Exhaust System (4.4l) Land Rover Range Rover L322

SPECIFICATIONS

RECOMMENDED LUBRICANT

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

* New nuts must be installed

** Apply suitable high temperature resistant anti-seize compound

Scheme 19

Note. X = Service repair cut point

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Note. X = Service repair cut point

The 4.4L V8 stainless steel exhaust system is supplied from the factory as a one-piece assembly and is connected to the engine with two exhaust manifolds. It is attached to the underside of the body with six rubber mountings.

The system consists of a two downpipes with flanges which attach to the exhaust manifolds. The downpipes are welded into the catalytic converters. Two intermediate pipes are welded to the opposite end of the catalytic converters and connect into welded joints with the two front cylindrical silencers. Two connecting pipes are welded between each front silencer and the rear silencer assembly. Internally the rear silencer assembly is divided into two independent silencers each with its own tailpipe. The tailpipes on the naturally aspirated derivative are curved downwards and not visible from the rear of the vehicle.

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

After the replacement sections are positioned, the system integrity is restored by sealing the service joints with one piece repair sleeves.

NAS Vehicles - From 2007MY stub pipes are used to connect the exhaust system to the new exhaust manifolds. The stub pipes contain a threaded boss which provides for the fitment of the pre-catalyst heated oxygen sensor (HO2S). The threaded boss for the post-catalyst heated oxygen sensor (HO2S) is relocated to a position mid-way between the starter catalyst and the main catalyst.

EXHAUST MANIFOLDS

ROW Vehicles - The fabricated stainless steel twin skin exhaust manifolds are unique for each cylinder bank. The bank B manifold has a connection for the exhaust gas recirculation (EGR) pipe. Spacers on the securing bolts allow the manifolds to expand and retract with changes of temperature while maintaining the clamping loads. Heat shields are integrated into the exhaust manifold gaskets.

NAS Vehicles - From 2007MY new manifolds are fitted to comply with NAS LEVII emission regulations. The use of these manifolds require the use of stub pipes to connect between the manifolds and the exhaust system down pipes. The fabricated stainless steel twin skin exhaust manifolds are unique for each cylinder bank. Spacers on the securing bolts allow the manifolds to expand and retract with changes of temperature while maintaining the clamping loads. Heat shields are integrated into the exhaust manifold gaskets. The bank B manifold has a connection for the exhaust gas recirculation (EGR) pipe.

CATALYTIC CONVERTERS

The engine management system provides accurately metered quantities of fuel to the combustion chambers to ensure the most efficient use of fuel and to minimize the exhaust emissions. Two threaded bosses are located each side of the catalytic converters to house the pre and post catalyst oxygen sensors. The engine management system monitors the sensors and uses the information to further improve the fuelling and exhaust emissions.

To further reduce the carbon monoxide and hydrocarbons content of the exhaust gases, two catalytic converters are integrated into the front down pipe from each exhaust manifold. In the catalytic converter the exhaust gases are passed through honeycombed ceramic elements coated with a special surface treatment called 'washcoat'. The washcoat increases the surface area of the ceramic elements by a factor of approximately 7000. On top of the washcoat is a coating containing metals, which are the active constituent for converting harmful emissions into inert by-products. The metals add oxygen to the carbon monoxide and the hydrocarbons in the exhaust gases, to convert them into carbon dioxide and water respectively.

Two catalytic converters are used in each cylinder bank down pipe. A starter and main catalyst are located below the downpipe flange and are monitored by two heated oxygen sensor (HO2S). Refer to Electronic Engine Controls .

CATALYTIC CONVERTER LH

SPECIAL TOOLS Tool Illustration Tool Name Tool Number Wrench, HO2S (LRT-19-014) 310-121 Pipe cutter-exhaust (LRT-99-027) 100-051

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1. Raise and support the vehicle.
2. Disconnect the LH catalytic converter from the exhaust manifold. Remove and discard the 2 nuts.
3. Disconnect the RH catalytic converter from the exhaust manifold. Remove and discard the 2 nuts.
4. Disconnect the 2 front exhaust hangers.
5. Disconnect the LH heated oxygen sensor (HO2S) electrical connector.
6. Disconnect the LH catalyst monitor sensor electrical connector. Release the wiring harness.
7. Remove the LH catalytic converter. Using the special tool, cut the exhaust pipe at the point indicated by a depression in the pipe.
8. Using the special tool, remove the HO2S.
9. Using the special tool, remove the catalyst monitor sensor.

INSTALLATION

1. Using the special tool, install the catalyst monitor sensor. Clean the components. Apply an anti-seize compound to the thread of the sensor. Tighten the catalyst monitor sensor to 45 Nm (33 lb.ft).
2. Using the special tool, install the HO2S. Clean the components. Apply an anti-seize compound to the thread of the sensor. Tighten the HO2S to 45 Nm (33 lb.ft).
3. Install the LH catalytic converter. Clean the components. Install the retaining clamp.
4. Attach the exhaust hangers.
5. Position the RH catalytic converter to the exhaust manifold. Clean the components. Tighten the new nuts to 20 Nm (15 lb.ft).
6. Position the LH catalytic converter to the exhaust manifold. Clean the components. Tighten the new nuts to 20 Nm (15 lb.ft).
7. Align the LH catalytic converter and tighten the retaining clamp to 55 Nm (40 lb.ft).
8. If required, carry out a long drive cycle. For additional information, refer to: «Powertrain Control Module (Pcm) Long Drive Cycle Self-Test»(/land-rover/range-rover/l322-2005-2009/remont/engine-control-systems/#electronic-engine-controls-42l__powertrain-control-module-pcm-long-drive)

