Range Rover Sport / L494 2017 ENGINE EMISSION CONTROL MANUAL

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

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1509508)

SPECIFICATIONS
 
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

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1868449)

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
 
OVERVIEW

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

 
DESCRIPTION

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.

 
OPERATION

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.

 
CONTROL DIAGRAM
NOTE:

A = Hardwired

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

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1883327)

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 CHART
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
 
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).

 
 

General Procedures

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

DIESEL EXHAUST FLUID TANK DRAIN AND REFILL (G1877405)

GENERAL PROCEDURES
 
  • 17.50.37
  • DIESEL EXHAUST FLUID (DEF) TANK - DRAIN AND REFILL
  • ALL DERIVATIVES
  • 0.50
  • USED WITHINS

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

 

 

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.
      General Equipment: Jaguar Land Rover approved diagnostic equipment
 
    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. CAUTIONS:

      • Make sure the 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. 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.
      General Equipment: Jaguar Land Rover approved diagnostic equipment
 
  1. Using the Jaguar Land Rover approved diagnostic equipment, follow the on-screen instructions and check the DEF level.
     

DIESEL EXHAUST FLUID LEVEL CHECK AND TOP-UP (G1935237)

GENERAL PROCEDURES
 
  • 17.50.51
  • DIESEL EXHAUST FLUID (DEF) TANK - LEVEL CHECK AND TOP-UP
  • ALL DERIVATIVES
  • 0.20
  • USED WITHINS

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.
    General Equipment: Jaguar Land Rover approved diagnostic equipment

 

 

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

 

 

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.
      General Equipment: Jaguar Land Rover approved diagnostic equipment
 
    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. CAUTIONS:

      • Make sure the 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. 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

CRANKCASE VENT OIL SEPARATOR (G1509509)

REMOVAL AND INSTALLATION
 
  • 17.10.04
  • ENGINE VENT OIL SEPARATOR - RENEW
  • 3000 CC, TDV6
  • 0.50
  • USED WITHINS
 
 
REMOVAL
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. 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. E142695
 
    1. E142698
 
    1. E142696
 
  1. CAUTIONS:

    • Make sure that all openings are sealed.

    • Lubricate the O-ring seals with clean engine oil.

    E142697
 
INSTALLATION
 
  1. To install, reverse the removal procedure.

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

LEFT EXHAUST GAS RECIRCULATION VALVE - TDV6 3.0L DIESEL - GEN 2 (G1875419)

REMOVAL AND INSTALLATION
 
  • 17.45.16
  • VALVE - EGR - LH - RENEW
  • 3000 CC, TDV6, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID
  • 1.30
  • USED WITHINS
 

PART(S)

STEP PART NAME QUANTITY
Removal Step 6 EGR valve RH to EGR outlet pipe gasket 1
 
REMOVAL
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. Refer to:Cooling System Partial Draining and Vacuum Filling (303-03C Engine Cooling - V8 S/C 5.0L Petrol, General Procedures).
 
    1. Refer to:Secondary Bulkhead Center Panel - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (501-02 Front End Body Panels, Removal and Installation).
 
    1. E178509
 
    1. E178510
 
    1. NOTE:

      Discard the gasket.

      E178511
      Renew Part: EGR valve RH to EGR outlet pipe gasket Quantity: 1.
      Torque: 5.5Nm
 
    1. E178512
      Torque: 10Nm
 
    1. E178513
 
    1. E178514
 
  1. E178515
    Torque: 10Nm
 
INSTALLATION
 
    1. To install reverse the removal procedure.
 
  1. If a new unit is installed, configure using the approved diagnostic tool.

RIGHT EXHAUST GAS RECIRCULATION VALVE (G1509511)

REMOVAL AND INSTALLATION
 
  • 17.45.17
  • VALVE - EGR - RH - RENEW
  • 3000 CC, TDV6
  • 1.30
  • USED WITHINS
 

PART(S)

STEP PART NAME QUANTITY
Removal Step 12 EGR pipe to exhaust manifold gasket 1
 
REMOVAL
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. Refer to:Cooling System Partial Draining and Vacuum Filling (303-03F Engine Cooling - TDV8 4.4L Diesel, General Procedures).
 
    1. Refer to:Secondary Bulkhead Center Panel - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (501-02 Front End Body Panels, Removal and Installation).
 
    1. Refer to:Right Exhaust Gas Recirculation Valve Outlet Tube (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. E147090
 
    1. E147086
 
    1. E147087
      Torque: 8Nm
 
    1. NOTE:

      If equipped.

      E144608
      Torque: 10Nm
 
    1. NOTE:

      If equipped.

      E178503
      Torque: 10Nm
 
    1. E147088
      Torque: 10Nm
 
    1. E147089
 
  1. NOTE:

    Install a new gasket.

