Published: 11-May-2011

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

Engine - TDV8 3.6L Diesel

Timing Drive Components (G946681)

IN-VEHICLE REPAIR
  • 12.65.13
  • Timing Chain and Tensioner Set - Renew
  • TDV8
  • 19.50
  • USED WITHINS

Special Tool(s)

E81371

303-1236

Camshaft holding tool

E81373

303-1238

Crankshaft timing pin

E81376

303-1244

Valve cover alignment tool

E54552

303-1127

Fuel Injector remover

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 oil pump. For additional information, refer to: Oil Pump (303-01D Engine - TDV8 3.6L Diesel, In-vehicle Repair).
  4. E77815
    Disconnect the glow plug electrical connectors.
      • Release the wiring harness.
  5. E77816
    Disconnect both exhaust gas recirculation (EGR) valve electrical connectors.
      • Release the wiring harness.
  6. E85161
    Release the engine wiring harness.
      • Remove the nut.
      • Release the 6 clips.
  7. E77818
    Disconnect the knock sensor (KS) electrical connectors.
      • Release the wiring harness.
  8. E77819
    Disconnect the fuel rail pressure (FRP) sensor electrical connector.
      • Release the wiring harness.
  9. E87865
    Disconnect the fuel temperature sensor electrical connector.
  10. E87866
    Disconnect the camshaft position (CMP) sensor electrical connector.
  11. E77822
    Remove the engine cover mounting bracket.
      • Release the vacuum line.
      • Remove the 4 bolts.
  12. NOTE:

    Left-hand shown, right-hand similar.

    E77823
    Release both EGR valve outlet tubes.
      • Remove the 4 bolts.
  13. E87867
    Reposition the intake manifold plenum chamber rear hoses.
      • Release the clips.
  14. E77825
    Disconnect both manifold absolute pressure and temperature (MAPT) sensor electrical connectors.
  15. E77827
    Release the intake manifold plenum chamber.
      • Release the 2 clips.
      • Fully loosen the 6 bolts.
  16. E77828
    Disconnect the 2 vacuum lines.
  17. E77829
    Disconnect both throttle body electrical connectors.
  18. CAUTION:

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

    E77830
    Remove the intake manifold plenum chamber.
      • Remove and discard the EGR valve outlet tube gaskets.
  19. E81463
    Release the coolant distribution manifold.
      • Remove the 5 bolts.
      • Release the 3 clips.
      • Remove and discard the O-ring seal.
  20. E87868
    Remove the fuel pump shield.
      • Release the vacuum solenoid.
      • Remove the 3 bolts.
  21. CAUTIONS:

    • Make sure that the high-pressure fuel supply line remains in contact with the fuel injection supply manifold and the fuel injection pump until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

    • Do not use any aggressive cleaning fluid or a wire brush to clean the fuel injector nozzle.

    Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply lines, the fuel rails and the fuel injection pump. For additional information, refer to: Fuel Injection Component Cleaning (303-04D Fuel Charging and Controls - TDV8 3.6L Diesel, General Procedures).
  22. E87869
    Disconnect the fuel metering valve electrical connector.
  23. E87870
    Disconnect the fuel injection control pressure sensor electrical connector.
  24. CAUTION:

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

    E87871
    Disconnect the low-pressure fuel lines.
  25. CAUTION:

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

    E77883
    Remove and discard the high-pressure fuel rail supply lines.
      • Release the vacuum hose.
      • Remove the 2 nuts.
  26. CAUTION:

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

    E87872
    Remove the fuel pump.
      • Remove the 3 bolts.
      • Remove and discard the gasket.
  27. E76535
    Remove the LH fuel line shield.
      • Remove the 7 nuts.
  28. NOTE:

    RH illustration shown, LH is similar.

    E76536
    Disconnect the fuel injector electrical connectors.
      • Release the fuel charging wiring harness.
  29. CAUTIONS:

    • Make sure that the high-pressure fuel supply line remains in contact with the fuel injection supply manifold and the fuel injection pump until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

    • Do not use any aggressive cleaning fluid or a wire brush to clean the fuel injector nozzle.

    Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply lines, the fuel injectors and the fuel rail. For additional information, refer to: Fuel Injection Component Cleaning (303-04D Fuel Charging and Controls - TDV8 3.6L Diesel, General Procedures).
  30. CAUTIONS:

    • Make sure that the high-pressure fuel supply line remains in contact with the fuel injection supply manifold and the fuel injection diverter rail until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

    • Make sure that the fuel injector adaptor union does not move when loosening the high-pressure fuel supply lines. Failure to follow this instruction may result in damage to the fuel injector or the fuel injector adaptor union.

    E124642
    Loosen the high-pressure fuel supply line from the fuel injector and fuel rail.
  31. CAUTION:

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

    NOTE:

    RH illustration shown, LH is similar.

    E124642
    Remove and discard the high-pressure fuel supply lines.
  32. NOTE:

    RH illustration shown, LH is similar.

    E76538
    Disconnect the fuel return line from the fuel injector.
      • Remove and discard the fuel return line clip.
  33. E76519
    Remove the 2 fuel injector bolts.
  34. Install the special tool studs.
  35. CAUTION:

    Make sure the fuel injector remover legs are correctly engaged to the fuel injector. Failure to follow this instruction may result in damage to the component.

    Install the special tool remover legs to the studs.
  36. E76522
    Install the special tool locking plate to the remover legs.
  37. Release the fuel injector.
      • Rotate the special tool bolts evenly, in a clockwise direction.
      • Remove the special tool.
  38. CAUTION:

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

    E79670
    Remove the fuel injector.
      • Remove and discard the fuel injector clamp.
      • Remove and discard the sealing washer.
  39. Remove the remaining fuel injectors.
  40. E87875
    Disconnect the intake manifold plenum chamber tuning valve vacuum hose.
  41. E85183
    Remove the fuel line support bracket.
      • Remove the 3 nuts.
      • Release the 2 wiring harness clips.
  42. E77847
    Remove the LH valve cover.
      • Fully loosen the 18 bolts.
      • Remove and discard the gasket.
  43. E76535
    Remove the RH fuel line shield.
      • Remove the 7 nuts.
  44. E76536
    Disconnect the fuel injector electrical connectors.
      • Release the fuel charging wiring harness.
  45. CAUTIONS:

    • Make sure that the high-pressure fuel supply line remains in contact with the fuel injection supply manifold and the fuel injection pump until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

    • Do not use any aggressive cleaning fluid or a wire brush to clean the fuel injector nozzle.

    Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply lines, the fuel injectors and the fuel rail. For additional information, refer to: Fuel Injection Component Cleaning (303-04D Fuel Charging and Controls - TDV8 3.6L Diesel, General Procedures).
  46. CAUTIONS:

    • Make sure that the high-pressure fuel supply line remains in contact with the fuel injection supply manifold and the fuel injection diverter rail until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

    • Make sure that the fuel injector adaptor union does not move when loosening the high-pressure fuel supply lines. Failure to follow this instruction may result in damage to the fuel injector or the fuel injector adaptor union.

    E124642
    Loosen the high-pressure fuel supply line from the fuel injector and fuel rail.
  47. CAUTION:

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

    NOTE:

    Right-hand shown, left-hand similar.

    E124642
    Remove and discard the high-pressure fuel supply line.
  48. E76538
    Disconnect the fuel return line from the fuel injector.
      • Remove and discard the fuel return line clip.
  49. E76519
    Remove the 2 fuel injector bolts.
  50. Install the special tool studs.
  51. CAUTION:

    Make sure the fuel injector remover legs are correctly engaged to the fuel injector. Failure to follow this instruction may result in damage to the component.

    Install the special tool remover legs to the studs.
  52. E76522
    Install the special tool locking plate to the remover legs.
  53. Release the fuel injector.
      • Rotate the special tool bolts evenly, in a clockwise direction.
      • Remove the special tool.
  54. CAUTION:

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

    E79670
    Remove the fuel injector.
      • Remove and discard the fuel injector clamp.
      • Remove and discard the sealing washer.
  55. Remove the remaining fuel injectors.
  56. E87878
    Disconnect the engine oil pick-up hose.
      • Release the clip.
  57. E87876
    Remove the brake vacuum pump.
      • Remove the nut.
      • Remove the stud.
      • Remove the 2 bolts.
      • Remove and discard the gasket.
  58. NOTE:

    Left-hand shown, right-hand similar.

