Range Rover Sport / L494 2017 User Manual Fuel Charging and Controls

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COMPONENT LOCATION – SHEET 1 OF 2 – VEHICLES WITH SINGLE TURBOCHARGER

E167929

 





ITEM DESCRIPTION
1 Variable Geometry Turbine (VGT) turbocharger

 

COMPONENT LOCATION – SHEET 2 OF 2 – VEHICLES WITH TWIN TURBOCHARGER

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ITEM DESCRIPTION
1 Charge air intake valve
2 Turbine intake shut-off valve solenoid
3 Charge air solenoid
4 Variable Geometry Turbine (VGT) turbocharger – Primary
5 Vacuum reservoir
6 Fixed vane turbocharger – Secondary

Depending on the market, the 3.0L V6 diesel engine is available in two variants. The single turbocharger variant uses a single VGT (Variable Geometry Turbine) type turbocharger, the twin turbocharger variant uses two turbochargers. The twin turbocharger variant comprises a VGT type turbocharger (primary turbocharger), and a fixed vane type (secondary turbocharger) turbocharger.

On the twin turbocharger variant, both turbochargers are used in a parallel sequential turbocharging system, which enables the engine to achieve quick throttle response at low engine speeds and efficient use of exhaust gas energy at high engine speeds. The primary turbocharger operates through the entire engine speed range, but is at its most efficient, at engine speeds of up to 2800 RPM it is running in a mono turbocharger mode. At engine speeds above 2800 RPM under load, the secondary turbocharger comes into operation, with both of the turbochargers running in a parallel bi-turbocharger mode.

The twin turbocharger system comprises the two turbochargers, the turbine intake shut-off valve solenoid, and the charge air intake valve, which incorporates the charge air recirculation solenoid and the charge air shut-off valve. The operation of the system is controlled by the ECM (Engine Control Module).

The turbochargers and the charge air intake valve are interconnected by the charge air ducts of the intake air distribution and filtering system. For additional information, refer to:Intake Air Distribution and Filtering (303-12A Intake Air Distribution and Filtering – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Description and Operation).

Each turbocharger consists of two turbo elements, a turbine wheel and compressor wheel, enclosed separately in cast housings and mounted on a common shaft. The shaft in the primary turbocharger rotates in two ball bearings, however the secondary turbocharger comprises two semi-floating bearings which provides the shaft rotation.

The turbocharger bearings are lubricated and cooled by an oil supply from the cylinder block. The primary turbocharger has a connection for the engine cooling circuit to provide the appropriate cooling efficiency of the ball bearing. The primary turbocharger return oil drains into a dedicated area of the oil pan, assisted by an oil scavenge element in the vacuum pump. If fitted, the secondary turbocharger return oil drains into a dedicated area of the crankcase directly via drain tube. For additional information, refer to:Engine (303-01A Engine – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Description and Operation).

VARIABLE GEOMETRY TURBINE (VGT) TURBOCHARGER – PRIMARY

E166495

 














ITEM DESCRIPTION
1 Charge air outlet
2 Exhaust inlet
3 Exhaust outlet
4 Oil feed connection
5 Coolant return connection
6 Coolant supply connection
7 Variable Geometry Turbine (VGT) vane actuator rod
8 Oil return connection
9 Variable Geometry Turbine (VGT) vane actuator
10 Clean air inlet

The primary turbocharger is attached to the left exhaust manifold and secured to 3 studs on a flange on the manifold with nuts. On production, no gasket is used to seal the joint surface between the turbocharger and the manifold. In-service vehicles will require a service gasket to be fitted if the joint surface is disturbed.

A second flange on the turbocharger provides for the attachment of the left down pipe of the exhaust system. Three screws secure the down pipe to the flange and a gasket seals the joint.

The compressor end of the turbocharger has two hose connections. The central hose connection provides a clean air supply from the air cleaner to the compressor. The second connection on the outside of the housing provides for the attachment of the charge air ducts.

The turbocharger comprises a turbine wheel and a machined compressor wheel, sharing a common shaft which is supported on ball bearings. The application of the machined compressor wheel and the ball bearing results improved durability, reduced NVH (Noise, Vibration and Harshness) and optimized fuel economy. The turbocharger receives an engine oil feed via a pipe from the cylinder block. The pipe supplies the turbocharger with engine oil for lubrication purposes. An oil drain pipe from the turbocharger allows oil to drain from the turbocharger into the cylinder block. The turbocharger also has a connection for the engine cooling circuit to provide the appropriate cooling efficiency of the ball bearing.

An integral bracket houses the VGT vane actuator. The VGT vane actuator is connected to an eccentric lever which moves the turbine housing to adjust the position of the vanes. When the actuator operates a boss is rotated, which in turn moves the lever and changes rotary motion into linear motion. The lever is connected to a rod attached to the outside of the turbine housing and the linear motion is converted back to rotary motion of the housing.

Operation of the VGT vane actuator is controlled by the ECM. The VGT vane actuator also provides the ECM with a feedback signal to determine the pitch angle of the vanes.

The variable vanes in the turbocharger improve the exhaust gas power transfer to the turbine wheel which in turn drives the compressor wheel. This greatly assists the increase in charge air pressure at low engine speeds.

SECONDARY TURBOCHARGER (WHERE FITTED)

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ITEM DESCRIPTION
1 Turbine intake shut-off valve
2 Exhaust intake
3 Oil feed connection
4 Seal pressurizing air pipe
5 Charge air outlet
6 Clean air intake
7 Compressor housing
8 Electrical connector – Turbine intake shut-off valve position sensor
9 Exhaust outlet
10 Vacuum connection
11 Turbine housing
12 Oil return connection

The secondary turbocharger is attached to the right exhaust manifold and is secured to 3 studs on a flange on the manifold with nuts. On production, no gasket is used to seal the joint surface between the turbocharger and the manifold. In-service vehicles will require a service gasket to be fitted if the joint surface is disturbed.

A second flange on the turbocharger provides for the attachment of the right down pipe of the exhaust system. Two screws secure the down pipe to the flange and a gasket seals the joint.

The compressor end of the turbocharger has two hose connections. The central connection provides a clean air supply from the air cleaner to the compressor. The second connection on the outside of the housing provides for the attachment of the charge air ducts.

A pipe on the center housing of the turbocharger provides for the connection of a bleed air pipe from the charge air duct connection with the electric throttle. The bleed air is used to pressurize the seals of the compressor stage to prevent oil leaking into the compressor housing when the turbocharger is not running.

Attached to the rear of the turbocharger is a turbine intake shut-off valve operated by a vacuum actuator. The ECM operates the turbine intake shut-off valve solenoid to apply and release the vacuum in the actuator, which opens the turbine intake shut-off valve when a vacuum is present. The turbine intake shut-off valve is closed when the system is operating in mono-turbocharger mode, diverting exhaust gases from the right exhaust manifold, via the exhaust cross-over duct to the left exhaust manifold. A position sensor in the turbine intake shut-off valve allows the ECM to monitor the shut-off valve for correct operation.

CHARGE AIR INTAKE VALVE (WHERE FITTED)

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ITEM DESCRIPTION
1 Charge air recirculation solenoid
2 Charge air shut-off valve connecting rod
3 Vacuum connection
4 Vacuum actuator
5 Charge air outlet connection (to charge air coolers)
6 Charge air shut-off valve body
7 Charge air recirculation solenoid body
8 Charge air intake (from secondary turbocharger)
9 Charge air recirculation solenoid outlet connection (to primary turbocharger clean air duct)

The charge air intake valve is attached to a bracket on the front subframe and the cooling pack protector. The ECM uses the valve to control the bi-turbocharger operation of the turbochargers.

The charge air intake valve consists of a recirculation solenoid and a shut-off valve that are connected together by four screws and a gasket. The charge air recirculation solenoid controls the flow of air from the compressor of the secondary turbocharger to the clean air duct of the primary turbocharger. The charge air shut-off valve controls the flow of air from the compressor of the secondary turbocharger to the charge air coolers.

The charge air recirculation solenoid is operated by a power feed from the EJB (Engine Junction Box) and a ground connection with the ECM. When it is de-energized, the charge air recirculation solenoid is closed.

If the charge air recirculation solenoid develops a fault it will default to the closed position. In this position an overspeed of the primary turbocharger will occur. This overspeed is sensed by the MAP (Manifold Absolute Pressure) sensor which detects the increase in pressure. The ECM registers the signals from the MAP sensor and operates the turbochargers in mono-turbo mode with restricted engine torque and DTC (Diagnostic Trouble Code)’s recorded.

The charge air shut-off valve is a flap valve operated by a vacuum actuator. The ECM operates the charge air solenoid to apply and release the vacuum in the actuator, which opens the valve when a vacuum is present. When the shut-off valve is open charge air from the secondary turbocharger flows through the valve to the charge air coolers in common with the air flow from the primary turbocharger.

VACUUM CONTROL SOLENOIDS (WHERE FITTED)

E144806

 













ITEM DESCRIPTION
1 Vacuum reservoir
2 Vacuum connection to turbine intake shut-off valve (secondary turbocharger)
3 Turbine intake shut-off valve solenoid
4 Charge air shut-off valve solenoid
5 Pipe from left air cleaner
6 Pipe to cooling bypass solenoid of Exhaust Gas Recirculation (EGR) system
7 Pipe to vacuum actuator of charge air shut-off valve
8 Non return valve
9 Pipe from vacuum pump

The turbine intake shut-off valve and charge air shut-off valve solenoids are installed on a bracket attached to the front of the Bank 2 cylinder head. The ECM operates the solenoids to apply and release the vacuum in the vacuum actuators of the turbine intake shut-off valve (located on the secondary turbocharger) and the charge air shut-off valve.

The vacuum for the actuators is produced by the vacuum pump on the rear of the Bank 1 cylinder head. For additional information, refer to:Engine (303-01A Engine – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Description and Operation).

The solenoids are normally-closed valves installed in the vacuum line between the vacuum reservoir and their related vacuum actuator. Each solenoid is also connected to a line from the left air cleaner, which allows air into the vacuum lines to the actuators when the solenoids are de-energized.

PRINCIPLES OF VARIABLE VANE OPERATION

The turbine wheel of each turbocharger uses the engine exhaust gases to drive the compressor wheel. The compressor wheel draws in clean air, which is supplied to the engine cylinders in a compressed form.

The primary, VGT turbocharger allows the optimum inlet geometry (inlet area and flow angle) to be used over a wide range of engine operating conditions. This allows a rapid speed of response and higher charge air pressures at low engine speeds. The variable vane angle determines both the inlet area as well as the flow angle, as controlled by the ECM via the VGT actuator. The variable vanes allow efficient use of the exhaust gas energy which in turn improves turbocharger and engine efficiency.

Schematic Diagram – Variable Vane Operation

E107579

 

A = LOW ENGINE SPEED; B = INTERMEDIATE ENGINE SPEED; C = MAXIMUM ENGINE SPEED.









ITEM DESCRIPTION
1 Engine Control Module (ECM)
2 Variable Geometry Turbine (VGT) vane actuator
3 Turbine housing
4 Variable vanes
5 Compressor wheel

Low Engine Speed. At low engine speeds the volume of exhaust gas is low so the vanes are moved towards the closed position to reduce the turbine inlet area. This reduction causes an increase in the gas velocity into the turbine wheel thereby increasing wheel speed and charge air pressure.

Intermediate Engine Speed. As the engine speed increases and the volume of exhaust gas increases the vanes are moved towards the open position to increase the turbine inlet area and maintain the gas velocity.

Maximum Engine Speed. At maximum engine speed the vanes are almost fully open maintaining the gas velocity into the turbine wheel.

When the vehicle is driven at high altitudes the ambient pressure reduces causing the compressor wheel to rotate faster to achieve the same charge air pressure. To prevent the turbine wheel from over-speeding under these conditions, the ECM protects the turbocharger by opening the vanes further to reduce the turbine wheel speed. This is known as the altitude margin of the turbocharger, which occurs at altitudes above 2000 meters. Below 2000 meters altitude compensation is not necessary. The ECM uses an internal barometric pressure sensor to monitor altitude.

The maximum position of the turbocharger vanes (fully open) is also an emergency default position in the event of an electrical fault. This lowers the chance of engine damage due to excessive charge air pressure.

DUAL MODE BOOSTING (WHERE FITTED)

CAUTION:

Ensure both ends of the pipe are securely connected to the secondary turbo and the air intake system to prevent damage to the turbo components.

The dual mode boosting system comprises two turbochargers and software within the ECM. The two turbochargers can operate in two modes; mono turbocharger operation or bi-turbocharger operation.

MONO TURBOCHARGER OPERATION

E144807

 

A = DIRTY AIR; B = CLEAN AIR; C = CHARGE AIR; D = EXHAUST GASES.



















ITEM DESCRIPTION
1 Engine
2 Exhaust system left intake pipe
3 Primary turbocharger
4 Left intake grills
5 Left air cleaner
6 Left charge air cooler
7 Charge air shut-off valve
8 Charge air recirculation solenoid
9 Right charge air cooler
10 Right air cleaner
11 Right intake grills
12 Electric throttle
13 Secondary turbocharger
14 Exhaust system right intake pipe
15 Turbine shut-off valve

Fresh air is drawn through the left air cleaner and the MAF (Mass Air Flow) sensor to the primary turbocharger compressor. The compressed air then passes through the charge air coolers and electric throttle to the intake manifolds.

The turbine shut-off valve on the secondary turbocharger is closed and therefore exhaust gases are unable to operate the secondary turbocharger turbine. In this condition all charge air pressure is produced by the primary turbocharger using the exhaust gases from all six cylinders.

If the engine idles for more than 3 minutes, the secondary turbocharger is actuated to keep the turbocharger shaft rotating, to prevent oil from leaking into the turbine housing. This is achieved by periodically opening the turbine intake shut-off valve to operate the turbocharger.

BI-TURBOCHARGER SWITCHING

E144808

 

A = DIRTY AIR; B = CLEAN AIR; C = CHARGE AIR; D = EXHAUST GASES.



















ITEM DESCRIPTION
1 Engine
2 Exhaust system left intake pipe
3 Primary turbocharger
4 Left intake grills
5 Left air cleaner
6 Left charge air cooler
7 Charge air shut-off valve
8 Charge air recirculation solenoid
9 Right charge air cooler
10 Right air cleaner
11 Right intake grills
12 Electric throttle
13 Secondary turbocharger
14 Exhaust system right intake pipe
15 Turbine shut-off valve

When the engine operating parameters approach the limits (approximately 2800 RPM under load) of the primary turbocharger, the ECM begins the switch to parallel bi-turbocharger operation. The secondary turbocharger is brought into operation by the opening of the turbine shut-off valve which allows exhaust gases to flow through the turbine. Fresh air is then drawn through the right air cleaner and the MAFT (Mass Air Flow and Temperature) sensor to the secondary turbocharger compressor.

Initially, the secondary turbocharger does not produce a charge air pressure to equal that of the primary turbocharger. Therefore, the charge air from the secondary turbocharger is fed via the recirculation solenoid into the clean air duct of the primary turbocharger.

BI-TURBOCHARGER OPERATION

E144809

 

A = DIRTY AIR; B = CLEAN AIR; C = CHARGE AIR; D = EXHAUST GASES.



















ITEM DESCRIPTION
1 Engine
2 Exhaust system left intake pipe
3 Primary turbocharger
4 Left intake grills
5 Left air cleaner
6 Left charge air cooler
7 Charge air shut-off valve
8 Charge air recirculation solenoid
9 Right charge air cooler
10 Right air cleaner
11 Right intake grills
12 Electric throttle
13 Secondary turbocharger
14 Exhaust system right intake pipe
15 Turbine shut-off valve

As the secondary turbocharger charge air pressure increases, the recirculation solenoid is closed and the charge air shut-off valve opened. This increases the charge air pressure from the secondary turbocharger and combines it with the charge air from the primary turbocharger.

The ECM maintains the turbochargers in bi-turbocharger mode until it determines that the engine operating parameters no longer require it. The ECM then switches the turbochargers back to mono turbocharger operation.

SHUT-OFF VALVE CONTROL

Turbine intake shut-off valve: If vacuum is released from the turbine intake shut-off valve it will default to the closed position. The turbine intake shut-off valve position sensor will inform the ECM, which will initiate mono-turbo mode, restrict engine performance and record a DTC.

Charge air shut-off valve: If vacuum is released from the charge air shut-off valve it will default to the closed position. In the default position, the ECM initiates mono-turbo operation and restricts engine torque. A DTC will also be recorded in the ECM.

CONTROL DIAGRAM – SHEET 1 OF 2 – VEHICLES WITH SINGLE TURBOCHARGER

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ITEM DESCRIPTION
1 Battery
2 Battery Junction Box 2 (BJB2)
3 Battery Junction Box (BJB)
4 Engine Junction Box (EJB)
5 Engine Control Module (ECM)
6 Variable Geometry Turbine (VGT) vane actuator
7 Charge air temperature sensor
8 Charge air pressure sensor

CONTROL DIAGRAM – SHEET 2 OF 2 – TWIN TURBOCHARGER VARIANT VEHICLES

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ITEM DESCRIPTION
1 Battery
2 Battery Junction Box 2 (BJB2)
3 Battery Junction Box (BJB)
4 Engine Junction Box (EJB)
5 Engine Control Module (ECM)
6 Variable Geometry Turbine (VGT) vane actuator
7 Charge air temperature sensor
8 Charge air pressure sensor
9 Turbine intake shut-off valve position sensor
10 Turbine intake shut-off valve solenoid
11 Charge air solenoid
12 Charge air recirculation solenoid

DESCRIPTION AND OPERATION

 

TDV6 3.0L DIESEL – GEN 2 SINGLE TURBOCHARGER

E201036

 








ITEM DESCRIPTION
1 Vacuum reservoir
2 Variable Geometry Turbine (VGT)- Turbocharger
3 Vacuum pump (Brake servo assist and turbocharger oil supply pump)
4 Electronic Vacuum Regulating Valve (EVRV) – EGR control

This variation of the TDV6 engine has a single Variable Geometry Turbine (VGT) turbocharger mounted on the left side of the engine. This turbocharger is slightly larger in size compared to the primary turbocharger fitted to the twin turbocharger variants of the TDV6 engine. The VGT makes it possible to vary the exhaust gas flow of the turbine, dependent on engine operation. This improves the power transfer to the turbine and compressor wheels, particularly at low engine speeds, thus increasing the boost pressure.

