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shabro

Member Since: 20 Sep 2019
Location: East Yorkshire
Posts: 10

2010 Freelander 2 TD4_e GS Manual Stornoway Grey

inlet manifold swap

I'm sure Ive seen an inlet manifold removal guide...... I've searched and not found.
Anyone have a link to where it is please?
I'm replacing my swirl flap manifold for a non swirl flap item.

1st Feb 2021 9:48 pm

IanMetro

Member Since: 11 Sep 2017
Location: Somerset BS21
Posts: 3133

2014 Freelander 2 SD4 Metropolis LE Auto Fuji White

Try this Thread, towards the end there is someone changing to a non-swirl manifold.

https://www.freel2.com/forum/topic19543.html FL2 XS SD4 Auto 2010 2012-2017 (21k - 91k miles) (MY2011)
FL2 Metropolis SD4 Auto 2014 2017- (16k - 77k+ miles) (MY2015)
Metro in its 11th Year of (Extended) LR Warranty / Full LR Service History
(Expensive, but Trouble/Worry free - hopefully?)

1st Feb 2021 11:24 pm

Nodge68

Member Since: 15 Jul 2020
Location: Newquay
Posts: 2082

2009 Freelander 2 TD4 SE Manual Rimini Red

Re: inlet manifold swap

shabro wrote:
I'm sure Ive seen an inlet manifold removal guide...... I've searched and not found.
Anyone have a link to where it is please?
I'm replacing my swirl flap manifold for a non swirl flap item.

Just remove the manifold and pull the control rod out. The flaps then fall out, it literally takes 2 minutes to remove them.
There's no need to replace the whole thing, it's just a waste of money. Hyundai Ioniq 5 Ultimate. The family car.
2009 Rimini Red SE TD4. Gone.
2006 Tonga Green i6 HSE. Gone.
Audi A5 convertible, my daily driver.
1972 Hillman Avenger GT, the project.

3rd Feb 2021 11:40 am

robblue

Member Since: 10 Jan 2017
Location: cornwall
Posts: 262

2012 Freelander 2 SD4 XS Auto Santorini Black

cool I am going to do what nodge68 has suggested to my 09 fl2 as soon as the rain stops here in Cornwall and it warms up a tad 2009 FL2 S now gone
2011 FL2 HSE AUTO
2012 FL2 XS AUTO
2000 Kawasaki er 5

3rd Feb 2021 12:54 pm

shabro

Member Since: 20 Sep 2019
Location: East Yorkshire
Posts: 10

I'd already bought the manifold, Oh well.
Cheers

3rd Feb 2021 9:30 pm

Grue

Member Since: 29 Apr 2018
Location: New Zealand
Posts: 366

2007 Freelander 2 TD4 SE Auto Sumatra Black

Re: inlet manifold swap

Nodge68 wrote:
shabro wrote:
I'm sure Ive seen an inlet manifold removal guide...... I've searched and not found.
Anyone have a link to where it is please?
I'm replacing my swirl flap manifold for a non swirl flap item.

Just remove the manifold and pull the control rod out. The flaps then fall out, it literally takes 2 minutes to remove them.
There's no need to replace the whole thing, it's just a waste of money.

Any photos that show where to seal up the hole once you've done this? Or pretty obvious one you get in there?

3rd Feb 2021 10:52 pm

Nodge68

Member Since: 15 Jul 2020
Location: Newquay
Posts: 2082

robblue wrote:
cool I am going to do what nodge68 has suggested to my 09 fl2 as soon as the rain stops here in Cornwall and it warms up a tad

I did mine while I was replacing the damaged piston. I was surprised just how easy the flaps come out the manifold, it literally takes 2 minutes to do. The vacuum actuator needs unhooking from the motion crank. The spring clip is then pulled off and kept safe for later use. The motion crank is pulled out the manifold, and kept safe for later refitting. The 3mm square brass rod is then visible, and needs pulling put the manifold. It'll be tight, as it'll have carbon sticking it in. The the rod is withdrawn, the flaps will fall out the manifold in turn. Once the rod is out, and all 4 flaps are removed, the motion crank can be refitted, and the clip put back in. There's no need to refit the vacuum actuator rod to the crank, as it'll no do anything now, but it looks OE if it's put back together properly.

That's it, the flaps are out, and the manifold can be refitted, unless you're cleaning too, which I did while it's off. Hyundai Ioniq 5 Ultimate. The family car.
2009 Rimini Red SE TD4. Gone.
2006 Tonga Green i6 HSE. Gone.
Audi A5 convertible, my daily driver.
1972 Hillman Avenger GT, the project.

