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

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)

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)

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)

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.

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

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)

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

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

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

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

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

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

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

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

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

FUEL CHARGING AND CONTROLS - TURBOCHARGER - TDV6 3.0L DIESEL

GEN 2 SINGLE TURBOCHARGER (G2055158)

DESCRIPTION AND OPERATION

 

 

COMPONENT LOCATION

TDV6 3.0L DIESEL - GEN 2 SINGLE TURBOCHARGER

 

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

 

DESCRIPTION

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

 

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

 

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.

 

OPERATION

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

 

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.

 

AIR FLOW DIAGRAM

TDV6 3.0L DIESEL - GEN 2 SINGLE TURBOCHARGER OPERATION

 

 

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.

 

OIL FLOW DIAGRAMS

 

Single Turbocharger Oil Flow

 

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

 

CONTROL DIAGRAM

TDV6 3.0L DIESEL - GEN 2 SINGLE TURBOCHARGER

 

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

 

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

FUEL CHARGING AND CONTROLS - TURBOCHARGER - TDV6 3.0L DIESEL

TURBOCHARGER (G1882792)

DIAGNOSIS AND TESTING

 

 

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 CHART

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	Turbocharger failure(s)	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

 

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

 

PINPOINT TESTS

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 GO toA2. 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 GO toA4. 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 GO toA6. No GO toA5.

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 GO toA7.

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 GO toA8. No GO toA9.

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 GO toA10. 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 GO toA18.

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 GO toA11.

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 GO toA12. No GO toA17.

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)
	Is the measured value for the turbocharger shut-off valve 98% or greater? (See screenshot for reference) Yes GO toA13. No GO toA19.

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 GO toA14. 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 GO toA15. 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)
	Did the signal value for Turbocharger Shut-off valve opening position - Measured change to <4%? (See screenshot for reference) Yes GO toA16. 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 GO toA18.

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
	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

 

DTC INDEX

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

FUEL CHARGING AND CONTROLS - TURBOCHARGER - TDV6 3.0L DIESEL

LEFT TURBOCHARGER (G2354514)

 

PART(S)

ALL VEHICLES

 

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

 

SPECIAL TOOL(S)

ALL VEHICLES

 

Adaptor, Cooling System Vacuum Refill Kit JLR-303-1634
Coolant System Vacuum Refill Kit HU-919
Oil Extraction Kit JLR-303-1644
Remover/Installer, Driveshaft Nut JLR-205-993
Viscous Coupling Wrench 303-1142
Wrench, H02S 310-121

REPAIR

 

 

Left Turbocharger - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5 (303-04B REMOVAL AND INSTALLATION G1509438)

 

PUBLISHED: 03-SEP-2019

2017.0 RANGE ROVER SPORT (LW), 303-04B

FUEL CHARGING AND CONTROLS - TURBOCHARGER - TDV6 3.0L DIESEL

LEFT TURBOCHARGER - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5 (G1509438)

REMOVAL AND INSTALLATION

 

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

 

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

 

REMOVAL

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.
   Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).

 

1. Drain the engine oil.
   Refer to:Engine Oil Vacuum Draining and Filling (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, General Procedures).

 

1. Remove the exhaust.
   Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
   Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

1. Remove the left Exhaust Gas Recirculation (EGR) valve.
   Refer to:Left Exhaust Gas Recirculation Valve - TDV6 3.0L Diesel - Gen 2 (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. 
   Release the intake air pipe.

 

1. CAUTION:

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

   
   • Remove the 2 bolts.
   • Remove and discard the gasket.

 

1. CAUTION:

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

   
   • Remove the turbocharger oil return pipe.
   • Remove and discard the gasket.

 

1. 
   Remove the turbocharger heatshield.

 

1. CAUTION:

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

   
   • Remove and discard the turbocharger oil feed pipe bolt.
   • Remove and discard the washers.

 

1. 
   Disconnect the Crankshaft Position Sensor (CKP) electrical connector.

 

1. 
   Disconnect the electrical connector from the turbocharger.

 

1. 
   Remove the 4 bolts.

 

1. WARNING:

   Be prepared to collect escaping fluids.

   
   Release the coolant pipe.

 

1. WARNING:

   Be prepared to collect escaping fluids.

   
   • Release the coolant pipe.

 

1. 
   Remove the exhaust manifold heatshield.

 

1. 
   Remove and discard the nut.

 

1. 
   • Remove and discard the nuts.
   • Remove and discard the gasket.

 

1. 
   • Remove the turbocharger coolant pipe.
   • Remove and discard the gasket.

 

INSTALLATION

 

1. • Install the turbocharger coolant pipe.
     Torque: 9Nm
   • Install a new gasket.
     Renew Part: Turbocharger coolant pipes to turbocharger gasket Quantity: 1.

 

1. • Install the turbocharger.
     Torque: 26Nm
   • Install new nuts.
     Renew Part: Exhaust manifold to turbocharger nuts Quantity: 3.
   • Install a new gasket.
     Renew Part: Turbocharger to exhaust manifold gasket Quantity: 1.

 

1. Install the exhaust manifold heatshield.

 

1. • 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

 

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

 

1. • Install a new turbocharger oil feed pipe bolt.
     Renew Part: Turbocharger oil supply pipe banjo bolt Quantity: 1.
     Torque: 30Nm
   • Install new washers.
     Renew Part: Turbocharger oil feed pipe banjo bolt washers Quantity: 2.

