Published: 19-Aug-2011

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

Fuel Charging and Controls - TDV8 3.6L Diesel

Left Fuel Rail (G938573)

REMOVAL AND INSTALLATION
  • 19.60.03
  • Fuel rail - LH bank - renew
  • TDV8
  • 2.50
  • USED WITHINS
Removal
WARNINGS:

  • 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.

  • 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.

  • If taken internally, do not induce vomiting, seek immediate medical attention. 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.

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

CAUTIONS:

  • Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

  • 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.

  • Do not disconnect the fuel injector electrical connectors with the engine running. Failure to follow this instruction may result in serious damage to the engine.

  • Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.

  1. Disconnect the battery ground cable. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).
  2. Remove the intake manifold plenum chamber. For additional information, refer to: Intake Manifold Plenum Chamber (303-01D Engine - TDV8 3.6L Diesel, In-vehicle Repair).
  3. E76535
    Remove the LH fuel line shield.
      • Release the fuel lines.
      • Remove the 7 nuts.
  4. CAUTIONS:

    • Make sure that the high-pressure fuel supply line remains in contact with the fuel pump and 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.

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

    Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel rail supply lines, the fuel injectors, the fuel rail and the fuel pump. For additional information, refer to: Fuel Injection Component Cleaning (303-04D Fuel Charging and Controls - TDV8 3.6L Diesel, General Procedures).
  5. 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.
  6. 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 rail supply line.
  7. E76516
    Disconnect the fuel injector electrical connectors.
      • Release the fuel charging wiring harness.
  8. CAUTION:

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

    E76517
    Remove and discard the high-pressure fuel supply lines.
  9. E77122
    Release the glow plug wiring harness.
  10. E77124
    Remove the fuel rail.
      • Remove the 2 bolts.
      • Remove the bracket.
Installation
  1. CAUTION:

    Only tighten the bolts finger-tight at this stage.

    Install the fuel rail.
      • Install the bracket.
      • Loosely install the bolts.
  2. 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.

    • 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.

    NOTE:

    Remove and discard the blanking caps.

    E124890
    Install the new high-pressure fuel injector 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.
  3. Secure the glow plug wiring harness.
  4. Connect the fuel injector electrical connectors.
      • Attach the fuel charging wiring harness.
  5. Install the LH fuel line shield.
      • Tighten the nuts to 10 Nm (7 lb.ft).
      • Secure the fuel lines.
  6. Install the intake manifold plenum chamber. For additional information, refer to: Intake Manifold Plenum Chamber (303-01D Engine - TDV8 3.6L Diesel, In-vehicle Repair).
  7. Connect the battery ground cable. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).