The VGT is connected by the charge air ducts of the intake air distribution and filtering system. For additional information, refer to:Intake Air Distribution and Filtering (303-12A Intake Air Distribution and Filtering – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Description and Operation). The operation of the system is controlled by the Powertrain Control Module (PCM).

The turbocharger is also cooled with a feed from the main engine cooling system.

VARIABLE GEOMETRY TURBINE (VGT) – TURBOCHARGER

E201050

 
















ITEM DESCRIPTION
1 Exhaust gas outlet to exhaust system
2 Exhaust gas inlet from exhaust manifold
3 Coolant outlet
4 Oil pressure supply from cylinder block
5 Vane actuator
6 Clean air inlet
7 Charge air outlet
8 Coolant feed from cylinder block
9 Oil feed connection
10 Oil return connection
11 Coolant connections
12 Vane actuator rod

The Variable Geometry Turbine (VGT) – turbocharger is mounted to the left (bank 2) exhaust manifold.

NOTE:

On production vehicles, no gasket is used to seal the joint surface between the turbocharger and the exhaust manifold. In-service vehicles require a service gasket to be fitted if the joint is disturbed.

The turbocharger consists of two main elements, a turbine wheel and compressor wheel, enclosed separately in cast housings and mounted on a common shaft rotating on two ball bearing races. The ball bearings receive an engine oil feed for lubrication from an outlet at the rear of the engine block, oil then returns to the engine oil pan via an oil drain pipe. Gen 2 engines also have a coolant feed to the primary turbocharger housing from the engine cooling system.

An integral bracket on the compressor side of the turbocharger locates the VGT vane actuator. The VGT vane actuator is connected to an actuator rod which moves the turbine housing to adjust the position of the vanes. When the VGT vane actuator operates, a lever is rotated by a lever arm, which in turn moves the actuator rod and changes rotary motion into linear motion. The actuator rod is connected to a second lever arm attached to the outside of the turbine housing. The linear motion is converted back to rotary motion of the housing and adjusts the variable vanes within the VGT.

The VGT has a connection for the engine cooling circuit to provide the appropriate cooling efficiency of the ball bearing races.

 

The Powertrain Control Module (PCM) controls the output to the vane actuator motor using a Pulse Width Modulation (PWM) signal. The VGT vane actuator also provides the PCM with a positional feedback signal to determine the pitch angle of the vanes. An angular position sensor in the motor is provided with a 5V reference voltage from the PCM. The position sensor returns a ground and a signal voltage proportional to the actuator position.

The variable vanes in the turbocharger improve the exhaust gas power transfer to the turbine wheel which in turn drives the compressor wheel. This greatly assists the increase in charge air pressure at low engine speeds.

TURBOCHARGER OIL LUBRICATION SYSTEM

E201034

 
















ITEM DESCRIPTION
1 Oil feed to turbocharger
2 Oil feed from cylinder block (T piece)
3 Vacuum pump (Brake servo assist and turbocharger oil supply pump)
4 Oil feed from turbocharger oil reservoir
5 Turbocharger oil reservoir oil filter
6 Vent pipe
7 Connection to oil pan oil return pipe
8 Turbocharger oil return pipe
9 Variable Geometry Turbine (VGT)- turbocharger
10 Turbocharger oil reservoir
11 Oil pan
12 Vent pipe

The TDV6 turbocharger system has an oil circuit which is primarily supplied by the engine oil pump and fed to the housing of the turbocharger via an outlet at the back of the cylinder block. Land Rover variants of the TDV6 engine have a vacuum pump driven off the the exhaust camshaft on bank 1, this provides brake booster vacuum and also turbocharger oil supply in certain conditions. The vacuum pump draws oil from a dedicated reservoir within the oil pan via a filter, this oil is then fed to the turbocharger via a port in the cylinder head. The secondary oil feed supplied by the vacuum pump is to make sure that there is adequate lubrication of the bearing races and housing when the vehicle is manoeuvring at extreme angles. The reservoir is replenished with oil from the drain tube below the turbocharger, it also has a breather tube into the cylinder block.

See oil flow diagram at the end of this document.

PRINCIPLES OF VARIABLE VANE OPERATION

Exhaust gases are used to drive the compressor wheel. The compressor wheel draws in clean air, which is supplied to the charge air coolers in a compressed form.

The VGT turbocharger allows the optimum inlet geometry (inlet area and flow angle) to be used over a wide range of engine operating conditions. This allows a rapid response speed and higher charge air pressures at low engine speeds. The variable vane angle determines both the inlet area as well as the flow angle, as controlled by the Powertrain Control Module (PCM) via the VGT vane actuator. The variable vanes allow efficient use of the exhaust gas energy which improves turbocharger and engine efficiency.

Schematic Diagram – Variable Vane Operation

E177096

 

A = LOW ENGINE SPEED; B = INTERMEDIATE ENGINE SPEED; C = MAXIMUM ENGINE SPEED.









ITEM DESCRIPTION
1 Powertrain Control Module (PCM)
2 Primary vane actuator
3 Turbine housing
4 Variable vanes
5 Compressor wheel

Low Engine Speed: At low engine speeds the volume of exhaust gas is low, so the vanes are moved towards the closed position to reduce the turbine inlet area. This reduction causes an increase in the gas velocity into the turbine wheel, thereby increasing turbine speed and charge air pressure.

Intermediate Engine Speed: As the engine speed increases and the volume of exhaust gas increases the vanes are moved towards the open position to increase the turbine inlet area and maintain the gas velocity.

Maximum Engine Speed: At maximum engine speed the vanes are almost fully open maintaining the gas velocity into the turbine wheel.

When the vehicle is driven at high altitudes the ambient pressure reduces, causing the compressor wheel to rotate faster to achieve the same charge air pressure. To prevent the turbine wheel from over-speeding under these conditions, the Powertrain Control Module (PCM) protects the turbocharger by opening the vanes further to reduce the turbine wheel speed. This is known as the altitude margin of the turbocharger, which occurs at altitudes above 2000 meters. Below 2000 meters altitude compensation is not necessary. The PCM uses an internal barometric pressure sensor to monitor altitude.

The maximum position of the turbocharger vanes (fully open) is also an emergency default position in the event of an electrical fault. This lowers the chance of engine damage due to excessive charge air pressure.

TDV6 3.0L DIESEL – GEN 2 SINGLE TURBOCHARGER OPERATION

 

E201037

 

A = DIRTY AIR: B = CLEAN AIR: C = COMPRESSED AIR: D = EXHAUST GAS.









ITEM DESCRIPTION
1 Engine
2 Variable Geometry Turbine (VGT)- Turbocharger
3 Intake air filter
4 Charge air cooler
5 Electric throttle

Fresh air is drawn through the left intake air filter to the turbocharger compressor. The compressed air then passes through the charge air cooler and electric throttle to the intake manifolds.

 

Single Turbocharger Oil Flow

E201035

 

A = COOL OIL: B = HOT OIL.











ITEM DESCRIPTION
1 Cylinder head
2 Cylinder block
3 Vacuum pump (Vacuum and turbocharger scavenge oil pump)
4 Turbocharger Oil Supply Filter
5 Turbocharger Oil Reservoir
6 Oil Pan
7 Turbocharger

TDV6 3.0L DIESEL – GEN 2 SINGLE TURBOCHARGER

E201032

 

A = HARDWIRED: AL = PULSE WIDTH MODULATION (PWM).










ITEM DESCRIPTION
1 Powertrain Control Module (PCM)
2 Vane actuator
3 Ground
4 Supply
5 Charge air pressure sensor
6 Charge air temperature sensor

VACUUM SYSTEM

E203359

 

A = VACUUM SUPPLY: B = VACUUM VENT: C = VACUUM SUPPLY AND VENT: D = FLOW













ITEM DESCRIPTION
1 Exhaust Gas Recirculation (EGR) valves
2 Electronic Vacuum Regulating Valve (EVRV) – (EGR) valve bypass valve
3 Active engine mounts
4 Clean air filter housing
5 Electronic Vacuum Regulating Valve (EVRV) – Active engine mount solenoid
6 Brake vacuum reservoir
7 Brake vacuum non return valve
8 Vacuum Pump (Vacuum and turbocharger scavenge oil pump)
9 Vacuum reservoir

 

PRINCIPLES OF OPERATION

For a detailed description of the fuel charging and controls system and operation, refer to the relevant Description and Operation section of the workshop manual. REFER to:Turbocharger (303-04B Fuel Charging and Controls – Turbocharger – TDV6 3.0L Diesel, Description and Operation).

 

INSPECTION AND VERIFICATION

WARNING:

The following tests may involve working in close proximity to hot components. Make sure adequate protection is used. Failure to follow this instruction may result in personal injury.

CAUTION:

Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does not guarantee confirmation of a fault and may also cause additional faults in the vehicle being checked and/or the donor vehicle.

NOTE:

Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

  1. Verify the customer concern.

  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection





MECHANICAL ELECTRICAL

  • Intake air system
  • Hose(s) / hose connections
  • Vacuum hoses
  • Turbine intake shut-off valve
  • Charge air shut-off valve
  • Charge air radiator
  • Turbocharger – primary/secondary
  • General engine condition

  • Fuses
  • Electrical connections and harnesses
  • Turbocharger actuators
  • Turbine intake shut-off valve
  • Turbine intake shut-off valve solenoid
  • Charge air shut-off valve solenoid
  • Powertrain Control Module (PCM)

  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.

  1. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for Diagnostic Trouble Code(s) (DTC)s and refer to the DTC Index.

  1. Check JLR claims submission system for open campaigns. Refer to the corresponding bulletins and SSMs which may be valid for the specific customer complaint and complete the recommendations as required.








SYMPTOM POSSIBLE CAUSES ACTION
Poor performance

  • Low/Contaminated fuel
  • Restricted intake air system
  • General engine condition
  • Powertrain control module failure

Check the fuel level and condition. Draw off approximately 1 ltr (2.11 pints) of fuel and allow to stand for 1 minute. Check to make sure there is no separation of the fuel indicating water or other liquid in the fuel. Check the intake air system for restriction. Check the engine condition, compressions, etc if there are indications of a mechanical fault. Check for DTCs indicating a module fault. Refer to the warranty policy and procedures manual if a powertrain control module is at fault
No boost

  • Electrical connections and harnesses
  • Restricted intake air system
  • Charge air cooler restricted/leaking
  • Turbocharger actuator failure(s)
  • Turbocharger failure(s)
  • Powertrain control module failure

Check the electrical connections and harnesses. Check the intake air system for restriction/leakage. Check the turbocharger actuators and circuits. Refer to the electrical guides. Check the turbochargers for wear. Disconnect the turbocharger intake and outlet pipework and turn the turbochargers by hand. Any roughness indicates a fault. Check any up and down movement in the turbocharger shafts. Excessive movement indicates a fault. If in doubt, compare the unit with a new turbocharger. Check for DTCs indicating an actuator or module fault. Refer to the warranty policy and procedures manual if a powertrain control module is at fault
No boost/excessive noise
Disconnect the turbocharger intake and outlet pipework and turn the turbochargers by hand. Any roughness indicates a fault. Check any up and down movement in the turbocharger shafts. Excessive movement indicates a fault. If in doubt, compare the unit with a new turbocharger.
Oil on the turbocharger assembly

  • Oil leak from connection(s) to the turbocharger assembly
  • Oil leak from engine above the turbocharger
  • Slight oil trace from the joint between turbocharger assembly and exhaust downpipe (RH Secondary Turbocharger)

NOTE:

DO NOT replace the turbocharger for an oil leak issue until investigations have been made to establish the source of the oil leak. In most cases it is NOT the turbocharger that is at fault.

  • Clean all oil residue from the turbocharger assembly and check for leaks from the oil feed and drain joints. Replace copper washers and gaskets as necessary. REFER to: Right Turbocharger (303-04B, Removal and Installation). Removal steps 9, 14 and installation steps 6, 10. Check and top up the engine oil as necessary. Perform a road test and check no oil leaks are evident
  • Clean all oil residue from the turbocharger assembly. Check for leaks from the inlet manifold/camshaft covers. Inspect the front and rear joints between the Inlet manifold/camshaft covers and cylinder heads. If a leak is evident, install a new camshaft cover gasket to the leaking side only as necessary REFER to: Right Valve Cover (303-01A, Removal and Installation) / Left Valve Cover (303-01A, Removal and Installation). Check and top up the engine oil as necessary. Perform a road test and check no oil leaks are evident
  • NOTE:

    DO NOT replace the turbocharger assembly for this possible cause, unless there are DTCs set and the vehicle has drivability issues. A small trace of oil is normal if the vehicle has light use or is used on short journeys.


    Clean all oil residue from the turbocharger assembly. Check and top up the engine oil as necessary. Perform a road test and check for traces of oil. If no oil traces are evident, return the vehicle to the customer

 

PARAMETER IDENTIFIER (PID)






PID DESCRIPTION ACTION
0X0347 Boost Pressure Actuator Bank 2 − Measured Position

NOTE:

The datalogger signals are applicable only for TDV6

  • Diagnosis may require using the manufacturer approved diagnostic system check datalogger signals

    • 0X0347 – Boost Pressure Actuator Bank 2 − Measured Position
    • Signal is displayed in %
    • Circuit reference VGT_FB
    • TDV6 engines the request will vary in between 20 – 80%
    • The scaling of the signal should be in seconds, a period of minimum 10 seconds would be ideal to view on the screen one stretch so that we filter the minute deviations or non alignments coming from the actuator control strategy and response
    • Check for an alignment of the two variables (Boost Pressure Actuator Bank 2 − Measured Position and Boost Pressure Actuator Bank 2 − Desired position) when the actuator is driven (a short drive with tip-in tip-out scenarios will do). Only if major deviations are taking place or any sticking of the measured position then this would signify a component operating deficiency

0X03E0 Boost Pressure Actuator Bank 2 − Desired position

NOTE:

The datalogger signals are applicable only for TDV6

  • Diagnosis may require using the manufacturer approved diagnostic system check datalogger signals

    • 0X03E0 – Boost Pressure Actuator Bank 2 − Desired position
    • Signal is displayed in %
    • Circuit reference not applicable
    • Check for an alignment of the two variables (Boost Pressure Actuator Bank 2 − Measured Position and Boost Pressure Actuator Bank 2 − Desired position) when the actuator is driven (a short drive with tip-in tip-out scenarios will do). Only if major deviations are taking place or any sticking of the measured position then this would signify a component operating deficiency

 

TDV6 3.0L DIESEL ENGINE – VACUUM SYSTEM LAYOUT. TWIN TURBOCHARGER VARIANTS ONLY

E196793

 























ITEM DESCRIPTION
1 High pressure Exhaust Gas Recirculation (EGR)(s) (1 or 2 may be fitted)
2 EGR Cooler bypass valve solenoid
3 Active engine mounts (x2) (where fitted)
4 Active engine mount solenoid (where fitted)
5 Turbine intake shut-off valve
6 Turbine intake shut-off valve solenoid
7 Charge air shut-off valve
8 Charge air shut-off valve solenoid
9 Air filter housing
10 Vacuum reservoir
11 Non return valve
12 Vacuum pump
13 Non return valve
14 Brake servo
A Vacuum supply hose
B Vacuum vent hose
C Actuator vacuum supply and vent hose
D Direction of flow
TP Pin point test reference – Test Point

NOTE:

Refit any hoses that have been disconnected before moving on to the next step

 









PINPOINT TEST A : VACUUM CONTROL SYSTEM TESTS – TWIN TURBOCHARGER VARIANTS ONLY

A1: VACUUM VENT HOSE TEST 1
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

With the ignition switched off, disconnect the vacuum vent hose from the air filter housing at point TP1

 

2

Connect a hand operated vacuum pump into the circuit at point TP1 and apply a vacuum

 

Can a vacuum be achieved and maintained?

Yes


No

Air leak, complete a smoke test to identify the leak point. If a leak is identified, repair fault and repeat step 1 to confirm repair








A2: VACUUM VENT HOSE TEST 2
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

Disconnect the vacuum vent hose from the turbine intake shut-off valve solenoid at point TP2

 

2

Connect the vacuum pump to the vent hose at point TP2 and apply a vacuum

 

Can a vacuum be achieved?

Yes

Check the vacuum vent hose for a blockage between the turbine intake shut-off valve solenoid and the air filter housing

No

If a vacuum cannot be achieved the vent hose is functioning correctly

Repeat the test for the charge air shut-off valve vent hose connecting the gauge at point TP3

If the turbine intake shut-off valve and the charge air shut-off valve vent hoses are functioning correctly GO toA3.







A3: TURBINE INTAKE SHUT-OFF VALVE CLOSED POSITION CHECK
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

Using the Jaguar Land Rover Approved Diagnostic Equipment, check datalogger signals – Turbocharger Shut-off valve opening position – Measured (0x03F1) and Turbocharger Shut-off valve opening position – Commanded (0x03F0)

 

With the ignition on and the engine off is the value for signal Turbocharger Shut-off valve opening position – Measured <4%?

Yes


No

Turbine intake shut-off valve is faulty and sticking open

Install a new turbine intake shut-off valve

After installing a new turbine intake shut-off valve, complete the calibration procedure. Using the Jaguar Land Rover Approved Diagnostic Equipment, perform routine – Powertrain set-up – Turbine shut-off valve









A4: CHARGE AIR SHUT-OFF VALVE OPERATION CHECK 1
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

Connect a hand operated vacuum pump to the charge air shut-off valve hose at point TP4

 

2

Check the operation of the charge air shut-off valve by gradually applying a vacuum and then releasing it while observing the charge air shut-off valve actuator connecting rod

 

3

Note: A clunk can be heard from the charge air shut-off valve as it closes

 

Did the charge air shut-off valve open as a vacuum was applied and close when the vacuum was released?

Yes


No










A5: CHARGE AIR SHUT-OFF VALVE OPERATION CHECK 2
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

Connect a hand operated vacuum pump directly to the charge air shut-off valve at point TP5

 

2

Check the operation of the charge air shut-off valve by gradually applying a vacuum and then releasing it while observing the charge air shut-off valve actuator connecting rod

 

3

Note: A clunk can be heard from the charge air shut-off valve as it closes

 

Did the charge air shut-off valve open as a vacuum was applied and close when the vacuum was released?

Yes

Blockage in the vacuum hose between the charge air shut-off valve solenoid and charge air shut-off valve

Inspect vacuum hose for blockages/defects and rectify as required

No

Faulty charge air shut-off valve

Install a new charge air shut-off valve








A6: CHARGE AIR SHUT-OFF VALVE ACTIVATION CHECK 1
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

Connect a hand operated vacuum pump using a ‘T’ piece between the charge air shut-off valve and the charge air shut-off valve solenoid at point TP4

 

2

Start the engine and allow to idle. View the vacuum reading while in mono turbocharger mode (during the first three minutes of idle)

 

Is a vacuum present?

