Range Rover. Manual — part 31
BMW DIESEL
15
REPAIR
63. Remove 4 nuts securing each engine mount to
chassis. Discard nuts.
64. Fit lifting bracket to engine lifting eyes. Attach
suitable hoist.
65. Raise engine slightly. Ensure that lifting bracket
does not foul bulkhead. Remove both engine
mountings.
NOTE: It may be necessary to lower
gearbox support slightly during above
operation.
66. Raise power unit and draw forward.
67. Lower support from transmission.
NOTE: Power unit must be tilted at an
angle of approximately 45 degrees before
it can be withdrawn from engine
compartment.
68. Remove engine/transmission assembly.
12
ENGINE
NEW RANGE ROVER
16
REPAIR
Refit
69. Raise power unit. Guide into engine bay.
70. Position transmission jack beneath transmission
brake drum.
71. With assistance, raise transmission and lower
engine until engine mountings can be fitted.
72. Attach mountings to chassis with new flange
nuts. Do not tighten at this stage.
CAUTION: Engine mountings must be
fitted with centre bolt head facing
outboard as shown.
73. Lower and guide engine onto mounting studs.
74. Attach engine to mountings with new flange
nuts. Do not tighten at this stage.
75. Release lifting bracket from engine lifting eyes.
Remove hoist.
76. Route gearbox harness. Secure with clips.
77. Connect multiplug to engine harness
78. Connect multiplugs to High/Low motor and
output shaft speed sensor.
Manual Vehicles:
79. Secure gearbox harness bracket with bolt.
Tighten to
6 Nm (4 lbf.ft).
80. Connect multiplugs to reverse and neutral
switches.
81. Secure harness to gearbox bracket with clips.
82. Connect Lucars to transfer box fluid temperature
sensor.
83. Raise transmission on jack.
84. Align harness bracket to gearbox.
Automatic Vehicles:
85. Connect multiplugs to gear selection position
switch and gearbox speed sensor.
86. Position selector cable abutment bracket to
gearbox. Secure with bolts.
87. Adjust gear selector cable.
See AUTOMATIC
GEARBOX, Adjustment.
All Vehicles:
88. Raise one wheel on each axle to allow rotation
of propeller shafts.
89. Position shafts to transfer box flanges. Align
marks.
90. Secure propeller shaft flanges with nuts and
bolts. Tighten to
48 Nm (35 lbf.ft)
91. Fit propeller shaft guard. Tighten bolts.
92. Guide hand brake cable through grommet in
transmission tunnel.
93. Fit exhaust front pipe.
See MANIFOLD AND
EXHAUST SYSTEM, Repair.
94. Fit chassis cross member.
See CHASSIS AND
BODY, Repair.
95. Remove support from under transmission.
96. Tighten engine mounting nuts to
45 Nm (33
lbf.ft)
97. Lower lift.
98. Connect handbrake cable to lever, secure with
clevis pin and clip.
BMW DIESEL
17
REPAIR
Manual Vehicles:
99. Fit seal around gearbox remote housing to
transmission tunnel aperture.
100. Fit gear lever bolts. Tighten to
25 Nm. (18 lbf.ft)
101. Fit gaiter and ring. Secure with nuts.
102. Fit centre console.
See CHASSIS AND BODY,
Repair.
Automatic Vehicles:
103. Fit window switch pack.
See ELECTRICAL,
Repair.
Manual Vehicles:
104. Connect clutch flexible hose. Remove hose
clamp.
105. Secure flexible hose union to gearbox bracket
with clip.
106. Bleed clutch hydraulic system.
See CLUTCH,
Repair.
All Vehicles:
107. With assistance, position radiator/condenser
assembly.
108. Connect multiplugs to condenser cooling fans.
109. Engage radiator in lower mounting rubbers.
Secure with nuts and bolts.
110. Align air conditioning pipe to condenser fans.
Secure with nuts.
111. Remove plugs from air conditioning compressor
and pipes.
112. Fit new ’O’ rings to compressor pipes. Lubricate
’O’ rings with compressor oil. Connect to
compressor.
113. Fit compressor connection bolts. Tighten to
23
Nm (17 lbs.ft)
114. Remove plugs from air conditioning condenser
and pipes.
115. Fit new ’O’ rings to condenser pipes. Lubricate
’O’ rings with compressor oil. Secure pipes to
condenser. Tighten to
15 Nm (11 lbf.ft)
116. Fit washer bottle filler neck. Secure with bolt and
screw.
117. Remove plugs from power steering pump and
pipes.
118. Using new sealing washers, secure feed pipe to
power steering pump. Tighten to
30 Nm (22
lbf.ft)
119. Untie power steering reservoir from engine.
Remove plugs. Connect return pipe. Secure
return pipe to reservoir with clip.
120. Secure fog lamp breather hoses to clips on
either side of radiator.
121. Connect heater hoses to engine coolant pipes.
Secure with clips.
122. Connect coolant bleed hose to radiator. Secure
with clip.
123. Connect bottom hose to radiator. Secure with
clip.
124. Remove plugs from transmission oil cooler and
pipes.
125. Lubricate pipes with transmission fluid, fit new
’O’ rings. Connect to oil cooler. Tighten to
30
Nm (22 lbf.ft)
126. Replenish transmission fluids.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
127. Fit engine oil cooler.
See this section.
128. Fit cooling fan.
See COOLING SYSTEM,
Repair.
129. Evacuate and recharge air conditioning system.
See AIR CONDITIONING, Adjustment.
130. Refill cooling system.
See COOLING SYSTEM,
Repair.
131. Refill engine oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
132. Connect multiplugs to fuel heater and turbo
boost sensor.
133. Connect fuel return hose to FIP. Secure with
clip.
134. Using new ’O’ rings, connect fuel feed hose to
fuel heater/filter head.
135. Route engine harness along valance. Secure
clip.
136. Connect engine harness multiplug to main
harness. Secure earth terminal to valance stud.
137. Connect engine harness multiplug to base of
fuse box.
138. Position fuse box. Secure with bolts.
139. Position earth lead to shock absorber turret.
Secure with bolt.
140. Fit battery tray. Secure with bolts.
141. Fit starter feed wire to battery positive terminal
clamp. Secure with nut.
142. Position engine harness to battery tray. Secure
harness grommets.
143. Secure harness clamp to battery tray with
screws.
12
ENGINE
NEW RANGE ROVER
18
REPAIR
144. Fit ECM.
See FUEL SYSTEM, Repair.
145. Fit inlet manifold.
See MANIFOLD AND
EXHAUST SYSTEM, Repair.
146. Refit battery.
See ELECTRICAL, Repair.
147. With assistance, release bonnet stay clips.
Engage bonnet struts.
CAUTION: Ensure bonnet stay clips are
returned to their original positions as
shown.
148. Start engine. Check for fuel, coolant and oil
leaks.
FLYWHEEL/DRIVE PLATE
Service repair no - 12.53.07
Remove
1. Disconnect battery negative lead.
2.
Manual gearbox: Remove clutch assembly. See
CLUTCH, Repair.
3.
Automatic gearbox: Remove gearbox. See
AUTOMATIC GEARBOX, Repair.
4. Lock flywheel/drive plate using LRT-12-106.
5. Remove and discard 8 bolts securing
flywheel/drive plate.
6. Remove flywheel/drive plate.
NOTE: Flywheel illustrated
Inspection
7. Inspect flywheel clutch face/drive plate for
cracks, scores or overheating.
8. Inspect ring gear for worn, chipped or broken
teeth.
9. Replace defective parts as necessary.
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