Published: 11-May-2011

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

Engine - TDV8 3.6L Diesel

Left Cylinder Head (G939953)

IN-VEHICLE REPAIR
  • 12.29.04
  • Cylinder head - assembly - left/one only - renew
  • TDV8
  • 17.80
  • 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. WARNING:

    Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

    Raise and support the vehicle.
  3. Remove the body. For additional information, refer to: Body - TDV8 3.6L Diesel (502-02 Full Frame and Body Mounting, Removal and Installation).
  4. Remove the LH camshafts. For additional information, refer to: Left Camshaft (303-01D Engine - TDV8 3.6L Diesel, In-vehicle Repair).
  5. Remove the LH exhaust gas recirculation (EGR) valve and cooler assembly. For additional information, refer to: Left Exhaust Gas Recirculation Valve (303-08D Engine Emission Control - TDV8 3.6L Diesel, Removal and Installation).
  6. E87319
    Remove the LH EGR valve inlet tube.
      • Remove the 3 bolts.
      • Remove and discard the gasket.
  7. E87099
    Remove the LH turbocharger heat shield.
      • Remove the 3 bolts.
  8. E87100
    Remove the LH exhaust manifold heat shield.
      • Remove the 3 bolts.
  9. E81717
    Loosen the turbocharger support bracket.
      • Loosen the 4 bolts.
  10. E87103
    Release the LH turbocharger.
      • Remove and discard the 3 nuts.
  11. E83393
    Remove the fuel pump crash protector.
      • Release the engine wiring harness.
      • Remove the 3 bolts.
  12. CAUTION:

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

    E87321
    Disconnect the air conditioning (A/C) compressor low-pressure refrigerant line.
      • Remove the bolt.
      • Remove and discard the O-ring seal.
  13. Release the cooling fan belt from the power steering pump pulley.
      • Release the tension from the belt.
  14. E87320
    Release the power steering pump and mounting bracket.
      • Remove the 3 bolts.
  15. E83368
    Release the vacuum solenoid.
  16. E87870
    Disconnect the fuel pressure regulator electrical connector.
  17. E87869
    Disconnect the fuel metering valve electrical connector.
  18. E81472
    Remove the LH timing chain tensioner guide pin.
      • Remove and discard the O-ring seal.
  19. E81407
    Remove the camshaft position (CMP) sensor.
      • Remove the bolt.
      • Remove and discard the O-ring seal.
  20. CAUTIONS:

    • The cylinder head must not be placed mating face down. Failure to follow this instruction may result in damage to the vehicle.

    • Make sure that no damage occurs to the timing chain and timing chain guides.

    E81490
    With assistance, remove the cylinder head assembly.
      • Remove and discard the 13 bolts.
      • Remove and discard the gasket.
  21. Remove and discard the turbocharger gasket.
  22. NOTE:

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

    Remove the fuel pump.
      • Remove the 3 bolts.
      • Remove and discard the gasket.
  23. Remove the exhaust manifold.
      • Remove and discard the 8 nuts.
      • Remove and discard the gasket.
  24. E81476
    Remove the hydraulic adjuster and rocker assemblies.
Installation
  1. NOTES:

    • Make sure that all the components are clean.

    • Lubricate the hydraulic adjuster and rocker assemblies with clean engine oil.

    Install the hydraulic adjuster and rocker assemblies.
  2. CAUTION:

    To make sure that the exhaust manifold is correctly installed and the exhaust manifold nuts are correctly torqued, it is critical that the tightening torque is checked 2 further times after the initial torque has been applied.

    NOTE:

    Tighten the nuts in the sequence shown.