Yes

Remove and inspect the charge air shut-off valve solenoid. Solenoid stuck open. Replace as required

No













A7: CHARGE AIR SHUT-OFF VALVE ACTIVATION CHECK 2
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

With the hand operated vacuum pump still connected at point TP4 through the “T” piece

 

2

Using the Jaguar Land Rover Approved Diagnostic Equipment, check datalogger signals – Turbocharger Shut-off valve opening position – Commanded (0x03F0) and Turbocharger Shut-off valve opening position – Measured (0x03F1)

 

3

After approximately 3 minutes at idle the turbine intake shut-off valve and charge air shut-off valve will automatically be triggered to open and activate the secondary turbocharger

 

4

This can be confirmed by datalogger signal – Turbocharger Shut-off valve opening position – Commanded changing value to 100%

 

5

When this occurs a vacuum of approximately 800mbar should be displayed on the gauge

 

6

Observe the value on the vacuum gauge as the secondary turbocharger is activated

 

Is the correct vacuum achieved and maintained?

Yes


No











A8: CHARGE AIR SHUT-OFF VALVE ACTIVATION CHECK 3
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

With the engine idling in bi-turbo mode an increase in engine speed will return the engine to mono turbocharger mode

 

2

Increase engine speed and then allow the engine to return to idle

 

3

The vacuum will return to zero (within 2-3 seconds)

 

4

Observe the value on the vacuum gauge as the secondary turbocharger is deactivated

 

Is the correct vacuum is achieved and maintained?

Yes


No

Check that the datalogger signal – Turbocharger Shut-off valve opening position – Commanded (0x03F0) has changed to 0%. If so, remove and inspect the charge air shut-off valve solenoid. Solenoid stuck open. Replace as required









A9: CHARGE AIR SHUT-OFF VALVE VACUUM SUPPLY CHECK
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

Connect the vacuum pump with gauge to the charge air shut-off valve solenoid vacuum supply hose at point TP6

 

2

Start the engine and allow to idle

 

3

Observe the gauge, a vacuum of approximately 800mbar should be displayed

 

Is the correct vacuum achieved and maintained?

Yes

Remove and inspect the charge air shut-off valve solenoid. Solenoid stuck closed. Replace as required

No









A10: TURBINE INTAKE SHUT-OFF VALVE ACTIVATION CHECK 1
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

Connect a hand operated vacuum pump using a ‘T’ piece between the turbine intake shut-off valve and the turbine intake shut-off valve solenoid at point TP7

 

2

Start the engine and allow to idle. View the vacuum reading while in mono turbocharger mode (during the first three minutes of idle)

 

Is a vacuum present?

Yes

Remove and inspect the turbine intake shut-off valve solenoid. Solenoid stuck open. Replace as required

No














A11: TURBINE INTAKE SHUT-OFF VALVE ACTIVATION CHECK 2
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

With the hand operated vacuum pump still connected into the circuit at point TP7

 

2

Allow the engine to idle

 

3

Using the Jaguar Land Rover Approved Diagnostic Equipment, record datalogger signals – Turbocharger Shut-off valve opening position – Commanded (0x03F0) and Turbocharger Shut-off valve opening position – Measured (0x03F1)

 

4

After approximately 3 minutes at idle the turbine intake shut-off valve will automatically be triggered to open and activate the secondary turbocharger

 

5

This can be confirmed by datalogger signal – Turbocharger Shut-off valve opening position – Commanded changing value to 100%

 

6

When this occurs a vacuum of approximately 800mbar should be displayed on the gauge

 

7

Observe the value on the vacuum gauge as the secondary turbocharger is activated

 

Is the correct vacuum is achieved and maintained?

Yes


No









A12: TURBINE INTAKE SHUT-OFF VALVE ACTIVATION CHECK 3
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

Look at the recorded datalogger signals 1 – Turbocharger Shut-off valve opening position – Commanded (0x03F0) and 2 – Turbocharger Shut-off valve opening position – Measured (0x03F1)

 

E198348

 

Is the measured value for the turbocharger shut-off valve 98% or greater? (See screenshot for reference)

Yes


No








A13: TURBINE INTAKE SHUT-OFF VALVE ACTIVATION CHECK 4
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

Look at the recording for the datalogger signal 2 – Turbocharger Shut-off valve opening position – Measured (0x03F1)

 

Does the signal show the valve moving smoothly and continuously to its maximum open position? (Refer to screenshot in step A12)

Yes


No

Turbine intake shut-off valve is sticking. Replace faulty turbine intake shut-off valve

After installing a new turbine intake shut-off valve, complete the calibration procedure. Using the Jaguar Land Rover Approved Diagnostic Equipment, perform routine – Powertrain set-up – Turbine shut-off valve











A14: TURBINE INTAKE SHUT-OFF VALVE ACTIVATION CHECK 5
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

Using the Jaguar Land Rover Approved Diagnostic Equipment, record datalogger signals – Turbocharger Shut-off valve opening position – Commanded (0x03F0) and Turbocharger Shut-off valve opening position – Measured (0x03F1)

 

2

If the engine speed is increased from idle then the turbine shut-off valve will automatically close returning to mono turbocharger mode

 

3

Increase engine speed and then allow the engine to return to idle

 

4

The vacuum will drop back to zero (within 2-3 seconds)

 

5

Observe the value on the vacuum gauge as the secondary turbocharger is deactivated

 

Is the correct vacuum achieved and maintained?

Yes


No

Check that the datalogger signal – Turbocharger Shut-off valve opening position – Commanded (0x03F0) has changed to 0%. If so, remove and inspect the charge air shut-off valve solenoid. Solenoid stuck open. Replace as required








A15: TURBINE INTAKE SHUT-OFF VALVE ACTIVATION CHECK 6
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

Look at the recorded datalogger signals 3 – Turbocharger Shut-off valve opening position – Commanded (0x03F0) and 4 – Turbocharger Shut-off valve opening position – Measured (0x03F1)

 

E198349

 

Did the signal value for Turbocharger Shut-off valve opening position – Measured change to <4%? (See screenshot for reference)

Yes


No

Turbine intake shut-off valve is sticking

Install a new turbine intake shut-off valve

After installing a new turbine intake shut-off valve, complete the calibration procedure. Using the Jaguar Land Rover Approved Diagnostic Equipment, perform routine – Powertrain set-up – Turbine shut-off valve







A16: TURBINE INTAKE SHUT-OFF VALVE ACTIVATION CHECK 7
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

Look at the recorded datalogger signals 3 – Turbocharger Shut-off valve opening position – Commanded (0x03F0) and 4 – Turbocharger Shut-off valve opening position – Measured (0x03F1)

 

Does the signal show the valve moving smoothly and continuously to its minimum closed position? (Refer to screenshot in step A15)

Yes

No fault present. Exit pin point test

No

Turbine intake shut-off valve is sticking

Install a new turbine intake shut-off valve

After installing a new turbine intake shut-off valve, complete the calibration procedure. Using the Jaguar Land Rover Approved Diagnostic Equipment, perform routine – Powertrain set-up – Turbine shut-off valve









A17: TURBINE INTAKE SHUT-OFF VALVE VACUUM SUPPLY CHECK
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

Connect the vacuum pump with gauge to the turbine intake shut-off valve solenoid vacuum supply line at point TP8

 

2

Start the engine and allow to idle

 

3

Observe the gauge, a vacuum of approximately 800mbar should be displayed

 

Is the correct vacuum is achieved and maintained?

Yes

Remove and inspect the turbine intake shut-off valve solenoid. Solenoid stuck closed. Replace as required

No









A18: VACUUM SUPPLY CHECK
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

Switch off the engine and the ignition

 

2

With the hand operated vacuum pump still connected into the circuit at point TP8, apply a vacuum

 

Does it hold vacuum pressure?

Yes

Look for air leaks on the vacuum supply line between the non return valve and the vacuum pump

Complete smoke test to identify leak point

Check the output pressure directly at the vacuum pump

No

Air leak in vacuum supply line between the non return valve and the turbine intake shut-off valve / charge air shut-off valve solenoids

Complete smoke test to identify leak point. Repair/replace as required









A19: TURBINE INTAKE SHUT-OFF VALVE OPERATION CHECK
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 

1

Connect a hand operated vacuum pump directly to the secondary turbocharger turbine intake shut-off valve at point TP9

 

2

Gradually apply a vacuum and observe the turbine intake shut-off valve actuator and monitor the position sensor signal with datalogger

 

E198350

 

Does the turbine intake shut-off valve operate and is this reflected by signal 5 – Turbocharger Shut-off valve opening position – Measured (0x03F1) value?

Yes

Blockage in vacuum supply line between the turbine intake shut-off valve and charge air shut-off valve solenoid

Inspect hose for defect and rectify as required

No

Turbine intake shut-off valve failure

Install a new turbine intake shut-off valve

After installing a new turbine intake shut-off valve, complete the calibration procedure. Using the Jaguar Land Rover Approved Diagnostic Equipment, perform routine – Powertrain set-up – Turbine shut-off valve

For a list of Diagnostic Trouble Codes that could be set on this vehicle, please refer to Section 100-00. REFER to: Diagnostic Trouble Code Index – TDV6 3.0L Diesel , DTC: Powertrain Control Module (PCM) (100-00 General Information, Description and Operation).

 

Repairs


















Name Quantity Part Number
EGR inlet pipe to exhaust gasket 1 LR078958
Engine compartment brace bolts 8 LR037935
Exhaust gas recirculation gasket 1 LR075627
Exhaust manifold to turbocharger nuts 3 LR106277
Left exhaust downpipe gasket 1 LR016619
Lower oil return pipe gasket 1 LR013234
Oil pan drain plug 1 1013938
Retaining clip 1 LR063121
Right exhaust downpipe gasket 1 LR016621
Turbocharger coolant pipes to turbocharger gasket 1 LR062102
Turbocharger oil feed pipe banjo bolt washers 2 1372726
Turbocharger oil supply pipe banjo bolt 1 LR023967
Turbocharger to exhaust manifold gasket 1 LR084664
Upper oil return pipe gasket 1 LR013235

MONO TURBO CHARGED ENGINES

 






Name Quantity Part Number VIN range from VIN range to
Turbocharger 1 LR061996 FA000001 GA568271
Turbocharger 1 LR084606 GA568272  

TWIN TURBO CHARGED ENGINES

 








Name Quantity Part Number VIN range from VIN range to
Primary turbocharger 1 LR029915   EA326005
Primary turbocharger 1 LR056369 EA326006  
Primary turbocharger 1 LR061998 FA000001 GA554433
Primary turbocharger 1 LR084605 GA554434  
Left Turbocharger – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5 (303-04B REMOVAL AND INSTALLATION G1509438)

 

REMOVAL AND INSTALLATION

 

  • 19.42.56
  • TURBOCHARGER – LH – RENEW
  • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
  • 4.80

 

GENERAL EQUIPMENT





EQUIPMENT NAME
Jaguar Land Rover approved diagnostic equipment

PART(S)











STEP PART NAME QUANTITY
Installation Step 1 Turbocharger coolant pipes to turbocharger gasket 1
Installation Step 2 Exhaust manifold to turbocharger nuts 3
Installation Step 2 Turbocharger to exhaust manifold gasket 1
Installation Step 7 Turbocharger oil supply pipe banjo bolt 1
Installation Step 7 Turbocharger oil feed pipe banjo bolt washers 2
Installation Step 9 Lower oil return pipe gasket 1
Installation Step 9 Upper oil return pipe gasket 1

CAUTION:

Before disconnecting any components, make sure the area is clean and free from foreign material. ​When ​disconnected all openings must be sealed.

NOTES:

  • This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.

  • This procedure contains illustrations showing certain components removed to provide extra clarity.

 

    1. Remove the engine undershield.

 

    1. Drain the engine oil.

 

    1. Remove the exhaust.

 

    1. Remove the left Exhaust Gas Recirculation (EGR) valve.

 

    1. E178639


      Release the intake air pipe.

 

    1. CAUTION:

      Make sure that the area around the component is clean and free of foreign material.


      E147280


      • Remove and discard the gasket.

 

    1. CAUTION:

      Make sure that the area around the component is clean and free of foreign material.


      E147281

      • Remove the turbocharger oil return pipe.

      • Remove and discard the gasket.

 

    1. E178323


      Remove the turbocharger heatshield.

 

    1. CAUTION:

      Make sure that the area around the component is clean and free of foreign material.


      E148088

      • Remove and discard the turbocharger oil feed pipe bolt.

      • Remove and discard the washers.

 

    1. E148082


      Disconnect the Crankshaft Position Sensor (CKP) electrical connector.

 

    1. E148083


      Disconnect the electrical connector from the turbocharger.

 

    1. E148087


      Remove the 4 bolts.

 

    1. WARNING:

      Be prepared to collect escaping fluids.


      E178331


      Release the coolant pipe.

 

    1. WARNING:

      Be prepared to collect escaping fluids.


      E178332

      • Release the coolant pipe.

 

    1. E178335


      Remove the exhaust manifold heatshield.

 

    1. E178337


      Remove and discard the nut.

 

    1. E178338

      • Remove and discard the nuts.

      • Remove and discard the gasket.

 

  1. E178339

    • Remove the turbocharger coolant pipe.

    • Remove and discard the gasket.

 

      • Install the turbocharger coolant pipe.

        Torque: 9Nm


 

      • Install the turbocharger.

        Torque: 26Nm



 

    1. Install the exhaust manifold heatshield.

 

      • Connect the turbocharger coolant pipes.

        Torque: 10Nm

 

    1. CAUTION:

      Apply Loctite 243 to the bolts.

      NOTE:

      Make sure to clean the threads prior to installation.

      • Install the turbocharger retaining bracket.

      • Install the 4 bolts.

        Torque: 32Nm

 

      • Connect the electrical connector to the turbocharger.

      • Connect the Crankshaft Position Sensor (CKP) electrical connector.

 



 

    1. Install the turbocharger heatshield.

      Torque: 9Nm

 

    1. CAUTION:

      Make sure that the area around the component is clean and free of foreign material.

      • Install the turbocharger oil return pipe.

        Torque: 9Nm


 

    1. Install the air intake pipe.

      Torque: 10Nm

 

    1. Install the left Exhaust Gas Recirculation (EGR) valve.

 

    1. Install the exhaust.

 

    1. Install the engine undershield.

 

    1. Fill the engine with oil.

 

  1. If a new component has been installed, configure using the Jaguar Land Rover approved diagnostic equipment.

 

Removal and Installation

REMOVAL AND INSTALLATION

 

  • 19.42.56
  • TURBOCHARGER – LH – RENEW
  • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
  • 4.80

 

SPECIAL TOOL(S)

GENERAL EQUIPMENT





EQUIPMENT NAME
Jaguar Land Rover approved diagnostic equipment

PART(S)











STEP PART NAME QUANTITY
Installation Step 1 Turbocharger coolant pipes to turbocharger gasket 1
Installation Step 2 Turbocharger to exhaust manifold gasket 1
Installation Step 2 Exhaust manifold to turbocharger nuts 3
Installation Step 7 Turbocharger oil feed pipe banjo bolt washers 2
Installation Step 7 Turbocharger oil supply pipe banjo bolt 1
Installation Step 9 Lower oil return pipe gasket 1
Installation Step 9 Upper oil return pipe gasket 1

CAUTION:

Before disconnecting any components, make sure the area is clean and free from foreign material. ​When ​disconnected all openings must be sealed.

NOTES:

  • This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.

  • This procedure contains illustrations showing certain components removed to provide extra clarity.

 

    1. Raise and support the vehicle on a suitable 2 post lift.
      Refer to:Lifting (100-02 Jacking and Lifting, Description and Operation).

 

    1. Drain the engine oil.

 

    1. Remove the exhaust system.

 

    1. Remove the transmission fluid cooler pipes.

 

    1. Remove the left exhaust gas recirculation valve.

 

    1. E178639


      • Reposition the air intake pipe away from the turbocharger.

 

    1. E147280


      • Remove and discard the gasket.

 

    1. E147281


      • Remove the turbocharger oil return pipe.

      • Remove and discard the gasket.

 

    1. E178323


      • Remove the turbocharger heatshield.

 

    1. WARNING:

      Be prepared to collect escaping oil.


      E148088

      • Remove and discard the bolt.

      • Remove and discard the sealing washers.

 

    1. E148082

      • Disconnect the electrical connector.


 

    1. E148083


      Disconnect the electrical connector.

 

    1. NOTE:

      Make sure to clean the threads prior to installation.


      E148087


      • Remove the turbocharger bracket.

 

    1. WARNING:

      Be prepared to collect escaping fluids.


      E178331


      • Reposition the turbocharger coolant pipe.

 

    1. WARNING:

      Be prepared to collect escaping fluids.


      E178332


      • Reposition the turbocharger coolant pipe.

 

    1. E178335


      • Remove the exhaust manifold heatshield.

 

    1. E148089


      Use the special tool to remove and discard the turbocharger nut.

 

    1. E178338

      • Remove and discard the 2 turbocharger nuts.


      • Remove and discard the turbocharger to manifold gasket.

 

  1. E178339


    • Remove the coolant pipe to turbocharger assembly.

    • Remove and discard the gasket.

 


      • Install the coolant pipe to turbocharger assembly.

      • Install and tighten the 2 bolts.

        Torque: 9Nm

 


      • Install the turbocharger.


      • Use the special tool to install and tighten the new nut.

        Torque: 26Nm

 

      • Install the exhaust manifold heatshield.

      • Install and tighten the 3 bolts.

        Torque: 9Nm

 

      • Reposition the turbocharger coolant pipes.

      • Install and tighten the 2 bolts.

        Torque: 10Nm

 

    1. CAUTION:

      Apply Loctite 243 to the bolts.

      NOTE:

      Make sure to clean the threads prior to installation.

      • Install the turbocharger bracket.

      • Install and tighten the 4 bolts.

        Torque: 32Nm

 

      • Connect the electrical connector to the turbocharger.

      • Connect the electrical connector to the Crankshaft Position Sensor (CKP).

 



 

      • Install the turbocharger heatshield.

      • Install and tighten the 2 bolts.

        Torque: 9Nm

 

    1. CAUTION:

      Make sure that the area around the component is clean and free of foreign material.


      • Install the turbocharger oil return pipe.

      • Install and tighten the 4 bolts.

