Range Rover Sport / L494 2017 ACCESSORY DRIVE MANUAL

303-05A: Accessory Drive - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2

303-04A: Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2

ACCESSORY DRIVE - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1509471)

SPECIFICATIONS
 

Torque Specification

NOTE:

A = refer to procedure for correct torque sequence

DESCRIPTION NM LB-FT
Accessory drive belt tensioner retaining bolt 48 35
Accessory drive belt idler pulley retaining bolt 48 35
Fuel injection pump sprocket retaining nut A -
Camshaft rear hub bolt Stage 1 - 80 Stage 2 - 80 degrees Stage 1 - 59 Stage 2 - 80 degrees
Camshaft rear pulley retaining bolts 23 17
Rear end accessory drive belt (READ) belt tensioner retaining bolt 23 17

ACCESSORY DRIVE - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1868447)

DESCRIPTION AND OPERATION
 
 
COMPONENT LOCATION

E178937
 
ITEM DESCRIPTION
1 Idler pulley
2 Accessory drive belt
3 Coolant pump
4 Idler pulley
5 Air Conditioning (A/C) compressor
6 Crankshaft pulley
7 Belt tensioner
8 Generator
 
OVERVIEW

The accessory drive is a belt system powered by a pulley attached to the front of the crankshaft. The crankshaft pulley, which incorporates a torsional vibration damper, transmits power to the drive belt. A belt tensioner is incorporated into the belt run to maintain the correct tension of the drive belt. Together with idler pulleys, the belt tensioner also guide the drive belt clear of obstructions and sets the correct 'wrap-around' of the accessory component drive pulleys to ensure a slip-free drive.

The drive belt is a six-ribbed poly-V belt that drives the:

  • Coolant pump
  • A/C (Air Conditioning) compressor
  • Generator

The belt tensioner consists of an idler pulley on the end of a spring loaded pivot arm. The pivot arm can be turned manually for removal and installation of the drive belt. The belt tensioner is calibrated to automatically maintain the correct tension in the drive belt.

 

Diagnosis and Testing

ACCESSORY DRIVE - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1883314)

DIAGNOSIS AND TESTING
 
 
PRINCIPLES OF OPERATION

For a detailed description of the accessory drive system and operation, refer to the relevant Description and Operation section of the workshop manual. REFER to:Accessory Drive (303-05A Accessory Drive - 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 damage.

Visual Inspection

MECHANICAL
  • Auxiliary drive belt condition (cracking/damage/contamination)
  • Idler assembly
  • Generator
  • Engine cooling fan
  • Tensioner assembly
  • Engine coolant pump
  • Power steering pump
  • Air Conditioning (A/C) compressor
  • Torsional vibration damper
  • Dynamic response pump
  • Tensioner assembly
  • Auxiliary drive belt
  • Security/correct installation of the fuel injection pump cover
  • Fuel injection pump belt condition (cracking/damage/contamination)
  • Fuel injection pump belt tensioner assembly
  • Fuel injection pump
  • Fuel injection pump belt
  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
CAUTION:

If the engine is run without the auxiliary drive belts connected to eliminate driven components, diagnostic trouble codes, (DTCs) may be set which must be cleared before the vehicle is returned to the owner. The engine should not be run for more than 2-3 minutes with the belts disconnected. Failure to follow this instruction may result in damage to the vehicle.

  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 CHART (ACCESSORY DRIVE BELT)
SYMPTOM POSSIBLE CAUSES ACTION
Noise
  • Auxiliary drive belt condition
  • Auxiliary drive belt tension
  • Pulleys misaligned
  • Driven components (including tensioners)
  • Check the auxiliary drive belt condition (see visual inspection)
  • Check the auxiliary drive belt tensioner function
  • Check the pulley alignment
  • Check the driven components for excessive resistance to rotation
Auxiliary drive belt does not hold tension
  • Belt condition
  • Tensioner fault
  • Check the auxiliary drive belt condition (see visual inspection)
  • Check the auxiliary drive belt tensioner function
 
SYMPTOM CHART (FUEL INJECTION PUMP BELT)
SYMPTOM POSSIBLE CAUSES ACTION
Noise
  • Fuel injection pump belt condition
  • Fuel injection pump belt fouling cover
  • Fuel injection pump belt tensioner bearing failure
  • Fuel injection pump failure
  • Check the fuel injection pump belt condition (see visual inspection)
  • Check the fuel injection pump belt cover for indications of fouling (this may indicate a pump misalignment), refer to the relevant workshop manual section
  • The fuel injection pump belt tensioner must be renewed if the belt is removed, making a check of the bearing impractical
  • Remove the fuel injection pump belt, check the fuel injection pump pulley for security. Check the fuel injection pump for excessive resistance to rotation (excessive resistance in the pump will cause the pulley securing nut to loosen as a design feature). Check for diagnostic trouble codes (DTCs) indicating a pump malfunction
Fuel injection pump belt does not hold tension
  • Fuel injection pump belt condition
  • Tensioner fault
  • Check the fuel injection pump belt condition (see visual inspection)
  • Check the tensioner function
Loss of drive (with no drive to the fuel injection pump, the engine will not run)
  • Fuel injection pump belt broken / stripped teeth
  • Drive pulleys loose
  • Investigate the cause of the fuel injection pump belt breakage/damage (a belt broken at a 45 degree angle normally indicates a shear, a break straight across the belt normally indicates that the belt has been crimped).
  • Check the fuel injection pump for excessive resistance to rotation (excessive resistance in the pump will cause the pulley securing nut to loosen as a design feature). Check for DTCs indicating a pump malfunction
 
DTC INDEX

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).

