Range Rover Classic. Manual — part 37
19
FUEL SYSTEM
2
REPAIR
THROTTLE CABLE
Service repair no - 19.20.06
Remove
1. Disconnect battery negative lead.
2. Remove pin and clevis pin securing throttle
cable to throttle lever.
3. Pull ferrule from abutment bracket and withdraw
throttle cable.
4. Release throttle cable from clip on bulkhead.
5. Remove pin and clevis pin securing throttle
cable to throttle lever.
6. Release grommet from bulkhead.
7. Withdraw throttle cable from engine
compartment.
Refit
8. Reverse removal procedure. Use new pins to
secure clevis pins.
9. Adjust throttle cable.
See Adjustment,
Throttle Cable Adjustment
INTAKE HOSE TURBOCHARGER
Service repair no - 19.42.11
Remove
1. Disconnect battery negative lead.
2. Loosen clip and disconnect intake hose from
turbocharger.
3. Loosen clip and disconnect breather hose from
intake hose.
4. Remove clip and disconnect hose from air
cleaner, discard clip.
5. Remove intake hose
Refit
6. Reverse removal procedure. Use a new clip to
secure intake hose to air cleaner.
Tdi
3
REPAIR
TURBOCHARGER OIL FEED PIPE
Service repair no - 19.42.14
Remove
1. Disconnect battery negative lead.
2. Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Manifold
and Exhaust System - Tdi
3. Remove banjo bolt securing oil feed pipe to
turbocharger, discard 2 sealing washers.
4. Unscrew union, disconnect oil feed pipe from
cylinder block.
CAUTION: Plug the connections.
5. Move oil feed pipe from behind turbocharger and
remove.
Refit
6. Reverse removal procedure. use new sealing
washers.
7. Tighten banjo bolt to
20 Nm.
8. Check/top-up engine oil level.
TURBOCHARGER OIL DRAIN PIPE
Service repair no - 19.42.12
Remove
1. Disconnect battery negative lead.
2. Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Manifold
and Exhaust System - Tdi
3. Unscrew union and disconnect oil drain pipe
from cylinder lock.
4. Remove 2 bolts securing oil drain pipe to
turbocharger.
5. Remove oil drain pipe, remove and discard
gasket.
CAUTION: Plug the connection.
Refit
6. Ensure mating surfaces of oil pipe, turbocharger
and engine block are clean.
7. Reverse removal procedure. Use a new gasket.
8. Tighten oil drain pipe to turbocharger bolts to
25
Nm.
9. Check/top-up engine oil level.
19
FUEL SYSTEM
4
REPAIR
TURBOCHARGER ACTUATOR
Service repair no - 19.42.31
Remove
1. Remove exhaust manifold and turbocharger.
See MANIFOLD AND EXHAUST SYSTEM,
Repair, Exhaust Manifold - Tdi
2. Remove 2 nuts securing the actuator to the
turbocharger bracket.
3. Release clip and disconnect hose from actuator.
4. Remove and discard clip securing control lever
to wastegate spindle.
5. Remove turbocharger actuator.
Refit
6. Fit the replacement actuator and secure with
nuts.
7. Push the control lever as far as possible towards
the actuator and apply pressure to keep the
lever in this position.
8. Pressurise the actuator to 57 - 62 cm Hg and
hold this pressure.
CAUTION: Use only the threaded end of
the lever to make adjustments. Forcing the
complete lever in or out will change the
calibration with the possibility of damaging engine
boost.
9. Screw the lever in either direction until the eye
on the end will locate easily over the wastegate
spindle and secure with a new clip.
10. Release the pressure and tighten the locknut.
11. Refit exhaust manifold and turbocharger.
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust Manifold - Tdi
TURBOCHARGER AND GASKET
Service repair no - Turbocharger - 19.42.01
Service repair no - Gasket - 19.42.25
Remove
1. Disconnect battery negative lead.
2. Remove air cleaner assembly.
See Air Cleaner
Assembly
3. Remove exhaust manifold assembly.
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust Manifold - Tdi
4. Remove and discard clip securing control lever
to wastegate spindle.
5. Remove 4 bolts and 2 clamp plates securing
turbocharger to exhaust manifold.
6. Remove turbocharger and discard gaskets.
Refit
7. Clean mating faces of turbocharger and exhaust
manifold.
8. Reverse removal procedure. Use new clip to
secure control lever to wastegate spindle.
Tighten to
45 Nm.
9. Check/top-up engine oil level.
Tdi
5
REPAIR
FUEL LIFT PUMP
Service repair no - 19.45.09
Remove
1. Loosen unions securing fuel injection pipes to
injectors and injector pump. Remove injection
pipes.
2. Plug the connections to prevent the ingress of
foreign material.
3. Loosen unions and disconnect fuel supply and
feed hoses from fuel lift pump.
4. Plug the connections to prevent the ingress of
foreign material.
5. Remove 2 bolts securing lift pump to engine
block.
6. Remove fuel lift pump and discard gasket.
Refit
7. Clean mating faces of fuel lift pump and engine
block.
8. Using a new gasket, fit fuel pump, ensure correct
location of lever with camshaft. Fit securing
bolts. Tighten to
25 Nm.
9. Connect fuel hoses to pump and secure unions.
Tighten to
33 Nm.
10. Fit injector pipes to injectors and injection pump,
and secure unions. Tighten to
28 Nm.
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