 

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
   • Install new gaskets.
     Renew Part: Lower oil return pipe gasket Quantity: 1.
     Renew Part: Upper oil return pipe gasket Quantity: 1.

 

1. Install the air intake pipe.
   Torque: 10Nm

 

1. Install the left Exhaust Gas Recirculation (EGR) valve.
   Refer to:Left Exhaust Gas Recirculation Valve - TDV6 3.0L Diesel - Gen 2 (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. Install the exhaust.
   Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
   Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

1. Install the engine undershield.
   Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).

 

1. Fill the engine with oil.
   Refer to:Engine Oil Vacuum Draining and Filling (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, General Procedures).

 

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

---

 

Removal and Installation

UEL CHARGING AND CONTROLS - TURBOCHARGER - TDV6 3.0L DIESEL

LEFT TURBOCHARGER - TDV6 3.0L DIESEL - GEN 2, VEHICLES WITHOUT: HYBRID SYSTEM (G1875337)

REMOVAL AND INSTALLATION

 

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

 

SPECIAL TOOL(S)

 

303-1069

Adapter, Wrench

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

 

REMOVAL

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.
   Refer to:Engine Oil Draining and Filling (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, General Procedures).

 

1. Remove the exhaust system.
   Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
   Refer to:Exhaust System - Vehicles Without: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

1. Remove the transmission fluid cooler pipes.
   Refer to:Transmission Fluid Cooler Pipes - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (307-02A Transmission/Transaxle Cooling - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Removal and Installation).

 

1. Remove the left exhaust gas recirculation valve.
   Refer to:Left Exhaust Gas Recirculation Valve - TDV6 3.0L Diesel - Gen 2 (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. 
   • Remove the nut.
   • Reposition the air intake pipe away from the turbocharger.

 

1. 
   • Remove the 2 bolts.
   • Remove and discard the gasket.

 

1. 
   • Remove the 2 bolts.
   • Remove the turbocharger oil return pipe.
   • Remove and discard the gasket.

 

1. 
   • Remove the 2 bolts.
   • Remove the turbocharger heatshield.

 

1. WARNING:

   Be prepared to collect escaping oil.

   
   • Remove and discard the bolt.
   • Remove and discard the sealing washers.

 

1. 
   • Disconnect the electrical connector.
   • Remove the 2 clips.

 

1. 
   Disconnect the electrical connector.

 

1. NOTE:

   Make sure to clean the threads prior to installation.

   
   • Remove the 4 bolts.
   • Remove the turbocharger bracket.

 

1. WARNING:

   Be prepared to collect escaping fluids.

   
   • Remove the bolt.
   • Reposition the turbocharger coolant pipe.

 

1. WARNING:

   Be prepared to collect escaping fluids.

   
   • Remove the bolt.
   • Reposition the turbocharger coolant pipe.

 

1. 
   • Remove the 3 bolts.
   • Remove the exhaust manifold heatshield.

 

1. 
   Use the special tool to remove and discard the turbocharger nut.
   Special Tool(s): 303-1069

 

1. 
   • Remove and discard the 2 turbocharger nuts.
   • Remove the turbocharger.
   • Remove and discard the turbocharger to manifold gasket.

 

1. 
   • Remove the 2 bolts.
   • Remove the coolant pipe to turbocharger assembly.
   • Remove and discard the gasket.

 

INSTALLATION

 

1. • Install a new gasket.
     Renew Part: Turbocharger coolant pipes to turbocharger gasket Quantity: 1.
   • Install the coolant pipe to turbocharger assembly.
   • Install and tighten the 2 bolts.
     Torque: 9Nm

 

1. • Install a new turbocharger to manifold gasket.
     Renew Part: Turbocharger to exhaust manifold gasket Quantity: 1.
   • Install the turbocharger.
   • Install and tighten 2 new nuts.
     Renew Part: Exhaust manifold to turbocharger nuts Quantity: 3.
     Torque: 26Nm
   • Use the special tool to install and tighten the new nut.
     Special Tool(s): 303-1069
     Torque: 26Nm

 

1. • Install the exhaust manifold heatshield.
   • Install and tighten the 3 bolts.
     Torque: 9Nm

 

1. • 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

 

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

 

1. • Install new washers.
     Renew Part: Turbocharger oil feed pipe banjo bolt washers Quantity: 2.
   • Install and tighten a new turbocharger oil feed pipe bolt.
     Renew Part: Turbocharger oil supply pipe banjo bolt Quantity: 1.
     Torque: 30Nm

 

1. • 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 new upper and lower turbocharger oil return pipe gaskets.
     Renew Part: Lower oil return pipe gasket Quantity: 1.
     Renew Part: Upper oil return pipe gasket Quantity: 1.
   • Install the turbocharger oil return pipe.
   • Install and tighten the 4 bolts.
     Torque: 9Nm

 

1. • Install the air intake pipe.
   • Install and tighten the nut.
     Torque: 10Nm

 

1. Install the left exhaust gas recirculation valve.
   Refer to:Left Exhaust Gas Recirculation Valve - TDV6 3.0L Diesel - Gen 2 (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. Install the transmission fluid cooler pipes.
   Refer to:Transmission Fluid Cooler Pipes - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (307-02A Transmission/Transaxle Cooling - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Removal and Installation).