        Torque: 9Nm

 

      • Install the air intake pipe.

      • Install and tighten the nut.

        Torque: 10Nm

 

    1. Install the left exhaust gas recirculation valve.

 

    1. Install the transmission fluid cooler pipes.

 

    1. Install the exhaust system.

 

    1. Refill the engine oil.

 

  1. If a new component has been installed, configure using the Jaguar Land Rover approved diagnostic equipment.

REMOVAL AND INSTALLATION

 

  • 19.42.63
  • TURBOCHARGER BYPASS VALVE – RENEW
  • 3000 CC, TDV6
  • 0.40

 

PART(S)





STEP PART NAME QUANTITY
Removal Step 4 Intake air shutoff throttle seals 1

NOTE:

Removal steps in this procedure may contain installation details.

 


 

    1. E147634

       

 

    1. E147635

      Torque: 10Nm

 



  1. E147636


    Torque: 9Nm

 

  1. To install, reverse the removal procedure.

REMOVAL AND INSTALLATION

 

  • 19.42.64
  • FIXED VANE TURBOCHARGER ACTUATOR – RENEW
  • 3000 CC, TDV6, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID
  • 2.40

 

PART(S)





STEP PART NAME QUANTITY
Installation Step 1 Fixed vane turbocharger actuator gasket kit 1

NOTE:

Some variation in the illustrations may occur, but the essential information is always correct.

 

    1. WARNING:

      Make sure to support the vehicle with axle stands.


      Raise and support the vehicle.

 



 


 

    1. NOTE:

      Engine shown removed for clarity.


      E124729

 

    1. E124980

 

    1. E125207

 



    1. E124968


      Using a suitable 130mm T30 Torx socket, remove the retaining bolts.

 



    1. E124969

 



  1. E124972

 

    1. CAUTION:

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



      E124969


 

    1. CAUTION:

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



      E124970

 



    1. E124968

      • Using a suitable 130mm T30 Torx socket, remove the retaining bolts.

        Torque: 12Nm

 

    1. E125207

      Torque: 9Nm

 

    1. E124980

 

    1. E124729

      Torque: 9Nm

 


 



 

  1. If a new fixed vane turbocharger actuator is installed, carry out the reset procedure for the fixed vane turbocharger actuator using approved diagnostic tool.

REMOVAL AND INSTALLATION

 

  • 19.42.56
  • TURBOCHARGER – LH – RENEW
  • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
  • 4.80

 

GENERAL EQUIPMENT





EQUIPMENT NAME
Jaguar Land Rover approved diagnostic equipment

PART(S)











STEP PART NAME QUANTITY
Installation Step 1 Turbocharger coolant pipes to turbocharger gasket 1
Installation Step 2 Exhaust manifold to turbocharger nuts 3
Installation Step 2 Turbocharger to exhaust manifold gasket 1
Installation Step 7 Turbocharger oil supply pipe banjo bolt 1
Installation Step 7 Turbocharger oil feed pipe banjo bolt washers 2
Installation Step 9 Lower oil return pipe gasket 1
Installation Step 9 Upper oil return pipe gasket 1

CAUTION:

Before disconnecting any components, make sure the area is clean and free from foreign material. ​When ​disconnected all openings must be sealed.

NOTES:

  • This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.

  • This procedure contains illustrations showing certain components removed to provide extra clarity.

 

    1. Remove the engine undershield.

 

    1. Drain the engine oil.

 

    1. Remove the exhaust.

 

    1. Remove the left Exhaust Gas Recirculation (EGR) valve.

 

    1. E178639


      Release the intake air pipe.

 

    1. CAUTION:

      Make sure that the area around the component is clean and free of foreign material.


      E147280


      • Remove and discard the gasket.

 

    1. CAUTION:

      Make sure that the area around the component is clean and free of foreign material.


      E147281

      • Remove the turbocharger oil return pipe.

      • Remove and discard the gasket.

 

    1. E178323


      Remove the turbocharger heatshield.

 

    1. CAUTION:

      Make sure that the area around the component is clean and free of foreign material.


      E148088

      • Remove and discard the turbocharger oil feed pipe bolt.

      • Remove and discard the washers.

 

    1. E148082


      Disconnect the Crankshaft Position Sensor (CKP) electrical connector.

 

    1. E148083


      Disconnect the electrical connector from the turbocharger.

 

    1. E148087


      Remove the 4 bolts.

 

    1. WARNING:

      Be prepared to collect escaping fluids.


      E178331


      Release the coolant pipe.

 

    1. WARNING:

      Be prepared to collect escaping fluids.


      E178332

      • Release the coolant pipe.

 

    1. E178335


      Remove the exhaust manifold heatshield.

 

    1. E178337


      Remove and discard the nut.

 

    1. E178338

      • Remove and discard the nuts.

      • Remove and discard the gasket.

 

  1. E178339

    • Remove the turbocharger coolant pipe.

    • Remove and discard the gasket.

 

      • Install the turbocharger coolant pipe.

        Torque: 9Nm


 

      • Install the turbocharger.

        Torque: 26Nm



 

    1. Install the exhaust manifold heatshield.

 

      • Connect the turbocharger coolant pipes.

        Torque: 10Nm

 

    1. CAUTION:

      Apply Loctite 243 to the bolts.

      NOTE:

      Make sure to clean the threads prior to installation.

      • Install the turbocharger retaining bracket.

      • Install the 4 bolts.

        Torque: 32Nm

 

      • Connect the electrical connector to the turbocharger.

      • Connect the Crankshaft Position Sensor (CKP) electrical connector.

 



 

    1. Install the turbocharger heatshield.

      Torque: 9Nm

 

    1. CAUTION:

      Make sure that the area around the component is clean and free of foreign material.

      • Install the turbocharger oil return pipe.

        Torque: 9Nm


 

    1. Install the air intake pipe.

      Torque: 10Nm

 

    1. Install the left Exhaust Gas Recirculation (EGR) valve.

 

    1. Install the exhaust.

 

    1. Install the engine undershield.

 

    1. Fill the engine with oil.

 

  1. If a new component has been installed, configure using the Jaguar Land Rover approved diagnostic equipment.

REMOVAL AND INSTALLATION

 

  • 19.42.56
  • TURBOCHARGER – LH – RENEW
  • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
  • 4.80

 

GENERAL EQUIPMENT





EQUIPMENT NAME
Jaguar Land Rover approved diagnostic equipment

PART(S)














STEP PART NAME QUANTITY
Removal Step 8 Turbocharger oil return pipe gasket(s) 1
Removal Step 9 Turbocharger oil return pipe gasket(s) 1
Removal Step 11 Turbocharger oil feed pipe banjo bolt washers 1
Removal Step 11 Turbocharger oil supply pipe banjo bolt 1
Removal Step 14 EGR inlet pipe to EGR valve gasket 1
Removal Step 18 Turbocharger coolant pipe 1
Removal Step 20 Exhaust manifold to turbocharger nuts 1
Removal Step 21 Exhaust manifold to turbocharger nuts 2
Removal Step 21 Turbocharger to exhaust manifold gasket 1
Removal Step 22 Turbocharger coolant pipes to turbocharger gasket 1

CAUTION:

Before disconnecting any components, make sure the area is clean and free from foreign material. ​When ​disconnected all openings must be sealed.

NOTES:

  • Some variation in the illustrations may occur, but the essential information is always correct.

  • Removal steps in this procedure may contain installation details.

 


 


 


 


 


 

    1. E159232

      Torque: 10Nm

 

    1. E178639

      Torque: 10Nm

 

    1. CAUTIONS:

      • Before disconnecting any components, make sure the area is clean and free from foreign material. ​When ​disconnected all openings must be sealed.

      • Make sure that the area around the component is clean and free of foreign material.



      E147280


      Torque: 9Nm

 

    1. CAUTIONS:

      • Make sure that the area around the component is clean and free of foreign material.

      • Before disconnecting any components, make sure the area is clean and free from foreign material. ​When ​disconnected all openings must be sealed.



      E147281


      Torque: 9Nm

 

    1. E178323

      Torque: 9Nm

 

    1. WARNING:

      Be prepared to collect escaping oil.

      CAUTIONS:

      • Make sure that new sealing washers are installed.

      • Make sure that the area around the component is clean and free of foreign material.

      • Make sure that a new bolt is installed.


      E148088



      Torque: 30Nm

 

    1. E148084

      Torque: 10Nm

 

    1. E148082

 

    1. E148086


      Torque: 6Nm

 

    1. E148083

 

    1. CAUTION:

      Apply Loctite 243 to the bolts.

      NOTE:

      Make sure to clean the threads prior to installation.


      E148087

      Torque: 32Nm

 

    1. WARNING:

      Be prepared to collect escaping fluids.


      E178331

      Torque: 11Nm

 

    1. WARNING:

      Be prepared to collect escaping fluids.

      CAUTION:

      Remove and discard the O-ring seal.


      E178332


      Torque: 10Nm

 

    1. E178335

 

    1. NOTE:

      Remove and discard the nut.


      E178337

    1. e.

 

    1. Install the exhaust manifold heatshield.

      Torque: 11Nm

 

    1. Install the exhaust heatshield.

      Torque: 9Nm

 

    1. CAUTION:

      Make sure that the area around the component is clean and free of foreign material.

      NOTES:

      • Install a new gasket.

      • Install a new seal.


      E200199


      Install the turbocharger oil return pipe.

      Torque: 9Nm

 



    1. E200055


      Install the exhaust down pipe.

 

    1. E200053


      Install the bolts.

      Torque: 28Nm

 

    1. E200052


      Install the exhaust gas temperature sensor.

      Torque: 35Nm

 

    1. E200051


      Install the exhaust clamp over the cut in the exhaust down pipe.

      Torque: 28Nm

 

    1. Install the starter motor.
      Refer to:Starter Motor (303-06A Starting System – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Removal and Installation).

 

    1. Install the EGR valve.

 

    1. Refill the engine oil.

 

    1. Reconnect the battery ground cable.
      Refer to:Specifications (414-00 Battery and Charging System – General Information, Specifications).

 

  1. If a new component has been installed, configure using the Jaguar Land Rover approved diagnostic equipment.

 



    1. E178338



      Torque: 26Nm

 

  1. NOTE:

    Remove and discard the gasket.


    E178339


    Torque: 9Nm

 

    1. To install reverse the removal procedure.

 


 

  1. If a new turbocharger is installed, the powertrain air path learn process must be done with the use of the Jaguar Land Rover (JLR) approved diagnostic equipment. 

REMOVAL AND INSTALLATION

 

  • 19.42.57
  • TURBOCHARGER – RH – RENEW
  • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
  • 3.10

 

SPECIAL TOOL(S)

GENERAL EQUIPMENT





EQUIPMENT NAME
Jaguar Land Rover approved diagnostic equipment

PART(S)











STEP PART NAME QUANTITY
Installation Step 1 Exhaust pipe to turbocharger gasket 1
Installation Step 1 Exhaust manifold to turbocharger nuts 3
Installation Step 6 Turbocharger oil feed pipe banjo bolt washers 1
Installation Step 6 Turbocharger oil supply pipe banjo bolt 1
Installation Step 10 Turbocharger oil return pipe gasket(s) 1
Installation Step 10 Turbocharger oil return pipe 1
Installation Step 11 Exhaust downpipe gasket(s) 1

CAUTION:

Before disconnecting any components, make sure the area is clean and free from foreign material. ​When ​disconnected all openings must be sealed.

NOTES:

  • This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.

  • This procedure contains illustrations showing certain components removed to provide extra clarity.

 

    1. Disconnect the battery ground cable.
      Refer to:Specifications (414-00 Battery and Charging System – General Information, Specifications).

 

    1. Drain the engine oil.

 

    1. Remove the EGR valve.

 

    1. Remove the starter motor.
      Refer to:Starter Motor (303-06A Starting System – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Removal and Installation).

 

    1. E200050


      Cut the exhaust in the position illustrated.

 

    1. E200052


      Remove the exhaust gas temperature sensor.

 

    1. E200053


      Remove the bolts.

 

    1. E200054

      • Remove the exhaust down pipe.

      • Remove and discard the gasket.

 

    1. CAUTION:

      Be prepared to collect escaping oil.

      NOTES:

      • Discard the seal.

      • Discard the gasket.


      E200199


      Remove the turbocharger oil return pipe.

 

    1. E144608


      Remove the Exhaust heatshield.

 

    1. E196878


      Remove the exhaust manifold heatshield.

 

    1. E124720


      Disconnect the harness.

 

    1. E124721


      Remove the vacuum pipe.

 

    1. CAUTION:

      Be prepared to collect escaping oil.


      E124730


      Remove the banjo bolt.

 

    1. E124733


      Remove the clip.

 

    1. E196872


      Remove the charge air hose.

 

    1. E196873


      Remove the intake air hose.

 

    1. E124732


      Remove the bracket.

 



  1. E196880



 

    1. CAUTION:

      Make sure that the area around the component is clean and free of foreign material.

      NOTES:

      • Install new nuts.

      • Install a new gasket.


      E196880


      Install the turbocharger.

      Torque: 24Nm

 



    1. E124732


      Install the bracket.

      Torque: 32Nm

 

    1. E196873


      Install the intake air hose.

 

    1. E196872


      Install the charge air hose.

 

    1. E124733


      Install the clip.

 

    1. CAUTION:

      Make sure that the area around the component is clean and free of foreign material.

      NOTE:

      Install new sealing washers.


      Install a new banjo bolt to the turbocharger oil feed pipe.

      Torque: 30Nm

 

    1. Install the vacuum pipe and connect the harness to the Turbocharger intake shut-off valve.

 

    1. Install the exhaust manifold heatshield.

      Torque: 11Nm

 

    1. Install the exhaust heatshield.

      Torque: 9Nm

 

    1. CAUTION:

      Make sure that the area around the component is clean and free of foreign material.

      NOTES:

      • Install a new gasket.

      • Install a new seal.


      E200199


      Install the turbocharger oil return pipe.

      Torque: 9Nm

 



    1. E200055


      Install the exhaust down pipe.

 

    1. E200053


      Install the bolts.

      Torque: 28Nm

 

    1. E200052


      Install the exhaust gas temperature sensor.

      Torque: 35Nm

 

    1. E200051


      Install the exhaust clamp over the cut in the exhaust down pipe.

      Torque: 28Nm

 

    1. Install the starter motor.
      Refer to:Starter Motor (303-06A Starting System – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Removal and Installation).

 

    1. Install the EGR valve.

 

    1. Refill the engine oil.

 

    1. Reconnect the battery ground cable.
      Refer to:Specifications (414-00 Battery and Charging System – General Information, Specifications).

 

  1. If a new component has been installed, configure using the Jaguar Land Rover approved diagnostic equipment.

  

303-08A: Engine Emission Control – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2










DESCRIPTION NM LB-FT LB-IN
Exhaust gas recirculation (EGR) valve to cylinder head retaining bolts 10 7 89
EGR valve to EGR cooler retaining bolts 10 7 89
EGR valve tube to exhaust manifold retaining bolts 10 7 89
EGR valve cooler mounting bracket retaining bolt 10 7 89
EGR valve outlet tube to EGR valve retaining bolts 10 7 89
EGR valve outlet tube to timing cover retaining bolt 5 4 35

  

 

Description and Operation

DESCRIPTION AND OPERATION

 

 

COMPONENT LOCATION – EXHAUST GAS RECIRCULATION

E146140

 











ITEM DESCRIPTION
1 Left vacuum tube
2 EGR cooler bypass valve solenoid
3 Left EGR cooler and valve housing
4 Left EGR outlet tube
5 Right EGR outlet tube
6 Right EGR cooler and valve housing
7 Right vacuum tube

 

COMPONENT LOCATION – LOW PRESSURE (LP) EXHAUST GAS RECIRCULATION SYSTEM

E171872

 










ITEM DESCRIPTION
1 Right EGR cooler and valve housing
2 Exhaust manifold
3 Low Pressure (LP) Exhaust Gas Recirculation (EGR) cooler and valve housing
4 Turbocharger
5 Exhaust gas inlet from post Diesel Particulate Filter (DPF)
6 Clean air inlet from air intake system

 

COMPONENT LOCATION – CRANKCASE VENTILATION

E146141

 








ITEM DESCRIPTION
1 Left camshaft cover ventilation tube
2 Oil separator
3 Right camshaft cover ventilation tube
4 Crankcase ventilation hose and tube assembly

EXHAUST GAS RECIRCULATION SYSTEM

The EGR system is used to control the amount of exhaust gas being recirculated in order to reduce exhaust emissions and combustion noise. EGR operation is calibrated and could operate at sub-zero ambient temperature as well as transient conditions.

CRANKCASE VENTILATION SYSTEM

The crankcase ventilation system ensures that all gasses emitted from the crankcase during engine running are separated from any oil particles and recirculated via the clean air induction system. It will also stop buildup of pressure inside the crankcase thereby ensuring integrity of engine seals

EXHAUST GAS RECIRCULATION SYSTEM

E146142

 















ITEM DESCRIPTION
1 Actuator rod
2 Cooler bypass valve vacuum actuator
3 Vacuum connection
4 EGR intake tube
5 Cooler
6 Valve housing
7 Coolant intake connection
8 Electrical connector
9 EGR valve motor
10 EGR outlet tube connection
11 Coolant outlet connection

The EGR system comprises an EGR cooler and valve housing assembly bolted to each cylinder head, above the exhaust manifolds. Each EGR cooler and valve housing assembly incorporates an EGR valve and motor, an EGR cooler, and a cooler bypass valve and actuator.

On each valve housing, an EGR intake tube is connected to the exhaust manifold and directs exhaust gasses into the valve housing. A second pipe from the valve housing connects to the electric throttle and passes the exhaust gasses into the electric throttle to mix with the clean air entering the engine from the turbochargers.

The EGR cooler is attached to the valve housing with a gasket and 5 screws. The valve housing has an engine coolant connection which allows coolant to flow into a water jacket within the cooler, which cools the exhaust gasses. The coolant returns to the engine cooling system through an outlet pipe on the cooler.

COOLER BYPASS VALVE

E107585

 








ITEM DESCRIPTION
1 Cooler bypass valve vacuum actuator
2 EGR valve motor
3 EGR valve
4 Cooler bypass valve

Each valve housing contains a cooler bypass valve, which either allows the exhaust gasses to flow direct to the electric throttle or diverts them through the EGR cooler.

A vacuum actuator is located on a bracket attached to each EGR cooler to operate the cooler bypass valves. The actuators receives a vacuum which is produced by the vacuum pump located at the rear of the engine. Each vacuum actuator is connected to its related bypass valve by an actuator rod.

