Manifold & Exhaust System Land Rover Range Rover L322

EXHAUST MANIFOLD COMPONENT LAYOUT

For exhaust manifold component layout (Scheme 1)

Scheme 1

INLET MANIFOLD COMPONENT LAYOUT

For inlet manifold component layout (Scheme 2)

Scheme 2

EXHAUST SYSTEM COMPONENT LAYOUT

For exhaust system component layout (Scheme 3)

Scheme 3

GENERAL

The inlet manifold on the V8 engine is located on the top of the engine, between the cylinder heads.

The two exhaust manifolds, one for each bank of four cylinders, directs the engine combustion gases from the cylinders to the exhaust system.

The exhaust system consists of two identical systems, sharing a common rear silencer assembly, connected to each exhaust manifold. Two catalytic converters are located in each of the front pipes from it's respective manifold and a silencer is installed midway along the system.

INLET MANIFOLD

The inlet manifold is a light weight, one piece plastic molding. The manifold is acoustically decoupled from the cylinder heads to reduce noise and vibrations.

The throttle plate has two wedges screwed directly to it, these provide a curved zone for smoother throttle response during idle, off-idle transition.

The combined output of the mixing plate ensures that the intake air is evenly distributed among all the cylinders, which can improve idle quality.

EXHAUST MANIFOLD

Note. The exhaust manifold gasket for cylinders 3 and 4 is not interchangeable with the gaskets for cylinders 1 and 2, 5 and 6 or 7 and 8.

Two handed, double skinned stainless steel sheet metal manifolds are used on the V8 engine. Each manifold has four ports which merge into one flanged outlet positioned centrally on the manifold.

Each manifold is secured to its cylinder head using eight studs with nuts and sealed with two gaskets. The flanged outlet on each manifold provides the attachment for the exhaust system.

The stainless steel exhaust system is supplied as a one-piece assembly.

It consists of two stub pipes and pre-catalytic converter HO2S, two intermediate catalytic converters, two main catalytic converters and down pipes, each with a post catalytic converter HO2S, two intermediate silencer assemblies and pipes joining the single rear silencer assembly. Internally the rear silencer assembly is divided into two independent silencers, each with its own tailpipe. The tail pipes are bent downwards and not normally visible.

The exhaust system is attached to the underside of the body with five rubber mountings and a mass damper. The mass damper is fitted forward of the right intermediate silencer.

Although supplied as a one-piece assembly, in service, sections of the system can be replaced individually. Service joints, identified by indentations on the pipes, show where the exhaust pipes can be cut to accommodate replacement sections.

After the replacement sections are positioned the system integrity is restored by sealing the service joints with one piece sleeves. See REMOVAL & INSTALLATION .

EXHAUST SYSTEM & MOUNTINGS

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.

Removal

1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Release pre-catalyst harness leads from clips, remove multiplugs from retaining clips and disconnect. (Scheme 4)
4. Release post catalyst HO2S harnesses from clips, remove multiplugs from clips and disconnect. (Scheme 5)
5. Remove and discard 4 nuts securing front pipe flanges to exhaust manifolds, release front pipe from flanges and move aside. (Scheme 6)
6. Remove and discard the 4 nuts securing intermediate silencer mountings to body. (Scheme 7)
7. Remove 8 nuts securing rear silencer rubber mountings to body and with assistance remove exhaust assembly from vehicle. (Scheme 8) NOTE: DO NOT carry out further dismantling if component is removed for access only.
8. Remove 2 nuts and collect mass damper.
9. Remove 6 mounting rubbers from main assembly, remove rubbers from body mounting brackets.
10. Remove HO2S sensors from exhaust assembly and discard sealing washers.

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Installation

1. Fit mass damper and tighten bolts to 25 Nm (18 ft. lbs).
2. Fit exhaust mountings.
3. Clean exhaust pipe and exhaust manifold down pipe flanges.
4. Clean HO2S, sealing washer and mating faces.
5. Fit new sealing washers and apply anti seize compound to threads of HO2S sensors. Fit and tighten sensors to 50 Nm (37 ft. lbs).
6. Fit rubbers to exhaust mounting brackets and main assembly.
7. With assistance fit exhaust system to vehicle, align flanges to manifolds, fit and lightly tighten bolts. Fit one pair of rear silencer brackets to body and lightly tighten bolts.
8. Align remaining mounting brackets to body, fit nuts and tighten to 25 Nm (18 ft. lbs).
9. Check exhaust for correct alignment.
10. Align exhaust flange and tighten new nuts evenly to 45 Nm (33 ft. lbs).
11. Connect battery earth lead.
12. Start and run engine to check for leaks.

FRONT PIPE

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.

