Published: 11-May-2011

2007.0 Range Rover Sport (LS), 303-08D

Engine Emission Control - TDV8 3.6L Diesel

Exhaust Gas Recirculation Cooler (G938902)

REMOVAL AND INSTALLATION
  • 17.45.38
  • Cooler - EGR - LH - renew
  • TDV8
  • 2.00
  • 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 intake manifold plenum chamber. For additional information, refer to: Intake Manifold Plenum Chamber (303-01D Engine - TDV8 3.6L Diesel, In-vehicle Repair).
  3. CAUTION:

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

    E77328
    Disconnect the exhaust gas recirculation (EGR) cooler coolant hoses.
      • Clamp the hoses to minimize coolant loss.
      • Release the 2 clips.
  4. E77329
    Release the EGR valve inlet tube.
      • Remove the 2 bolts.
  5. E77330
    Remove the fuel rail support bracket.
      • Remove the 2 bolts.
  6. CAUTION:

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

    E77331
    Remove the EGR valve and cooler assembly.
      • Remove the 4 bolts.
      • Remove and discard the gasket.
  7. NOTE:

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

    E86072
    Remove the EGR cooler.
      • Remove the 2 bolts.
      • Remove and discard the gasket.
Installation
  1. CAUTION:

    Make sure that the mating faces are clean and free of foreign material.

    Install the EGR cooler.
      • Install a new gasket.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  2. CAUTION:

    Make sure that the mating faces are clean and free of foreign material.

    NOTE:

    Remove and discard the blanking caps.

    Install the EGR valve and cooler assembly.
      • Install a new gasket.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  3. Install the fuel rail support bracket.
      • Tighten the bolts to 23 Nm (17 lb.ft).
  4. Secure the EGR valve inlet tube.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  5. NOTE:

    Remove and discard the blanking caps.

    Connect the EGR cooler coolant hoses.
      • Secure with the clips.
      • Remove the hose clamps.
  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).
  8. Check and top-up the coolant if required.