The vacuum supply to the actuators is controlled by the ECM. When bypass control is required, the ECM energizes a cooler bypass valve solenoid, which applies vacuum to the vacuum actuators. The vacuum causes the actuators to move the connecting rods in a linear direction. The linear movement of the rods is transferred to rotary movement of the cooler bypass valves within the valve housings.

Cooler Bypass Valve Closed

E112407

When the cooler bypass valve is closed, exhaust gasses are directed through the cooler before being passed to the electric throttle.

Cooler By-Pass Valve Open

E112408

When the cooler bypass valve is open, exhaust gasses are passed directly through the valve housing into the electric throttle with no cooling applied to the gasses.

EXHAUST GAS RECIRCULATION VALVE

The EGR valve motor is located on the valve housing. A 5 pin connector provides the power, ground and ECM signal and feedback connections for the motor.

The motor is secured to the valve housing with 4 torx screws. A pinion gear on the motor spindle drives a geared rack which is connected to the EGR valve in the valve housing.

The motor is controlled by the ECM which provides power to operate the motor as required. A 5 Volt feedback signal is passed to the ECM which is used to establish motor position for precise control.

LOW PRESSURE (LP) EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Low Pressure (LP) Exhaust Gas Recirculation (EGR)

E171873

 













ITEM DESCRIPTION
1 Exhaust Gas Recirculation (EGR) valve motor
2 Exhaust Gas Recirculation (EGR) outlet temperature sensor
3 Coolant inlet connection
4 Differential pressure sensor
5 Exhaust gas inlet from Post-Diesel Particulate Filter (DPF)
6 Cooler
7 Exhaust Gas Recirculation (EGR) valve housing
8 Coolant outlet connection
9 Exhaust gas outlet to clean air duct

The function of LP EGR is to re-circulate the exhaust gases after DPF (Diesel Particulate Filter) to further improve ability to meet the emission level as well as reducing the CO2 thereby improving the fuel economy. It also improves engine transient performance due to more exhaust energy being diverted to the turbocharger(s).

As per HP EGR the function is electronically controlled and calibrated. It is governed and controlled by both hot end exhaust mounted throttle as well as unit mounted valve.

Low Pressure (LP) Exhaust Gas Recirculation (EGR) Schematic Diagram

E171874

 



















ITEM DESCRIPTION
A Exhaust gas
B Charge air
C Clean air
1 Coolant outlet from Low Pressure (LP) Exhaust Gas Recirculation (EGR) system
2 Engine
3 Coolant inlet from engine
4 Low Pressure (LP) Exhaust Gas Recirculation (EGR) system
5 Low Pressure (LP) EGR pipe
6 Post-DPF exhaust gases
7 Diesel Particulate Filter (DPF)
8 Catalytic converter
9 Turbocharger
10 Charge air outlet
11 Clean air form Air intake system
12 Air intake system

CRANKCASE VENTILATION SYSTEM

The crankcase ventilation system comprises an oil separator and associated ventilation hoses and tubes.

The oil separator is connected to the top of the cylinder block with two seals. An oil outlet connection locates in the high pressure fuel pump mounting bracket. Two ventilation tubes connect the top of the oil separator to the camshaft covers. A ventilation tube and hose assembly connects the top of the oil separator to the intake duct of the primary turbocharger.

HIGH PRESSURE (HP) EXHAUST GAS RECIRCULATION SYSTEM

NOTE:

Twin HP EGR (GEN 1.5) system at 16MY is used on EU4 AND EU5 Derivatives.

The HP EGR valve is attached to the cylinder head. Exhaust gases are routed to the EGR valve from the exhaust manifold.

The EGR valve is cooled using engine coolant in the vehicle interior heating circuit; this is to protect the electrical components from over-heating.

The EGR valve controls the amount of EGR exhaust gas flow depending on the ECM map.

The exhaust gases are passed directly into the intake manifold via a simple EGR pipe.

The design of the EGR pipe attachment to the inlet manifold helps mix the exhaust gases with the main fresh air from the intake air system and also insulates the plastic intake manifold from the hot EGR pipe.

On EU4 market vehicles, a separate EGR pipe attachment is used to connect between the intake manifold and the EGR cooler.

LOW PRESSURE (LP) EXHAUST GAS RECIRCULATION SYSTEM

NOTE:

HP/LP EGR (GEN 2) system is used from 15.5MY on EU5, EU6 and NAS derivatives.

The LP EGR system is used on EU5, EU6, Japan, Brazil and NAS market vehicles only.

The LP system takes exhaust gases from the exit of the Diesel Particulate Filter (DPF) system, and mixes it with the fresh air from the intake air system into the turbocharger.

The gases are transported from the DPF outlet to the LP EGR cooler via a pipe. The LP cooler has no bypass mode, so only cools.

There is a simple mesh filter fitted before the gases reach the outlet of the cooler that prevents larger particles of soot etc. from entering the turbocharger system.

The cooled gases are then directed through the LP EGR valve.

The valve consists of a tube between the fresh air duct and the turbocharger, with the butterfly valve covering the EGR inlet, in the centre bottom of the EGR valve.

The butterfly valve opens into the fresh air stream, promoting both thorough mixing before the gas enters the turbocharger, and also provides ‘suction’ to drive the LP EGR gas through the system.

CRANKCASE VENTILATION SYSTEM

Clean air being drawn into the primary turbocharger when the engine is running creates a vacuum in the ventilation tube and hose assembly. This vacuum in turn creates a vacuum in the oil separator and draws gasses from the crankcase and camshaft covers into the separator. The gasses are circulated around the oil separator, allowing oil particles to be separated from the gas. The gasses are drawn into the ventilation tube and hose assembly and are mixed with the clean air being drawn into the turbocharger. The oil drains out of the oil separator, and down through the high pressure fuel pump mounting bracket and cylinder block into the oil pan.

DIFFERENTIAL PRESSURE SENSOR

The LP EGR differential pressure sensor monitors the pressure across the LP EGR cooler to detect issues such as cooler or gauze filter (between valve and cooler) reduced flow/blockage.

The Malfunction Indicator Lamp (MIL) will be illuminated on the Instrument Cluster (IC) if an issue is detected.

E148856

 













ITEM DESCRIPTION
1 Battery
2 Battery Junction Box (BJB)2
3 Battery Junction Box (BJB)
4 Auxiliary Junction Box (AJB)
5 EGR cooler bypass valve solenoid
6 Engine Junction Box (EJB)
7 Left EGR valve motor
8 Right EGR valve motor
9 Engine Control Module (ECM)

 

 

Diagnosis and Testing

 

PRINCIPLES OF OPERATION

For a detailed description of the engine emission control system and operation, refer to the relevant Description and Operation section of the workshop manual. REFER to:Engine Emission Control (303-08A Engine Emission Control – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Description and Operation).

 

INSPECTION AND VERIFICATION

CAUTION:

Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does not guarantee confirmation of a fault and may also cause additional faults in the vehicle being checked and/or the donor vehicle.

NOTE:

Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

  1. Verify the customer concern.

  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection





MECHANICAL ELECTRICAL

  • Engine breather system
  • Oil separator
  • Exhaust Gas Recirculation (EGR) pipes/hoses (check for cracks)
  • Exhaust Gas Recirculation (EGR) valve(s)
  • Exhaust Gas Recirculation (EGR) cooler(s)
  • Vacuum system

  • Fuse(s)
  • Wiring harness
  • Loose or corroded electrical connector(s)
  • Intake air shut off throttle
  • Exhaust Gas Recirculation (EGR) valve(s)
  • Powertrain Control Module (PCM)

  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.

  1. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for Diagnostic Trouble Codes (DTCs) and refer to the DTC Index.














SYMPTOM POSSIBLE CAUSES ACTION
Difficult to start

  • Exhaust Gas Recirculation (EGR) valve stuck open

  • Using the manufacturer approved diagnostic system, perform routine – Inline diagnostic unit 2 diagnostic test – Exhaust gas recirculation valve. Clear the DTCs and retest

Poor/erratic idle
Lack of power when accelerating
Engine stops/stalls

  • Exhaust Gas Recirculation (EGR) valve stuck open
  • Breather system disconnected/restricted/blocked

  • Using the manufacturer approved diagnostic system, perform routine – Inline diagnostic unit 2 diagnostic test – Exhaust gas recirculation valve. Clear the DTCs and retest
  • Check for Exhaust Gas Recirculation (EGR) DTCs
  • Check the engine breather system
  • Check the oil separator

Excessive fuel consumption

  • Exhaust Gas Recirculation (EGR) valve stuck open
  • Exhaust Gas Recirculation (EGR) not operating
  • Breather system restricted/blocked

Excessive black smoke
Excessive emissions
Excessive blow-by

  • Breather system restricted/blocked

  • Check the engine breather hoses
  • Check the oil separator

Engine oil leaks

  • Breather system restricted/blocked

  • Check the engine breather hoses
  • Check the oil separator

Rattling noise from the EGR valve / cooler Leak in the vacuum system which controls the cooler bypass valve Check the integrity of the vacuum pipes and pump

For a list of Diagnostic Trouble Codes (DTCs) that could be logged on this vehicle, please refer to Section 100-00. REFER to:Diagnostic Trouble Code Index – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, DTC: Powertrain Control Module B10A2-07 to P02D7-32 (100-00 General Information, Description and Operation).

 

 

General Procedures

  • 17.50.37
  • DIESEL EXHAUST FLUID (DEF) TANK – DRAIN AND REFILL
  • ALL DERIVATIVES
  • 0.50

GENERAL EQUIPMENT





EQUIPMENT NAME
Jaguar Land Rover approved diagnostic equipment

 

DRAINING

 

 

The following step(s) applies to:

All vehicles

 

CAUTION:

Extreme cleanliness must be exercised when handling these components.

NOTES:

  • This procedure contains filling instructions for both versions of the Diesel Exhaust Fluid (DEF) dispensing kit.

  • This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.

  • This procedure contains illustration showing certain components removed to provide extra clarity.

 

    1. Raise and support the vehicle on a suitable 2 post lift.
      Refer to:Lifting (100-02 Jacking and Lifting, Description and Operation).

 

    1. E191691


      Remove the Diesel Exhaust Fluid (DEF) filler cap.

 

    1. E194139


      Remove the 5 bolts and the retaining clip.

 

    1. E194140


      Remove the drain tube from the retaining clip.

 

    1. WARNING:

      Be prepared to catch escaping fluid.


      E190505


      Allow the fluid to drain.

 

    1. E190505


      Install the blanking cap.

 

  1. E194140


    Install the drain tube into the retaining clip.

 

 

The following step(s) applies to:

All vehicles

 

 

  1. E194139


    Install the 5 bolts and retaining clip.

    Torque: 26Nm

 

FILLING

 

 

The following step(s) applies to:

Using JLR approved equipment: JLR-F00100010

 

NOTE:

Make sure to add 1 liter of fluid to the upper tank and drain it through the clear hose, if the Diesel Exhaust Fluid (DEF) dispensing kit is being used for the first time.

 

    1. Using the Jaguar Land Rover approved diagnostic equipment, follow the on-screen instructions and check the DEF level.

 

    1. CAUTION:

      Failure to carry out this instruction may cause damage to the vehicle.


      E183165


      Check the quality of the DEF using a hydrometer.

 

    1. WARNING:

      Failure to carry out this instruction may result in personal injury.


      E190061


      Make sure the operating levers of the DEF dispensing kit are in the positions indicated.

 

    1. CAUTION:

      Make sure that the Diesel Exhaust Fluid (DEF) dispensing kit flow meter is reset.


      E195071


      Check the gauge.

 

    1. CAUTION:

      Make sure that the upper tank is not overfilled. Observe at all times.


      E195070


      Fill the upper tank to the correct amount of DEF previously specified by the JLR approved diagnostic equipment.

 

    1. CAUTIONS:

      • Failure to carry out this instruction may cause damage to the vehicle.

      • If any Diesel Exhaust Fluid (DEF) is visible in the clear filler pipe, this must be drained and discarded before proceeding to the next step.


      E190017


      Make sure that the inner rubber feed hose is in the position shown.

 

    1. CAUTIONS:

      • Make sure the Diesel Exhaust Fluid (DEF) dispensing kit is correctly installed onto the DEF filler pipe.

      • Make sure that the vehicle paintwork is protected.


      E191692


      Install the DEF dispensing kit on to the DEF filler pipe.

 

    1. CAUTION:

      Do not overfill the vehicle.

      NOTE:

      Fluid may be visible in the outer hose.


      E190062


      Position the DEF dispensing kit upper operating lever in the position indicated. The DEF tank top-up procedure will now commence. Immediately proceed to the next step.

 

    1. E190063

      • Fill the vehicle with the correct amount of DEF specified by the JLR approved diagnostic equipment.

      • When the correct amount has been drained, position the DEF dispensing kit upper operating lever in the position indicated.

 

    1. E190064

      1. Position the DEF dispensing kit lower operating lever in the position indicated.

      1. Operate the pump on the DEF dispensing kit to recover any DEF remaining in the clear filler pipe. The DEF is recovered through the inner pipe at the vehicle filler pipe. The pipe may need to be raised to assist recovery.

 

    1. NOTE:

      Make sure the pump on the Diesel Exhaust Fluid (DEF) dispensing kit is switched off before this step is carried out.


      E190257


      Position the DEF dispensing kit lower operating lever in the position indicated.

 

    1. CAUTIONS:

      • If any fluid remains in the clear filler pipe after the Diesel Exhaust Fluid (DEF) dispensing kit is disconnected from the vehicle, this must be drained and discarded before the equipment can be used again.

      • Make sure that the vehicle paintwork is protected.


      E191692


      Disconnect the DEF dispensing kit from the DEF filler pipe.

 

    1. CAUTION:

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


      E191691


      Install the DEF filler cap until an audible click is heard 3 times.

 

    1. Using the Jaguar Land Rover approved diagnostic equipment, prime the DEF system.

 

  1. Using the Jaguar Land Rover approved diagnostic equipment, follow the on-screen instructions and check the DEF level.

 

 

The following step(s) applies to:

Using JLR approved equipment: JLR-F00100010A

 

 

    1. Using the Jaguar Land Rover approved diagnostic equipment, follow the on-screen instructions and check the DEF level.

 

    1. CAUTION:

      Failure to carry out this instruction may cause damage to the vehicle.


      E183165


      Check the quality of the DEF using a hydrometer.

 

    1. CAUTION:

      Failure to carry out this instruction may cause damage to the vehicle.


      E244574


      Make sure that the inner rubber feed hose is in the position shown.

 



    1. E191692


      Install the DEF dispensing kit on to the DEF filler pipe.

 

    1. NOTE:

      Refer to the manufacturers instructions.


      E244579

      • Select the amount of DEF to be filled as indicated at step 24.

 

    1. E244577

      • Set the DEF dispensing kit to auto fill.

      • Fill the vehicle with DEF.

 

    1. CAUTION:

      Make sure that the vehicle paintwork is protected.


      E191692


      Disconnect the DEF dispensing kit from the DEF filler pipe.

 

    1. CAUTION:

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


      E191691


      Install the DEF filler cap until an audible click is heard 3 times.

 

    1. Using the Jaguar Land Rover approved diagnostic equipment, prime the DEF system.

 

  1. Using the Jaguar Land Rover approved diagnostic equipment, follow the on-screen instructions and check the DEF level.

     

  • 17.50.51
  • DIESEL EXHAUST FLUID (DEF) TANK – LEVEL CHECK AND TOP-UP
  • ALL DERIVATIVES
  • 0.20

GENERAL EQUIPMENT





EQUIPMENT NAME
Jaguar Land Rover approved diagnostic equipment

 

CHECK

 

 

The following step(s) applies to:

Using JLR approved equipment: JLR-F00100010

 

 

  1. Using the Jaguar Land Rover approved diagnostic equipment, follow the on-screen instructions and check the diesel exhaust fluid level.

 

 

The following step(s) applies to:

Using JLR approved equipment: JLR-F00100010A

 

 

  1. Using the Jaguar Land Rover approved diagnostic equipment, follow the on-screen instructions and check the diesel exhaust fluid level.

 

ADJUSTMENT

CAUTION:

Extreme cleanliness must be exercised when handling these components.

NOTES:

  • Make sure to add 1 liter of fluid to the upper tank and drain it through the clear hose, if the Diesel Exhaust Fluid (DEF) dispensing kit is being used for the first time.

  • This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.

  • This procedure contains illustration showing certain components removed to provide extra clarity.

 

 

The following step(s) applies to:

Using JLR approved equipment: JLR-F00100010

 

 

    1. Using the Jaguar Land Rover approved diagnostic equipment, follow the on-screen instructions and check the DEF level.

 

    1. CAUTION:

      Failure to carry out this instruction may cause damage to the vehicle.


      E183165


      Check the quality of the DEF using a hydrometer.

 

    1. WARNING:

      Failure to carry out this instruction may result in personal injury.


      E190061


      Make sure the operating levers of the DEF dispensing kit are in the positions indicated.

 

    1. CAUTION:

      Make sure that the Diesel Exhaust Fluid (DEF) dispensing kit flow meter is reset.


      E195071


      Check the gauge.

 

    1. CAUTION:

      Make sure that the upper tank is not overfilled. Observe at all times.


      E195070


      Fill the upper tank to the correct amount of DEF previously specified by the JLR approved diagnostic equipment.

 

    1. CAUTIONS:

      • Failure to carry out this instruction may cause damage to the vehicle.

      • If any Diesel Exhaust Fluid (DEF) is visible in the clear filler pipe, this must be drained and discarded before proceeding to the next step.


      E190017


      Make sure that the inner rubber feed hose is in the position shown.

 

    1. CAUTIONS:

      • Make sure the Diesel Exhaust Fluid (DEF) dispensing kit is correctly installed onto the DEF filler pipe.

      • Make sure that the vehicle paintwork is protected.


      E191692


      Install the DEF dispensing kit on to the DEF filler pipe.

 

    1. CAUTION:

      Do not overfill the vehicle.

      NOTE:

      Fluid may be visible in the outer hose.


      E190062


      Position the DEF dispensing kit upper operating lever in the position indicated. The DEF tank top-up procedure will now commence. Immediately proceed to the next step.

 

    1. E190063

      • Fill the vehicle with the correct amount of DEF specified by the JLR approved diagnostic equipment.

      • When the correct amount has been drained, position the DEF dispensing kit upper operating lever in the position indicated.