1. Position vehicle on lift. Raise and support vehicle.
2. Disconnect battery earth lead.
3. Remove exhaust system. See «EXHAUST SYSTEM & MOUNTINGS»(/land-rover/range-rover/l322-2002-2005/remont/exhaust/#manifold-exhaust-system__exhaust-system-mountings).
4. Remove HO2S sensors from exhaust assembly and discard sealing washers.
5. Using LRT-99-027, cut pipe at point indicated by depression in pipe. (Scheme 9)

Scheme 9

1. Fit new sealing washers and apply anti seize compound to threads of HO2S. Fit and tighten sensors to 50 Nm (37 ft. lbs).
2. Clean front pipe and mating face.
3. Fit front pipe and align flange, fit nuts but do not tighten at this stage.
4. Clean front pipe and intermediate pipe, fit joining sleeve.
5. Fit exhaust system. See «EXHAUST SYSTEM & MOUNTINGS»(/land-rover/range-rover/l322-2002-2005/remont/exhaust/#manifold-exhaust-system__exhaust-system-mountings) .
6. Centralize connecting sleeve over joint, align intermediate pipe with front pipes and tighten sleeve clamp nuts to 48 Nm (35 ft. lbs).
7. Check exhaust for correct alignment.
8. Connect battery earth lead.

INTERMEDIATE PIPE

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.

1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Using LRT-99-027, cut pipe at point indicated by depression in pipe. (Scheme 10)
4. Remove 4 nuts securing intermediate silencer mountings to body. (Scheme 7)
5. With assistance, remove intermediate exhaust pipe.
6. Remove and discard 2 nuts securing exhaust vibration damper to intermediate exhaust pipe.
7. Remove mounting rubber.

Scheme 10

1. Fit mounting rubber.
2. Fit vibration damper to intermediate exhaust pipe and secure with 2 new nuts.
3. Clean tail pipe and fit joining sleeves.
4. With assistance, fit intermediate pipe locate mounting and fit nuts. Tighten mounting nuts to 25 Nm (18 ft. lbs).
5. Centralize connecting sleeve over joint, align intermediate pipe with front pipes and tighten sleeve clamp nuts to 48 Nm (35 ft. lbs).
6. Centralize connecting sleeve over joint, align intermediate pipe with tail pipe and tighten sleeve clamp nuts to 48 Nm (35 ft. lbs).
7. Check exhaust for correct alignment.
8. Connect battery earth lead.
9. Start and run engine to check for leaks.

1. Position vehicle on lift.
2. Using LRT-99-027, cut pipe at point indicated by depression in pipe. (Scheme 11)
3. Remove 8 nuts securing mountings and with assistance, remove tail pipe and silencer assembly. (Scheme 8)
4. Remove 4 exhaust mountings.

Scheme 11

1. Fit 4 exhaust mountings.
2. Clean intermediate pipe and fit sleeve.
3. With assistance, fit tail pipe and silencer assembly, locate mountings and fit nuts. Tighten nuts to 25 Nm (18 ft. lbs).
4. Centralize connecting sleeve over joint, align intermediate pipe with tail pipe and tighten sleeve clamp nuts to 48 Nm (35 ft. lbs).
5. Check exhaust for correct alignment.
6. Connect battery earth lead.
7. Start and run engine to check for leaks.

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.

