Member Since: 23 Dec 2013
Location: under the car
Posts: 402
Manifold cracked LH side – Restricted Performance P006A –00
It hit me on the way to Italy, just got past Garmisch going uphill. Boing….
It is the LH side valve cover around middle injector. All misty black.
New part is LR 166213 from island 4x4.
What other bits and pieces are suggested to have handy?
Thx for your suggestionsAchim
own garage certified LR tech
Disco 2 TD5 MY 2001 - gone but still driven by another owner
Defender 110 TD5 driving me bananas with all faults
Disco 3 TDV 6 HSE MY 2005 gone @280.000 km
Disco 4 SDV 6 HSE MY 2012
17th Oct 2021 6:42 pm
PROFSR G
Member Since: 06 Mar 2017
Location: Lost
Posts: 4626
A new set of injector copper washers and injector seals for the manifold side you're replacing (kit!DA7014 ) as well as the manifold gasket itself.
If you're careful with the high pressure lines you can reuse them. yµ (idµ - eAµ) ψ=mψ
18th Oct 2021 1:52 am
disco4ever
Member Since: 23 Dec 2013
Location: under the car
Posts: 402
OK, I started tackling the repair. I'll post the work progress as I am moving forward with the repair. Perhaps it will help someone to decide "Make or buy".
Took a 10 mm ratchet spanner to unscrew the EGR coolant pipe from the rear bracket linking both cylinder heads. Disconnected the hose from the connecting hoses left and right.
A ratchet with extension and 8 mm socket I unscrewed the pipe for the gas re-circulation between exhaust EGR and throttle housing. The 2 screws on the housing so are T30. The hose was full of black gunk towards the throttle housing. Which I will clean of course.Achim
own garage certified LR tech
Disco 2 TD5 MY 2001 - gone but still driven by another owner
Defender 110 TD5 driving me bananas with all faults
Disco 3 TDV 6 HSE MY 2005 gone @280.000 km
Disco 4 SDV 6 HSE MY 2012
20th Oct 2021 11:34 am
disco4ever
Member Since: 23 Dec 2013
Location: under the car
Posts: 402
after a break I continued to disconnect the harness of the injectors, pulled the white cap to unplug the pipes, and pulled out the injectors. Have clogged the injector holes to prevent anything falling into the engine.
Got the bottom insulation mat off.
Big question now. Do I need to get the fuel rail off? the 30 cm pipe where the fuel pipes connect to?
Thanks for your advice.Achim
own garage certified LR tech
Disco 2 TD5 MY 2001 - gone but still driven by another owner
Defender 110 TD5 driving me bananas with all faults
Disco 3 TDV 6 HSE MY 2005 gone @280.000 km
Disco 4 SDV 6 HSE MY 2012
20th Oct 2021 2:14 pm
PROFSR G
Member Since: 06 Mar 2017
Location: Lost
Posts: 4626
Yes you can remove it as it will only be in your way. Take care to keep all the HP lines, fuel rail and injector ports spotlessly clean!yµ (idµ - eAµ) ψ=mψ
20th Oct 2021 3:09 pm
disco4ever
Member Since: 23 Dec 2013
Location: under the car
Posts: 402
I have taken a few bits and pieces off to have better access. The left manifold housing seems to be less accessible. especially the front bolt of the housing covered by the drive belt housing.
Does the drive belt need to come off so I can gain access to this bolt? If so I need to take the center pull off as well?Achim
own garage certified LR tech
Disco 2 TD5 MY 2001 - gone but still driven by another owner
Defender 110 TD5 driving me bananas with all faults
Disco 3 TDV 6 HSE MY 2005 gone @280.000 km
Disco 4 SDV 6 HSE MY 2012
21st Oct 2021 4:34 pm
PROFSR G
Member Since: 06 Mar 2017
Location: Lost
Posts: 4626
No the belt stays on but the cover needs to come off, or as good as. Remove the throttle body first.
It would be worth considering doing the belts if they have not been done previously, or if approaching replacement time.
And if you decide to do them you might as well throw in the R/H manifold now as well!
If you intend keeping the car you don't want to be doing this again!yµ (idµ - eAµ) ψ=mψ
21st Oct 2021 5:48 pm
disco4ever
Member Since: 23 Dec 2013
Location: under the car
Posts: 402
thanks for your guidance.
have loosened the bolts of the timing belt housing.
however the movement of the housing is limited to the travel on the pulley.
Belts been done by the stealer from the previous owner. throttle housing is off as well and soaked in gasoline. both manifold inlet housing will come tomorrow from island4x4.
