Published: 11-May-2011

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

Engine - TDV8 3.6L Diesel (G953332)

DISASSEMBLY

Special Tool(s)

E81371

303-1236

Camshaft holding tool

E81373

303-1238

Crankshaft timing pin

E81375

303-1243

Flexplate locking tool

E54552

303-1127

Remover - Fuel Injector

Disassembly
  1. Disconnect the battery ground cable. For additional information, refer to: Specifications (414-00, 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. Drain the engine oil. For additional information, refer to: Engine Oil Draining and Filling (303-01, General Procedures).
  4. Remove the engine. For additional information, refer to: Engine (303-01, Removal).
  5. Install the engine to a suitable engine stand.
  6. Disconnect the air conditioning (A/C) compressor electrical connector.
  7. E81290
    Remove the A/C compressor rear bolt.
  8. E85851
    Remove the A/C compressor and support bracket.
      • Remove the 2 bolts.
  9. E81294
    Remove the engine oil filler cap.
      • Remove and discard the O-ring seal.
  10. E81296
    Remove the special tools.
      • Remove the 4 bolts.
  11. CAUTION:

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

    E88159
    Remove the LH turbocharger intake tube.
      • Remove the nut.
  12. CAUTION:

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

    E88160
    Remove the charge air cooler LH intake pipe.
      • Release the clip.
      • Remove the 2 bolts.
  13. E88161
    Remove the LH turbocharger heat shield and the LH exhaust manifold heat shield.
      • Remove the 4 bolts.
  14. E88167
    Remove the breather line.
      • Release the clip.
      • Remove the 3 bolts.
  15. CAUTION:

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

    E87637
    Remove the oil level indicator and tube.
      • Remove and discard the O-ring seal.
      • Remove the 2 bolts.
  16. CAUTION:

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

    E88168
    Remove the RH turbocharger intake tube.
      • Remove the nut.
  17. CAUTION:

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

    E88169
    Remove the charge air cooler RH intake pipe.
      • Release the clip.
      • Remove the 2 bolts.
  18. E88170
    Remove the RH turbocharger heat shield and the RH exhaust manifold heat shield.
      • Remove the 4 bolts.
  19. E81300
    Remove the charge air cooler LH outlet hose.
      • Release the clip.
  20. E81301
    Remove the charge air cooler RH outlet hose.
      • Release the clip.
  21. E81299
    Remove the special tool.
      • Remove the 2 bolts.
  22. E88163
    Remove the coolant pump pulley and the cooling fan belt idler pulleys.
      • Remove and discard the 2 access covers.
      • Remove the 5 bolts.
  23. E81303
    Remove the cooling fan belt tensioner.
      • Remove the 2 bolts.
  24. E88164
    Remove the generator mounting bracket.
      • Remove the 6 bolts.
  25. NOTE:

    Right-hand shown, left-hand similar.

    E81618
    Drain the coolant.
      • Remove the drain plugs.
      • Position a container to collect the fluid.
      • Allow the fluid to drain.
      • Clean the component mating faces.
      • Apply loctite 572 to the drain plug threads.
      • Install the drain plugs and tighten to 18 Nm (13 lb.ft).
      • Remove the container.
  26. E88166
    Remove the exhaust gas recirculation (EGR) valve inlet tubes.
      • Remove the 10 bolts.
      • Remove the RH EGR valve inlet tube heat shield.
      • Remove and discard the 4 gaskets.
  27. E81306
    Disconnect the LH turbocharger electrical connector.
  28. E81307
    Release the LH turbocharger oil return tube.
      • Remove the 2 bolts.
      • Remove and discard the gasket.
  29. E81717
    Remove the LH turbocharger support bracket.
      • Remove the 4 bolts.
  30. CAUTION:

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

    E81338
    Disconnect the LH turbocharger oil supply pipe.
      • Remove the banjo bolt.
      • Remove and discard the 2 sealing washers.
  31. E81349
    Remove the LH exhaust manifold and turbocharger assembly.
      • Remove and discard the 8 nuts.
      • Remove and discard the gasket.
  32. E88162
    Remove the LH engine mount bracket.
      • Remove the 4 bolts.
  33. CAUTION:

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

    E87636
    Release the oil pick-up pipe.
      • Remove the 3 bolts.
      • Remove the nut.
      • Remove and discard the O-ring seal.
  34. E88165
    Remove the oil pick-up pipe.
      • Release the clip.
      • Release the wiring harness.
  35. E81339
    Disconnect the RH turbocharger electrical connector.
  36. E81440
    Release the RH turbocharger oil return tube.
      • Remove the 3 bolts.
      • Remove and discard the gasket.
  37. E88226
    Remove the RH turbocharger support bracket.
      • Remove the 5 bolts.
  38. CAUTION:

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

    E81342
    Disconnect the RH turbocharger oil supply pipe.
      • Remove the banjo bolt.
      • Remove and discard the 2 sealing washers.
  39. E81343
    Remove the RH exhaust manifold and turbocharger assembly.
      • Remove and discard the 8 nuts.
      • Remove and discard the gasket.
  40. E88171
    Remove the RH engine mount bracket.
      • Remove the 4 bolts.
  41. E88172
    Remove the support bracket.
      • Remove the 3 bolts.
  42. NOTE:

    RH illustration shown, LH is similar

    E76535
    Remove the LH fuel line shield.
      • Remove the 7 nuts.
  43. E76535
    Remove the RH fuel line shield.
      • Remove the 7 nuts.
  44. NOTE:

    Left-hand shown, right-hand similar.