 

1. Install the exhaust system.
   Refer to:Exhaust System - Vehicles Without: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
   Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

1. Refill the engine oil.
   Refer to:Engine Oil Draining and Filling (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, General Procedures).

 

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

FUEL CHARGING AND CONTROLS - TURBOCHARGER - TDV6 3.0L DIESEL

TURBOCHARGER BYPASS VALVE (G1509440)

REMOVAL AND INSTALLATION

 

• 19.42.63
• TURBOCHARGER BYPASS VALVE - RENEW
• 3000 CC, TDV6
• 0.40
• USED WITHINS

 

PART(S)

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

 

REMOVAL

NOTE:

Removal steps in this procedure may contain installation details.

 

1. Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).

 

1. 

    

 

1. 
   Torque: 10Nm

 

1. NOTE:

   Discard the seal.

   
   Renew Part: Intake air shutoff throttle seals Quantity: 1.
   Torque: 9Nm

 

INSTALLATION

 

1. To install, reverse the removal procedure.

FUEL CHARGING AND CONTROLS - TURBOCHARGER - TDV6 3.0L DIESEL

FIXED VANE TURBOCHARGER ACTUATOR (G1509441)

REMOVAL AND INSTALLATION

 

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

 

PART(S)

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

 

REMOVAL

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. Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
   Refer to:Exhaust System - Vehicles Without: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

1. Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).

 

1. NOTE:

   Engine shown removed for clarity.

   

 

1. 

 

1. 

 

1. CAUTIONS:

   • Remove the Torx screws evenly and progressively.

   • Make sure component mating faces are not damaged during removal.

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

 

1. NOTES:

   • Make a note of the orientation of the gasket tang.

   • Remove and discard the gasket using the gasket tang.

   

 

1. NOTES:

   • Remove and discard the gasket.

   • Turbocharger shown removed for clarity.

   

 

INSTALLATION

 

1. CAUTION:

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

   NOTES:

   • Install a new gasket.

   • Make sure that the gasket tang is installed in the correct orientation as noted in the removal step.

   
   Renew Part: Fixed vane turbocharger actuator gasket kit Quantity: 1.

 

1. CAUTION:

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

   NOTES:

   • Install a new gasket.

   • Apply a small amount of grease in the areas indicated to allow the gasket to remain in the position for installation.

   

 

1. CAUTIONS:

   • Install all the bolts finger tight before final tightening.

   • Tighten the Torx screws evenly and progressively.

   
   • Using a suitable 130mm T30 Torx socket, remove the retaining bolts.
     Torque: 12Nm

 

1. 
   Torque: 9Nm

 

1. 

 

1. 
   Torque: 9Nm

 

1. Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).

 

1. Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
   Refer to:Exhaust System - Vehicles Without: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

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.

FUEL CHARGING AND CONTROLS - TURBOCHARGER - TDV6 3.0L DIESEL

LEFT TURBOCHARGER - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5 (G1509438)

REMOVAL AND INSTALLATION

 

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

 

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

 

REMOVAL

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.
   Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).

 

1. Drain the engine oil.
   Refer to:Engine Oil Vacuum Draining and Filling (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, General Procedures).

 

1. Remove the exhaust.
   Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
   Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

1. Remove the left Exhaust Gas Recirculation (EGR) valve.
   Refer to:Left Exhaust Gas Recirculation Valve - TDV6 3.0L Diesel - Gen 2 (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. 
   Release the intake air pipe.

 

1. CAUTION:

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

   
   • Remove the 2 bolts.
   • Remove and discard the gasket.

 

1. CAUTION:

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

   
   • Remove the turbocharger oil return pipe.
   • Remove and discard the gasket.

 

1. 
   Remove the turbocharger heatshield.

 

1. CAUTION:

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

   
   • Remove and discard the turbocharger oil feed pipe bolt.
   • Remove and discard the washers.

 

1. 
   Disconnect the Crankshaft Position Sensor (CKP) electrical connector.

 

1. 
   Disconnect the electrical connector from the turbocharger.

 

1. 
   Remove the 4 bolts.

 

1. WARNING:

   Be prepared to collect escaping fluids.

   
   Release the coolant pipe.

 

1. WARNING:

   Be prepared to collect escaping fluids.

   
   • Release the coolant pipe.

 

1. 
   Remove the exhaust manifold heatshield.

 

1. 
   Remove and discard the nut.

 

1. 
   • Remove and discard the nuts.
   • Remove and discard the gasket.

 

1. 
   • Remove the turbocharger coolant pipe.
   • Remove and discard the gasket.

 

INSTALLATION

 

1. • Install the turbocharger coolant pipe.
     Torque: 9Nm
   • Install a new gasket.
     Renew Part: Turbocharger coolant pipes to turbocharger gasket Quantity: 1.

 

1. • Install the turbocharger.
     Torque: 26Nm
   • Install new nuts.
     Renew Part: Exhaust manifold to turbocharger nuts Quantity: 3.
   • Install a new gasket.
     Renew Part: Turbocharger to exhaust manifold gasket Quantity: 1.

 

1. Install the exhaust manifold heatshield.

 

1. • 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

 

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

 

1. • Install a new turbocharger oil feed pipe bolt.
     Renew Part: Turbocharger oil supply pipe banjo bolt Quantity: 1.
     Torque: 30Nm
   • Install new washers.
     Renew Part: Turbocharger oil feed pipe banjo bolt washers Quantity: 2.