    E147091
    Renew Part: EGR pipe to exhaust manifold gasket Quantity: 1.
    Torque: 10Nm
 
INSTALLATION
 
    1. To install reverse the removal procedure.
 
  1. If a new unit is installed, configure using the approved diagnostic tool.

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

RIGHT EXHAUST GAS RECIRCULATION VALVE OUTLET TUBE (G1509513)

REMOVAL AND INSTALLATION
 
  • 17.45.22
  • TUBE - EGR VALVE OUTLET - RH - RENEW
  • 3000 CC, TDV6
  • 0.20
  • USED WITHINS
 

PART(S)

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

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


 
    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. E121965
 
    1. NOTE:

      Discard the retaining clips.

      E121967
 
    1. E121966
 
  1. CAUTION:

    Make sure that all openings are sealed.

    NOTE:

    Discard the gasket.

    E121968
 
INSTALLATION
 
    1. CAUTION:

      Only tighten the bolts finger-tight at this stage.

      NOTE:

      Install a new gasket.

      E145192
      Renew Part: EGR pipe to exhaust manifold gasket Quantity: 1.
 
    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
      Renew Part: Retaining clip(s) Quantity: 1.
 
    1. E121966
      Torque: 5Nm
 
    1. E122268
      Torque: 10Nm
 
    1. E121965
 
  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).
 

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

DIESEL EXHAUST FLUID INJECTOR (G1875977)

REMOVAL AND INSTALLATION
 
  • 17.50.34
  • DIESEL EXHAUST FLUID INJECTOR - RENEW
  • 3000 CC, TDV6
  • 0.40
  • USED WITHINS
 

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
 
REMOVAL
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.
      Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).
 
    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
      • Release the clamp.
      • Remove the DEF injector.
      • Discard the clamp.
 
  1. E193034
    Remove and discard the gasket form the DEF injector.
 
INSTALLATION
 
      • 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.
      Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).
 
  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.

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

DIESEL EXHAUST FLUID PIPE (G1875980)

REMOVAL AND INSTALLATION
 
  • 17.50.49
  • PIPE - DIESEL EXHAUST FLUID INJECTOR FEED - RENEW
  • 3000 CC, TDV6
  • 1.30
  • USED WITHINS
 
 
REMOVAL
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
      • Release the DEF pipe.
      • Remove the DEF tank cover.
 
  1. E192621
    Remove the DEF pipe.
 
INSTALLATION
 
    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).

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

LEFT EXHAUST GAS RECIRCULATION VALVE - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5 (G1509510)

REMOVAL AND INSTALLATION
 
  • 17.45.16
  • VALVE - EGR - LH - RENEW
  • 3000 CC, TDV6, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID
  • 1.30
  • USED WITHINS
 

PART(S)

STEP PART NAME QUANTITY
Removal Step 11 Exhaust gas recirculation gasket 1
 
REMOVAL
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. Refer to:Cooling System Partial Draining and Vacuum Filling (303-03F Engine Cooling - TDV8 4.4L Diesel, General Procedures).
 
    1. Refer to:Secondary Bulkhead Center Panel - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (501-02 Front End Body Panels, Removal and Installation).
 
    1. Refer to:Left Exhaust Gas Recirculation Valve Outlet Tube - TDV6 3.0L Diesel - Gen 1.5 (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. E146652
 
    1. E146653
 
    1. E146654
 
    1. E146655
      Torque: 10Nm
 
    1. E146656
      Torque: 10Nm
 
    1. E146657
 
  1. NOTE:

    Install a new gasket.

    E146658
    Renew Part: Exhaust gas recirculation gasket Quantity: 1.
    Torque: 10Nm
 
INSTALLATION
 
    1. To install reverse the removal procedure.
 
  1. If a new unit is installed, configure using the approved diagnostic tool.

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

DIESEL EXHAUST FLUID INJECTION PUMP (G1937878)

REMOVAL AND INSTALLATION
 
  • 17.50.35
  • DIESEL EXHAUST FLUID INJECTION PUMP - RENEW
  • ALL DERIVATIVES
  • 0.70
  • USED WITHINS
 

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
 
REMOVAL
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. Refer to:Diesel Exhaust Fluid Tank Drain and Refill (303-08A Engine Emission Control - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, General Procedures).
 
    1. WARNING:

      Be prepared to collect escaping fluid.

      E186511
 
    1. CAUTION:

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

      E179912
 
    1. CAUTION:

      Discard the bolts.

      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. CAUTION:

      Discard the components.

      E179122
      If a new pump is being installed this step is not required.
 
  1. CAUTIONS:

    • Using a suitable tool, remove the seals.

    • Discard the components.

    E179123
    If a new pump is being installed this step is not required.
 
INSTALLATION
 
    1. CAUTIONS:

      • Lubricate seals with deionized water.