    E81442
    Disconnect the 8 fuel injector electrical connectors.
      • Release the fuel charging wiring harness.
  45. E81352
    Disconnect the knock sensor (KS) electrical connectors.
      • Release the wiring harness.
  46. E77815
    Disconnect the glow plug electrical connectors.
      • Release the wiring harness.
  47. E77816
    Disconnect both exhaust gas recirculation (EGR) valve electrical connectors.
      • Release the wiring harness.
  48. E81353
    Disconnect the fuel rail pressure (FRP) sensor electrical connector.
  49. E81350
    Disconnect the fuel temperature sensor electrical connector.
  50. E81351
    Disconnect the camshaft position (CMP) sensor electrical connector.
  51. E77825
    Disconnect both manifold absolute pressure and temperature (MAPT) sensor electrical connectors.
  52. E81354
    Disconnect the fuel pressure control valve electrical connector.
  53. E81403
    Disconnect the fuel metering valve electrical connector.
  54. E77829
    Disconnect both throttle body electrical connectors.
      • Release the locking tangs.
  55. E81443
    Disconnect the engine coolant temperature (ECT) sensor electrical connector.
  56. E81617
    Disconnect the air suspension solenoid electrical connector.
  57. E81444
    Disconnect the engine oil pressure (EOP) sensor electrical connector.
  58. E81445
    Disconnect the vacuum solenoid electrical connectors.
  59. E81344
    Disconnect the crankshaft position (CKP) sensor electrical connector.
  60. E87633
    Disconnect the engine oil temperature sensor electrical connector.
  61. Remove the engine wiring harness.
      • Release the clips.
  62. E77822
    Remove the engine cover mounting bracket.
      • Release the vacuum line.
      • Remove the 4 bolts.
  63. NOTE:

    Left-hand shown, right-hand similar.

    E77823
    Release both EGR valve outlet tubes.
      • Remove the 4 bolts.
  64. E81404
    Reposition the intake manifold plenum chamber rear hoses.
      • Release the clips.
  65. E81446
    Release the fuel temperature sensor.
  66. E77828
    Disconnect the vacuum lines.
  67. CAUTION:

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

    E81447
    Remove the intake manifold plenum chamber.
      • Release the clips.
      • Fully loosen the 6 bolts.
      • Remove and discard the EGR valve outlet tube gaskets.
  68. E81448
    Remove the brake vacuum pump.
      • Remove the 2 bolts.
      • Remove and discard the gasket.
  69. E81449
    Remove the fuel pump shield.
      • Remove the 3 bolts.
  70. 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 (303-04, General Procedures).
  71. CAUTION:

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

    E81405
    Disconnect the low-pressure fuel return line.
  72. CAUTION:

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

    E81450
    Remove and discard the high-pressure fuel supply lines.
      • Remove the 2 bolts.
  73. E81451
    Remove the fuel pump.
      • Release the low-pressure fuel supply line.
      • Remove the 3 bolts.
      • Remove and discard the gasket.
  74. E81452
    Disconnect the fuel return line from the fuel injectors.
      • Remove and discard the 8 fuel return line clips.
  75. CAUTION:

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

    NOTE:

    Left-hand shown, right-hand similar.

    E81453
    Remove and discard the high-pressure fuel supply lines.
  76. E76519
    Remove the 2 fuel injector bolts.
  77. Install the special tool studs.
  78. 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.
  79. E76522
    Install the special tool locking plate to the remover legs.
  80. E79670
    Remove the fuel injector.
      • Rotate the special tool bolts evenly, in a clockwise direction.
      • Remove the special tool.
  81. Remove the remaining fuel injectors.
  82. NOTE:

    Left-hand shown, right-hand similar.

    E81455
    Remove the fuel rails.
      • Release the glow plug wiring harness.
      • Remove the 4 bolts.
      • Remove the brackets.
  83. CAUTION:

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

    NOTE:

    Left-hand shown, right-hand similar.

    E77328
    Disconnect the EGR cooler coolant hoses.
      • Release the 4 clips.
  84. NOTE:

    Left-hand shown, right-hand similar.

