Engine - Intake Manifold Fluid Leaks

No: 30/01/00/NAS
Ref: 12/01/97/NAS
12/02/97/NAS
Issue: 1
Date: 03/24/00

Inlet Gasket Replacement

AFFECTED VEHICLE RANGE:

Range Rover (LP) Up to WA379043
Discovery (LJ) Up to VA727032
Defender (LD) Up to VA127670

SITUATION:

FLUID LEAKAGE OR AIR LEAK FROM INLET MANIFOLD

NOTE:
This TIB amplifies and modifies the information contained in TIB 12/01/97/NAS and 12/02/97NAS.

Rough running or visible seepage of fluids from around the inlet valley gasket may result from the loss of "clamp" of the gasket.

RESOLUTION:

INSTALL NEW STYLE VALLEY GASKET

NOTE:
Vehicles before the safe VIN may have had updated valley gasket components installed based on TIB12/01/97/NAS and 12/02/97NAS. The end clamp on these vehicles may be reused if the correct ERR7282 clamp (approximately 1 inch wide) has been used.

For vehicles before the safe VINs, installation of a complete set of gaskets and new style bolts will provide effective sealing.

PARTS INFORMATION:

ERR7306 Inlet Gasket Qty 1
ERR7282 End Clamp Qty 2 May be installed on vehicles before the safe
VIN from earlier repairs. Can be reused.
ERR7283 End Seal Qty 2
LYG101440 Short Bolt Qty10
LYG101450 Long Bolt Qty2

WARRANTY CLAIMS:

30.15.08 Range Rover Time 2.95 hrs.
Discovery Time 2.80 hrs.
Defender Time 2.80 hrs
Replace Valley Gasket

FAULT CODE: N

Normal warranty policy and procedures apply

REPAIR PROCEDURE

1. Refer to Workshop Manual Section 30.15 for the vehicle under repair.

2. Remove the inlet manifold and valley gasket.





3. Inspect valley clamp and discard if of old design. (Figure 1)





4. Position the new valley gasket and end seals. (Figure 2)

5. Apply sealer as specified in the WSM.

6. Install the correct end seal clamps (ERR7282) and start the bolts.

7. Tighten the two clamp bolts preliminarily to 1 Nm (9 lbf.in.).





CAUTION:
Two of the bolts used to secure the inlet manifold are longer than the other 10. These bolts must be positioned in locations 10 and 11 as shown in Figure 3.

8. Position the inlet manifold and insert the bolts taking care to place the two long bolts in the correct holes (Figure 3 locations 10 and 11).

9. Refer to Figure 3 and tighten the bolts in the indicated sequence to 30 Nm (22 lbf.ft.).

10. Wait at least five minutes for the gasket to "bed-in".

11. Torque the end clamp bolts completely to 18 Nm (13.3 lbf.ft).

12. Torque the 12 inlet manifold bolts completely in the specified sequence to 51 Nm (37.6 lbf.ft.).

13. Complete the repair following WSM procedures.