I'll keep trying to get is done....but it is tricky jobAchim
own garage certified LR tech
Disco 2 TD5 MY 2001 - gone but still driven by another owner
Defender 110 TD5 driving me bananas with all faults
Disco 3 TDV 6 HSE MY 2005 gone @280.000 km
Disco 4 SDV 6 HSE MY 2012
21st Oct 2021 5:54 pm
PROFSR G
Member Since: 06 Mar 2017
Location: Lost
Posts: 4626
Yeah it's fiddly, you have to strip off most of the front but you'll get there, wise decision to do both manifolds.
If the belts are recent then it's not necessary to do them again. Use paraffin/heating oil for soaking if you can rather than petrol.yµ (idµ - eAµ) ψ=mψ
21st Oct 2021 6:25 pm
SeanZwissler
Member Since: 16 Sep 2018
Location: Ludwigsburg
Posts: 21
If you do the other side remove as much as you can, i mean the whole airfilter and batterytray assembly you have to remove the fuel rail, and therefore you have to remove the egr. The biggest problem for me was the backside left cover screw.
good luck, i did it twice
PM for German
Sean
21st Oct 2021 8:33 pm
disco4ever
Member Since: 23 Dec 2013
Location: under the car
Posts: 402
great advice, did you do the left side as well.Achim
own garage certified LR tech
Disco 2 TD5 MY 2001 - gone but still driven by another owner
Defender 110 TD5 driving me bananas with all faults
Disco 3 TDV 6 HSE MY 2005 gone @280.000 km
Disco 4 SDV 6 HSE MY 2012
21st Oct 2021 9:06 pm
SeanZwissler
Member Since: 16 Sep 2018
Location: Ludwigsburg
Posts: 21
No I did only the left side, that´s enough so far.[/img]
22nd Oct 2021 10:44 am
disco4ever
Member Since: 23 Dec 2013
Location: under the car
Posts: 402
so you did the left side seeing it from the front of the engine....
I did the left side seeing it from behind the steering wheel
What a painful job....in order to pull the manifold housing I had to release the tension of the aux belt, unscrew the idler pulley and pull forward the timing belt housing. Brute force helped to remove the inlet manifold housing.
It took me some tile to figure that the rear brackets of the supply lines need to come of in order to access the 2 rearmost housing bolts. On top of this, these 10 mm bolt resp. nuts require deep sockets 1/4'' to unscrew.
Now I know why the "left" side is more time consuming than the other. Fu. ng job to fix a bl. .dy car.Achim
own garage certified LR tech
Disco 2 TD5 MY 2001 - gone but still driven by another owner
Defender 110 TD5 driving me bananas with all faults
Disco 3 TDV 6 HSE MY 2005 gone @280.000 km
Disco 4 SDV 6 HSE MY 2012
22nd Oct 2021 1:35 pm
Moo D3 Decade
Member Since: 13 Aug 2010
Location: Wiltshire
Posts: 13871
Good effort . I took the asy way out and had both mine done by my Indi.New Defender L663 110 SE (known as Noddy!)
Sold Volvo XC90 R-Design (known as Basil)
Sold - D4 HSE (Known as Gerty)
No longer the Old Buses original owner
231,000 miles and counting
05 S manual owned from March 2005
D4 Face lifted
Still original injectors and turbo
V8 Front brakes
BAS Remap, Allisport Intercooler and deCat
EGRs blanked
T-Max split charge
Hanibal Expeedition rack
Prospeed ladder
Duratrac tyres
IID BT
BAS FBH control
22nd Oct 2021 2:11 pm
disco4ever
Member Since: 23 Dec 2013
Location: under the car
Posts: 402
The Saga continues….
LR calls it the „oil separator pipe“. Linking the left bank with the middle of the engine and the right bank. When I took the 90 degrees ruber pipe off from the inlet manifold housing the pipe fell apart in bits and pieces. Hard PVC exposed to heat…….
LR wants some 50€ for thereplacement, Part no. LR013531. WTF
I ordered 4 POM pipe connectors along with a silicon hose – all in 4 mm size – resisting up to 200 degrees for 8€. It will do the Job.
Achim
own garage certified LR tech
Disco 2 TD5 MY 2001 - gone but still driven by another owner
Defender 110 TD5 driving me bananas with all faults
Disco 3 TDV 6 HSE MY 2005 gone @280.000 km
Disco 4 SDV 6 HSE MY 2012
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ng job to fix a bl. 
