Published: 19-Aug-2011

2007.0 Range Rover Sport (LS), 303-04D

Fuel Charging and Controls - TDV8 3.6L Diesel

Left Fuel Injectors (G938570)

REMOVAL AND INSTALLATION
  • 19.60.09
  • Injectors - LH bank set - renew
  • TDV8
  • 2.80
  • USED WITHINS

Special Tool(s)

E54552

303-1127

Remover - Fuel Injector

Removal
WARNINGS:

  • Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

  • The spilling of fuel is unavoidable during this operation. Make sure that all necessary precautions are taken to prevent fire and explosion.

  • Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

  • Wait at least 30 seconds after the engine stops before commencing any repair to the high-pressure fuel injection system. Failure to follow this instruction may result in personal injury.

  • Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the system can be as high as 1700 bar (24,656 lb-sq-in). Failure to follow this instruction may result in personal injury.

CAUTION:

Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

  1. Disconnect the battery ground cable. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).
  2. Remove the engine cover. For additional information, refer to: Engine Cover - TDV8 3.6L Diesel (501-05 Interior Trim and Ornamentation, Removal and Installation).
  3. Remove the battery tray. For additional information, refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
  4. Recover the air conditioning (A/C) refrigerant. For additional information, refer to: Air Conditioning System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures).
  5. E85160
    Release the coolant lines.
      • Remove the 2 nuts.
  6. CAUTION:

    Make sure that all openings are sealed. Use new blanking caps.

    E85170
    Disconnect the high and low-pressure A/C lines.
      • Remove the 2 bolts.
      • Remove and discard the 2 O-ring seals.
  7. CAUTION:

    Make sure that all openings are sealed. Use new blanking caps.

    E51206
    Remove the 2 A/C lines.
      • Remove the bolt.
      • Remove the nut.
      • Release the clamp.
      • Remove and discard the 2 O-ring seals.
  8. E76535
    Remove the fuel line shield.
      • Remove the 7 nuts.
  9. E76536
    Disconnect the fuel injector electrical connectors.
      • Release the fuel charging wiring harness.
  10. Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply lines, the fuel injectors and the fuel rail. For additional information, refer to: Fuel Injection Component Cleaning (303-04D Fuel Charging and Controls - TDV8 3.6L Diesel, General Procedures).
  11. CAUTIONS:

    • Make sure that the high-pressure fuel supply line remains in contact with the fuel injection supply manifold and the fuel injection diverter rail until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

    • Make sure that the fuel injector adaptor union does not move when loosening the high-pressure fuel supply lines. Failure to follow this instruction may result in damage to the fuel injector or the fuel injector adaptor union.

    E124642
    Loosen the high-pressure fuel supply line from the fuel injector and fuel rail.
  12. CAUTION:

    Make sure that all openings are sealed. Use new blanking caps.

    NOTE:

    Right-hand shown, left-hand similar.

    E124642
    Remove and discard the high-pressure fuel supply line.
  13. E76538
    Disconnect the fuel return line from the fuel injector.
      • Remove and discard the fuel return line clip.
  14. E76519
    Remove the 2 fuel injector bolts.
  15. Install the special tool studs.
  16. CAUTION:

    Make sure the fuel injector remover legs are correctly engaged to the fuel injector. Failure to follow this instruction may result in damage to the component.

    Install the special tool remover legs to the studs.
  17. E76522
    Install the special tool locking plate to the remover legs.
  18. Release the fuel injector.
      • Rotate the special tool bolts evenly, in a clockwise direction.
      • Remove the special tool.
  19. CAUTION:

    Make sure that all openings are sealed. Use new blanking caps.

    E79670
    Remove the fuel injector.
      • Remove and discard the fuel injector clamp.
      • Remove and discard the sealing washer.
  20. Remove the remaining fuel injectors.
  21. CAUTION:

    Make sure that the high-pressure fuel supply line remains in contact with the fuel injection supply manifold and the fuel injection pump until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

    Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply line, the fuel injectors and the fuel rail. For additional information, refer to: Fuel Injection Component Cleaning (303-04D Fuel Charging and Controls - TDV8 3.6L Diesel, General Procedures).
Installation
  1. CAUTIONS:

    • Do not disassemble the fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new fuel injectors when required.

    • Do not use tools to install the new fuel return line clip. Failure to follow this instruction will result in damage to the clip.

    Install a new fuel injector clamp.
      • Install a new sealing washer.
      • Install a new fuel return line clip.
  2. CAUTION:

    Only tighten the bolts finger-tight at this stage.

    NOTE:

    Remove and discard the blanking caps.

    Install the fuel injector.
      • Loosely install the bolts.
  3. CAUTION:

    Make sure the fuel return line clip is correctly installed to the fuel injector before installing the fuel return line.

    Connect the fuel return line to the fuel injector.
      • Visually inspect the fuel return line O-ring seal for damage.
      • Lubricate the O-ring seal with a suitable lubricant.
  4. Install the remaining fuel injectors.
  5. CAUTIONS:

    • Maintain pressure on the high-pressure fuel supply line to keep the olives in contact with the fuel injectors and the fuel rail cones while installing unions.

    • Do not allow the unions to hit the olive ends of the high-pressure fuel supply line as this may damage the ends of the high-pressure fuel supply line and allow foreign matter to enter the fuel injection system.

    • Only tighten the unions finger-tight at this stage.

    NOTE:

    Remove and discard the blanking caps.

    Loosely install the new high-pressure fuel supply lines.
  6. Secure the fuel injectors.
      • Evenly and progressively tighten the bolts to 10 Nm (7 lb.ft).
  7. CAUTIONS:

    • Do not allow the unions to hit the olive ends of the high-pressure fuel supply line as this may damage the ends of the line and allow foreign matter to enter the fuel injection system.

    • Caution | Fuel | Maintain pressure on the high-pressure fuel supply lines to keep the olives in contact with the fuel rail and the fuel injector cones while installing unions.

    • Do not use any aggressive cleaning fluid or a wire brush to clean the fuel injector nozzle.

    NOTE:

    Remove and discard the blanking caps.

    E124890
    Install the new high-pressure fuel supply lines.
      • Install the new high-pressure fuel supply line, tighten the fuel supply line unions finger tight.
      • Tighten the high-pressure fuel supply line in the shown sequence.
      • Tighten the high-pressure fuel supply line union 1 to fuel injector to 15 Nm.
      • Tighten the high-pressure fuel supply line union 2 to fuel rail to 15 Nm.
      • Tighten the high-pressure fuel supply line union 1 to fuel injector to 35 Nm.
      • Tighten the high-pressure fuel supply line union 2 to fuel rail to 35 Nm.
  8. Connect the fuel injector electrical connectors.
      • Secure the fuel charging wiring harness.
  9. Install the fuel line shield.
      • Tighten the nuts to 10 Nm (7 lb.ft).
  10. Secure the coolant lines.
      • Tighten the bolt.
      • Tighten the nuts.
  11. NOTE:

    Remove and discard the blanking caps.

    Install the A/C lines.
      • Install new O-ring seals.
      • Tighten the bolt.
      • Attach the clamp.
      • Tighten the nut.
  12. NOTE:

    Remove and discard the blanking caps.

    Connect the high and low-pressure A/C lines.
      • Install new O-ring seals.
      • Tighten the bolts.
  13. Recharge the A/C system. For additional information, refer to: Air Conditioning System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures).
  14. Install the battery tray. For additional information, refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
  15. Install the engine cover. For additional information, refer to: Engine Cover - TDV8 3.6L Diesel (501-05 Interior Trim and Ornamentation, Removal and Installation).
  16. Connect the battery ground cable. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).