 

    1. E190064

      1. Position the DEF dispensing kit lower operating lever in the position indicated.

      1. Operate the pump on the DEF dispensing kit to recover any DEF remaining in the clear filler pipe. The DEF is recovered through the inner pipe at the vehicle filler pipe. The pipe may need to be raised to assist recovery.

 

    1. NOTE:

      Make sure the pump on the Diesel Exhaust Fluid (DEF) dispensing kit is switched off before this step is carried out.


      E190257


      Position the DEF dispensing kit lower operating lever in the position indicated.

 

    1. CAUTIONS:

      • If any fluid remains in the clear filler pipe after the Diesel Exhaust Fluid (DEF) dispensing kit is disconnected from the vehicle, this must be drained and discarded before the equipment can be used again.

      • Make sure that the vehicle paintwork is protected.


      E191692


      Disconnect the DEF dispensing kit from the DEF filler pipe.

 

    1. CAUTION:

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


      E191691


      Install the DEF filler cap until an audible click is heard 3 times.

 

    1. Using the Jaguar Land Rover approved diagnostic equipment, prime the DEF system.

 

  1. Using the Jaguar Land Rover approved diagnostic equipment, follow the on-screen instructions and check the DEF level.

 

 

The following step(s) applies to:

Using JLR approved equipment: JLR-F00100010A

 

 

    1. Using the Jaguar Land Rover approved diagnostic equipment, follow the on-screen instructions and check the DEF level.

 

    1. CAUTION:

      Failure to carry out this instruction may cause damage to the vehicle.


      E183165


      Check the quality of the DEF using a hydrometer.

 

    1. CAUTION:

      Failure to carry out this instruction may cause damage to the vehicle.


      E244574


      Make sure that the inner rubber feed hose is in the position shown.

 



    1. E191692


      Install the DEF dispensing kit on to the DEF filler pipe.

 

    1. NOTE:

      Refer to the manufacturers instructions.


      E244579

      • Select the amount of DEF to be filled as indicated at step 24.

 

    1. E244577

      • Set the DEF dispensing kit to auto fill.

      • Fill the vehicle with DEF.

 

    1. CAUTION:

      Make sure that the vehicle paintwork is protected.


      E191692


      Disconnect the DEF dispensing kit from the DEF filler pipe.

 

    1. CAUTION:

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


      E191691


      Install the DEF filler cap until an audible click is heard 3 times.

 

  1. Using the Jaguar Land Rover approved diagnostic equipment, prime the DEF system.

     

 

Removal and Installation

REMOVAL AND INSTALLATION

 

  • 17.10.04
  • ENGINE VENT OIL SEPARATOR – RENEW
  • 3000 CC, TDV6
  • 0.50

 

NOTES:

  • Some variation in the illustrations may occur, but the essential information is always correct.

  • Removal steps in this procedure may contain installation details.

 

    1. Refer to:Specifications (414-00 Battery and Charging System – General Information, Specifications).

 

    1. Refer to:Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).

 


 

    1. E142695

 

    1. E142698

 

    1. E142696

 



  1. E142697

 

  1. To install, reverse the removal procedure.

REMOVAL AND INSTALLATION

 

  • 17.45.16
  • VALVE – EGR – LH – RENEW
  • 3000 CC, TDV6, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID
  • 1.30

 

PART(S)





STEP PART NAME QUANTITY
Removal Step 6 EGR valve RH to EGR outlet pipe gasket 1

NOTES:

  • Removal steps in this procedure may contain installation details.

  • Some illustrations may show the engine removed for clarity.

  • Make sure that all openings are sealed.

 

    1. Refer to:Specifications (414-00 Battery and Charging System – General Information, Specifications).

 


 


 

    1. E178509

 

    1. E178510

 



    1. E178511


      Torque: 5.5Nm

 

    1. E178512

      Torque: 10Nm

 

    1. E178513

 

    1. E178514

 

  1. E178515

    Torque: 10Nm

 

    1. To install reverse the removal procedure.

 

  1. If a new unit is installed, configure using the approved diagnostic tool.

REMOVAL AND INSTALLATION

 

  • 17.45.17
  • VALVE – EGR – RH – RENEW
  • 3000 CC, TDV6
  • 1.30

 

PART(S)





STEP PART NAME QUANTITY
Removal Step 12 EGR pipe to exhaust manifold gasket 1

NOTES:

  • Removal steps in this procedure may contain installation details.

  • Some illustrations may show the engine removed for clarity.

  • Make sure that all openings are sealed.

 

    1. Refer to:Specifications (414-00 Battery and Charging System – General Information, Specifications).

 


 


 


 

    1. E147090

 

    1. E147086

 

    1. E147087

      Torque: 8Nm

 



    1. E144608

      Torque: 10Nm

 



    1. E178503

      Torque: 10Nm

 

    1. E147088

      Torque: 10Nm

 

    1. E147089

 



  1. E147091


    Torque: 10Nm

 

    1. To install reverse the removal procedure.

 

  1. If a new unit is installed, configure using the approved diagnostic tool.

REMOVAL AND INSTALLATION

 

  • 17.45.22
  • TUBE – EGR VALVE OUTLET – RH – RENEW
  • 3000 CC, TDV6
  • 0.20

 

PART(S)






STEP PART NAME QUANTITY
Installation Step 1 EGR pipe to exhaust manifold gasket 1
Installation Step 2 Retaining clip(s) 1

NOTE:

Some variation in the illustrations may occur, but the essential information is always correct.

 


 

    1. E121965

 

    1. NOTE:

      Discard the retaining clips.


      E121967

 

    1. E121966

 

  1. CAUTION:

    Make sure that all openings are sealed.



    E121968

 

    1. CAUTION:

      Only tighten the bolts finger-tight at this stage.



      E145192


 

    1. CAUTION:

      Install a new clamp. Close the clamp to the first audible click by hand. Making sure that the clamp is in a central position to the joint, close to the second audible click using a suitable tool.


      E121967


 

    1. E121966

      Torque: 5Nm

 

    1. E122268

      Torque: 10Nm

 

    1. E121965

 


 

REMOVAL AND INSTALLATION

 

  • 17.50.34
  • DIESEL EXHAUST FLUID INJECTOR – RENEW
  • 3000 CC, TDV6
  • 0.40

 

GENERAL EQUIPMENT





EQUIPMENT NAME
Jaguar Land Rover approved diagnostic equipment

PART(S)





STEP PART NAME QUANTITY
Installation Step 1 Diesel exhaust fluid injector refit kit 1

WARNING:

Observe due care when working near a hot exhaust system.

CAUTION:

Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.

NOTE:

  • This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
  • This procedure contains illustrations showing certain components removed to provide extra clarity.

 

    1. Raise and support the vehicle on a suitable 2 post lift.
      Refer to:Lifting (100-02 Jacking and Lifting, Description and Operation).

 

    1. Remove the engine undershield.

 

    1. E179069


      Reposition the Diesel Exhaust Fluid (DEF) injector supply pipe heatshield.

 

    1. WARNING:

      Be prepared to collect escaping fluid.


      E179068


      Disconnect the DEF injector supply pipe.

 

    1. E179067


      Disconnect the DEF injector electrical connector.

 

    1. E179066


      • Remove the DEF injector.


 

  1. E193034


    Remove and discard the gasket form the DEF injector.

 


      • Install the DEF injector.

      • Install and tighten the clamp.

        Torque: 5Nm

 

    1. Connect the DEF injector electrical connector.

 

    1. Connect the DEF injector supply pipe.

 

    1. Reposition the DEF injector supply pipe heatshield.

 

    1. Install the engine undershield.

 

  1. NOTE:

    SRO to be claimed separately.

    • Connect the Jaguar Land Rover (JLR) approved diagnostic equipment.

       

    • Select ‘Powertrain – Diesel Exhaust Fluid Prime and Pressure Test’ from the diagnostic menu.

    • Make sure that all steps from the on-screen instructions are followed.

REMOVAL AND INSTALLATION

 

  • 17.50.49
  • PIPE – DIESEL EXHAUST FLUID INJECTOR FEED – RENEW
  • 3000 CC, TDV6
  • 1.30

 

NOTE:

  • This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
  • This procedure contains illustrations showing certain components removed to provide extra clarity.

 

    1. Raise and support the vehicle on a suitable 2 post lift.
      Refer to:Lifting (100-02 Jacking and Lifting, Description and Operation).

 

    1. Remove the Diesel Exhaust Fluid (DEF) tank.
      Refer to:Diesel Exhaust Fluid Pipe (303-08A Engine Emission Control – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Removal and Installation).

 

    1. E192620


      • Remove the DEF tank cover.

 

  1. E192621


    Remove the DEF pipe.

 

    1. Install the Diesel Exhaust Fluid (DEF) pipe.

 

  1. Install the DEF tank.
    Refer to:Diesel Exhaust Fluid Pipe (303-08A Engine Emission Control – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Removal and Installation).

REMOVAL AND INSTALLATION

 

  • 17.45.16
  • VALVE – EGR – LH – RENEW
  • 3000 CC, TDV6, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID
  • 1.30

 

PART(S)





STEP PART NAME QUANTITY
Removal Step 11 Exhaust gas recirculation gasket 1

NOTES:

  • Removal steps in this procedure may contain installation details.

  • Some illustrations may show the engine removed for clarity.

  • Make sure that all openings are sealed.

 

    1. Refer to:Specifications (414-00 Battery and Charging System – General Information, Specifications).

 


 


 


 

    1. E146652

 

    1. E146653

 

    1. E146654

 

    1. E146655

      Torque: 10Nm

 

    1. E146656

      Torque: 10Nm

 

    1. E146657

 



  1. E146658


    Torque: 10Nm

 

    1. To install reverse the removal procedure.

 

  1. If a new unit is installed, configure using the approved diagnostic tool.

REMOVAL AND INSTALLATION

 

  • 17.50.35
  • DIESEL EXHAUST FLUID INJECTION PUMP – RENEW
  • ALL DERIVATIVES
  • 0.70

 

GENERAL EQUIPMENT





EQUIPMENT NAME
Jaguar Land Rover approved diagnostic equipment

PART(S)







STEP PART NAME QUANTITY
Installation Step 1 Diesel exhaust fluid injection pump seals 1
Installation Step 3 Sleeve and isolator assemblies 1
Installation Step 4 Diesel exhaust fluid injection pump bolts 1

NOTES:

  • Some variation in the illustrations may occur, but the essential information is always correct.

  • Some components shown removed for clarity.

 

    1. WARNING:

      Make sure to support the vehicle with axle stands.


      Raise and support the vehicle.

 


 

    1. WARNING:

      Be prepared to collect escaping fluid.


      E186511

 

    1. CAUTION:

      Make sure that all disconnected electrical connectors and sockets are sealed.


      E179912

 



    1. E179121

 

    1. WARNING:

      Be prepared to collect escaping fluid.

      CAUTION:

      Do not use excessive force to remove the component.


      E179124

 

    1. CAUTION:

      Using a suitable tool, remove the seals.


      E179120


      If a new pump is being installed this step is not required.

 



    1. E179122


      If a new pump is being installed this step is not required.

 



  1. E179123


    If a new pump is being installed this step is not required.

 

    1. CAUTIONS:

      • Lubricate seals with deionized water.

      • Make sure that the components are clean, dry and free from corrosion and foreign material.



      E179123


      If a new pump is being installed this step is not required.

 

    1. CAUTION:

      Make sure that new components are installed.


      E179122


      If a new pump is being installed this step is not required.

 

    1. CAUTION:

      Install the new sleeves and isolators to the Diesel Exhaust Fluid pump.


      E179120


      If a new pump is being installed this step is not required.

 



    1. E179868


      Torque: 6Nm

 

    1. E179912

 

    1. CAUTION:

      Lubricate with deionized water.


      E186469

 

    1. E186511


      The quick connector is pushed in an axial direction onto the SAE spigot, until you hear a audible click.

 

    1. NOTE:

      This step is only required if a new component is installed.

      • Connect the Jaguar Land Rover (JLR) approved diagnostic equipment.

         

      • Select ‘Powertrain – Diesel exhaust fluid injection pump replacement’ from the diagnostic menu.

      • Make sure that all steps from the on-screen instructions are followed.

 


REMOVAL AND INSTALLATION

 

  • 17.50.36
  • DIESEL EXHAUST FLUID TANK – RENEW
  • 3000 CC, TDV6
  • 0.80

 

GENERAL EQUIPMENT





EQUIPMENT NAME
Jaguar Land Rover approved diagnostic equipment

NOTE:

  • Some variation in the illustrations may occur, but the essential information is always correct.
  • Some components shown removed for clarity.

 

 

The following step(s) applies to:

All vehicles

 

 

    1. WARNING:

      Make sure to support the vehicle with axle stands.


      Raise and support the vehicle.

 

    1. Drain the diesel exhaust fluid tank.

 

  1. E195344

 

 

The following step(s) applies to:

Vehicles with 2.0L diesel engine

 

 

  1. WARNING:

    Be prepared to collect escaping fluid.

    CAUTION:

    Before disconnecting any components, make sure the area is clean and free from foreign material. ​When ​disconnected all openings must be sealed.


    E192617

 

 

The following step(s) applies to:

Vehicles with 3.0L diesel engine

 

 

  1. WARNING:

    Be prepared to collect escaping fluid.

    CAUTION:

    Before disconnecting any components, make sure the area is clean and free from foreign material. ​When ​disconnected all openings must be sealed.


    E193004

 

 

The following step(s) applies to:

Vehicles with 4.4L diesel engine

 

 

  1. WARNING:

    Be prepared to collect escaping fluid.

    CAUTION:

    Before disconnecting any components, make sure the area is clean and free from foreign material. ​When ​disconnected all openings must be sealed.


    E192617

 

 

The following step(s) applies to:

All vehicles

 

 

    1. WARNING:

      Be prepared to collect escaping fluid.

      CAUTION:

      Before disconnecting any components, make sure the area is clean and free from foreign material. ​When ​disconnected all openings must be sealed.


      E192618

 

    1. NOTE:

      Do not disassemble further if the component is removed for access only.


      E193003

 

    1. E192620

 

  1. WARNING:

    Be prepared to collect escaping fluid.


    E192621

 

 

The following step(s) applies to:

All vehicles

 

 

    1. NOTE:

      This step is only required if previously removed.


      E192621

 

    1. NOTE:

      This step is only required if previously removed.


      E192620

      Torque: 10Nm

 

    1. E193003

      Torque: 24Nm

 

  1. E192618

 

 

The following step(s) applies to:

Vehicles with 2.0L diesel engine

 

 

  1. E192617

 

 

The following step(s) applies to:

Vehicles with 3.0L diesel engine

 

 

  1. E193004

 

 

The following step(s) applies to:

Vehicles with 4.4L diesel engine

 

 

  1. E192617

 

 

The following step(s) applies to:

All vehicles

 

 

    1. E195344

 

    1. NOTES:

      • This step is only required if a new component is installed.

      • Diesel Exhaust Fluid (DEF) Tank comes as an assembly with DEF Injection Pump, if a new DEF Tank is installed make sure to configure the new DEF injection pump.


      • Make sure that all steps from the on-screen instructions are followed.

 

  1. Fill the diesel exhaust fluid tank.

REMOVAL AND INSTALLATION

 

 

WARNING:

Injuries such as scalding can be caused by escaping steam or engine coolant, make sure the vehicle cooling system is cool prior to doing this procedure.

CAUTION:

Be prepared to collect escaping engine coolant.

NOTES:

  • This procedure contains illustrations showing certain components removed to provide extra clarity.

  • Be prepared to collect escaping coolant.

  • This procedure contains information for the right and the left side Exhaust Gas Recirculation cooler filter.

 

    1. Raise and support the vehicle on a suitable 2 post lift.
      Refer to:Lifting (100-02 Jacking and Lifting, Description and Operation).

 

    1. Remove the left Exhaust Gas Recirculation (EGR) valve and cooler assembly.

 

    1. E253942


      • Reposition the hose away from the EGR cooler.

 

    1. E253943


      Remove and discard the 4 bolts.

 

    1. E253944

      • Remove the EGR cooler away from the EGR valve.

      • Make sure the mating faces are throughly cleaned when the EGR cooler and EGR valve are separated.

 

  1. E253945

    • Remove and discard the EGR cooler filter gasket.

    • Use a suitable solvent based cleaner to throughly clean the EGR cooler and the EGR valve.

 

    1. E253945


      Install a new Exhaust Gas Recirculation (EGR) cooler filter gasket.

 

    1. E253944


      Install the EGR cooler onto the EGR valve.

 

    1. E253946

      • Install and tighten the 4 new bolts in the sequence illustrated.

        Torque: 7Nm

      • Tighten bolt (1) for the second time.

        Torque: 7Nm

 

    1. E253942

      • Reposition the hose into the correct location.


 

  1. Install the left EGR valve and cooler assembly.

 

REMOVAL AND INSTALLATION

 

  • 17.45.17
  • VALVE – EGR – RH – RENEW
  • 3000 CC, TDV6
  • 1.30

 

PART(S)





STEP PART NAME QUANTITY
Removal Step 12 EGR pipe to exhaust manifold gasket 1

NOTES:

  • Removal steps in this procedure may contain installation details.

  • Some illustrations may show the engine removed for clarity.

  • Make sure that all openings are sealed.

 

    1. Refer to:Specifications (414-00 Battery and Charging System – General Information, Specifications).

 


 


 


 

    1. E147090

 

    1. E147086

 

    1. E147087

      Torque: 8Nm

 



    1. E144608

      Torque: 10Nm

 



    1. E178503

      Torque: 10Nm

 

    1. E147088

      Torque: 10Nm

 

    1. E147089

 



  1. E147091


    Torque: 10Nm

 

    1. To install reverse the removal procedure.

 

  1. If a new unit is installed, configure using the approved diagnostic tool.

 

REMOVAL AND INSTALLATION

 

  • 17.45.22
  • TUBE – EGR VALVE OUTLET – RH – RENEW
  • 3000 CC, TDV6
  • 0.20

 

PART(S)






STEP PART NAME QUANTITY
Installation Step 1 EGR pipe to exhaust manifold gasket 1
Installation Step 2 Retaining clip(s) 1

NOTE:

Some variation in the illustrations may occur, but the essential information is always correct.

 


 

    1. E121965

 

    1. NOTE:

      Discard the retaining clips.


      E121967

 

    1. E121966

 

  1. CAUTION:

    Make sure that all openings are sealed.



    E121968

 

    1. CAUTION:

      Only tighten the bolts finger-tight at this stage.