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

      NOTE:

      Install new seals.

      E179123
      If a new pump is being installed this step is not required.
      Renew Part: Diesel exhaust fluid injection pump seals Quantity: 1.
 
    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.
      Renew Part: Sleeve and isolator assemblies Quantity: 1.
 
    1. CAUTIONS:

      • Make sure that new bolts are installed.

      • The bolts must be re-torqued after 2 minutes.

      E179868
      Renew Part: Diesel exhaust fluid injection pump bolts Quantity: 1.
      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.
 
  1. Refer to:Diesel Exhaust Fluid Tank Drain and Refill (303-08A Engine Emission Control - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, General Procedures).

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

DIESEL EXHAUST FLUID TANK (G1958061)

REMOVAL AND INSTALLATION
 
  • 17.50.36
  • DIESEL EXHAUST FLUID TANK - RENEW
  • 3000 CC, TDV6
  • 0.80
  • USED WITHINS
 

GENERAL EQUIPMENT

EQUIPMENT NAME
Jaguar Land Rover approved diagnostic equipment
 
REMOVAL
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.
      Refer to:Diesel Exhaust Fluid Tank Drain and Refill (303-08E Engine Emission Control - INGENIUM I4 2.0L Diesel, General Procedures).
 
  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
 
INSTALLATION

 

 

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.
    Refer to:Diesel Exhaust Fluid Tank Drain and Refill (303-08E Engine Emission Control - INGENIUM I4 2.0L Diesel, General Procedures).

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

EXHAUST GAS RECIRCULATION COOLER FILTER (G2422281)

REMOVAL AND INSTALLATION
 
 
 
REMOVAL
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.
      Refer to:Left Exhaust Gas Recirculation Valve - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5 (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. E253942
      • Release the hose clamp.
      • 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.
 
INSTALLATION
 
    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.
      • Install the hose clamp.
 
  1. Install the left EGR valve and cooler assembly.
    Refer to:Left Exhaust Gas Recirculation Valve - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5 (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

 

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

RIGHT EXHAUST GAS RECIRCULATION VALVE (G1509511)

REMOVAL AND INSTALLATION
 
  • 17.45.17
  • VALVE - EGR - RH - RENEW
  • 3000 CC, TDV6
  • 1.30
  • USED WITHINS
 

PART(S)

STEP PART NAME QUANTITY
Removal Step 12 EGR pipe to exhaust manifold gasket 1
 
REMOVAL
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. Refer to:Cooling System Partial Draining and Vacuum Filling (303-03F Engine Cooling - TDV8 4.4L Diesel, General Procedures).
 
    1. Refer to:Secondary Bulkhead Center Panel - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (501-02 Front End Body Panels, Removal and Installation).
 
    1. Refer to:Right Exhaust Gas Recirculation Valve Outlet Tube (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. E147090
 
    1. E147086
 
    1. E147087
      Torque: 8Nm
 
    1. NOTE:

      If equipped.

      E144608
      Torque: 10Nm
 
    1. NOTE:

      If equipped.

      E178503
      Torque: 10Nm
 
    1. E147088
      Torque: 10Nm
 
    1. E147089
 
  1. NOTE:

    Install a new gasket.

    E147091
    Renew Part: EGR pipe to exhaust manifold gasket Quantity: 1.
    Torque: 10Nm
 
INSTALLATION
 
    1. To install reverse the removal procedure.
 
  1. If a new unit is installed, configure using the approved diagnostic tool.

 

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

RIGHT EXHAUST GAS RECIRCULATION VALVE OUTLET TUBE (G1509513)

REMOVAL AND INSTALLATION
 
  • 17.45.22
  • TUBE - EGR VALVE OUTLET - RH - RENEW
  • 3000 CC, TDV6
  • 0.20
  • USED WITHINS
 

PART(S)

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

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


 
    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. E121965
 
    1. NOTE:

      Discard the retaining clips.

      E121967
 
    1. E121966
 
  1. CAUTION:

    Make sure that all openings are sealed.

    NOTE:

    Discard the gasket.

    E121968
 
INSTALLATION
 
    1. CAUTION:

      Only tighten the bolts finger-tight at this stage.

      NOTE:

      Install a new gasket.

      E145192
      Renew Part: EGR pipe to exhaust manifold gasket Quantity: 1.
 
    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
      Renew Part: Retaining clip(s) Quantity: 1.
 
    1. E121966
      Torque: 5Nm
 
    1. E122268
      Torque: 10Nm
 
    1. E121965
 
  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).

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

DIESEL EXHAUST FLUID INJECTOR (G1875977)

REMOVAL AND INSTALLATION
 
  • 17.50.34
  • DIESEL EXHAUST FLUID INJECTOR - RENEW
  • 3000 CC, TDV6
  • 0.40
  • USED WITHINS
 

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
 
REMOVAL
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.
      Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).
 
