Published: 11-May-2011

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

Engine - TDV8 3.6L Diesel

Right Exhaust Manifold (G939958)

IN-VEHICLE REPAIR
  • 30.15.11
  • Manifold - exhaust - RH/rear - renew
  • TDV8
  • 8.30
  • 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 engine undershield. For additional information, refer to: Engine Undershield (501-02 Front End Body Panels, Removal and Installation).
  4. E85744
    Remove the RH splash shield.
      • Remove the 4 clips.
  5. E81728
    Disconnect the RH turbocharger electrical connector.
  6. E87131
    Remove the turbocharger support bracket.
      • Remove the 5 bolts.
  7. CAUTION:

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

    E81729
    Remove the RH turbocharger oil return tube.
      • Remove the 5 bolts.
      • Remove and discard the 2 gaskets.
  8. Remove the body. For additional information, refer to: Body - TDV8 3.6L Diesel (502-02 Full Frame and Body Mounting, Removal and Installation).
  9. E81723
    Release the breather line.
      • Remove the 3 bolts.
  10. 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.
  11. E77257
    Release the RH catalytic converter.
      • Remove the 2 nuts.
  12. E77147
    Remove the RH catalytic converter.
      • Remove the 3 bolts.
      • Remove and discard the gasket.
  13. E87111
    Remove the RH turbocharger heat shield.
      • Remove the 3 bolts.
  14. E87112
    Remove the RH exhaust manifold heat shield.
      • Remove the 3 bolts.
  15. CAUTION:

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

    E85738
    Release the RH turbocharger intake tube.
      • Remove the nut.
  16. E87115
    Release the RH turbocharger outlet pipe clip.
  17. CAUTION:

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

    E81727
    Disconnect the RH turbocharger oil supply pipe.
      • Remove the banjo bolt.
      • Remove and discard the 2 sealing washers.
  18. E87113
    Release the RH exhaust gas recirculation (EGR) valve inlet tube.
      • Remove the 2 bolts.
      • Remove and discard the gasket.
  19. E87114
    Release the RH turbocharger.
      • Loosen the 3 nuts.
  20. E87118
    Reposition the RH exhaust manifold and turbocharger assembly.
      • Remove and discard the 8 nuts.
      • Remove and discard the gasket.
      • Remove and discard the 8 studs.
  21. Disconnect the RH turbocharger outlet pipe.
  22. Remove the RH exhaust manifold and turbocharger assembly.
      • Remove and discard the gasket.
  23. E87117
    Remove the exhaust manifold from the turbocharger.
      • Remove and discard the 3 nuts.
      • Remove and discard the gasket.
Installation
  1. Install the exhaust manifold to the turbocharger.
      • Clean the components mating faces.
      • Install a new gasket.
      • Loosely install the nuts.
  2. Install the 8 studs.
      • Tighten the new studs to 13 Nm (10 lb.ft).
  3. Install the RH exhaust manifold and turbocharger assembly.
      • Clean the component mating faces.
      • Install a new gasket.
  4. Connect the RH turbocharger outlet pipe.
      • Tighten the clip.
  5. CAUTION:

    To make sure that the exhaust manifold and turbocharger assembly 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
    Secure the RH exhaust manifold and turbocharger assembly.
      • Clean the component mating face.
      • Stage 1: Tighten the new nuts to 24 Nm (18 lb.ft).
      • Stage 2: Wait for 2 minutes and tighten the nuts to 24 Nm (18 lb.ft).
      • Stage 3: Wait for 2 minutes and tighten the nuts to 24 Nm (18 lb.ft).
  6. CAUTION:

    Install but do not fully tighten the turbocharger support bracket bolts. This will allow for movement of components during the final torque stages. Failure to follow this instruction may result in damage to the vehicle.

    Install the RH turbocharger support bracket.
      • Install the bolts.
  7. Secure the RH turbocharger.
      • Tighten the nuts to 24 Nm (18 lb.ft).
  8. Secure the RH turbocharger support bracket.
      • Stage 1: Tighten the RH turbocharger support bracket bolts at the cylinder block to 24 Nm (18 lb.ft).
      • Stage 2: Tighten the RH turbocharger support bracket bolts at the turbocharger to 24 Nm (18 lb.ft).
  9. Check tightness of the turbocharger nuts.
      • Tighten the nuts to 24 Nm (18 lb.ft).
  10. Secure the RH EGR valve inlet tube.
      • Clean the component mating faces.
      • Install a new gasket.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  11. NOTE:

    Remove and discard the blanking caps.

    Connect the RH turbocharger oil supply pipe.
      • Clean the component mating faces.
      • Install new sealing washers.
      • Tighten the banjo bolt to 24 Nm (18 lb.ft).
  12. Tighten the RH turbocharger outlet pipe clip.
  13. NOTE:

    Remove and discard the blanking caps.

    Secure the RH turbocharger intake tube.
      • Tighten the nut to 10 Nm (7 lb.ft).
  14. Install the RH exhaust manifold heat shield.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  15. Install the RH turbocharger heat shield.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  16. Install the RH catalytic converter.
      • Clean the components mating faces.
      • Install a new gasket.
      • Tighten the bolts to 25 Nm (18 lb.ft).
  17. Secure the RH catalytic converter.
      • Clean the components mating faces.
      • Tighten the nuts to 55 Nm (40 lb.ft).
  18. 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 to 9 Nm (7 lb.ft).
  19. Secure the breather line.
      • Tighten the M6 bolts to 10 Nm (7 lb.ft).
      • Tighten the M8 bolts to 23 Nm (17 lb.ft).
  20. Install the body. For additional information, refer to: Body - TDV8 3.6L Diesel (502-02 Full Frame and Body Mounting, Removal and Installation).
  21. NOTE:

    Remove and discard the blanking caps.

    Install the RH turbocharger oil return tube.
      • Clean the component mating faces.
      • Install new gaskets.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  22. Connect the RH turbocharger electrical connector.
  23. Install the RH splash shield.
      • Install the clips.
  24. Install the engine undershield. For additional information, refer to: Engine Undershield (501-02 Front End Body Panels, Removal and Installation).
  25. Connect the battery ground cable. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).