Published: 11-May-2011

2007.0 Range Rover Sport (LS), 303-04F

Fuel Charging and Controls - Turbocharger - TDV8 3.6L Diesel

Left Turbocharger (G947955)

REMOVAL AND INSTALLATION
  • 19.42.56
  • Turbocharger - LH - 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. CAUTION:

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

    E87107
    Release the LH turbocharger oil return tube.
      • Remove and discard the gasket.
      • Remove the 2 bolts.
  5. Remove the body. For additional information, refer to: Body - TDV8 3.6L Diesel (502-02 Full Frame and Body Mounting, Removal and Installation).
  6. NOTE:

    Right-hand shown, left-hand similar.

    E77147
    Release the exhaust system from the turbochargers.
      • Remove the 6 bolts.
      • Remove and discard the 2 gaskets.
  7. E87106
    Remove the LH catalytic converter.
      • Loosen the clamp.
  8. NOTE:

    The heat shield consists of 3 parts.

    E49805
    Remove the upper suspension arm and brake line heat shields for access.
      • Remove the 3 nuts.
      • Remove the 3 bolts.
      • Remove the bracket.
  9. CAUTION:

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

    E87108
    Remove the LH turbocharger intake tube.
      • Remove the nut.
      • Loosen the clip.
  10. E87099
    Remove the LH turbocharger heat shield.
      • Remove the 3 bolts.
  11. E87100
    Remove the LH exhaust manifold heat shield.
      • Remove the 3 bolts.
  12. CAUTION:

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

    E81715
    Disconnect the LH turbocharger oil supply pipe.
      • Remove the banjo bolt.
      • Remove and discard the 2 sealing washers.
  13. CAUTION:

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

    E87101
    Reposition the LH turbocharger outlet pipe.
      • Release the turbocharger outlet pipe clip.
      • Remove the 2 bolts.
  14. E87102
    Release the LH exhaust gas recirculation (EGR) valve inlet tube.
      • Remove the 2 bolts.
      • Remove and discard the gasket.
  15. E81717
    Remove the LH turbocharger support bracket.
      • Remove the 4 bolts.
  16. E81714
    Disconnect the LH turbocharger electrical connector.
  17. E87103
    Release the LH turbocharger.
      • Loosen the 3 nuts.
  18. E87109
    Remove the LH exhaust manifold and turbocharger assembly.
      • Remove and discard the 8 nuts.
      • Remove and discard the gasket.
  19. 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.

    E87104
    Remove the turbocharger oil return tube.
      • Remove the 2 bolts.
      • Remove and discard the gasket.
  20. CAUTION:

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

    E87105
    Remove the LH turbocharger.
      • Remove the 3 nuts.
      • Remove and discard the gasket.
Installation
  1. NOTE:

    Remove and discard the blanking caps.

    Install the LH turbocharger.
      • Clean the component mating faces.
      • Install a new gasket.
      • Loosely install the nuts.
  2. NOTE:

    Remove and discard the blanking caps.

    Install the LH turbocharger oil return tube.
      • Clean the component mating faces.
      • Install a new gasket.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  3. 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.

    E79269
    Install the LH 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).
  4. Connect the LH turbocharger electrical connector.
  5. 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 LH turbocharger support bracket.
      • Install the bolts.
  6. Secure the LH turbocharger.
      • Tighten the nuts to 24 Nm (18 lb.ft).
  7. Secure the LH turbocharger support bracket.
      • Stage 1: Tighten the LH turbocharger support bracket bolts at the cylinder block to 24 Nm (18 lb.ft).
      • Stage 2: Tighten the LH turbocharger support bracket bolts at the turbocharger to 24 Nm (18 lb.ft).
  8. Check tightness of the turbocharger nuts.
      • Tighten the nuts to 24 Nm (18 lb.ft).
  9. Secure the LH EGR valve inlet tube.
      • Clean the component mating faces.
      • Install a new gasket.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  10. NOTE:

    Remove and discard the blanking caps.

    Secure the LH turbocharger outlet pipe.
      • Tighten the bolts to 10 Nm (7 lb.ft).
      • Tighten the clip.
  11. NOTE:

    Remove and discard the blanking caps.

    Connect the LH turbocharger oil supply pipe.
      • Clean the component mating faces.
      • Install new sealing washers.
      • Tighten the banjo bolt to 24 Nm (18 lb.ft).
  12. Install the LH exhaust manifold heat shield.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  13. Install the LH turbocharger heat shield.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  14. NOTE:

    Remove and discard the blanking caps.

    Install the LH turbocharger intake tube.
      • Tighten the nut to 10 Nm (7 lb.ft).
      • Tighten the clip.
  15. NOTE:

    The heat shield consists of 3 parts.

    Install the upper suspension arm and brake line heat shields.
      • Install the bolts.
      • Install the nuts.
      • Tighten to 6 Nm (4 lb.ft).
  16. NOTE:

    Do not tighten the clamp at this stage.

    Install the LH catalytic converter.
      • Clean the component 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 25 Nm (18 lb.ft).
  18. Secure the LH catalytic converter.
      • Tighten the nut to 55 Nm (40 lb.ft).
  19. Install the body. For additional information, refer to: Body - TDV8 3.6L Diesel (502-02 Full Frame and Body Mounting, Removal and Installation).
  20. NOTE:

    Remove and discard the blanking caps.

    Secure the LH turbocharger oil return tube.
      • Clean the component mating faces.
      • Install a new gasket.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  21. Install the engine undershield. For additional information, refer to: Engine Undershield (501-02 Front End Body Panels, Removal and Installation).
  22. Connect the battery ground cable. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).