    E87875
    Disconnect the intake manifold plenum chamber tuning valve vacuum hose.
  59. E87877
    Remove the RH valve cover.
      • Fully loosen the 17 bolts.
      • Remove and discard the gasket.
  60. Disconnect the breather line.
      • Release the clip.
  61. E85738
    Remove the RH turbocharger intake tube.
      • Remove the nut.
  62. E87284
    Release the RH turbocharger outlet pipe.
      • Remove the 2 bolts.
  63. E81663
    Remove the crankshaft timing pin plug.
  64. CAUTION:

    Crankshaft timing tool pistons number 2,4,7&8 are roughly at TDC as pin may lock on web instead of machined face.

    E81664
    Install the special tool.
      • Rotate the crankshaft on to the crankshaft timing pin.
  65. E81666
    Install the special tools to both the LH bank and RH bank camshafts.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  66. E81469
    Remove and discard both hydraulic timing chain tensioners.
  67. E81470
    Remove the LH timing chain sprocket and gears.
      • Remove and discard the 2 bolts.
  68. E81471
    Remove the LH timing chain.
  69. E81472
    Remove the LH timing chain tensioner guide pin.
      • Remove and discard the O-ring seal.
  70. E81473
    Remove the LH timing chain tensioner guides.
  71. E81484
    Remove the RH timing chain sprocket and gears.
      • Remove and discard the 2 bolts.
  72. E81478
    Remove the RH timing chain.
  73. E81485
    Remove the RH timing chain tensioner guide pin.
      • Remove and discard the O-ring seal.
  74. E81486
    Remove the RH timing chain tensioner guides.
Installation
  1. Install the RH timing chain tensioner guides.
      • Tighten the bolts to 10 Nm (7 Ib.ft).
  2. 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).
  3. Install the RH timing chain.
  4. CAUTION:

    Do not tighten the camshaft sprocket bolts at this stage.

    Install the RH timing chain sprocket and gears.
      • Loosely install the new bolts.
  5. NOTE:

    Lubricate the O-ring seals with clean engine oil.

    Install a new RH hydraulic timing chain tensioner.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  6. Install the vacuum pump cap.
      • Clean the component mating faces.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  7. Install the LH timing chain tensioner guides.
      • Tighten the bolts to 10 Nm (7 Ib.ft).
  8. 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).
  9. Install the LH timing chain.
  10. CAUTION:

    Do not tighten the camshaft sprocket bolts at this stage.

    Install the LH timing chain sprocket and gears.
      • Loosely install the new bolts.
  11. NOTE:

    Lubricate the O-ring seals with clean engine oil.

    Install a new LH hydraulic timing chain tensioner.
      • Install a new O-ring seal.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  12. Release the hydraulic timing chain tensioners.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  13. CAUTION:

    Make sure that the crankshaft is still touching the timing pin.

    Tighten the LH camshaft sprocket and gears.
      • Stage 1: Tighten the exhaust camshaft gear bolt to 80 Nm (59 lb.ft).
      • Stage 2: Tighten the exhaust camshaft gear bolt a further 80 degrees.
      • Stage 3: Tighten the intake camshaft sprocket and gear bolt to 80 Nm (59 lb.ft).
      • Stage 4: Tighten the intake camshaft sprocket and gear bolt a further 80 degrees.
  14. Tighten the RH camshaft sprocket and gears.
      • Stage 1: Tighten the exhaust camshaft gear bolt to 80 Nm (59 lb.ft).
      • Stage 2: Tighten the exhaust camshaft gear bolt a further 80 degrees.
      • Stage 3: Tighten the intake camshaft sprocket and gear bolt to 80 Nm (59 lb.ft).
      • Stage 4: Tighten the intake camshaft sprocket and gear bolt a further 80 degrees.
  15. E81666
    Remove the special tools from the LH and RH bank camshafts.
      • Remove the bolts.
  16. E81664
    Remove the special tool.
  17. Rotate the crankshaft 2 complete turns in the clockwise direction using the crankshaft pulley bolt.
      • Install the crankshaft pulley bolt.
  18. CAUTION:

    Repeat the engine timing steps until the engine timing is correct.

    Install the special tools and check the engine timing.
      • Reset the engine timing if it is not correct.
  19. Remove the special tools.
      • Remove the crankshaft pulley bolt.
  20. Install the crankshaft timing pin plug.
  21. Secure the RH turbocharger outlet pipe.
      • Tighten the bolts to 10 Nm (7 Ib.ft).
  22. Install the RH turbocharger intake tube.
      • Tighten the nut to 10 Nm (7 lb.ft).
  23. Connect the breather line.
      • Secure the clip.
  24. CAUTION:

    Tighten the bolts in the sequence shown.

