Published: 18-Jan-2017

2007.0 Range Rover Sport (LS), 502-02

Full Frame and Body Mounting

Body - TDV8 3.6L Diesel (G940881)

REMOVAL AND INSTALLATION
Removal
NOTE:

This procedure can only be carried out on a 2 post ramp.

  1. 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.
  2. Disconnect the battery ground cable. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).
  3. Recover the air conditioning (A/C) refrigerant. For additional information, refer to: Air Conditioning System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures).
  4. Remove the air cleaner. For additional information, refer to: Air Cleaner (303-12D Intake Air Distribution and Filtering - TDV8 3.6L Diesel, Removal and Installation).
  5. Remove the engine cover. For additional information, refer to: Engine Cover - TDV8 3.6L Diesel (501-05 Interior Trim and Ornamentation, Removal and Installation).
  6. E83390
    Disconnect the brake booster vacuum line from the brake vacuum pump.
  7. Remove the auxiliary battery tray. For additional information, refer to: Auxiliary Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
  8. E57282
    Disconnect the steering column lower shaft from the steering column.
      • Remove and discard the bolt.
  9. Remove the four-wheel drive (4WD) control module.
  10. E86048
    Release the battery positive cable.
      • Remove the bolt.
  11. E86049
    Release and disconnect the engine wiring harness electrical connector.
  12. E86050
    Remove the battery compartment side wall.
      • Release the 4 clips.
  13. Remove the battery compartment side wall extension.
  14. E70748
    Release and disconnect the 2 transmission wiring harness electrical connectors.
  15. E54041
    Disconnect the 3 electrical connectors from the engine control module (ECM).
  16. E86051
    Disconnect the glow plug electrical connector.
  17. E70749
    Release the engine and transmission wiring harness cassettes, position the wiring harnesses aside.
      • Carefully release the 4 clips.
  18. E48705
    Remove the battery tray.
      • Remove the screw securing the air conditioning (A/C) pipes to the battery tray.
      • Remove the 3 nuts.
  19. Remove the coolant expansion tank. For additional information, refer to: Coolant Expansion Tank (303-03E Engine Cooling - TDV8 3.6L Diesel, Removal and Installation).
  20. Remove the front bumper.
  21. E85454
    Disconnect the cooling fan control electrical connector.
  22. E86052
    Release the battery positive cable.
      • Release the battery positive cable bracket.
  23. E86053
    Disconnect the fuel fired booster heater fuel line.
  24. CAUTION:

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

    E85170
    Disconnect the high and low-pressure A/C lines.
      • Remove the 2 bolts.
      • Remove and discard the 2 O-ring seals.
  25. E86067
    Disconnect the A/C low-pressure switch electrical connector.
      • Release the wiring harness.
  26. Remove the front LH fender splash shield. For additional information, refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
  27. E86054
    Release the front LH integrated body frame shock absorber.
  28. E86055
    LH side front: Release the integrated body frame ground cable.
      • Release the 2 clips.
      • Remove the nut.
      • Release the 3 cables.
  29. E57290
    LH side front: Release the ABS sensor lead.
      • Release the 2 clips.
      • Disconnect the electrical connector.
  30. E57291
    LH side front: Disconnect the brake pad wear sensor electrical connector.
      • Release from the 4 clips.
  31. LH side front: Release the 2 air lines.
      • Release from the 5 clips.
  32. CAUTION:

    Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

    E57296
    LH side front: Disconnect the brake line.
      • Position an absorbent cloth to collect fluid spillage.
      • Disconnect the line union.
      • Remove the clip.
  33. E85823
    Disconnect the washer reservoir 3 electrical connectors.
  34. NOTE:

    Note the fitted position.

    Disconnect the 2 hoses from the windshield washer reservoir pump.
      • Position a container to collect any windshield washer reservoir spillage.
  35. E86056
    Release and reposition the fuel fired booster heater exhaust bracket.
      • Remove the bolt.
  36. E86057
    Release the 2 windshield washer pump hoses.
  37. E86058
    Disconnect the 3 electrical connectors from the body harness.
      • Release the 2 clips.
  38. E51455
    Remove the RH fender splash shield.
  39. E86060
    Disconnect the body harness electrical connector.
      • Release the 3 clips.
  40. NOTE:

    LH illustration shown, RH is similar.

