Published: 11-May-2011

2007.0 Range Rover Sport (LS), 310-01D

Fuel Tank and Lines - TDV8 3.6L Diesel

Fuel Cooler (G942389)

REMOVAL AND INSTALLATION
Removal
WARNINGS:

  • Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

  • Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

  • If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek immediate medical attention.

  • Wash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention.

  • Release the cooling system pressure by slowly turning the coolant expansion tank cap a quarter of a turn. Cover the expansion tank cap with a thick cloth to prevent the possibility of scalding. Failure to follow this instruction may result in personal injury.

  • The spilling of fuel is unavoidable during this operation. Make sure that all necessary precautions are taken to prevent fire and explosion.

CAUTION:

Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

  1. Raise and support the vehicle.
  2. Remove the engine undershield. For additional information, refer to: Engine Undershield (501-02 Front End Body Panels, Removal and Installation).
  3. E86626
    Release the fuel cooler.
      • Remove the bolt.
  4. CAUTION:

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

    E86627
    Disconnect the 2 fuel lines.
      • Position a container to collect the fluid spillage.
  5. CAUTIONS:

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

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

    E86628
    Remove the fuel cooler.
      • Disconnect the 2 coolant lines.
Installation
  1. NOTE:

    Remove and discard the blanking caps.

    Install the fuel cooler.
      • Connect the coolant lines.
  2. NOTE:

    Remove and discard the blanking caps.

    Connect the fuel lines.
      • Remove the container.
  3. Secure the fuel cooler.
      • Tighten the bolt to 23 Nm (17 lb.ft).
  4. Install the engine undershield. For additional information, refer to: Engine Undershield (501-02 Front End Body Panels, Removal and Installation).
  5. Carry out the low-pressure fuel system bleeding. For additional information, refer to: Low-Pressure Fuel System Bleeding - TDV6 2.7L Diesel (310-00 Fuel System - General Information, General Procedures).
  6. Check and top-up the coolant.