4th Feb 2021 11:54 am

Nodge68

Member Since: 15 Jul 2020
Location: Newquay
Posts: 2082

Re: inlet manifold swap

Grue wrote:
Nodge68 wrote:
shabro wrote:
I'm sure Ive seen an inlet manifold removal guide...... I've searched and not found.
Anyone have a link to where it is please?
I'm replacing my swirl flap manifold for a non swirl flap item.

Just remove the manifold and pull the control rod out. The flaps then fall out, it literally takes 2 minutes to remove them.
There's no need to replace the whole thing, it's just a waste of money.

Any photos that show where to seal up the hole once you've done this? Or pretty obvious one you get in there?

There's no holes to seal, other than to put the motion crank back in the manifold.
It's an easy job, and definitely not worth replacing the manifold for.

There's the actuator assembly. The crank needs removing, by pulling out the spring clip and removing out the manifold. It's sealed with a simple O ring. It's also refitted once the flaps are out.

Click image to enlarge

These are the flaps and long actuator rod, which is pulled from the manifold. I broke the flaps, to make removing the rod easier.

Click image to enlarge

This the manifold without the flaps.

Click image to enlarge

I cleaned it before it was refitted. Hyundai Ioniq 5 Ultimate. The family car.
2009 Rimini Red SE TD4. Gone.
2006 Tonga Green i6 HSE. Gone.
Audi A5 convertible, my daily driver.
1972 Hillman Avenger GT, the project.

4th Feb 2021 11:55 am

Grue

Member Since: 29 Apr 2018
Location: New Zealand
Posts: 366

Nice. Thanks

4th Feb 2021 6:04 pm

gasman

Member Since: 02 May 2013
Location: Tyneside
Posts: 893

2009 Freelander 2 TD4_e GS Manual Zermatt Silver

Nice post Nodge68 Now at the point when I learn something new something old is lost out the other side !
Now retired so it doesn't matter anymore.
Freelander now gone.

5th Feb 2021 10:42 am

grubby

Member Since: 20 Apr 2019
Location: Northants
Posts: 25

2008 Freelander 2 TD4 HSE Manual Rimini Red

Just done mine today; rod and flaps came out easy enough.
Do you remove the bushing between the ports that the brass rod runs through as well?

Current: FL2 TD4 2008 HSE

Previous: FL1 TD4 2002 // FL2 TD4 2008 // FL1 TD4 2003 // TD5 Disco 2003 // 300TDi Disco 1994

24th Apr 2021 9:15 pm

Nodge68

Member Since: 15 Jul 2020
Location: Newquay
Posts: 2082

Just put the whole square rod out and leave it out. It serves no purpose, once there's no flaps to hold. Hyundai Ioniq 5 Ultimate. The family car.
2009 Rimini Red SE TD4. Gone.
2006 Tonga Green i6 HSE. Gone.
Audi A5 convertible, my daily driver.
1972 Hillman Avenger GT, the project.

25th Apr 2021 5:14 pm

grubby

Member Since: 20 Apr 2019
Location: Northants
Posts: 25

Yeah, the rod is removed, just put it back in as it highlighted the bushing better...

The bit I mean is the plastic bushings that the rod runs through - one cleaned, they become apparent and without the rod, they move about 1-2mm inside the manifold.
You can see the front part of it just in front of the rod in the pic...

Seems to be clipped in, but wondered if anyone else removed these as well as the flaps Current: FL2 TD4 2008 HSE

Previous: FL1 TD4 2002 // FL2 TD4 2008 // FL1 TD4 2003 // TD5 Disco 2003 // 300TDi Disco 1994

3rd May 2021 8:28 am

Nodge68

Member Since: 15 Jul 2020
Location: Newquay
Posts: 2082

I never removed the bushings, I assumed the manifold was simply drilled to take the rod. I suppose its a potential issue if bushings come adrift and enter the cylinder. I suspect they wouldn't do much damage though, unless they get trapped under a valve head, preventing it from closing.
I'll investigate these when I change my cylinder head. Hyundai Ioniq 5 Ultimate. The family car.
2009 Rimini Red SE TD4. Gone.
2006 Tonga Green i6 HSE. Gone.
Audi A5 convertible, my daily driver.
1972 Hillman Avenger GT, the project.

3rd May 2021 4:19 pm

Jaguarman22

Member Since: 30 Sep 2021
Location: Somerset
Posts: 11

2007 Freelander 2 TD4 SE Manual Nazca Sand

This was very helpfull Thanks

14th Oct 2021 4:13 pm

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