Published: 11-May-2011

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

Engine - TDV8 3.6L Diesel

Right Cylinder Head (G939954)

IN-VEHICLE REPAIR
  • 12.29.05
  • Cylinder head - assembly - right - renew
  • TDV8
  • 17.90
  • 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 RH camshafts. For additional information, refer to: Right Camshaft (303-01D Engine - TDV8 3.6L Diesel, In-vehicle Repair).
  5. Remove the RH exhaust gas recirculation (EGR) valve and cooler assembly. For additional information, refer to: Right Exhaust Gas Recirculation Valve (303-08D Engine Emission Control - TDV8 3.6L Diesel, Removal and Installation).
  6. E87316
    Remove the RH EGR valve inlet tube heat shield.
      • Remove the 2 bolts.
  7. E87317
    Remove the RH EGR valve inlet tube.
      • Remove the 2 bolts.
      • Remove and discard the gasket.
  8. E87111
    Remove the RH turbocharger heat shield.
      • Remove the 3 bolts.
  9. E87112
    Remove the RH exhaust manifold heat shield.
      • Remove the 3 bolts.
  10. E88226
    Loosen the turbocharger support bracket.
      • Loosen the 5 bolts.
  11. E87114
    Release the RH turbocharger.
      • Remove and discard the 3 nuts.
  12. E87318
    Release the turbocharger oil feed pipe.
      • Remove the bolt.
  13. E83362
    Remove the RH cylinder head coolant elbow.
      • Release the 2 clips.
  14. E81444
    Disconnect the engine oil pressure (EOP) sensor electrical connector.
  15. E85541
    Release the coolant hose bracket.
      • Remove the nut.
  16. CAUTIONS:

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

    • 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.

    E77804
    Remove and discard the high-pressure fuel rail supply line.
      • Release the clip.
  17. E83365
    Release the engine lifting eye bracket.
      • Remove the 4 bolts.
  18. E81485
    Remove the RH timing chain tensioner guide pin.
      • Remove and discard the O-ring seal.
  19. 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 the 13 bolts.
      • Remove and discard the gasket.
  20. Remove and discard the turbocharger gasket.
  21. NOTE:

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

    E81489
    Remove the hydraulic adjuster and rocker assemblies.
  22. Remove the exhaust manifold.
      • Remove and discard the 8 nuts.
      • Remove and discard the gasket.
Installation
  1. 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.

    E79272
    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).
  2. 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.
  3. Install a new turbocharger gasket.
      • Clean the components mating faces.
  4. NOTE:

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

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

    E83657
    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).
  7. NOTE:

    Lubricate the O-ring seal with clean engine oil.

    Install the RH timing chain tensioner guide pin.
      • Install a new O-ring seal.
      • Tighten to 28 Nm (21 lb.ft).
  8. Secure the engine lifting eye bracket.
      • Tighten the bolts to 25 Nm (18 lb.ft).
  9. 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 line to keep the olives in contact with the fuel rail and the fuel injection pump cones while installing unions.

    NOTE:

    Remove and discard the blanking caps.

    Install the new high-pressure fuel rail supply line.
      • Stage 1: Tighten the high-pressure fuel supply line union at the fuel injection pump to 15 Nm (11 lb.ft).
      • Stage 2: Tighten the high-pressure fuel supply line union at the fuel rail to 15 Nm (11 lb.ft).
      • Stage 3: Tighten the high-pressure fuel supply line union at the fuel injection pump to 30 Nm (22 lb.ft).
      • Stage 4: Tighten the high-pressure fuel supply line union at the fuel rail to 30 Nm (22 lb.ft).
      • Tighten the clip to 10 Nm (7 lb.ft).
  10. Secure the coolant hose support bracket.
      • Tighten the nut to 9 Nm (7 lb.ft)
  11. Connect the EOP sensor electrical connector.
  12. Install the RH cylinder head coolant elbow.
      • Secure with the 2 clips.
  13. Secure the turbocharger oil feed pipe.
      • Tighten the bolt to 10 Nm (7 lb.ft).
  14. WARNING:

    Make sure that new nuts are installed.

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