    E79269
    Install the exhaust manifold.
      • Install the new gasket.
      • Clean the component mating face.
      • Stage 1: Tighten the new nuts to 23 Nm (17 lb.ft).
      • Stage 2: Wait for 2 minutes and tighten the nuts to 23 Nm (17 lb.ft).
      • Stage 3: Wait for 2 minutes and tighten the nuts to 23 Nm (17 lb.ft).
  3. 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.
  4. Install a new turbocharger gasket.
      • Clean the components mating faces.
  5. NOTE:

    The cylinder head gasket must be installed over the cylinder head to cylinder block dowels.

    Install a new LH cylinder head gasket.
      • Clean the component mating face.
  6. Check cylinder head face for distortion, across the center and from corner to corner.
  7. CAUTIONS:

    • Tighten the bolts in the sequence shown.

    • Use care when installing the cylinder head. Damage to the cylinder block, cylinder head or cylinder head gasket may result.

    • Make sure that no damage occurs to the timing chain and timing chain guides.

    NOTE:

    Make sure the cylinder head is installed in its original position.

    E83621
    With assistance, install the cylinder head assembly.
      • Clean the component mating faces.
      • Stage 1: Tighten the M13 bolts to 20 Nm (15 lb.ft).
      • Stage 2: Tighten the M13 bolts to 40 Nm (30 lb.ft).
      • Stage 3: Tighten the M13 bolts to 80 Nm (59 lb.ft).
      • Stage 4: Tighten the M13 bolts a further 180 degrees.
      • Stage 5: Tighten the M8 bolts to 20 Nm (15 lb.ft).
  8. Install the CMP sensor.
      • Install a new O-ring seal.
      • Tighten the bolt to 10 Nm (7 lb.ft).
  9. NOTE:

    Lubricate the O-ring seal with clean engine oil.

    Install the LH timing chain tensioner guide pin.
      • Install a new O-ring seal.
      • Tighten to 28 Nm (21 lb.ft).
  10. Connect the fuel metering valve electrical connector.
  11. Connect the fuel pressure regulator electrical connector.
  12. Secure the vacuum solenoid.
  13. Secure the power steering pump and mounting bracket.
      • Tighten the bolts to 23 Nm (17 lb.ft).
  14. NOTE:

    Make sure that the cooling fan belt is correctly located on each pulley.

    Secure the cooling fan belt around the power steering pump pulley.
  15. NOTE:

    Remove and discard the blanking caps.

    Connect the A/C compressor low-pressure refrigerant line.
      • Install a new O-ring seal.
      • Install the bracket.
      • Tighten the bolt to 23 Nm (17 lb.ft).
  16. Install the fuel pump crash protector.
      • Tighten the bolts to 23 Nm (17 lb.ft).
      • Secure the engine wiring harness.
  17. WARNING:

    Make sure that new nuts are installed.

    Secure the LH turbocharger.
      • Tighten the nuts to 24 Nm (18 lb.ft).
  18. Secure the LH turbocharger support bracket.
      • Stage 1: Tighten the LH turbocharger support bracket bolts at the turbocharger to 24 Nm (18 lb.ft).
      • Stage 2: Tighten the LH turbocharger support bracket bolts at the cylinder block to 24 Nm (18 lb.ft).
  19. Check tightness of the turbocharger nuts.
      • Tighten the nuts to 24 Nm (18 lb.ft).
  20. Install the LH exhaust manifold heat shield.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  21. Install the LH turbocharger heat shield.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  22. Install the LH EGR valve inlet tube.
      • Clean the component mating faces.
      • Install a new gasket.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  23. Install the LH EGR valve and cooler assembly. For additional information, refer to: Left Exhaust Gas Recirculation Valve (303-08D Engine Emission Control - TDV8 3.6L Diesel, Removal and Installation).
  24. Install the LH camshafts. For additional information, refer to: Left Camshaft (303-01D Engine - TDV8 3.6L Diesel, In-vehicle Repair).
  25. Install the body. For additional information, refer to: Body - TDV8 3.6L Diesel (502-02 Full Frame and Body Mounting, Removal and Installation).
  26. Connect the battery ground cable. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).