My inlet manifold is split where it joins the plenum chamber hoses and I’m going to replace the inlet manifold. Other than ordering the manifold and gasket is there anything else that needs replacing to complete the job? Any top tips also welcome.

Several of manifolds have been reported as splitting near the short plenum hose, but I can’t remember actually reading a detailed report (with pictures) of the job to replace one, so hope you are willing to take lots of pictures so we can all learn .
Good luck,
Cheers
Mike.

One point, have you got the very common EGR temp fault code PO40D-00 (2F) showing??
Just thought changing the failed sensor would be much easier whilst you have the inlet manifold etc removed.
Mike G reg 2.5VM Vogue Portofino red 1991- 1999
V reg 2.5td P38 Rioja red 1999- 2006
53 reg td6 Vogue Oslo blue 2006- 2015
11 reg 4.4 TdV8 Vogue SE. Baltic blue 2015- date.
https://www.fullfatrr.com/forum/topic56162...tty+affair

No fault codes at all in the IID tool. Just a pop sound as it went into Restricted Performance mode as I pulled away from a roundabout and now I see the split in the intake just like others have had. I’ve scanned it for fault codes multiple times but it doesn’t come up with any other than the usual standard ones.

No fault codes at all in the IID tool. Just a pop sound as it went into Restricted Performance mode as I pulled away from a roundabout and now I see the split in the intake just like others have had. I’ve scanned it for fault codes multiple times but it doesn’t come up with any other than the usual standard ones.

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Can't see where the split is. Is it along the seam separating the upper and lower part or a circular split ? If it was mine I'd be attempting to repair it in situ with a sleeve and or some strapping and epoxy glue as AFAIK removing the whole intake is a pig of a job 2012 TDV8 Vogue (L322)

This shows it better. It’s begun to split further round.

Click image to enlarge

Anything you do to 'fix' that will only be of a temporary nature, replace it now before it goes from inconvenience to full-blown journey-stopper.
You'll need the copper injector seals - Bosch F 00V C17 503 - if you search you can find them a lot cheaper that >£22 for eight! I'd also recommend replacing the leak-off 'O'ring seals LR022994 but don't buy them from LR!
The manifold should come with the gasket pre-fitted, just make sure everything is fully clean and give it a swipe of red rubber grease before fitting. It's not too different a job to the 3.6TDV8 so you can probably read-up on that to see what to expect.

Phoenix thanks for the reply and the useful info re the washers and the model numbers for them. Reading the LR workshop manual it states I need an alignment tool for the injector ports in the manifold to hold it in place whilst it’s torqued up by the look of it. My previous experience of such special tools is that I’ve not needed them. Did you use an alignment tool? I’ll be replacing the whole manifold as a repair would only be temporary, as you say.

is the foam cover bonded to the manifold somewhere? It feels that it may be attached at the bottom

Downhillerffrr wrote:

I’ll be replacing the whole manifold as a repair would only be temporary, as you say.

The 'special tool' is just a close-fitting round bar that goes in an injector port, every time I've done them I've just used two (clean!) injectors in alternate ports - never had a problem.

WRT repairing, there is a mechanical load, it's the load (pressure) that caused the split in the first place, coupled with the resultant contamination of the joint surfaces and the potential weakening of the welded joints around the one that has split. It's a plastic part that has had oily, hot air & exhaust gases pushed through it, has been heated and cooled repetitively for >10 years, what could possibly be a worse candidate for a temporary bodge?

Doesn't have to be a 'bodge' or temporary - depends on what you do and are capable of. 2012 TDV8 Vogue (L322)

Downhillerffrr wrote:

is the foam cover bonded to the manifold somewhere? It feels that it may be attached at the bottom

Thanks Phoenix

Had one done a few years ago. Parts numbers here.

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Click image to enlarge