      E145192


 

    1. CAUTION:

      Install a new clamp. Close the clamp to the first audible click by hand. Making sure that the clamp is in a central position to the joint, close to the second audible click using a suitable tool.


      E121967


 

    1. E121966

      Torque: 5Nm

 

    1. E122268

      Torque: 10Nm

 

    1. E121965

 


REMOVAL AND INSTALLATION

 

  • 17.50.34
  • DIESEL EXHAUST FLUID INJECTOR – RENEW
  • 3000 CC, TDV6
  • 0.40

 

GENERAL EQUIPMENT





EQUIPMENT NAME
Jaguar Land Rover approved diagnostic equipment

PART(S)





STEP PART NAME QUANTITY
Installation Step 1 Diesel exhaust fluid injector refit kit 1

WARNING:

Observe due care when working near a hot exhaust system.

CAUTION:

Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.

NOTE:

  • This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
  • This procedure contains illustrations showing certain components removed to provide extra clarity.

 

    1. Raise and support the vehicle on a suitable 2 post lift.
      Refer to:Lifting (100-02 Jacking and Lifting, Description and Operation).

 

    1. Remove the engine undershield.

 

    1. E179069


      Reposition the Diesel Exhaust Fluid (DEF) injector supply pipe heatshield.

 

    1. WARNING:

      Be prepared to collect escaping fluid.


      E179068


      Disconnect the DEF injector supply pipe.

 

    1. E179067


      Disconnect the DEF injector electrical connector.

 

    1. E179066


      • Remove the DEF injector.


 

  1. E193034


    Remove and discard the gasket form the DEF injector.

 


      • Install the DEF injector.

      • Install and tighten the clamp.

        Torque: 5Nm

 

    1. Connect the DEF injector electrical connector.

 

    1. Connect the DEF injector supply pipe.

 

    1. Reposition the DEF injector supply pipe heatshield.

 

    1. Install the engine undershield.

 

  1. NOTE:

    SRO to be claimed separately.

    • Connect the Jaguar Land Rover (JLR) approved diagnostic equipment.
    • Select ‘Powertrain – Diesel Exhaust Fluid Prime and Pressure Test’ from the diagnostic menu.

    • Make sure that all steps from the on-screen instructions are followed.

REMOVAL AND INSTALLATION

 

  • 17.50.49
  • PIPE – DIESEL EXHAUST FLUID INJECTOR FEED – RENEW
  • 3000 CC, TDV6
  • 1.30

 

NOTE:

  • This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
  • This procedure contains illustrations showing certain components removed to provide extra clarity.

 

    1. Raise and support the vehicle on a suitable 2 post lift.
      Refer to:Lifting (100-02 Jacking and Lifting, Description and Operation).

 

    1. Remove the Diesel Exhaust Fluid (DEF) tank.
      Refer to:Diesel Exhaust Fluid Pipe (303-08A Engine Emission Control – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Removal and Installation).

 

    1. E192620


      • Remove the DEF tank cover.

 

  1. E192621


    Remove the DEF pipe.

 

    1. Install the Diesel Exhaust Fluid (DEF) pipe.

 

  1. Install the DEF tank.
    Refer to:Diesel Exhaust Fluid Pipe (303-08A Engine Emission Control – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Removal and Installation).

REMOVAL AND INSTALLATION

 

  • 17.45.16
  • VALVE – EGR – LH – RENEW
  • 3000 CC, TDV6, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID
  • 1.30

 

PART(S)





STEP PART NAME QUANTITY
Removal Step 11 Exhaust gas recirculation gasket 1

NOTES:

  • Removal steps in this procedure may contain installation details.

  • Some illustrations may show the engine removed for clarity.

  • Make sure that all openings are sealed.

 

    1. Refer to:Specifications (414-00 Battery and Charging System – General Information, Specifications).

 


 


 


 

    1. E146652

 

    1. E146653

 

    1. E146654

 

    1. E146655

      Torque: 10Nm

 

    1. E146656

      Torque: 10Nm

 

    1. E146657

 



  1. E146658


    Torque: 10Nm

 

    1. To install reverse the removal procedure.

 

  1. If a new unit is installed, configure using the approved diagnostic tool.

REMOVAL AND INSTALLATION

 

  • 17.50.35
  • DIESEL EXHAUST FLUID INJECTION PUMP – RENEW
  • ALL DERIVATIVES
  • 0.70

 

GENERAL EQUIPMENT





EQUIPMENT NAME
Jaguar Land Rover approved diagnostic equipment

PART(S)







STEP PART NAME QUANTITY
Installation Step 1 Diesel exhaust fluid injection pump seals 1
Installation Step 3 Sleeve and isolator assemblies 1
Installation Step 4 Diesel exhaust fluid injection pump bolts 1

NOTES:

  • Some variation in the illustrations may occur, but the essential information is always correct.

  • Some components shown removed for clarity.

 

    1. WARNING:

      Make sure to support the vehicle with axle stands.


      Raise and support the vehicle.

 


 

    1. WARNING:

      Be prepared to collect escaping fluid.


      E186511

 

    1. CAUTION:

      Make sure that all disconnected electrical connectors and sockets are sealed.


      E179912

 



    1. E179121

 

    1. WARNING:

      Be prepared to collect escaping fluid.

      CAUTION:

      Do not use excessive force to remove the component.


      E179124

 

    1. CAUTION:

      Using a suitable tool, remove the seals.


      E179120


      If a new pump is being installed this step is not required.

 



    1. E179122


      If a new pump is being installed this step is not required.

 



  1. E179123


    If a new pump is being installed this step is not required.

 

    1. CAUTIONS:

      • Lubricate seals with deionized water.

      • Make sure that the components are clean, dry and free from corrosion and foreign material.



      E179123


      If a new pump is being installed this step is not required.

 

    1. CAUTION:

      Make sure that new components are installed.


      E179122


      If a new pump is being installed this step is not required.

 

    1. CAUTION:

      Install the new sleeves and isolators to the Diesel Exhaust Fluid pump.


      E179120


      If a new pump is being installed this step is not required.

 



    1. E179868


      Torque: 6Nm

 

    1. E179912

 

    1. CAUTION:

      Lubricate with deionized water.


      E186469

 

    1. E186511


      The quick connector is pushed in an axial direction onto the SAE spigot, until you hear a audible click.

 

    1. NOTE:

      This step is only required if a new component is installed.


      • Select ‘Powertrain – Diesel exhaust fluid injection pump replacement’ from the diagnostic menu.

      • Make sure that all steps from the on-screen instructions are followed.

 


REMOVAL AND INSTALLATION

 

  • 17.50.36
  • DIESEL EXHAUST FLUID TANK – RENEW
  • 3000 CC, TDV6
  • 0.80

 

GENERAL EQUIPMENT





EQUIPMENT NAME
Jaguar Land Rover approved diagnostic equipment

NOTE:

  • Some variation in the illustrations may occur, but the essential information is always correct.
  • Some components shown removed for clarity.

 

 

The following step(s) applies to:

All vehicles

 

 

    1. WARNING:

      Make sure to support the vehicle with axle stands.


      Raise and support the vehicle.

 

    1. Drain the diesel exhaust fluid tank.

 

  1. E195344

 

 

The following step(s) applies to:

Vehicles with 2.0L diesel engine

 

 

  1. WARNING:

    Be prepared to collect escaping fluid.

    CAUTION:

    Before disconnecting any components, make sure the area is clean and free from foreign material. ​When ​disconnected all openings must be sealed.


    E192617

 

 

The following step(s) applies to:

Vehicles with 3.0L diesel engine

 

 

  1. WARNING:

    Be prepared to collect escaping fluid.

    CAUTION:

    Before disconnecting any components, make sure the area is clean and free from foreign material. ​When ​disconnected all openings must be sealed.


    E193004

 

 

The following step(s) applies to:

Vehicles with 4.4L diesel engine

 

 

  1. WARNING:

    Be prepared to collect escaping fluid.

    CAUTION:

    Before disconnecting any components, make sure the area is clean and free from foreign material. ​When ​disconnected all openings must be sealed.


    E192617

 

 

The following step(s) applies to:

All vehicles

 

 

    1. WARNING:

      Be prepared to collect escaping fluid.

      CAUTION:

      Before disconnecting any components, make sure the area is clean and free from foreign material. ​When ​disconnected all openings must be sealed.


      E192618

 

    1. NOTE:

      Do not disassemble further if the component is removed for access only.


      E193003

 

    1. E192620

 

  1. WARNING:

    Be prepared to collect escaping fluid.


    E192621

 

 

The following step(s) applies to:

All vehicles

 

 

    1. NOTE:

      This step is only required if previously removed.


      E192621

 

    1. NOTE:

      This step is only required if previously removed.


      E192620

      Torque: 10Nm

 

    1. E193003

      Torque: 24Nm

 

  1. E192618

 

 

The following step(s) applies to:

Vehicles with 2.0L diesel engine

 

 

  1. E192617

 

 

The following step(s) applies to:

Vehicles with 3.0L diesel engine

 

 

  1. E193004

 

 

The following step(s) applies to:

Vehicles with 4.4L diesel engine

 

 

  1. E192617

 

 

The following step(s) applies to:

All vehicles

 

 

    1. E195344

 

    1. NOTES:

      • This step is only required if a new component is installed.

      • Diesel Exhaust Fluid (DEF) Tank comes as an assembly with DEF Injection Pump, if a new DEF Tank is installed make sure to configure the new DEF injection pump.

      • Connect the Jaguar Land Rover (JLR) approved diagnostic equipment.
      • Select ‘Powertrain – Diesel exhaust fluid injection pump replacement’ from the diagnostic menu.

      • Make sure that all steps from the on-screen instructions are followed.

 

  1. Fill the diesel exhaust fluid tank.

REMOVAL AND INSTALLATION

 

 

WARNING:

Injuries such as scalding can be caused by escaping steam or engine coolant, make sure the vehicle cooling system is cool prior to doing this procedure.

CAUTION:

Be prepared to collect escaping engine coolant.

NOTES:

  • This procedure contains illustrations showing certain components removed to provide extra clarity.

  • Be prepared to collect escaping coolant.

  • This procedure contains information for the right and the left side Exhaust Gas Recirculation cooler filter.

 

    1. Raise and support the vehicle on a suitable 2 post lift.
      Refer to:Lifting (100-02 Jacking and Lifting, Description and Operation).

 

    1. Remove the left Exhaust Gas Recirculation (EGR) valve and cooler assembly.

 

    1. E253942


      • Reposition the hose away from the EGR cooler.

 

    1. E253943


      Remove and discard the 4 bolts.

 

    1. E253944

      • Remove the EGR cooler away from the EGR valve.

      • Make sure the mating faces are throughly cleaned when the EGR cooler and EGR valve are separated.

 

  1. E253945

    • Remove and discard the EGR cooler filter gasket.

    • Use a suitable solvent based cleaner to throughly clean the EGR cooler and the EGR valve.

 

    1. E253945


      Install a new Exhaust Gas Recirculation (EGR) cooler filter gasket.

 

    1. E253944


      Install the EGR cooler onto the EGR valve.

 

    1. E253946

      • Install and tighten the 4 new bolts in the sequence illustrated.

        Torque: 7Nm

      • Tighten bolt (1) for the second time.

        Torque: 7Nm

 

    1. E253942

      • Reposition the hose into the correct location.


 

  1. Install the left EGR valve and cooler assembly.

 

 

303-12A: Intake Air Distribution and Filtering – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2

Torque Specification










DESCRIPTION NM LB-FT LB-IN
Air cleaner outlet pipe clip 3.5 31
*Charge air cooler torx bolt 9 7
Charge air cooler M6 5 4
Charge air cooler nut 9 7
Charge air cooler inlet pipe clip 5 44
Charge air cooler outlet pipe clip 5 44

* A new nut must be installed.

Description and Operation

DESCRIPTION AND OPERATION

 

 

COMPONENT LOCATION – SHEET 1 OF 3

E178991

 
















ITEM DESCRIPTION
1 Right dirty air duct (if fitted)
2 Right intake grilles (if fitted)
3 Right air cleaner (if fitted)
4 Electric throttle
5 Right intake manifold (integral with camshaft cover)
6 Left intake manifold (integral with camshaft cover)
7 EGR pipe (if fitted)
8 Left intake grilles
9 Left dirty air duct
10 Left air cleaner
11 Left clean air ducts with resonator
12 Right clean air ducts

 

COMPONENT LOCATION – SHEET 2 OF 3 – TWIN-TURBO VARIANT

E178992

 













ITEM DESCRIPTION
1 Charge air duct – charge air intake valve to left clean air duct
2 Charge air ducts – secondary turbocharger to charge air intake valve
3 Charge air ducts – charge air cooler to electric throttle
4 Secondary turbocharger
5 Primary turbocharger
6 Charge air ducts – primary turbocharger to charge air cooler
7 Charge air cooler
8 Charge air ducts – charge air intake valve to charger air cooler
9 Charge air intake valve

 

COMPONENT LOCATION – SHEET 3 OF 3 – MONO-TURBO VARIANT

E178993

 








ITEM DESCRIPTION
1 Charge air ducts – charge air cooler to electric throttle
2 Turbocharger
3 Charge air cooler
4 Charge air ducts – turbocharger to charge air cooler

The intake air distribution and filtering system cleans, compresses and cools the intake air. The system comprises according to bi- or mono-turbo variant is equipped:














Bi-turbo engines Mono-turbo engines
Two dirty air ducts. A dirty air duct.
Two air cleaners. An air cleaner.
Two clean air ducts, one with resonator. A clean air duct with resonator.
Two turbochargers. A turbocharger.
Charge air ducts. A charge air duct.
A charge air intake valve.
A water cooled charge air cooler. A water cooled charge air cooler.
An electric throttle. An electric throttle.
Two intake manifolds. Two intake manifolds.
A low pressure EGR duct A low pressure EGR duct

Air flows through the dirty air ducts, air cleaners and clean air ducts to the compressor intakes of the turbochargers. The turbochargers compress the air, which is then transferred through the charge air ducts to the charge air intake valve, charge air cooler, electric throttle and the intake manifolds.

DIRTY AIR DUCTS

E144241

 












ITEM DESCRIPTION
1 Front fender support
2 Screw
3 Intake grille
4 Screw
5 Intake grille
6 Front upper bracket
7 Front lower bracket
8 Non-porous sleeve

The dirty air ducts are installed in the front fenders to transfer ambient air from under the edges of the hood to the air cleaners. If mono-turbo variant is equipped one air duct is fitted on the left side.

Each dirty air duct locates in the intake of the related air cleaner and is attached to the front inner fender with two brackets. The intake of each dirty air duct is attached to two intake grilles on top of the front fender support. When the hood is closed, the intake grilles locate in guides attached to the hood inner panel.

A porous section, covered by a non-porous sleeve to prevent moisture ingress, is incorporated into each dirty air duct to reduce induction noise.

AIR CLEANERS

E144242

 














ITEM DESCRIPTION
1 Screw (6 off)
2 Lid
3 Isolators
4 Air intake
5 Drain valve
6 Isolator
7 Base
8 Engine vacuum system connection (left air cleaner only)
9 Air outlet
10 Mass Air Flow (MAF) sensor (left air cleaner) or Mass Air Flow and Temperature (MAFT) sensor (right air cleaner)

An air cleaner is located in each front corner of the engine compartment if bi-turbo variant is equipped and one air cleaner is located in the left front corner of the engine compartment if mono-turbo variant is equipped. Three spigots fitted with isolator bushes locate each air cleaner in holes in the related front inner fender and front suspension housing.

Each air cleaner consists of a filter element installed in a base and enclosed with a lid secured by six screws. The filter element is a pleated, paper type with an integral seal. Air intake and outlet connections are incorporated into the base and lid respectively. The bottom of the base incorporates a drain valve to prevent the accumulation of water in the air cleaner.

The lid of the left air cleaner incorporates a connection for the engine vacuum system. For additional information, refer to:

Turbocharger (303-04B Fuel Charging and Controls – Turbocharger – TDV6 3.0L Diesel, Description and Operation),
Engine Emission Control (303-08A Engine Emission Control – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Description and Operation).

 

The air outlet connection of each air cleaner incorporates either a mass air flow (MAF) sensor (right air cleaner, if equipped) and a mass air flow and temperature (MAFT) sensor (left air cleaner). If mono-tubro variant if equipped only a MAFT sensors is fitted. The sensors are connected to the Engine Control module (ECM). For additional information, refer to:Electronic Engine Controls (303-14A Electronic Engine Controls – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Description and Operation).

CLEAN AIR DUCTS

E179197

 














ITEM DESCRIPTION
1 Air intake – twin-turbo variant only
2 Convolute – twin-turbo variant only
3 Bracket – twin-turbo variant only
4 Air outlet – twin-turbo variant only
5 Air intake
6 Convolute
7 Resonator
8 Air outlet
9 Bracket
10 Charge air bypass hose connection

The clean air ducts transfer air from the air cleaner outlets to the compressor intakes on the turbochargers. Each clean air duct incorporates a convolute section to accommodate relative movement between the engine mounted turbochargers and the body mounted air cleaners. The left clean air duct also incorporates a quarter wave resonator to reduce air induction noise.

If bi-turbo variant is fitted the left clean air duct also incorporates connection for the bypass hose from the charge air intake valve.For additional information, refer to:Turbocharger (303-04B Fuel Charging and Controls – Turbocharger – TDV6 3.0L Diesel, Description and Operation).

Brackets on the clean air ducts attach the ducts to the A/C compressor (left air duct) and the generator mounting bracket (right clean air duct, if equipped).

TURBOCHARGERS

The turbochargers are attached to the exhaust manifolds. A VGT (variable geometry turbine) turbocharger, designated as the primary turbocharger, is located on the left side of the engine. A fixed vane turbocharger, designated as the secondary turbocharger, is installed on the right side of the engine.For additional information, refer to:Turbocharger (303-04B Fuel Charging and Controls – Turbocharger – TDV6 3.0L Diesel, Description and Operation).

CHARGE AIR DUCTS

Charge Air Ducts – Twin-turbo variant

E179199

 







ITEM DESCRIPTION
1 Secondary turbocharger air tube connection
2 Charge air temperature sensor
3 Secondary turbocharger charge air pressure connection

Charge Air Ducts – Mono-turbo variant

E179198

 






ITEM DESCRIPTION
1 Secondary turbocharger air tube connection
2 Charge air temperature sensor

The charge air ducts interconnect the turbocharger compressor outlets, charge air intake valve (if bi-turbo variant is equipped), charge air cooler and electric throttle.