 

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
   • Install new gaskets.
     Renew Part: Lower oil return pipe gasket Quantity: 1.
     Renew Part: Upper oil return pipe gasket Quantity: 1.

 

1. Install the air intake pipe.
   Torque: 10Nm

 

1. Install the left Exhaust Gas Recirculation (EGR) valve.
   Refer to:Left Exhaust Gas Recirculation Valve - TDV6 3.0L Diesel - Gen 2 (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. Install the exhaust.
   Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
   Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

1. Install the engine undershield.
   Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).

 

1. Fill the engine with oil.
   Refer to:Engine Oil Vacuum Draining and Filling (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, General Procedures).

 

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

FUEL CHARGING AND CONTROLS - TURBOCHARGER - TDV6 3.0L DIESEL

LEFT TURBOCHARGER - TDV6 3.0L DIESEL - GEN 2, VEHICLES WITH: HYBRID SYSTEM (G1883049)

REMOVAL AND INSTALLATION

 

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

 

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

 

REMOVAL

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. Refer to:Hybrid Electric Vehicle Power Down/Up (414-01 Battery, Mounting and Cables, General Procedures).

 

1. Refer to:Engine Oil Draining and Filling (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, General Procedures).

 

1. Refer to:Exhaust System - Vehicles With: Diesel Exhaust Fluid (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

1. Refer to:Transmission Fluid Cooler Pipes - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (307-02B Transmission/Transaxle Cooling - Vehicles With: 8HP70 8-Speed - Hybrid Electric Vehicle - Automatic Transmission – AWD, Removal and Installation).

 

1. Refer to:Left Exhaust Gas Recirculation Valve - TDV6 3.0L Diesel - Gen 2 (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. 
   Torque: 10Nm

 

1. 
   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.

   NOTE:

   Install a new gasket.

   
   Renew Part: Turbocharger oil return pipe gasket(s) Quantity: 1.
   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.

   NOTE:

   Install new gaskets.

   
   Renew Part: Turbocharger oil return pipe gasket(s) Quantity: 1.
   Torque: 9Nm

 

1. 
   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.

   
   Renew Part: Turbocharger oil feed pipe banjo bolt washers Quantity: 1.
   Renew Part: Turbocharger oil supply pipe banjo bolt Quantity: 1.
   Torque: 30Nm

 

1. 
   Torque: 10Nm

 

1. 

 

1. 
   Renew Part: EGR inlet pipe to EGR valve gasket Quantity: 1.
   Torque: 6Nm

 

1. 

 

1. CAUTION:

   Apply Loctite 243 to the bolts.

   NOTE:

   Make sure to clean the threads prior to installation.

   
   Torque: 32Nm

 

1. WARNING:

   Be prepared to collect escaping fluids.

   
   Torque: 11Nm

 

1. WARNING:

   Be prepared to collect escaping fluids.

   CAUTION:

   Remove and discard the O-ring seal.

   
   Renew Part: Turbocharger coolant pipe Quantity: 1.
   Torque: 10Nm

 

1. 

 

1. NOTE:

   Remove and discard the nut.

   

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.

   
   Install the turbocharger oil return pipe.
   Renew Part: Turbocharger oil return pipe gasket(s) Quantity: 1.
   Renew Part: Turbocharger oil return pipe Quantity: 1.
   Torque: 9Nm

 

1. NOTE:

   Install a new gasket.

   
   Install the exhaust down pipe.
   Renew Part: Exhaust downpipe gasket(s) Quantity: 1.

 

1. 
   Install the bolts.
   Torque: 28Nm

 

1. 
   Install the exhaust gas temperature sensor.
   Torque: 35Nm

 

1. 
   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.
   Refer to:Right Exhaust Gas Recirculation Valve (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. Refill the engine oil.
   Refer to:Engine Oil Draining and Filling (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, General Procedures).

 

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.
   General Equipment: Jaguar Land Rover approved diagnostic equipment

 

1. NOTES:

   • Remove and discard the nut.

   • Remove and discard the gasket.

   
   Renew Part: Exhaust manifold to turbocharger nuts Quantity: 2.
   Renew Part: Turbocharger to exhaust manifold gasket Quantity: 1.
   Torque: 26Nm

 

1. NOTE:

   Remove and discard the gasket.

   
   Renew Part: Turbocharger coolant pipes to turbocharger gasket Quantity: 1.
   Torque: 9Nm

 

INSTALLATION

 

1. To install reverse the removal procedure.

 

1. Refer to:Hybrid Electric Vehicle Power Down/Up (414-01 Battery, Mounting and Cables, General Procedures).

 

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. 

FUEL CHARGING AND CONTROLS - TURBOCHARGER - TDV6 3.0L DIESEL

RIGHT TURBOCHARGER (G1875338)

REMOVAL AND INSTALLATION

 

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

 

SPECIAL TOOL(S)

 

100-051

Cutter, Exhaust Pipe

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

 

REMOVAL

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.
   Refer to:Engine Oil Draining and Filling (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, General Procedures).

 

1. Remove the EGR valve.
   Refer to:Right Exhaust Gas Recirculation Valve (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. 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. 
   Cut the exhaust in the position illustrated.
   Special Tool(s): 100-051

 

1. 
   Remove the exhaust gas temperature sensor.

 

1. 
   Remove the bolts.

 

1. 
   • 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.

   
   Remove the turbocharger oil return pipe.