    E80513
    Install the RH valve cover.
      • Install a new gasket.
      • Install the special tool.
      • Tighten the bolts to 10 Nm (7 lb.ft).
      • Remove the special tool.
  25. Connect the intake manifold plenum chamber tuning valve vacuum hose.
  26. CAUTION:

    Make sure that the mating faces are clean and free of foreign material.

    Install the brake vacuum pump.
      • Install a new gasket.
      • Tighten the stud to 10 Nm (7 lb.ft).
      • Tighten the nut to 23 Nm (17 lb.ft).
      • Tighten the bolts to 23 Nm (17 lb.ft).
  27. Connect the engine oil pick-up hose.
      • Secure with the clip.
  28. CAUTIONS:

    • Do not disassemble the fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new fuel injectors when required.

    • Do not use tools to install the new fuel return line clip. Failure to follow this instruction will result in damage to the clip.

    Install a new fuel injector clamp.
      • Install a new sealing washer.
      • Install a new fuel return line clip.
  29. CAUTION:

    Only tighten the bolts finger-tight at this stage.

    NOTE:

    Remove and discard the blanking caps.

    Install the fuel injector.
      • Loosely install the bolts.
  30. Install the remaining fuel injectors.
  31. CAUTION:

    Make sure the fuel return line clip is correctly installed to the fuel injector before installing the return line.

    Connect the fuel return line to the fuel injector.
      • Visually inspect the fuel return line O-ring seal for damage.
      • Lubricate the O-ring seal with petroleum jelly.
  32. CAUTIONS:

    • Maintain pressure on the high-pressure fuel supply line to keep the olives in contact with the fuel injectors and the fuel rail cones while installing unions.

    • 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 high-pressure fuel supply line and allow foreign matter to enter the fuel injection system.

    • Only tighten the unions finger-tight at this stage.

    NOTE:

    Remove and discard the blanking caps.

    Loosely install the new high-pressure fuel supply lines.
  33. Secure the fuel injectors.
      • Evenly and progressively tighten the bolts to 10 Nm (7 lb.ft).
  34. 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 lines to keep the olives in contact with the fuel rail and the fuel injector cones while installing unions.

    NOTE:

    Remove and discard the blanking caps.

    E124890
    Loosen the high-pressure fuel supply line from the fuel injector and fuel rail.
      • Tighten the high-pressure fuel supply line unions in the following sequence:
      • Stage 1: Tighten the high-pressure fuel rail supply line unions at the fuel rail to 15 Nm (11 lb.ft).
      • Stage 2: Tighten the high-pressure fuel rail supply line unions at the fuel injectors to 15 Nm (11 lb.ft).
      • Stage 3: Tighten the high-pressure fuel supply line unions at the fuel rail to 30 Nm (22 lb.ft).
      • Stage 4: Tighten the high-pressure fuel rail supply line unions at the fuel injectors to 30 Nm (22 lb.ft).
  35. Connect the fuel injector electrical connectors.
      • Attach the fuel charging wiring harness.
  36. Install the fuel line shield.
      • Tighten the nuts to 5 Nm (4 lb.ft).
  37. CAUTION:

    Tighten the bolts in the sequence shown.

    E80512
    Install the LH valve cover.
      • Install a new gasket.
      • Install the special tool.
      • Tighten the bolts to 10 Nm (7 lb.ft).
      • Remove the special tool.
  38. Install the fuel line support bracket.
      • Tighten the bolts to 10 Nm (7 Ib.ft).
      • Secure the wiring harness clips.
  39. Connect the intake manifold plenum chamber tuning valve vacuum hose.
  40. CAUTIONS:

    • Do not disassemble the fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new fuel injectors when required.

    • Do not use tools to install the new fuel return line clip. Failure to follow this instruction will result in damage to the clip.

    Install a new fuel injector clamp.
      • Install a new sealing washer.
      • Install a new fuel return line clip.
  41. CAUTION:

    Only tighten the bolts finger-tight at this stage.

    NOTE:

    Remove and discard the blanking caps.

    Install the fuel injector.
      • Loosely install the bolts.
  42. CAUTION:

    Make sure the fuel return line clip is correctly installed to the fuel injector before installing the fuel return line.