1. Disconnect battery earth lead.
2. Remove air intake hose. See «HOSE - AIR FLOW METER TO THROTTLE BODY»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation).
3. Remove LH ignition coil cover. See «COVER - IGNITION COILS - LH»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation__cover-ignition-coils-lh).
4. Remove RH ignition coil cover. See «COVER - IGNITION COILS - RH»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation__cover-ignition-coils-rh).
5. Disconnect multiplugs from ignition coils. (Scheme 12)
6. Disconnect multiplugs from throttle body, thermostat heater, CMP sensor and ECT sensor. Cut cable ties and release engine harness. (Scheme 13)
7. Disconnect multiplugs from VCC solenoids. (Scheme 14)
8. Release VCC multiplug harness from clip.
9. Disconnect multiplug from alternator. (Scheme 15)
10. Release alternator harness from 4 clips.
11. Disconnect multiplugs from KS and CMP sensor. (Scheme 16)
12. Remove 2 nuts securing fuel injector harness to fuel rail. (Scheme 17)
13. Release vacuum reservoir and mounting bracket from LH fuel injector harness securing stud.
14. Remove fuel hose and mounting bracket from LH fuel injector harness securing stud.
15. Release alternator harness from 2 clips on engine cover mounting brackets.
16. Disconnect multiplugs from fuel injectors. (Scheme 18)
17. Release engine harness from clips and move clear of camshaft cover.
18. Disconnect multiplug from charcoal canister purge solenoid valve. (Scheme 19)
19. Remove 2 nuts securing engine harness to inlet manifold. (Scheme 20)
20. If fitted: Disconnect multiplug from SAI solenoid. (Scheme 21)
21. If fitted: Remove SAI solenoid valve from RH fuel injector harness securing stud.
22. Disconnect multiplug from knock sensor. (Scheme 22)
23. Remove washer from fuel injector harness securing stud.
24. Disconnect multiplugs from fuel injectors.
25. Reposition injector harness.
26. Remove air intake plenum. See «80.15.62 PLENUM -- AIR INTAKE»(/land-rover/range-rover/l322-2002-2005/remont/heater/#heating-and-ventilation-removal-installation).
27. Release terminal cover, remove nut and disconnect 2 cables from terminal post. (Scheme 23)
28. Depressurize fuel system. See «FUEL SYSTEM - DEPRESSURIZE»(/land-rover/range-rover/l322-2002-2005/remont/fuel-system/#fuel-delivery-system__fuel-system-depressurize).
29. Disconnect fuel feed hose from fuel rail. (Scheme 24) CAUTION: Always fit plugs to open connections to prevent contamination.
30. Release 2 clips and disconnect 2 breather hoses. (Scheme 25)
31. Remove clip and disconnect brake vacuum hose.
32. Remove 2 bolts securing oil separator to manifold.
33. Remove clip and disconnect purge solenoid valve vacuum hose. Disconnect SAI vacuum pipe. (Scheme 26)
34. Remove 10 nuts securing inlet manifold to cylinder heads and remove 10 spacers. (Scheme 27)
35. Position brake servo vacuum pipe aside.
36. Lift inlet manifold and disconnect breather pipe. (Scheme 28)
37. Remove inlet manifold and discard 4 gaskets. NOTE: DO NOT carry out further dismantling if component is removed for access only.
38. Disconnect vacuum pipe and remove solenoid valve.
39. Remove 4 bolts securing engine cover brackets and remove brackets from inlet manifold. (Scheme 29)
40. Remove bolt securing fuel rail to inlet manifold and remove fuel rail with injectors. (Scheme 30)
41. Remove and discard lower "O" rings from injectors.
42. Remove 4 bolts securing throttle housing to inlet manifold and remove throttle body. (Scheme 31)
43. Remove and discard "O" ring from throttle housing.
44. Remove 6 Torx screws securing front cover to inlet manifold and remove front cover.
45. Remove and discard front cover "O" ring.
46. Remove 3 bolts securing 2 brackets to manifold rear cover. (Scheme 32)
47. Remove 2 brackets.
48. Remove 4 Torx screws securing inlet manifold rear cover and remove cover.
49. Remove and discard "O" ring. (Scheme 33)
50. Depress locking collars and remove vent pipe from inlet manifold.

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

1. Fit vent pipe to inlet manifold.
2. Fit new "O" ring to rear cover.
3. Fit rear cover to inlet manifold and tighten 4 Torx screws to 10 Nm (7 ft. lbs).
4. Fit 2 brackets and secure with 3 bolts and tighten to 10 Nm (7 ft. lbs).
5. Fit new "O" ring to front cover.
6. Fit front cover to manifold and tighten 6 Torx screws to 10 Nm (7 ft. lbs).
7. Fit new throttle body seal.
8. Fit throttle housing to inlet manifold and tighten 4 bolts to 10 Nm (7 ft. lbs).
9. Lubricate new "O" rings and fit to injectors.
10. Fit fuel rail with injectors to inlet manifold and fit bolt.
11. Fit 2 new brackets to manifold and tighten 5 bolts to 10 Nm (7 ft. lbs).
12. Fit solenoid valve and connect vacuum pipe.
13. Fit 4 new gaskets and install inlet manifold.
14. Connect breather pipe and install inlet manifold to studs.
15. Position brake servo vacuum pipe.
16. Fit 10 spacers and tighten 10 inlet manifold securing nuts to 15 Nm (11 ft. lbs).
17. Connect vacuum hose to inlet manifold front cover.
18. Connect brake vacuum hose and secure with clip.
19. Connect 2 breather hoses and secure with 2 clips.
20. Clean fuel hose connections.
21. Connect fuel feed hose to fuel rail.
22. Connect 2 cables to terminal post secure with nut and fit terminal cover.
23. Fit air intake plenum. See «80.15.62 PLENUM -- AIR INTAKE»(/land-rover/range-rover/l322-2002-2005/remont/heater/#heating-and-ventilation-removal-installation) .
24. Position injector harness.
25. Fit washer to fuel injector harness securing stud.
26. If fitted: Fit SAI vacuum switching valve to RH fuel injector securing stud.
27. Fit 2 nuts securing fuel injector harness to inlet manifold and tighten.
28. Connect multiplug to charcoal canister purge solenoid valve.
29. Position and secure engine harness to brackets with clips.
30. Connect fuel injector harness multiplugs.
31. Connect alternator harness to 2 clips on engine cover mounting brackets.
32. Fit fuel hose and mounting bracket to LH fuel injector harness securing stud.
33. Fit vacuum reservoir and mounting bracket to LH fuel injector harness securing stud.
34. Fit 2 nuts securing fuel injector harness to inlet manifold and tighten.
35. Connect knock sensor multiplug.
36. Connect multiplug to CMP sensor.
37. Connect alternator harness to 4 clips.
38. Connect alternator multiplug.
39. Connect multiplug to charcoal canister purge solenoid valve.
40. Connect VCC multiplug harness to clip.
41. Connect multiplugs to valve body solenoids.
42. Fit new cable ties, align and secure harness.
43. Connect multiplug to CMP sensor.
44. Connect multiplug to throttle body.
45. Connect multiplugs to ECT sensors.
46. Connect multiplugs to ignition coils.
47. Fit coil cover. See «COVER - IGNITION COILS - RH»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation__cover-ignition-coils-rh) .
48. Fit coil cover. See «COVER - IGNITION COILS - LH»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation__cover-ignition-coils-lh) .
49. Connect air intake hose. See «HOSE - AIR FLOW METER TO THROTTLE BODY»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation) .
50. Connect battery earth lead.