 

1. 
   Remove the Exhaust heatshield.

 

1. 
   Remove the exhaust manifold heatshield.

 

1. 
   Disconnect the harness.

 

1. 
   Remove the vacuum pipe.

 

1. CAUTION:

   Be prepared to collect escaping oil.

   
   Remove the banjo bolt.

 

1. 
   Remove the clip.

 

1. 
   Remove the charge air hose.

 

1. 
   Remove the intake air hose.

 

1. 
   Remove the bracket.

 

1. NOTE:

   Discard the gasket.

   
   • Remove the bolts.
   • Remove the turbocharger.

 

INSTALLATION

 

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.

   
   Install the turbocharger.
   Renew Part: Exhaust pipe to turbocharger gasket Quantity: 1.
   Renew Part: Exhaust manifold to turbocharger nuts Quantity: 3.
   Torque: 24Nm

 

1. NOTES:

   • Make sure to clean the threads prior to installation.

   • Apply loctite 243 to the bolts.

   
   Install the bracket.
   Torque: 32Nm

 

1. 
   Install the intake air hose.

 

1. 
   Install the charge air hose.

 

1. 
   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.
   Renew Part: Turbocharger oil feed pipe banjo bolt washers Quantity: 1.
   Renew Part: Turbocharger oil supply pipe banjo bolt Quantity: 1.
   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.

   
   Install the turbocharger oil return pipe.
   Renew Part: Turbocharger oil return pipe gasket(s) Quantity: 1.
   Renew Part: Turbocharger oil return pipe Quantity: 1.
   Torque: 9Nm

 

1. NOTE:

   Install a new gasket.

   
   Install the exhaust down pipe.
   Renew Part: Exhaust downpipe gasket(s) Quantity: 1.

 

1. 
   Install the bolts.
   Torque: 28Nm

 

1. 
   Install the exhaust gas temperature sensor.
   Torque: 35Nm

 

1. 
   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.
   Refer to:Right Exhaust Gas Recirculation Valve (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. Refill the engine oil.
   Refer to:Engine Oil Draining and Filling (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, General Procedures).

 

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

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

 

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

 

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

 

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

 

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

 

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

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

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)

 

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

 

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

 

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. 
   Remove the Diesel Exhaust Fluid (DEF) filler cap.

 

1. 
   Remove the 5 bolts and the retaining clip.

 

1. 
   Remove the drain tube from the retaining clip.

 

1. WARNING:

   Be prepared to catch escaping fluid.

   
   Allow the fluid to drain.

 

1. 
   Install the blanking cap.

 

1. 
   Install the drain tube into the retaining clip.

 

 

The following step(s) applies to:

All vehicles

 

 

1. 
   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.

   
   Check the quality of the DEF using a hydrometer.

 

1. WARNING:

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

   
   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.

   
   Check the gauge.

 

1. CAUTION:

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

   
   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.

   
   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.

   
   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.

   
   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. 
   • 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. 
   1. Position the DEF dispensing kit lower operating lever in the position indicated.
   2. 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.

   
   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.

   
   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.

   
   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.

   
   Check the quality of the DEF using a hydrometer.

 

1. CAUTION:

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

   
   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.

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

 

1. NOTE:

   Refer to the manufacturers instructions.

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

 

1. 
   • Set the DEF dispensing kit to auto fill.
   • Fill the vehicle with DEF.

 

1. CAUTION:

   Make sure that the vehicle paintwork is protected.

   
   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.

   
   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.

   
   Check the quality of the DEF using a hydrometer.

 

1. WARNING:

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

   
   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.

   
   Check the gauge.

 

1. CAUTION:

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

   
   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.

   
   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.

   
   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.

   
   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. 
   • 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. 
   1. Position the DEF dispensing kit lower operating lever in the position indicated.
   2. 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.

   
   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.

   
   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.

   
   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.

   
   Check the quality of the DEF using a hydrometer.

 

1. CAUTION:

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

   
   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.

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

 

1. NOTE:

   Refer to the manufacturers instructions.

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

 

1. 
   • Set the DEF dispensing kit to auto fill.
   • Fill the vehicle with DEF.

 

1. CAUTION:

   Make sure that the vehicle paintwork is protected.

   
   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.

   
   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. 

 

1. 

 

1. 

 

1. CAUTIONS:

   • Make sure that all openings are sealed.

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

   

 

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. 

 

1. 

 

1. NOTE:

   Discard the gasket.

   
   Renew Part: EGR valve RH to EGR outlet pipe gasket Quantity: 1.
   Torque: 5.5Nm

 

1. 
   Torque: 10Nm

 

1. 

 

1. 

 

1. 
   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. 

 

1. 

 

1. 
   Torque: 8Nm

 

1. NOTE:

   If equipped.

   
   Torque: 10Nm

 

1. NOTE:

   If equipped.

   
   Torque: 10Nm

 

1. 
   Torque: 10Nm

 

1. 

 

1. NOTE:

   Install a new gasket.

   
   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. 

 

1. NOTE:

   Discard the retaining clips.

   

 

1. 

 

1. CAUTION:

   Make sure that all openings are sealed.

   NOTE:

   Discard the gasket.

   

 

INSTALLATION

 

1. CAUTION:

   Only tighten the bolts finger-tight at this stage.

   NOTE:

   Install a new gasket.

   
   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.

   
   Renew Part: Retaining clip(s) Quantity: 1.

