Published: 11-May-2011

2007.0 Range Rover Sport (LS), 303-01D

Engine - TDV8 3.6L Diesel

Intake Manifold Plenum Chamber (G938655)

IN-VEHICLE REPAIR
  • 30.15.02
  • Intake Manifold - Renew
  • TDV8
  • 2.10
  • USED WITHINS
Removal
  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. E85160
    Release the coolant lines.
      • Remove the 2 nuts.
  4. Remove the auxiliary battery tray. For additional information, refer to: Auxiliary Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
  5. CAUTION:

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

    E85153
    Remove the oil level indicator and upper oil level indicator tube.
      • Remove the bolt.
      • Remove and discard the 2 O-ring seals.
  6. E76535
    Remove the fuel line shield.
      • Remove the 7 nuts.
  7. E76536
    Disconnect the fuel injector electrical connectors.
      • Release the fuel charging wiring harness.
  8. E77815
    Disconnect the glow plug electrical connectors.
      • Release the wiring harness.
  9. E77816
    Disconnect both exhaust gas recirculation (EGR) valve electrical connectors.
      • Release the wiring harness.
  10. E85161
    Release the engine wiring harness.
      • Remove the nut.
      • Release the 6 clips.
  11. E77818
    Disconnect the knock sensor (KS) electrical connectors.
      • Release the wiring harness.
  12. E77819
    Disconnect the fuel rail pressure (FRP) sensor electrical connector.
      • Release the wiring harness.
  13. E77820
    Disconnect the fuel temperature sensor electrical connector.
  14. E77821
    Disconnect the camshaft position (CMP) sensor electrical connector.
  15. E77822
    Remove the engine cover mounting bracket.
      • Release the vacuum line.
      • Remove the 4 bolts.
  16. NOTE:

    Left-hand shown, right-hand similar.

    E77823
    Release both EGR valve outlet tubes.
      • Remove the 4 bolts.
  17. E77824
    Reposition the intake manifold plenum chamber rear hoses.
      • Release the clips.
  18. E77825
    Disconnect both manifold absolute pressure and temperature (MAPT) sensor electrical connectors.
  19. E77826
    Disconnect the 2 charge air cooler outlet hoses.
      • Release the 2 clips.
  20. E77827
    Release the intake manifold plenum chamber.
      • Release the clips.
      • Fully loosen the 6 bolts.
  21. E77828
    Disconnect the vacuum lines.
  22. E77829
    Disconnect both throttle body electrical connectors.
  23. CAUTION:

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

    E77830
    Remove the intake manifold plenum chamber.
      • Remove and discard the EGR valve outlet tube gaskets.
  24. NOTE:

    Do not disassemble further if the component is removed for access only.

    E77831
    Remove the throttle bodies.
      • Remove the 8 bolts.
      • Remove and discard the 2 O-ring seals.
  25. E77832
    Remove the intake manifold plenum chamber front hoses.
      • Release the clips.
  26. E77833
    Remove the engine cover locating studs.
  27. E77834
    Remove the MAPT sensors.
      • Remove the 2 screws.
  28. E77838
    Remove both EGR valve outlet tubes.
      • Remove the 4 bolts.
      • Remove and discard the 2 O-ring seals.
      • Remove and discard the 2 gaskets.
  29. E77840
    Remove the intake manifold plenum chamber rear hoses.
Installation
  1. Install the intake manifold plenum chamber rear hoses.
  2. NOTE:

    Only fully tighten the EGR valve outlet tube bolts when the intake manifold plenum chamber bolts are fully tightened.

    Install both EGR valve outlet tubes.
      • Clean the components mating faces.
      • Install new O-ring seals.
      • Install new gaskets.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  3. Install both MAPT sensors.
      • Clean the components mating faces.
      • Tighten the screws to 3 Nm (2 lb.ft).
  4. Install the engine cover locating studs.
  5. Install the intake manifold plenum chamber front hoses.
      • Tighten the clips to 3 Nm (2 lb.ft).
  6. Install the throttle bodies.
      • Clean the components mating faces.
      • Install new O-ring seals.
      • Tighten the bolts to 8 Nm (6 lb.ft).
  7. NOTE:

    Remove and discard the blanking caps.

    Install the intake manifold plenum chamber.
      • Clean the components mating faces.
      • Install new gaskets to the EGR valve outlet tubes.
      • Loosely install the EGR valve outlet tube bolts.
      • Loosely install the intake manifold plenum chamber bolts.
  8. Connect both throttle body electrical connectors.
  9. Connect the vacuum lines.
  10. Secure the intake manifold plenum chamber.
      • Tighten the bolts to 10 Nm (7 lb.ft).
      • Tighten the clips to 3 Nm (2 lb.ft).
  11. Connect both charge air cooler outlet hoses.
      • Tighten the clips to 5 Nm (4 lb.ft).
  12. Connect both MAPT sensor electrical connectors.
  13. Reposition the intake manifold plenum chamber rear hoses.
      • Tighten the clips to 3 Nm (2 lb.ft).
  14. Secure both EGR valve outlet tubes.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  15. Install the engine cover mounting bracket.
      • Tighten the bolts to 10 Nm (7 lb.ft).
      • Secure the vacuum line.
  16. Connect the CMP sensor electrical connector.
  17. Connect the fuel temperature sensor electrical connector.
  18. Connect the FRP sensor electrical connector.
      • Secure the wiring harness.
  19. Connect the KS electrical connectors.
      • Secure the wiring harness.
  20. Secure the engine wiring harness.
      • Tighten the nut.
      • Secure the clips.
  21. Connect both EGR valve electrical connectors.
      • Secure the wiring harness.
  22. Connect the glow plug electrical connectors.
      • Secure the wiring harness.
  23. Connect the fuel injector electrical connectors.
      • Attach the fuel charging wiring harness.
  24. Install the fuel line shield.
      • Tighten the nuts to 5 Nm (4 lb.ft).
  25. CAUTION:

    Make sure the upper oil level indicator tube nut is not damaged, replace the nut as required. Failure to follow this instruction may result in damage to the vehicle.

    NOTE:

    Remove and discard the blanking caps.

    Install the oil level indicator and upper oil level indicator tube.
      • Clean the components mating faces.
      • Install new O-ring seals.
      • Tighten the bolt.
  26. Install the auxiliary battery tray. For additional information, refer to: Auxiliary Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
  27. Secure the coolant lines.
      • Tighten the nuts.
  28. Install the engine cover. For additional information, refer to: Engine Cover - TDV8 3.6L Diesel (501-05 Interior Trim and Ornamentation, Removal and Installation).
  29. Connect the battery ground cable. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).