    E77331
    Remove the EGR valve and cooler assemblies.
      • Remove the 8 bolts.
  85. NOTE:

    Some fluid spillage is inevitable during this operation.

    E81406
    Remove the coolant pump.
      • Position a container to collect the fluid spillage.
      • Remove the 4 bolts.
      • Remove and discard the O-ring seal.
  86. E81619
    Install the special tool.
  87. NOTE:

    The crankshaft pulley bolt will be very tight.

    E81457
    Remove the crankshaft pulley.
      • Remove and discard the bolt.
  88. E81347
    Remove the flexplate.
      • Remove and discard the 8 bolts.
  89. E81619
    Remove the special tool.
  90. CAUTION:

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

    E81458
    Remove the turbocharger oil supply line.
      • Remove the 3 bolts.
      • Remove and discard the 2 O-ring seals.
  91. NOTE:

    Left-hand shown, right-hand similar.

    E81459
    Release the vacuum and fuel return lines.
      • Release the fuel return line from the valve covers.
      • Disconnect the vacuum hose.
  92. CAUTION:

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

    E81460
    Remove the vacuum and fuel return lines.
      • Disconnect the fuel return line from the fuel cooler.
  93. E81461
    Remove the vacuum solenoids and lines.
      • Remove the 4 bolts.
  94. E81463
    Remove the cylinder block coolant elbow and hose assembly.
      • Disconnect the coolant hoses.
      • Release the 3 clips.
      • Remove the 5 bolts.
      • Remove and discard the O-ring seal.
  95. E81464
    Remove the EOP sensor.
  96. E81407
    Remove the CMP sensor.
      • Remove the bolt.
      • Remove and discard the O-ring seal.
  97. NOTES:

    • CKP sensor blanking cover shown removed for clarity.

    • The CKP sensor bolt should not be removed from the CKP sensor.

    E81346
    Remove the CKP sensor.
      • Fully loosen the bolt.
  98. E81466
    Remove the oil filter housing.
      • Remove the 12 bolts.
      • Remove and discard the gasket.
  99. E81467
    Remove the knock sensors (KS).
      • Remove the bolts.
  100. E77847
    Remove the LH valve cover.
      • Fully loosen the 18 bolts.
      • Remove and discard the gasket.
  101. E81408
    Remove the RH valve cover.
      • Fully loosen the 17 bolts.
      • Remove and discard the gasket.
  102. E81663
    Remove the crankshaft timing pin plug.
  103. E81664
    Install the special tool.
      • Rotate the crankshaft clockwise until the crankshaft touches the crankshaft timing pin.
  104. E81666
    Install the special tools.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  105. E87528
    Remove the oil pan.
      • Remove the 22 bolts.
      • Remove and discard the gasket.
  106. E81468
    Remove the oil pump.
      • Remove the 11 bolts.
      • Remove and discard the gasket.
      • Remove and discard the crankshaft front seal.
  107. E81469
    Remove and discard both hydraulic timing chain tensioners.
  108. E81470
    Remove the LH timing chain sprocket and gears.
      • Remove and discard the 2 bolts.
  109. E81471
    Remove the LH timing chain.
  110. E81472
    Remove the LH timing chain tensioner guide pin.
      • Remove and discard the O-ring seal.
  111. E81473
    Remove the LH timing chain tensioner guides.
  112. E81666
    Remove the special tools.
      • Remove the bolts.
  113. E81474
    Remove the camshaft bearing caps.
      • Remove the 20 bolts.
  114. E81475
    Remove the LH camshafts.
  115. E81476
    Remove the hydraulic adjuster and rocker assemblies.
  116. CAUTION:

    The cylinder head must not be placed mating face down. Failure to follow this instruction may result in damage to the vehicle.

    E81477
    Remove the LH cylinder head assembly.
      • Remove and discard the 13 bolts.
      • Remove and discard the gasket.
  117. E81722
    Remove the vacuum pump cap.
      • Remove the 2 bolts.
  118. E81484
    Remove the RH timing chain sprocket and gears.
      • Remove and discard the 2 bolts.
      • Remove the vacuum pump drive gear.
  119. E81478
    Remove the RH timing chain.
  120. Remove the engine lifting eye bracket.
      • Remove the 4 bolts.
  121. E81485
    Remove the RH timing chain tensioner guide pin.
      • Remove and discard the O-ring seal.
  122. E81486
    Remove the RH timing chain tensioner guides.
  123. E81666
    Remove the special tools.
  124. E81487
    Remove the camshaft bearing caps.
      • Remove the 20 bolts.
  125. E81488
    Remove the RH camshafts.
  126. E81489
    Remove the hydraulic adjuster and rocker assemblies.
  127. CAUTION:

    The cylinder head must not be placed mating face down. Failure to follow this instruction may result in damage to the vehicle.

    E81490
    Remove the RH cylinder head assembly.
      • Remove and discard the 13 bolts.
      • Remove and discard the gasket.