 

1. 
   Torque: 5Nm

 

1. 
   Torque: 10Nm

 

1. 

 

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

 

1. WARNING:

   Be prepared to collect escaping fluid.

   
   Disconnect the DEF injector supply pipe.

 

1. 
   Disconnect the DEF injector electrical connector.

 

1. 
   • Release the clamp.
   • Remove the DEF injector.
   • Discard the clamp.

 

1. 
   Remove and discard the gasket form the DEF injector.

 

INSTALLATION

 

1. • Install a new gasket to the DEF injector.
     Renew Part: Diesel exhaust fluid injector refit kit Quantity: 1.
   • 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. 
   • Release the DEF pipe.
   • Remove the DEF tank cover.

 

1. 
   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. 

 

1. 

 

1. 

 

1. 
   Torque: 10Nm

 

1. 
   Torque: 10Nm

 

1. 

 

1. NOTE:

   Install a new gasket.

   
   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.

   

 

1. CAUTION:

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

   

 

1. CAUTION:

   Discard the bolts.

   

 

1. WARNING:

   Be prepared to collect escaping fluid.

   CAUTION:

   Do not use excessive force to remove the component.

   

 

1. CAUTION:

   Using a suitable tool, remove the seals.

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

 

1. CAUTION:

   Discard the components.

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

 

1. CAUTIONS:

   • Using a suitable tool, remove the seals.

   • Discard the components.

   
   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.

   
   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.

   
   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.

   
   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.

   
   Renew Part: Diesel exhaust fluid injection pump bolts Quantity: 1.
   Torque: 6Nm

 

1. 

 

1. CAUTION:

   Lubricate with deionized water.

   

 

1. 
   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. 

 

 

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.

   

 

 

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.

   

 

 

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.

   

 

 

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.

   

 

1. NOTE:

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

   

 

1. 

 

1. WARNING:

   Be prepared to collect escaping fluid.

   

 

INSTALLATION

 

 

The following step(s) applies to:

All vehicles

 

 

1. NOTE:

   This step is only required if previously removed.

   

 

1. NOTE:

   This step is only required if previously removed.

   
   Torque: 10Nm

 

1. 
   Torque: 24Nm

 

1. 

 

 

The following step(s) applies to:

Vehicles with 2.0L diesel engine

 

 

1. 

 

 

The following step(s) applies to:

Vehicles with 3.0L diesel engine

 

 

1. 

 

 

The following step(s) applies to:

Vehicles with 4.4L diesel engine

 

 

1. 

 

 

The following step(s) applies to:

All vehicles

 

 

1. 

 

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. 
   • Release the hose clamp.
   • Reposition the hose away from the EGR cooler.

 

1. 
   Remove and discard the 4 bolts.

 

1. 
   • 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. 
   • 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. 
   Install a new Exhaust Gas Recirculation (EGR) cooler filter gasket.

 

1. 
   Install the EGR cooler onto the EGR valve.

 

1. 
   • Install and tighten the 4 new bolts in the sequence illustrated.
     Torque: 7Nm
   • Tighten bolt (1) for the second time.
     Torque: 7Nm

 

1. 
   • 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. 

 

1. 

 

1. 
   Torque: 8Nm

 

1. NOTE:

   If equipped.

   
   Torque: 10Nm

 

1. NOTE:

   If equipped.

   
   Torque: 10Nm

 

1. 
   Torque: 10Nm

 

1. 

 

1. NOTE:

   Install a new gasket.

   
   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. 

 

1. NOTE:

   Discard the retaining clips.

   

 

1. 

 

1. CAUTION:

   Make sure that all openings are sealed.

   NOTE:

   Discard the gasket.

   

 

INSTALLATION

 

1. CAUTION:

   Only tighten the bolts finger-tight at this stage.

   NOTE:

   Install a new gasket.

   
   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.

   
   Renew Part: Retaining clip(s) Quantity: 1.

 

1. 
   Torque: 5Nm

 

1. 
   Torque: 10Nm

 

1. 

 

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

 

1. WARNING:

   Be prepared to collect escaping fluid.

   
   Disconnect the DEF injector supply pipe.

 

1. 
   Disconnect the DEF injector electrical connector.

 

1. 
   • Release the clamp.
   • Remove the DEF injector.
   • Discard the clamp.

 

1. 
   Remove and discard the gasket form the DEF injector.

 

INSTALLATION

 

1. • Install a new gasket to the DEF injector.
     Renew Part: Diesel exhaust fluid injector refit kit Quantity: 1.
   • 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. 
   • Release the DEF pipe.
   • Remove the DEF tank cover.

 

1. 
   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. 

 

1. 

 

1. 

 

1. 
   Torque: 10Nm

 

1. 
   Torque: 10Nm

 

1. 

 

1. NOTE:

   Install a new gasket.

   
   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.

   

 

1. CAUTION:

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

   

 

1. CAUTION:

   Discard the bolts.

   

 

1. WARNING:

   Be prepared to collect escaping fluid.

   CAUTION:

   Do not use excessive force to remove the component.

   

 

1. CAUTION:

   Using a suitable tool, remove the seals.

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

 

1. CAUTION:

   Discard the components.

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

 

1. CAUTIONS:

   • Using a suitable tool, remove the seals.

   • Discard the components.

   
   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.

   
   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.

   
   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.

   
   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.