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.

1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Release clips securing LH and RH pre-catalyst HO2S harness leads. (Scheme 34)
4. Release clips securing LH and RH post-catalyst HO2S harness leads. (Scheme 35)
5. Support weight of exhaust with jack.
6. Remove 4 nuts securing front exhaust rubber mountings to body. (Scheme 7)
7. Remove 4 nuts securing front pipe flanges to exhaust manifolds and discard nuts. (Scheme 6)
8. Lower exhaust on jack.
9. Remove 8 nuts securing exhaust manifold, remove exhaust manifold and discard nuts and 2 gaskets. (Scheme 36)

Scheme 34

Scheme 35

Scheme 36

1. Clean exhaust front pipe and manifold mating faces and fit new gaskets.
2. Apply copper grease to exhaust manifold studs, fit exhaust manifold, fit 8 new nuts securing exhaust manifold and tighten to 23 Nm (17 ft. lbs).
3. Raise exhaust with jack, locate exhaust flange to exhaust manifold studs.
4. Fit 4 new nuts securing exhaust front pipes to exhaust manifolds and tighten to 45 Nm (33 ft. lbs).
5. Fit 4 nuts securing front exhaust rubber mountings to body and tighten to 25 Nm (18 ft. lbs).
6. Lower support jack.
7. Secure RH and LH HO2S harnesses to clips on center heat shields and bell housing.
8. Connect battery earth lead.

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.

1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Release clips securing LH and RH pre-catalyst HO2S harness leads. (Scheme 34)
4. Release clips securing LH and RH post-catalyst HO2S harness leads. (Scheme 35)
5. Support weight of exhaust with jack.
6. Remove 4 nuts securing front exhaust rubber mountings to body. (Scheme 7)
7. Remove 4 nuts securing front pipe flanges to exhaust manifolds and discard nuts. (Scheme 6)
8. Lower exhaust on jack.
9. Remove 8 nuts securing exhaust manifold, remove exhaust manifold and discard nuts and 2 gaskets. (Scheme 37)

Scheme 37

1. Clean exhaust front pipe and manifold mating faces and fit new gaskets.
2. Apply copper grease to exhaust manifold studs, fit exhaust manifold, fit 8 new nuts securing exhaust manifold and tighten to 23 Nm (17 ft. lbs).
3. Raise exhaust with jack, locate exhaust flange to exhaust manifold studs.
4. Fit 4 new nuts securing exhaust front pipes to exhaust manifolds and tighten to 45 Nm (33 ft. lbs).
5. Fit 4 nuts securing front exhaust rubber mountings to body and tighten to 25 Nm (18 ft. lbs).
6. Lower support jack.
7. Secure RH and LH HO2S harnesses to clips on center heat shields and bell housing.
8. Connect battery earth lead.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• HOSE - AIR FLOW METER TO THROTTLE BODY
• COVER - IGNITION COILS - LH
• COVER - IGNITION COILS - RH
• 80.15.62 PLENUM -- AIR INTAKE
• FUEL SYSTEM - DEPRESSURIZE
• REMOVAL & INSTALLATION
• EXHAUST SYSTEM & MOUNTINGS