    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
      • Release the clamp.
      • Remove the DEF injector.
      • Discard the clamp.
 
  1. E193034
    Remove and discard the gasket form the DEF injector.
 
INSTALLATION
 
      • 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.
      Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).
 
  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.

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

DIESEL EXHAUST FLUID PIPE (G1875980)

REMOVAL AND INSTALLATION
 
  • 17.50.49
  • PIPE - DIESEL EXHAUST FLUID INJECTOR FEED - RENEW
  • 3000 CC, TDV6
  • 1.30
  • USED WITHINS
 
 
REMOVAL
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
      • Release the DEF pipe.
      • Remove the DEF tank cover.
 
  1. E192621
    Remove the DEF pipe.
 
INSTALLATION
 
    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).

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

LEFT EXHAUST GAS RECIRCULATION VALVE - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5 (G1509510)

REMOVAL AND INSTALLATION
 
  • 17.45.16
  • VALVE - EGR - LH - RENEW
  • 3000 CC, TDV6, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID
  • 1.30
  • USED WITHINS
 

PART(S)

STEP PART NAME QUANTITY
Removal Step 11 Exhaust gas recirculation gasket 1
 
REMOVAL
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. Refer to:Cooling System Partial Draining and Vacuum Filling (303-03F Engine Cooling - TDV8 4.4L Diesel, General Procedures).
 
    1. Refer to:Secondary Bulkhead Center Panel - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (501-02 Front End Body Panels, Removal and Installation).
 
    1. Refer to:Left Exhaust Gas Recirculation Valve Outlet Tube - TDV6 3.0L Diesel - Gen 1.5 (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. E146652
 
    1. E146653
 
    1. E146654
 
    1. E146655
      Torque: 10Nm
 
    1. E146656
      Torque: 10Nm
 
    1. E146657
 
  1. NOTE:

    Install a new gasket.

    E146658
    Renew Part: Exhaust gas recirculation gasket Quantity: 1.
    Torque: 10Nm
 
INSTALLATION
 
    1. To install reverse the removal procedure.
 
  1. If a new unit is installed, configure using the approved diagnostic tool.

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

DIESEL EXHAUST FLUID INJECTION PUMP (G1937878)

REMOVAL AND INSTALLATION
 
  • 17.50.35
  • DIESEL EXHAUST FLUID INJECTION PUMP - RENEW
  • ALL DERIVATIVES
  • 0.70
  • USED WITHINS
 

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
 
REMOVAL
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. Refer to:Diesel Exhaust Fluid Tank Drain and Refill (303-08A Engine Emission Control - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, General Procedures).
 
    1. WARNING:

      Be prepared to collect escaping fluid.

      E186511
 
    1. CAUTION:

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

      E179912
 
    1. CAUTION:

      Discard the bolts.

      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. CAUTION:

      Discard the components.

      E179122
      If a new pump is being installed this step is not required.
 
  1. CAUTIONS:

    • Using a suitable tool, remove the seals.

    • Discard the components.

    E179123
    If a new pump is being installed this step is not required.
 
INSTALLATION
 
    1. CAUTIONS:

      • Lubricate seals with deionized water.

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

      NOTE:

      Install new seals.

      E179123
      If a new pump is being installed this step is not required.
      Renew Part: Diesel exhaust fluid injection pump seals Quantity: 1.
 
    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.
      Renew Part: Sleeve and isolator assemblies Quantity: 1.
 
    1. CAUTIONS:

      • Make sure that new bolts are installed.

      • The bolts must be re-torqued after 2 minutes.

      E179868
      Renew Part: Diesel exhaust fluid injection pump bolts Quantity: 1.
      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.
 
  1. Refer to:Diesel Exhaust Fluid Tank Drain and Refill (303-08A Engine Emission Control - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, General Procedures).

ENGINE EMISSION CONTROL - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

DIESEL EXHAUST FLUID TANK (G1958061)

REMOVAL AND INSTALLATION
 
  • 17.50.36
  • DIESEL EXHAUST FLUID TANK - RENEW
  • 3000 CC, TDV6
  • 0.80
  • USED WITHINS
 

GENERAL EQUIPMENT

EQUIPMENT NAME
Jaguar Land Rover approved diagnostic equipment
 
REMOVAL
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.
      Refer to:Diesel Exhaust Fluid Tank Drain and Refill (303-08E Engine Emission Control - INGENIUM I4 2.0L Diesel, General Procedures).
 
  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
 
INSTALLATION

 

 

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.
    Refer to:Diesel Exhaust Fluid Tank Drain and Refill (303-08E Engine Emission Control - INGENIUM I4 2.0L Diesel, General Procedures).