   
   Renew Part: Diesel exhaust fluid injection pump bolts Quantity: 1.
   Torque: 6Nm

 

1. 

 

1. CAUTION:

   Lubricate with deionized water.

   

 

1. 
   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.
     General Equipment: Jaguar Land Rover 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. 

 

 

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.

   

 

 

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.

   

 

 

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.

   

 

 

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.

   

 

1. NOTE:

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

   

 

1. 

 

1. WARNING:

   Be prepared to collect escaping fluid.

   

 

INSTALLATION

 

 

The following step(s) applies to:

All vehicles

 

 

1. NOTE:

   This step is only required if previously removed.

   

 

1. NOTE:

   This step is only required if previously removed.

   
   Torque: 10Nm

 

1. 
   Torque: 24Nm

 

1. 

 

 

The following step(s) applies to:

Vehicles with 2.0L diesel engine

 

 

1. 

 

 

The following step(s) applies to:

Vehicles with 3.0L diesel engine

 

 

1. 

 

 

The following step(s) applies to:

Vehicles with 4.4L diesel engine

 

 

1. 

 

 

The following step(s) applies to:

All vehicles

 

 

1. 

 

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. 
   • Release the hose clamp.
   • Reposition the hose away from the EGR cooler.

 

1. 
   Remove and discard the 4 bolts.

 

1. 
   • 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. 
   • 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. 
   Install a new Exhaust Gas Recirculation (EGR) cooler filter gasket.

 

1. 
   Install the EGR cooler onto the EGR valve.

 

1. 
   • Install and tighten the 4 new bolts in the sequence illustrated.
     Torque: 7Nm
   • Tighten bolt (1) for the second time.
     Torque: 7Nm

 

1. 
   • 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).

 

 

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

INTAKE AIR DISTRIBUTION AND FILTERING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1509519)

SPECIFICATIONS

 

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

INTAKE AIR DISTRIBUTION AND FILTERING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1868450)

DESCRIPTION AND OPERATION

 

 

COMPONENT LOCATION - SHEET 1 OF 3

 

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

 

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

 

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

 

OVERVIEW

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.

 

DESCRIPTION

DIRTY AIR DUCTS

 

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

 

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

 

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

 

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

 

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

 

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

 

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

NTAKE AIR DISTRIBUTION AND FILTERING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G2718601)

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 CHART

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

 

CONDITION SUMMARY

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.

 

PARTS:

DESCRIPTION	QUANTITY
Charge air cooler hose	1

 

DIAGNOSTIC PROCEDURE

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.

 

SERVICE INSTRUCTION:

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.

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.

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.

1. Renew the charge air cooler hose.

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

 

DTC INDEX

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

 

INTAKE AIR DISTRIBUTION AND FILTERING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

LEAKAGE TEST USING SMOKE TEST EQUIPMENT (G2374824)

GENERAL PROCEDURES

 

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

SPECIAL TOOL(S)

 

JLR-303-1704-1

Blanking Plug for (Diesel) Air Intake Systems

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.
   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. 
   • Release the hose clamp.
   • 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.

   
   Insert the appropriate adaptor into the clean air duct.
   General Equipment: Adapter - High Pressure Diagnostic Leak Detector
   Torque: 3.5Nm

 

1. 
   • Release the hose clamp.
   • 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.

     Insert the appropriate adaptor into the air filter outlet pipe.
     General Equipment: Adapter - High Pressure Diagnostic Leak Detector
   • Tighten the hose clamp.
     Torque: 3.5Nm

 

1. 
   Install the block off adaptor.

 

1. 
   • Release the hose clamp.
   • Disconnect the breather hose.

 

1. WARNING:

   Failure to follow this step may result in injury.

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

 

1. 
   Install the special tool into the breather hose.
   Install the Special Tool(s): JLR-303-1704-1

 

1. CAUTION:

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

   NOTES:

   • Only use Jaguar Land rover (JLR) approved vapor producing fluid.

   • 60 ml maximum to refill the vapor producing fluid when the reservoir is empty.

   • 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.

   NOTES:

   • Only use Jaguar Land rover (JLR) approved vapor producing fluid.

   • 60 ml maximum to refill the vapor producing fluid when the reservoir is empty.

   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. 
   Switch the flow control valve to the 'OFF' position.

 

1. 
   Pull the pressure regulator valve out.

 

1. 
   Set the test pressure to 0.35 bar (5 psi, 34.5 kPA).

 

1. 
   Push the pressure regulator valve in to lock it.

 

1. 
   • Connect the high pressure diagnostic leak detector outlet pipe to the adaptor.
     General Equipment: High Pressure Diagnostic Leak Detector

 

1. 
   Press the 'START' switch to begin a 10 minute vapor cycle.

 

1. 
   Turn the flow control valve to the 'ON' position to release pressure / vapor.

 

1. • Use the inspection light supplied with the high pressure diagnostic leak detector, to inspect for leaks.
   • If a leak is detected, rectify the cause.

 

1. • 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.
   Remove the Special Tool(s): JLR-303-1704-1

 

1. Install the breather hose.

 

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

 

1. • 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.

 

1. • Install the right air filter outlet pipe.
   • Tighten the hose clamp.
     Torque: 3.5Nm

 

1. Install the engine cover.
   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).

Removal and Installation

INTAKE AIR DISTRIBUTION AND FILTERING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

AIR CLEANER ELEMENT (G1509521)

REMOVAL AND INSTALLATION

 

• 19.10.10
• AIR FILTER ELEMENT - RENEW
• 3000 CC, TDV6
• 0.10
• USED WITHINS

 

REMOVAL

NOTE:

Removal steps in this procedure may contain installation details.