CATALYTIC CONVERTER RH

SPECIAL TOOLS Tool Illustration Tool Name Tool Number Wrench, HO2S (LRT-19-014) 310-121 Pipe cutter-exhaust (LRT-99-027) 100-051

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1. Raise and support the vehicle.
2. Disconnect the LH catalytic converter from the exhaust manifold. Remove and discard the 2 nuts.
3. Disconnect the RH catalytic converter from the exhaust manifold. Remove and discard the 2 nuts.
4. Disconnect the 2 front exhaust hangers.
5. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
6. Disconnect the RH catalyst monitor sensor electrical connector. Release the wiring harness.
7. Remove the RH catalytic converter. Using the special tool, cut the exhaust pipe at the point indicated by a depression in the pipe.
8. Using the special tool, remove the HO2S.
9. Using the special tool, remove the catalyst monitor sensor.

1. Using the special tool, install the catalyst monitor sensor. Clean the components. Apply an anti-seize compound to the thread of the sensor. Tighten the catalyst monitor sensor to 45 Nm (33 lb.ft).
2. Using the special tool, install the HO2S. Clean the components. Apply an anti-seize compound to the thread of the sensor. Tighten the HO2S to 45 Nm (33 lb.ft).
3. Install the RH catalytic converter. Clean the components. Install the retaining clamp.
4. Attach the exhaust hangers.
5. Position the RH catalytic converter to the exhaust manifold. Clean the components. Tighten the new nuts to 20 Nm (15 lb.ft).
6. Position the LH catalytic converter to the exhaust manifold. Clean the components. Tighten the new nuts to 20 Nm (15 lb.ft).
7. Align the RH catalytic converter and tighten the retaining clamp to 55 Nm (40 lb.ft).
8. If required, carry out a long drive cycle. For additional information, refer to: «Powertrain Control Module (Pcm) Long Drive Cycle Self-Test»(/land-rover/range-rover/l322-2005-2009/remont/engine-control-systems/#electronic-engine-controls-42l__powertrain-control-module-pcm-long-drive)

SPECIAL TOOLS Tool Illustration Tool Name Tool Number Wrench, HO2S (LRT-19-014) 310-121

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1. Disconnect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2005-2009/remont/charging-system/#charging-system-general-information__specifications) .
2. Raise and support the vehicle.
3. Disconnect the LH catalytic converter from the exhaust manifold. Remove and discard the 2 nuts.
4. Disconnect the RH catalytic converter from the exhaust manifold. Remove and discard the 2 nuts.
5. Disconnect the LH heated oxygen sensor (HO2S) electrical connector. Repeat the above procedure for the RH side.
6. Disconnect the LH catalyst monitor sensor electrical connector. Release the wiring harness. Repeat the above procedure for the RH side.
7. Disconnect the 2 front exhaust hangers.
8. With assistance, remove the exhaust system. Remove the 2 nuts.
9. Remove both rear exhaust hanger assemblies.
10. Using the special tool, remove the HO2S. Repeat the above procedure for the remaining sensor.
11. Using the special tool, remove the catalyst monitor sensor. Repeat the above procedure for the remaining sensor.

1. Using the special tool, install the catalyst monitor sensor. Clean the components. Apply an anti-seize compound to the thread of the sensor. Tighten the catalyst monitor sensor to 45 Nm (33 lb.ft). Repeat the above procedure for the remaining sensor.
2. Using the special tool, install the HO2S. Clean the components. Apply an anti-seize compound to the thread of the sensor. Tighten the HO2S to 45 Nm (33 lb.ft). Repeat the above procedure for the remaining sensor.
3. Install the rear exhaust hanger assemblies.
4. With assistance, install the exhaust system. Attach the exhaust hangers. Tighten the nuts to 45 Nm (33 lb.ft).
5. Connect the catalyst monitor sensors. Secure the wiring harness.
6. Connect the HO2S electrical connectors.
7. Position the RH catalytic converter to the exhaust manifold. Clean the components. Tighten the new nuts to 20 Nm (15 lb.ft).
8. Position the LH catalytic converter to the exhaust manifold. Clean the components. Tighten the new nuts to 20 Nm (15 lb.ft).
9. Connect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2005-2009/remont/charging-system/#charging-system-general-information__specifications) .

TAILPIPE

SPECIAL TOOLS Tool Illustration Tool Name Tool Number Pipe cutter-exhaust (LRT-99-027) 100-051

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1. Raise and support the vehicle.
2. Release the tail pipe. Using 100-051, cut the tail pipe at the point indicated by a depression in the pipe. Repeat the above procedure for the remaining pipe.
3. With assistance, remove the tail pipe. Remove the 2 nuts.
4. Remove both rear exhaust hanger assemblies.

1. Install the rear exhaust hanger assemblies.
2. With assistance, install the tail pipe. Clean the components. Install the retaining clamps.
3. Align the tail pipe and tighten the retaining clamps to 55 Nm (40 lb.ft).

See also:
• Electronic Engine Controls
• Powertrain Control Module (Pcm) Long Drive Cycle Self-Test
• Specifications