Published: 19-Aug-2011

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

Fuel Charging and Controls - TDV8 3.6L Diesel

Fuel Pump (G938572)

REMOVAL AND INSTALLATION
Removal
WARNINGS:

  • The spilling of fuel is unavoidable during this operation. Ensure 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.

  • 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.

  • If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek immediate medical attention.

  • Wash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention.

  • 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 1650 bar (23,931 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. Raise and support the vehicle.
  3. Remove the intake manifold. For additional information, refer to: Intake Manifold Plenum Chamber (303-01D Engine - TDV8 3.6L Diesel, In-vehicle Repair).
  4. Remove the cooling fan assembly. For additional information, refer to: Cooling Fan (303-03E Engine Cooling - TDV8 3.6L Diesel, Removal and Installation).
  5. E77879
    Remove the fuel pump shield.
      • Release the vacuum solenoid.
      • Remove the 3 bolts.
  6. Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply lines, the fuel rails and the fuel injection pump. For additional information, refer to: Fuel Injection Component Cleaning (303-04D Fuel Charging and Controls - TDV8 3.6L Diesel, General Procedures).
  7. E77880
    Disconnect the fuel metering valve electrical connector.
  8. E77881
    Disconnect the fuel injection control pressure sensor electrical connector.
  9. CAUTION:

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

    E77882
    Disconnect the low-pressure fuel lines.
  10. CAUTION:

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

    E77883
    Remove and discard the high-pressure fuel supply lines.
      • Release the vacuum hose.
      • Remove the 2 nuts.
  11. CAUTION:

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

    E77884
    Remove the fuel pump.
      • Remove the 3 bolts.
      • Remove and discard the gasket.
Installation
  1. Install the fuel pump.
      • Clean the component mating faces.
      • Install a new gasket.
      • Apply loctite 572 to the fuel pump bolt threads.
      • Loosely install the bolts.
  2. Loosely install the new high-pressure fuel supply lines.
  3. Secure the fuel pump.
      • Tighten the bolts to 23 Nm (17 lb.ft).
  4. NOTE:

    Remove and discard the blanking caps.

    Secure the high-pressure fuel supply lines.
      • Stage 1: Tighten the high-pressure fuel supply line unions at the fuel rails to 15 Nm (11 lb.ft).
      • Stage 2: Tighten the high-pressure fuel supply line unions at the fuel pump to 15 Nm (11 lb.ft).
      • Stage 3: Tighten the high-pressure fuel supply line unions at the fuel rail to 35 Nm (26 lb.ft).
      • Stage 4: Tighten the high-pressure fuel supply line unions at the fuel pump to 35 Nm (26 lb.ft).
      • Secure the vacuum hose.
  5. Secure the high-pressure fuel supply line clips.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  6. NOTE:

    Remove and discard the blanking caps.

    Connect the low-pressure fuel lines.
  7. Connect the fuel injection control pressure sensor electrical connector.
  8. Connect the fuel metering valve electrical connector.
  9. Install the fuel pump shield.
      • Tighten the bolts to 10 Nm (7 lb.ft).
      • Secure the vacuum solenoid.
  10. Install the intake manifold. For additional information, refer to: Intake Manifold Plenum Chamber (303-01D Engine - TDV8 3.6L Diesel, In-vehicle Repair).
  11. Install the cooling fan assembly. For additional information, refer to: Cooling Fan (303-03E Engine Cooling - TDV8 3.6L Diesel, Removal and Installation).
  12. Carry out the low-pressure fuel system bleeding. For additional information, refer to: Low-Pressure Fuel System Bleeding - TDV8 3.6L Diesel (310-00 Fuel System - General Information, General Procedures).
  13. Connect the battery ground cable. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).