 

Removal and Installation

ACCESSORY DRIVE BELT - VEHICLES WITHOUT: DYNAMIC SUSPENSION (G1509472)

REMOVAL AND INSTALLATION
 
  • 12.10.40
  • ACCESSORY DRIVE BELT - RENEW
  • 3000 CC, TDV6, DIESEL, WITH DYNAMIC RESPONSE, IC
  • 0.40
  • 12.10.40
  • ACCESSORY DRIVE BELT - RENEW
  • 3000 CC, TDV6, DIESEL, WITHOUT DYNAMIC RESPONSE, IC
  • 0.10
 
 
REMOVAL
NOTE:

Removal steps in this procedure may contain installation details.


 
    1. Disconnect the battery ground cable.
      Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).
 
    1. Refer to:Engine Cover - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (501-05 Interior Trim and Ornamentation, Removal and Installation).
 
  1. NOTES:
    • Note the fitted position of the accessory drive belt.

    • Engine shown removed for clarity.

    E142466
 
INSTALLATION
 
  1. CAUTIONS:
    • Make sure that the accessory drive belt is correctly located on each pulley.

    • Clean and inspect the accessory drive belt pulleys for damage.

    To install, reverse the removal procedure.

ACCESSORY DRIVE - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

ACCESSORY DRIVE BELT - VEHICLES WITH: DYNAMIC SUSPENSION (G1606539)

REMOVAL AND INSTALLATION
 
  • 12.10.40
  • ACCESSORY DRIVE BELT - RENEW
  • 3000 CC, TDV6, DIESEL, WITH DYNAMIC RESPONSE, IC
  • 0.40
  • 12.10.40
  • ACCESSORY DRIVE BELT - RENEW
  • 3000 CC, TDV6, DIESEL, WITHOUT DYNAMIC RESPONSE, IC
  • 0.10
 
 
REMOVAL
CAUTION:

Dynamic Response system components are manufactured to very precise tolerances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the dynamic response system.

NOTES:
  • Removal steps in this procedure may contain installation details.

  • Some components shown removed for clarity.


 
    1. Disconnect the battery ground cable.
      Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).
 
    1. Refer to:Engine Cover - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (501-05 Interior Trim and Ornamentation, Removal and Installation).
 
    1. E156586
 
    1. E156818
 
    1. E156422
      Clamp the suction pipe in the area shown.
 
    1. Using a suitable suction device drain the fluid reservoir.
 
    1. CAUTION:

      Be prepared to collect escaping fluids.

      NOTE:

      Note the orientation of the component prior to removal.

      E149035
 
    1. E156374
      Torque: 25Nm
 
    1. E156424
      Torque: 48Nm
 
  1. E156425
 
INSTALLATION
 
    1. To install, reverse the removal procedure.
 
    • Check and top up the fluid reservoir.
    • Squeeze the suction pipe several times to expel the all the air.

ACCESSORY DRIVE - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

ACCESSORY DRIVE BELT PULLEY (G1509473)

REMOVAL AND INSTALLATION
 
 
 
REMOVAL
NOTE:

Removal steps in this procedure may contain installation details.


 
    1. Disconnect the battery ground cable.
      Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).
 
    1. Refer to:Engine Cover - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (501-05 Interior Trim and Ornamentation, Removal and Installation).
 
    1. NOTES:
      • Note the fitted position of the accessory drive belt.

      • Engine shown removed for clarity.

      E142466
 
  1. E142467
    Torque: 50Nm
 
INSTALLATION
 
  1. CAUTIONS:
    • Make sure that the accessory drive belt is correctly located on each pulley.

    • Clean and inspect the accessory drive belt pulleys for damage.

    To install, reverse the removal procedure.

ACCESSORY DRIVE - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

ACCESSORY DRIVE BELT TENSIONER (G1509474)

REMOVAL AND INSTALLATION
 
  • 86.10.06
  • TENSIONER - ALTERNATOR DRIVE BELT - RENEW
  • 3000 CC, TDV6, DIESEL, IC
  • 0.20
 
 
REMOVAL
NOTE:

Removal steps in this procedure may contain installation details.


 
    1. Disconnect the battery ground cable.
      Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).
 
    1. Refer to:Engine Cover - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (501-05 Interior Trim and Ornamentation, Removal and Installation).
 