    Connect the fuel return line to the fuel injector.
      • Visually inspect the fuel return line O-ring seal for damage.
      • Lubricate the O-ring seal with a suitable lubricant.
  43. Install the remaining fuel injectors.
  44. Secure the fuel injectors.
      • Evenly and progressively tighten the bolts to 10 Nm (7 lb.ft).
  45. 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 lines to keep the olives in contact with the fuel rail and the fuel injector cones while installing unions.

    NOTE:

    Remove and discard the blanking caps.

    E124890
    Secure the high-pressure fuel supply lines.
      • Tighten the high-pressure fuel supply line unions in the following sequence:
      • Stage 1: Tighten the high-pressure fuel rail supply line unions at the fuel rail to 15 Nm (11 lb.ft).
      • Stage 2: Tighten the high-pressure fuel rail supply line unions at the fuel injectors to 15 Nm (11 lb.ft).
      • Stage 3: Tighten the high-pressure fuel supply line unions at the fuel rail to 30 Nm (22 lb.ft).
      • Stage 4: Tighten the high-pressure fuel rail supply line unions at the fuel injectors to 30 Nm (22 lb.ft).
  46. Connect the fuel injector electrical connectors.
      • Secure the fuel charging wiring harness.
  47. Install the fuel line shield.
      • Tighten the nuts to 5 Nm (4 lb.ft).
  48. 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.
  49. Loosely install the new high-pressure fuel rail supply lines.
  50. Secure the fuel pump.
      • Tighten the bolts to 23 Nm (17 lb.ft).
  51. NOTE:

    Remove and discard the blanking caps.

    Secure the high-pressure fuel supply lines.
      • Install the new high-pressure fuel supply line, tighten the fuel supply line unions finger tight.
      • Tighten the high-pressure fuel supply line in the shown sequence.
      • Tighten the high-pressure fuel supply line union 1 to fuel injector to 15 Nm.
      • Tighten the high-pressure fuel supply line union 2 to fuel rail to 15 Nm.
      • Tighten the high-pressure fuel supply line union 1 to fuel injector to 30 Nm.
      • Tighten the high-pressure fuel supply line union 2 to fuel rail to 30 Nm.
  52. Secure the high-pressure fuel supply line clips.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  53. NOTE:

    Remove and discard the blanking caps.

    Connect the low-pressure fuel lines.
  54. Connect the fuel injection control pressure sensor electrical connector.
  55. Connect the fuel metering valve electrical connector.
  56. Install the fuel pump shield.
      • Tighten the bolts to 10 Nm (7 lb.ft).
      • Secure the vacuum solenoid.
  57. NOTE:

    Lubricate the O-ring seal with clean coolant.

    Secure the coolant distribution manifold.
      • Install a new O-ring seal.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  58. NOTE:

    Remove and discard the blanking caps.

    Install the intake manifold plenum chamber.
      • Clean the components mating faces.
      • Install new gaskets to the EGR valve outlet tubes.
      • Loosely install the EGR valve outlet tube bolts.
      • Loosely install the intake manifold plenum chamber bolts.
  59. Connect both throttle body electrical connectors.
  60. Connect the vacuum lines.
  61. Secure the intake manifold plenum chamber.
      • Tighten the bolts to 10 Nm (7 lb.ft).
      • Tighten the clips to 3 Nm (2 lb.ft).
  62. Connect both MAPT sensor electrical connectors.
  63. Reposition the intake manifold plenum chamber rear hoses.
      • Tighten the clips to 3 Nm (2 lb.ft).
  64. Secure both EGR valve outlet tubes.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  65. Install the engine cover mounting bracket.
      • Tighten the bolts to 10 Nm (7 lb.ft).
      • Secure the vacuum line.
  66. Connect the CMP sensor electrical connector.
  67. Connect the fuel temperature sensor electrical connector.
  68. Connect the FRP sensor electrical connector.
      • Secure the wiring harness.
  69. Connect the KS electrical connectors.
      • Secure the wiring harness.
  70. Secure the engine wiring harness.
      • Tighten the nut.
      • Secure the clips.
  71. Connect both EGR valve electrical connectors.
      • Secure the wiring harness.
  72. Connect the glow plug electrical connectors.
      • Secure the wiring harness.
  73. Install the oil pump. For additional information, refer to: Oil Pump (303-01D Engine - TDV8 3.6L Diesel, In-vehicle Repair).
  74. Connect the battery ground cable. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).