The charge air duct connection with the electric throttle incorporates connections for:

  • An air tube connected to the secondary turbocharger. For additional information, refer to:Turbocharger (303-04B Fuel Charging and Controls – Turbocharger – TDV6 3.0L Diesel, Description and Operation).
  • A charge air temperature sensor connected to the ECM.For additional information, refer to:Electronic Engine Controls (303-14A Electronic Engine Controls – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Description and Operation).

The charge air duct connected to the outlet of the secondary turbocharger incorporates a connection for the charge air pressure sensor.For additional information, refer to:Electronic Engine Controls (303-14A Electronic Engine Controls – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Description and Operation).

CHARGE AIR INTAKE VALVE – ONLY FOR BI-TURBO VARIANT

The charge air intake valve is attached to a bracket on the front subframe and the cooling pack protector.

The charge air intake valve is used by the ECM to change turbocharger operation between mono and bi-turbo modes. The valve controls the flow of air from the compressor of the secondary turbocharger to the clean air duct of the primary turbocharger and to the charge air cooler.For additional information, refer to:Turbocharger (303-04B Fuel Charging and Controls – Turbocharger – TDV6 3.0L Diesel, Description and Operation).

CHARGE AIR COOLERS

E179031

 















ITEM DESCRIPTION
1 Isolator bush
2 Air intake
3 Isolator bush
4 Front air duct
5 Rear air duct
6 Charge air cooler
7 Cooling water connection
8 Isolator
9 Air outlet
10 Isolator
11 Cooling water connection

The charge air cooler is a water cooled charge air cooler that reduce the intake air temperature.

A charge air cooler is installed on the left side of the cooling pack, behind the left outer air intake in the front bumper. The charge air cooler is installed in air duct attached to the front bumper armature and the front end carrier. The lower end tank of the charge air cooler is located in the air ducts by two spigots fitted with isolator bushes. The upper end tank of each charge air cooler is attached to the front end carrier and the air ducts with two isolator bushes, nuts and bolts.

ELECTRIC THROTTLE

E144246

 











ITEM DESCRIPTION
1 Air intake
2 Electric motor
3 Right Exhaust Gas Recirculation (EGR) pipe connection
4 Right intake manifold connection
5 Manifold Absolute Pressure (MAP) sensor
6 Left intake manifold connection
7 Left EGR pipe connection

The electric throttle regulates the air flow from the charge air coolers to the intake manifolds.

The electric throttle is installed at the front of the engine, between the cylinder heads. Two outlets on the electric throttle locate in the two intake manifolds. A stud bolt attaches the electric throttle to the right cylinder head.

The throttle plate is operated by a DC (Direct Current) electric motor attached to the throttle body. The motor is controlled by the ECM and is constantly adjusted the throttle according to the EGR valve opening, and in response to driver inputs with the throttle pedal, to control the amount of air allowed into the intake manifolds.For additional information, refer to:Electronic Engine Controls (303-14A Electronic Engine Controls – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Description and Operation).

Pipe connections on both sides of the throttle body allow for the attachment of the outlet pipes from the Exhaust Gas Recirculation (EGR) valves. The pipe attachments in the throttle body are specifically designed to mix the recirculated exhaust gas with the intake air and provide an even distribution to each side of the engine.

A manifold absolute pressure (MAP) sensor is located in the top of the throttle body where the air flow splits for the two intake manifolds.For additional information, refer to:Electronic Engine Controls (303-14A Electronic Engine Controls – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Description and Operation).

INTAKE MANIFOLDS

The intake manifolds are an integral part of the camshaft covers. Each intake manifold is connected to the electric throttle by a push fit, sealed connection.For additional information, refer to:Engine (303-01A Engine – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Description and Operation).

Diagnosis and Testing

 

PRINCIPLES OF OPERATION

For a detailed description of the intake air distribution and filtering system and operation, refer to the relevant Description and Operation section of the workshop manual. REFER to:Intake Air Distribution and Filtering (303-12A Intake Air Distribution and Filtering – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, Description and Operation).

 

INSPECTION AND VERIFICATION

CAUTION:

Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does not guarantee confirmation of a fault and may also cause additional faults in the vehicle being checked and/or the donor vehicle.

NOTE:

Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

  1. Verify the customer concern.

  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection





MECHANICAL ELECTRICAL

  • Hoses and ducts condition and installation
  • Air filter condition and installation
  • Restricted air intake
  • Vacuum hoses condition and installation
  • Pipework to turbocharger condition and installation
  • Turbocharger condition and installation
  • Charge air coolers

  • Fuse(s)
  • Wiring harness
  • Loose or corroded electrical connector(s)
  • Mass Air Flow and Temperature (MAFT) sensor
  • Air Charge Temperature (ACT) sensor
  • Manifold absolute pressure (MAP) sensor
  • Intake Air Temperature (IAT) sensor
  • Intake air shut-off throttle solenoid

  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.

  1. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for Diagnostic Trouble Code(s) (DTC)s and refer to the DTC Index.







SYMPTOM POSSIBLE CAUSES ACTION
Vehicle does not start/hard starting

  • Restricted/blocked air intake
  • Restricted/blocked air filter

  • Clear the restriction
  • Install a new air filter as necessary

Poor performance

  • Turbocharger fault
  • Throttle body fault
  • Charge air cooler hoses

  • Inspect the turbochargers
  • Test the intake air shutoff throttle function (make sure the throttle body returns to the open position)
  • Inspect the charge air cooler hoses

Excessive intake noise

  • Intake air leak after the turbocharger
  • Intake pipe disconnected/damaged after the air cleaner
  • Air cleaner assembly incorrectly assembled/damaged

  • Inspect the joint between the air intake elbow and the intake air shutoff throttle. Inspect the joints between the throttle body outlets and the intake manifolds. Inspect the charge air cooler seals
  • Check the intake system and hoses for correct installation/damage
  • Check the air cleaner assembly for correct installation/damage

 

MALFUNCTION INDICATOR LAMP ILLUMINATED ON THE INSTRUMENT CLUSTER (IC) WITH DTC P0299-77 STORED

Affected Vehicle Range











MODEL: MODEL YEAR: VEHICLE IDENTIFICATION NUMBER (VIN): ASSEMBLY PLANT: APPLICABILITY:
Range Rover (LG) 2015-2018 202850-510666 Solihull TDV6 3.0L Diesel – Gen 2
Discovery (LR) 2017-2018 000001-075312 Solihull TDV6 3.0L Diesel
Range Rover Sport (LW) 2016-2018 100003-199996 Solihull TDV6 3.0L Diesel – Gen 2
Range Rover Sport (LW) 2015-2016 512861-599999 Solihull TDV6 3.0L Diesel – Gen 2
Range Rover Sport (LW) 2018 400291-413163 Solihull TDV6 3.0L Diesel – Gen 2
Range Rover Sport (LW) 2015-2018 600440-699492 Solihull TDV6 3.0L Diesel – Gen 2
Range Rover Sport (LW) 2018 800000-808712 Solihull TDV6 3.0L Diesel – Gen 2

Situation:

A customer may express a concern of restricted performance accompanied by an illuminated Malfunction Indicator Lamp on the Instrument Cluster (IC), with DTC P0299-77 stored in the Powertrain Control Module (PCM).

Cause:

Charge air cooler hose collapsing internally.

Action:

Should a customer express this concern, follow the service instruction below.





DESCRIPTION QUANTITY
Charge air cooler hose 1

2017 Onwards Model Year (MY) vehicles

CAUTION:

This procedure requires a minimum of Pathfinder 190 loaded or later.

NOTES:

  • The Jaguar Land Rover (JLR) approved diagnostic equipment will read the VIN for the vehicle and automatically take the vehicle out of ‘Transportation mode’ if required.

  • DTC P0299-77 can be set for multiple reasons, work through all required checks against this DTC before determining the charge air cooler hose requires renewal.

  1. Connect the JLR approved battery support unit.

  1. Connect the JLR approved diagnostic equipment to the vehicle and begin a new session.

  1. Follow the JLR approved diagnostic equipment prompts.

  1. Select ‘ECU Diagnostics’.

  1. Select ‘All DTCs’.

    1. If DTC P0299-77 is present, continue to the service instruction.
    2. If DTC P0299-77 is not present, do not continue with this bulletin and continue diagnosis using TOPIx Worksop Manual section 100-00: General Information – Diagnostic Trouble Code Index.

  1. Select ‘Clear all DTCs’.

  1. Follow all on-screen instructions to complete this task.

  1. When all of the tasks are complete, exit the current session.

  1. Disconnect the JLR approved diagnostic equipment and the JLR approved battery support unit.

NOTES:

  • This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.

  • This procedure contains illustrations showing certain components removed to provide extra clarity.

  • DTC P0299-77 can be set for multiple reasons, work through all required checks against this DTC before determining the charge air cooler hose requires renewal.

  1. Check the vehicle for an excessive engine oil level.

    1. If an excessive engine oil level is discovered, rectify the oil level using TOPIx repair procedures, recheck the vehicle and submit a separate warranty claim.
    2. If the oil level is ok, go to the next step.

  1. Check for excessive oil within the air induction system.

    1. If excessive levels of oil are discovered within the induction system, investigate and rectify using TOPIx repair procedures, recheck the vehicle and submit a separate warranty claim.
    2. If no excessive oil is detected, go to the next step.

  1. Check the vehicles exhaust system for leakage.

    1. If an exhaust system leak is discovered, please correct the leak using TOPIx repair procedures, recheck the vehicle and submit a separate warranty claim.
    2. If no exhaust leak is discovered, go to the next step.

  1. Check the charge air pressure sensor for signs of blockage.

    1. If the charge air sensor is found to be blocked, rectify the blocked sensor using TOPIx repair procedures, recheck the vehicle and submit a separate warranty claim.
    2. If the charge pressure sensor is ok, go to the next step.

  1. Check the turbocharger system/vanes mechanical integrity.

    1. If the turbocharger appears to be faulty, investigate and rectify using TOPIx repair procedures, recheck the vehicle and submit a separate warranty claim.
    2. If the turbocharger is ok, go to the next step.

  1. Complete a leakage test on the vehicles induction system, (see TOPIx Workshop Manual – 303-00: Engine System – General Information – General Procedures – Leakage Test Using Smoke Test Equipment).

    1. If a leak has been detected do not continue with this technical bulletin, please correct the leak using TOPIx repair procedures, retest the vehicle and submit a separate warranty claim.
    2. If no leak has been detected, go to step 7.

  1. Replace the charge air cooler hose, refer to steps 8 – 13.

  1. Remove the engine cover (See TOPIx workshop manual section: 501-05 Interior Trim and Ornamentation – Removal and Installation – Engine Cover – TDV6 3.0L Diesel – Gen 2/TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5).

    1. For Range Rover and Range Rover Sport vehicles, go to step 9.
    2. For Discovery vehicles, go to step 10.

  1. Remove the engine compartment front trim covers.

    1. Remove fasteners and lift both outer covers upwards.
    2. Pull the center trim upwards for removal.

NOTE:

Some components are removed for clarity.

E235204

  1. Remove the engine compartment front trim covers.

    1. Remove fasteners and lift both outer covers upwards.
    2. Remove fasteners and lift the center cover upwards.

NOTE:

Some components are removed for clarity.

E235289

  1. Disconnect the vacuum pipe and the electrical connector from the charge air cooler hose, release the securing clip and disconnect the charge air cooler hose from the electronic throttle body, disconnect the charge air cooler hose from the top of the charge air cooler.

NOTE:

Some components are removed for clarity.

E235205

  1. Renew the charge air cooler hose.

  1. Repeat steps 11 – 8 in reverse to complete the operation.

For a list of DTCs that could be set on this vehicle, please refer to Section 100-00. REFER to:Diagnostic Trouble Code Index – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2, DTC: Powertrain Control Module B10A2-07 to P02D7-32 (100-00 General Information, Description and Operation).

General Procedures

 

  • 01.01.28
  • LEAKAGE TEST USING SMOKE TEST EQUIPMENT
  • 3000 CC, TDV6
  • 0.40

SPECIAL TOOL(S)

GENERAL EQUIPMENT






EQUIPMENT NAME
Adapter – High Pressure Diagnostic Leak Detector
High Pressure Diagnostic Leak Detector

 

ACTIVATION

CAUTION:

  • Do not exceed 0.35 bar (5 psi, 34.5 kPA) test pressure, when testing the engine intake system.

  • Only use calibrated equipment recommended by Jaguar Land Rover.

NOTE:

  • This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
  • This procedure contains illustrations showing certain components removed to provide extra clarity.

 

    1. Remove the engine cover.

 

    1. E244895


      • Disconnect the air filter outlet pipe.

 

    1. NOTE:

      Make sure the adapter is a good fit to the clean air duct. This must be an air tight seal.


      E244898


      Insert the appropriate adaptor into the clean air duct.

      Torque: 3.5Nm

 

    1. E244896


      • Disconnect the air filter outlet pipe.

 

    1. E244897


      • Tighten the hose clamp.

        Torque: 3.5Nm

 

    1. E244899


      Install the block off adaptor.

 

    1. E244893


      • Disconnect the breather hose.

 

    1. WARNING:

      Failure to follow this step may result in injury.


      E247528


      When using the special tool JLR-303-1704-1, secure the tether to a suitable position.

 

    1. E244894


      Install the special tool into the breather hose.

 

    1. CAUTION:

      Never use dye/UV dye in intake or exhaust systems because it may coat or harm critical sensors.


      • Check the high pressure diagnostic leak detector vapor producing fluid level. Top up if required.

 

    1. CAUTION:

      Never use dye/UV dye in intake or exhaust systems. Failure to follow this instruction may coat or harm critical sensors.



      Check the high pressure diagnostic leak detector vapor producing fluid level. Top up if required.

 

    1. CAUTIONS:

      • Do not connect the high pressure diagnostic leak detector to a battery charger, battery support unit or jumper box.

      • Never connect the high pressure diagnostic leak detector to the vehicle with the engine running.


      Connect the high pressure diagnostic leak detector to a suitable power supply.

 

    1. Connect the high pressure diagnostic leak detector to a suitable air supply.

 

    1. E185823


      Switch the flow control valve to the ‘OFF’ position.

 

    1. E185825


      Pull the pressure regulator valve out.

 

    1. E185834


      Set the test pressure to 0.35 bar (5 psi, 34.5 kPA).

 

    1. E185835


      Push the pressure regulator valve in to lock it.

 

    1. E244900


 

    1. E185826


      Press the ‘START’ switch to begin a 10 minute vapor cycle.

 

    1. E185824


      Turn the flow control valve to the ‘ON’ position to release pressure / vapor.

 

      • Use the inspection light supplied with the high pressure diagnostic leak detector, to inspect for leaks.

      • If a leak is detected, rectify the cause.

 

      • Disconnect the high pressure diagnostic leak detector from the power supply.

      • Disconnect the high pressure diagnostic leak detector from the air supply.

      • Disconnect the high pressure diagnostic leak detector from the adaptor.

 

    1. Remove the special tool from the breather hose.

 

    1. Install the breather hose.

 

    1. Remove the adaptor from the left air filter outlet pipe.

 

      • Install the left air filter outlet pipe.

      • Tighten the hose clamp.

        Torque: 3.5Nm

 

    1. Remove the block off adaptor.

 

    1. Remove the adaptor from the right air filter outlet pipe.

 

      • Install the right air filter outlet pipe.

      • Tighten the hose clamp.

        Torque: 3.5Nm

 

  1. Install the engine cover.

Removal and Installation

REMOVAL AND INSTALLATION

 

  • 19.10.10
  • AIR FILTER ELEMENT – RENEW
  • 3000 CC, TDV6
  • 0.10

NOTE:

Removal steps in this procedure may contain installation details.

 

    1. E142432

 

  1. E142433

 

  1. To install, reverse the removal procedure.

REMOVAL AND INSTALLATION

 

  • 19.10.03
  • AIR CLEANER – LH – RENEW
  • 3000 CC, TDV6
  • 0.30

 

NOTE:

Removal steps in this procedure may contain installation details.

 

    1. E142427

 

    1. NOTE:

      Make sure the retaining clip is correctly installed and tightened..


      E142428

      Torque: 3Nm

 

    1. E142429

 

    1. E142430

 

    1. Do not disassemble further if the component is removed for access only.

 

  1. CAUTION:

    Inspect the O-ring seal, install a new component if damaged.


    E142431

 

  1. To install, reverse the removal procedure.

REMOVAL AND INSTALLATION

 

  • 19.10.04
  • AIR CLEANER – RH – RENEW
  • 3000 CC, TDV6
  • 0.30

 

NOTE:

Removal steps in this procedure may contain installation details.

 

    1. E142563

 

    1. NOTES:

      • Make sure the retaining clip is correctly installed and tightened..

      • Left-hand shown, right-hand similar.


      E142428

      Torque: 3Nm

 

    1. NOTE:

      Left-hand shown, right-hand similar.


      E142429

 

    1. NOTE:

      Left-hand shown, right-hand similar.


      E142430

 

    1. Do not disassemble further if the component is removed for access only.

 

  1. CAUTION:

    Inspect the O-ring seal, install a new component if damaged.

    NOTE:

    Left-hand shown, right-hand similar.


    E142431

 

  1. To install, reverse the removal procedure.

REMOVAL AND INSTALLATION

 

  • 19.44.02
  • INTERCOOLER – LH – RENEW
  • 3000 CC, TDV6, GEN 2
  • 1.70

 

PART(S)






STEP PART NAME QUANTITY
Removal Step 4 Retaining clip 1
Removal Step 9 Retaining clip 1

NOTES:

  • Some variation in the illustrations may occur, but the essential information is always correct.

  • Removal steps in this procedure may contain installation details.

 


 


 

    1. E178782

      Torque: 5Nm

 

    1. NOTE:

      Make sure that new components are installed.


      E178783


 

    1. E178784

 

    1. E178785

      Torque: 5Nm

 

    1. E178867

      Torque: 7Nm

 

    1. E178786

      Torque: 4Nm

 

    1. NOTE:

      Make sure that new components are installed.


      E178787


 

    1. NOTE:

      Do not disassemble further if the component is removed for access only.


      E178788

 

    1. E178789

      Torque: 9Nm

 

    1. E178790


      Inspect the components and renew if damaged or worn.

 

  1. E178791

 

  1. To install, reverse the removal procedure.

 

303-14A: Electronic Engine Controls – TDV6 3.0L Diesel /TDV6 3.0L Diesel – Gen 1.5/TDV6 3.0L Diesel – Gen 2

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