    1. NOTES:
      • Note the fitted position of the accessory drive belt.

      • Engine shown removed for clarity.

      E142466
 
  1. E142468
    Torque: 47Nm
 
INSTALLATION
 
  1. CAUTIONS:
    • Make sure that the accessory drive belt is correctly located on each pulley.

    • Clean and inspect the accessory drive belt pulleys for damage.

    To install, reverse the removal procedure.

ACCESSORY DRIVE - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

FUEL INJECTION PUMP PULLEY (G1509475)

REMOVAL AND INSTALLATION
 
  • 12.10.24
  • PULLEY - FUEL PUMP DRIVE - RENEW
  • 3000 CC, TDV6
  • 6.50
 
 
REMOVAL
 
  1. Refer to:Fuel Pump (303-04A Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
INSTALLATION
 
  1. To install, reverse the removal procedure.

REAR END ACCESSORY DRIVE (G1509476)

REMOVAL AND INSTALLATION
 
  • 12.10.27
  • BELT - FUEL PUMP DRIVE - RENEW
  • 3000 CC, TDV6
  • 2.80
 

SPECIAL TOOL(S)

E54540
 

303-1117

Timing Peg, Automatic Transmission

 
E116926
 

310-212

Rear End Accessory Drive (READ) belt Timing Tool

PART(S)

STEP PART NAME QUANTITY
Installation Step 1 Timing belt tensioner 1
 
REMOVAL
WARNINGS:
  • Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

  • Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the system can be as high as 1650 bar (23,931 lb-sq-in). Failure to follow this instruction may result in personal injury.

  • Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

  • This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.

CAUTIONS:
  • Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.

  • Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

  • Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

  • Do not disassemble or clean inside the fuel pump, even with an ultrasonic cleaner. Always install a new fuel pump when required.

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

      Make sure to support the vehicle with axle stands.

      Raise and support the vehicle.
 
    1. 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. E144251
 
    1. E145031
 
    1. E145030
 
    1. NOTE:

      Engine shown removed for clarity.

      E145028
 
    1. NOTE:

      Engine shown removed for clarity.

      E145032
 
    1. E145029
 
    1. NOTE:

      Engine shown removed for clarity.

      E123757
 
    1. NOTE:

      Engine shown removed for clarity.

      E123758
 
    1. E123764
 
    1. CAUTION:

      Only rotate the crankshaft clockwise.

      NOTES:
      • This step requires the aid of another technician.

      • Engine shown removed for clarity.

      E116628
      Rotate the crankshaft until the mark on the rear camshaft pulley is in the illustrated position.
 
    1. E116629
 
    1. E116630
      • Install the special tool.
 
    1. E130870
 
    1. CAUTION:

      Discard the component.

      E126058
 
  1. NOTE:

    Do not loosen the bolts more than 2 turns.

    E116633
 
INSTALLATION
 
    1. CAUTION:

      Make sure that the READ belt tensioner tang is correctly located to the READ belt rear cover. Failure to follow this instruction may result in damage to the engine.

      NOTE:

      Make sure that the READ belt tensioner locking pin is not removed until the READ belt is fully installed.

      E126058
      Renew Part: Timing belt tensioner Quantity: 1.
      Torque: 23Nm
 
    1. NOTE:

      Make sure the new READ belt is correctly seated onto the fuel pump pulley.

      E144811
 
    1. E116634
      • Install the special tool.
 
    1. NOTES:
      • The READ rotates in a counter-clockwise direction when viewed from the rear of the engine.

      • Make sure the new READ belt is correctly seated onto the camshaft and fuel pump pulleys.

      E144812
      Install the READ belt onto the camshaft pulley (1) and on to the tensioner (2).
 
    1. NOTE:

      Make sure that the READ belt tensioner locking pin is not removed until the READ belt is fully installed.

      E144813
      Make sure that the rear end accessory drive (READ) belt is aligned with the marks on the rear camshaft pulley and fuel injection pump pulley as illustrated.
 
    1. NOTE:

      Engine shown removed for clarity.

      E116638
 
    1. NOTE:

      Engine shown removed for clarity.

      E116639
      Torque: 23Nm
 
    1. NOTE:

      Engine shown removed for clarity.

      E116635
      • Remove the special tool.
 
    1. E116630
      Remove the special tool.
      Special Tool(s): 303-1117
 
    1. E116629
 
    1. E123764
 
    1. NOTE:

      Engine shown removed for clarity.

      E123758
      • Torque: 10Nm
 
    1. NOTE:

      Engine shown removed for clarity.

      E123757
 
    1. E145029
      • Torque: 5Nm
 
    1. NOTE:

      Engine shown removed for clarity.

      E145032
 
    1. E145028
 
    1. E145030
      • Torque: 10Nm
 
    1. E145031
      • Torque: 10Nm
 
    1. E144251
      • Torque: 10Nm
 
    1. 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. Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).