    E86054
    Release the front RH integrated body frame shock absorber.
      • Remove the nut and bolt.
  41. RH side front: Release the air suspension line from the wiring harness clip.
  42. RH side front: Release the ABS sensor lead.
      • Release the 2 clips.
      • Disconnect the electrical connector.
  43. E57287
    RH side front: Disconnect the engine ground cable from the body.
      • Remove the nut.
  44. CAUTION:

    Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

    E57296
    RH side front: Disconnect the brake line.
      • Position an absorbent cloth to collect fluid spillage.
      • Disconnect the line union.
      • Remove the clip.
  45. E86061
    Release the auxiliary radiator.
      • Remove the 5 bolts.
  46. Remove the fuel filler flap latch assembly. For additional information, refer to: Fuel Filler Door Assembly (501-03 Body Closures, Removal and Installation).
  47. E86059
    Release the fuel filler neck.
      • Remove the bolt.
  48. CAUTION:

    Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

    E57294
    RH side rear: Disconnect the brake line.
      • Position an absorbent cloth to collect fluid spillage.
      • Disconnect the line union.
      • Remove the clip.
  49. CAUTION:

    Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

    E57296
    LH side rear: Disconnect the brake line.
      • Position an absorbent cloth to collect fluid spillage.
      • Disconnect the line union.
      • Remove the clip.
  50. Remove the rear bumper cover.
  51. NOTE:

    RH illustration shown, LH is similar.

    E86062
    Release both rear integrated body frame shock absorbers.
      • Remove the 2 bolts.
  52. E70763
    LH side rear: Disconnect the 2 electrical connectors from the frame wiring harness.
  53. CAUTIONS:

    • Make sure that the area around the component is clean and free of foreign material.

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

    E57297
    LH side rear: Disconnect the suspension air compressor intake line.
  54. CAUTION:

    Note the fitted position of the seal.

    E49860
    Release the parking brake emergency release cable.
  55. E44596
    Remove the transmission heat shield.
      • Remove the 4 bolts.
  56. E86063
    Disconnect the combined lateral accelerometer and yaw rate sensor.
  57. E48356
    Release the selector lever cable.
      • Using an additional wrench, restrain the clamping bush and loosen the locknut.
      • Compress the latch and release the cable.
  58. E86064
    Disconnect the body harness electrical connector.
  59. E86065
    Disconnect the heater supply and return hoses.
      • Disconnect the 2 quick release connectors.
      • Remove the 2 nuts.
  60. E70765
    Remove and discard the 10 body mount bolts.
      • Remove the 10 spacing washers.
  61. CAUTION:

    To prevent the body becoming unstable when raised from the integrated body frame, install the vehicle tie down straps.

    NOTE:

    Note the fitted position of the body mounts.

    E88624
    Using an assistant raise and support the body.
      • Remove the body mounts.
Installation
  1. CAUTIONS:

    • Make sure that new bolts are installed.

    • Make sure that all components are free and do not get caught up whilst lowering the body onto the integrated body frame.

    Using an assistant install the body to the integrated body frame.
      • Install the body mounts.
      • With assistance align the body and integrated body frame mounts.
      • Install the bolts, but do not tighten fully at this stage.
  2. Remove the tie down straps securing the body.
  3. Raise and support the vehicle.
  4. Tighten the integrated body frame to body bolts to 133 Nm (98 lb.ft).
  5. Attach the selector cable.
  6. Secure the parking brake emergency release cable.
  7. Connect the combined lateral accelerometer and yaw rate sensor.
  8. NOTE:

    Remove and discard the blanking caps.

    LH side rear: Connect the suspension air compressor intake line.
      • Clean the component mating faces.
  9. LH side rear: Connect the 2 body harness electrical connectors.
  10. NOTE:

    Remove and discard the blanking caps.

    LH side rear: Connect the brake line.
      • Clean the component mating faces.
      • Secure the clip.
      • Tighten the brake line union to 16 Nm (12 lb.ft).
  11. Secure both rear integrated body frame shock absorbers.
      • Tighten the nuts and bolts to 45 Nm (33 lb.ft).
  12. NOTE:

    Remove and discard the blanking caps.

