass

shield (if fitted) to the mounting bracket at the

centre catalyst.

Right hand

Removing

3. Withdraw the grass shield from the bracket.

1. Disconnect the front exhaust pipe(s) from the

manifold(s).

2. Tap back the bolt locking tabs and remove the

eight bolts, lock tabs and washers.

3. Remove the manifold(s) and old gaskets.

4. Disconnect the electrical plugs from the

Lambda sensors.

5. Remove the nuts and disconnect the front

pipe(s) from the manifold(s) and remove the

gaskets.

6. Loosen the pinch bolt clamps securing the

front pipe to the intermediate pipe.

7. Withdraw the front pipe(s) with catalysts.

8. Remove three bolts securing the intermediate

pipe to the centre catalyst and withdraw the

doughnut.

Refitting

4. Ensure that the mating surfaces of the cylinder

head and exhaust manifold are clean and

smooth.

5. Coat the threads of each bolt with anti-seize

compound.

9. Remove the U-bolt from the pipe mounting

bracket.

6. Place the manifold and new gaskets in position

on the cylinder head and fit the securing bolts,

new lockplates and plain washers. The plain

washers are fitted between the manifold and

lockplates.

* 10. Withdraw the intermediate pipe.

11. Remove the U-bolt securing the centre catalyst

to the main muffler.

12. Withdraw the catalyst.

13. Remove the U-bolt from the tail pipe

mounting bracket.

14. Withdraw the tail pipe and rear muffler.

7. Evenly tighten the manifold bolts to the

correct torque, see torque values-section 06,

and bend over the lockplate tabs. i

8. Reconnect the front exhaust pipe, using new

exhaust flange gaskets.

Refitting

NOTE: Apply Firegum Putty, Part No. 15608

to all exhaust system joints with the

exception of the exhaust flange to manifold

flange where new gaskets should be fitted.

INTAKE MANIFOLD

The removal and refit of the intake manifold is

incorporated

‘. . .

in the Fuel Injection System,

15. Reverse the removal instructions.

Section 19.

REVISED: DEC. 87

.‘&S

MANIFOLD AND EXHAUST SYSTEM

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RR2387E

.,,

EXHAUST SYSTEM COMPLETE

Remove and refit

NOTE: Ensure that no exhaust leaks are evident

in either a new or old exhaust system, as this

will affect vehicle performance, and contravene

Federal emission regulations.

Removing

Tail pipe and rear muffler

Raise the vehicle on a suitable hoist and apply

the parking brake.

Remove the three bolts s&uring the tail pipe

assembly to the intermediate pipe assembly.

Remove the bolt securing the rear mounting

bracket. to the chassis.

Maneuver the tail pipe over the rear axle and

remove from the vehicle.

Retain the doughnut from the intermediate

pipe for reassembly.

WARNING: To prevent personal injury occurring

from a hot exhaust system, DO NOT attempt to

disconnect any ot the components until ample

time has elapsed to allow the exhaust system to

cool.

Continued

ADDITION: SEPT. 88

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6. Detach the rubber from the tailpipe and

hanger.

intermediate pipe and centre muffler

7. Remove the three bolts securing the right

hand branch of the intermediate pipe to the

right hand catalyst.

8. Release the pinch bolt clamp securing the left

hand branch of the intermediate pipe to the

left hand catalyst and slide the clamp along

the pipe.

9. Remove the bolts securing the front and rear

hanger brackets to the chassis.

10. Detach the rubbers from the main muffler

assembly and hangers.

11. Carefully separate the intermediate pipes from

the front downpipes.

12. Retain the doughnut from the right hand joint.

Front downpipes

13. Disconnect both Lambda sensor multiplugs.

14. Remove the nuts and release the front

downpipes from the manifolds, discard the

gaskets.

Refitting

15. lf the original system is being refitted, examine

the system for damage and general condition

renew sections as necessary.

16. Clean any previous putty from the doughnuts

and exhaust pipe joints.

17. Fit NEW gaskets to the manifold joint face.

NOTE: Apply exhaust sealer to all exhaust system

joints with the exception of the exhaust flange

to manifold flange.

18. Reverse the removal instructions.

19. Examine a new or original system for leaks and

ensure that the system does not foul any

underbody components. If exhaust leaks or

interference exists loosen the joints reseal and

reset as necessary.

ADDITION: SEPT. 88

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MANIFOLD AND EXHAUST SYSTEM 130 1

RR277-m

EXHAUST SYSTEM COMPLETE

Remove and refit

To improve sealing and accuracy of assembly, 1990

model year vehicles have a new two piece exhaust

svstem.

Removing

Raise the vehicle on a suit$ble ramp. apply the

parking brake.

Catalyst vehicles only: Disconnect the two

lambda sensor wiring connectors.

Remove the two bolts securing the rear

exhaust

NOTE: Ensure that no exhaust leaks are evident

in either a new or old exhaust system, as this

will affect vehicle performance.

assembly to the front exhaust

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disconnect any of the components until ample

time has elapsed to allow the exhaust system to

cool.

assembly.

Remove the nuts and release the front

downpipes fromt the manifolds. Discard the

gaskets.

ADDITION: SEPT. 89

WARNING: To prevent personal injury occurring

from a hot exhaust system, DO NOT attempt to

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