    RH side rear: Connect the brake line.
      • Clean the component mating faces.
      • Secure the clip.
      • Tighten the brake line union to 16 Nm (12 lb.ft).
  13. Secure the fuel filler neck.
      • Tighten the bolt to 10 Nm (7 lb.ft).
      • Install the fuel filler cap.
  14. Install the fuel filler flap latch assembly. For additional information, refer to: Fuel Filler Door Assembly (501-03 Body Closures, Removal and Installation).
  15. Install the rear bumper cover.
  16. Connect the body harness electrical connector.
      • Secure the 3 clips.
  17. Secure the integrated body frame shock absorber.
      • Tighten the nut and bolt to 45 Nm (33 lb.ft).
  18. RH side front: Secure the air suspension line to the wiring harness clip.
  19. RH side front: Connect the ABS sensor lead.
      • Connect the electrical connector.
      • Secure the 2 clips.
  20. RH side front: Connect the engine ground cable to the body.
      • Tighten the nut.
  21. NOTE:

    Remove and discard the blanking caps.

    RH side front: Connect the brake line.
      • Clean the component mating faces.
      • Secure the clip.
      • Tighten the brake line union to 16 Nm (12 lb.ft).
  22. Secure the auxiliary radiator.
      • Tighten the bolts to 20 Nm (15 lb.ft).
  23. Install the front RH fender splash shield.
  24. Secure the integrated body frame shock absorber.
      • Tighten the nut and bolt to 45 Nm (33 lb.ft).
  25. LH side front: Secure the integrated body frame ground cable.
      • Secure the 4 wires.
      • Tighten the nut.
      • Secure the 2 clips.
  26. LH side front: Secure the ABS sensor lead.
      • Connect the electrical connector.
      • Secure the 2 clips.
  27. LH side front: Connect the brake pad wear sensor electrical connector.
      • Secure to the 4 clips.
  28. LH side front: Secure the air lines.
      • Secure to the clips.
  29. NOTE:

    Remove and discard the blanking caps.

    LH side front: Connect the brake line.
      • Clean the component mating faces.
      • Secure the clip.
      • Tighten the brake line union to 16 Nm (12 lb.ft).
  30. Connect the washer reservoir electrical connectors.
  31. Connect the hoses to the windshield washer reservoir pump.
  32. Reposition and secure the fuel fired booster heater exhaust bracket.
      • Tighten the bolt to 10 Nm (7 lb.ft).
  33. Secure the windshield washer pump hoses.
  34. Install the front LH fender splash shield. For additional information, refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
  35. Connect the electrical connectors to the body harness.
      • Secure the clips.
  36. NOTE:

    Remove and discard the blanking caps.

    Connect the high and low-pressure A/C lines.
      • Clean the component mating faces.
      • Install new O-ring seals.
  37. Connect the A/C low-pressure switch electrical connector.
      • Secure the wiring harness.
  38. Connect the brake booster vacuum line to the brake vacuum pump.
  39. Connect the fuel fired booster heater fuel line.
  40. Install the coolant expansion tank. For additional information, refer to: Coolant Expansion Tank (303-03E Engine Cooling - TDV8 3.6L Diesel, Removal and Installation).
  41. Connect the cooling fan control electrical connector.
  42. Install the battery tray.
      • Tighten the nuts.
      • Tighten the screw securing the air conditioning pipes to the battery tray.
  43. Secure the engine and transmission harness cassettes.
  44. Connect the heater supply and return hoses.
      • Tighten the nuts to 10 Nm (7 lb.ft).
  45. Connect the ECM electrical connectors.
  46. Connect the glow plug electrical connector.
  47. Install the battery compartment side wall extension.
  48. Install the battery compartment side wall.
      • Secure with the clips.
  49. Connect and secure the engine wiring harness electrical connector.
  50. Secure the battery positive cable.
      • Tighten the bolt.
  51. Install the TCM.
  52. WARNING:

    Make sure that a new bolt is installed.

    Connect the steering column lower shaft to the steering column.
      • Tighten the bolt to 25 Nm (18 lb.ft).
  53. Install the auxiliary battery tray. For additional information, refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
  54. Install the engine cover. For additional information, refer to: Engine Cover - TDV8 3.6L Diesel (501-05 Interior Trim and Ornamentation, Removal and Installation).
  55. Install the air cleaner. For additional information, refer to: Air Cleaner (303-12D Intake Air Distribution and Filtering - TDV8 3.6L Diesel, Removal and Installation).
  56. Recharge the A/C system. For additional information, refer to: Air Conditioning System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures).
  57. Check and top-up the coolant.
  58. Bleed the brake system.
  59. Adjust the selector cable.
  60. Connect the battery ground cable. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).