 

1. 

 

1. 

 

INSTALLATION

 

1. To install, reverse the removal procedure.

INTAKE AIR DISTRIBUTION AND FILTERING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

LEFT AIR CLEANER (G1519884)

REMOVAL AND INSTALLATION

 

• 19.10.03
• AIR CLEANER - LH - RENEW
• 3000 CC, TDV6
• 0.30
• USED WITHINS

 

 

REMOVAL

NOTE:

Removal steps in this procedure may contain installation details.

 

1. 

 

1. NOTE:

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

   
   Torque: 3Nm

 

1. 

 

1. 

 

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.

   

 

INSTALLATION

 

1. To install, reverse the removal procedure.

NTAKE AIR DISTRIBUTION AND FILTERING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

RIGHT AIR CLEANER (G1519885)

REMOVAL AND INSTALLATION

 

• 19.10.04
• AIR CLEANER - RH - RENEW
• 3000 CC, TDV6
• 0.30
• USED WITHINS

 

 

REMOVAL

NOTE:

Removal steps in this procedure may contain installation details.

 

1. 

 

1. NOTES:

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

   • Left-hand shown, right-hand similar.

   
   Torque: 3Nm

 

1. NOTE:

   Left-hand shown, right-hand similar.

   

 

1. NOTE:

   Left-hand shown, right-hand similar.

   

 

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.

   

 

INSTALLATION

 

1. To install, reverse the removal procedure.

INTAKE AIR DISTRIBUTION AND FILTERING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

LEFT CHARGE AIR COOLER - TDV6 3.0L DIESEL - GEN 2 (G1875612)

REMOVAL AND INSTALLATION

 

• 19.44.02
• INTERCOOLER - LH - RENEW
• 3000 CC, TDV6, GEN 2
• 1.70
• USED WITHINS

 

PART(S)

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

 

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:Cooling System Draining and Vacuum Filling (303-03A Engine Cooling - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, General Procedures).

 

1. Refer to:Front Bumper Cover (501-19 Bumpers, Removal and Installation).

 

1. 
   Torque: 5Nm

 

1. NOTE:

   Make sure that new components are installed.

   
   Renew Part: Retaining clip Quantity: 1.

 

1. 

 

1. 
   Torque: 5Nm

 

1. 
   Torque: 7Nm

 

1. 
   Torque: 4Nm

 

1. NOTE:

   Make sure that new components are installed.

   
   Renew Part: Retaining clip Quantity: 1.

 

1. NOTE:

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

   

 

1. 
   Torque: 9Nm

 

1. 
   Inspect the components and renew if damaged or worn.

 

1. 

 

INSTALLATION

 

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

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1509550)

SPECIFICATIONS

 

Torque Specification

DESCRIPTION	NM	LB-FT	LB-IN
Camshaft position (CMP) sensor retaining bolt	10	7	-
Crankshaft position (CKP) sensor retaining bolt	5	-	44
Engine control module (ECM) retaining nuts	7	-	62
Engine oil pressure (EOP) sensor	14	11	-
Engine oil level sensor retaining bolts	12	9	-
Mass air flow (MAF) sensor	2	-	18
Manifold absolute pressure (MAP) sensor	3	-	27
Exhaust gas temperature sensor RH	35	26	-
Catalytic converter pre temperature sensor	35	26	-
Catalytic converter post temperature sensor	35	26	-
Diesel particulate filter (DPF) post exhaust gas temperature sensor	35	26	-
Heated oxygen sensor (HO2S)	48	35	-

 

Description and Operation

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1950037)

DESCRIPTION AND OPERATION

 

 

COMPONENT LOCATION

COMPONENT LOCATION - 1 OF 9

 

ITEM	DESCRIPTION
1	Accelerator pedal
2	Brake pedal
3	Brake pedal switch
4	Instrument Cluster (IC)
5	Transmission Control Switch (TCS)
6	Terrain Response (TR) switchpack
7	Diesel Exhaust Fluid (DEF) heater control unit
8	Restraints Control Module (RCM)
9	Ambient Air Temperature (AAT) sensor
10	Diesel Exhaust Fluid (DEF) tank module
11	Diesel Exhaust Fluid (DEF) tank
12	Body Control Module/Gateway Module assembly (BCM/GWM) assembly
13	Powertrain Control Module (PCM)
14	Transmission Control Module (TCM)
15	Transmission - automatic
16	Engine cooling fan control module - auxiliary
17	Charge air coolant pump
18	Engine cooling fan control module - main
19	Active grille air shutter motor
20	Anti-lock Brake System (ABS) control module
21	Active engine mount solenoid
22	Glow plug control module
23	Brake vacuum sensor

COMPONENT LOCATION - 2 OF 9

 

ITEM	DESCRIPTION
1	Throttle body
2	Manifold Absolute Pressure (MAP) sensor
3	Oil pressure switch
4	Cylinder head temperature sensor
5	Camshaft Position (CMP) sensor
6	Variable Geometry Turbocharger (VGT) vane actuator
7	Oil level and temperature sensor
8	Variable coolant pump
9	Engine Coolant Temperature (ECT) sensor

COMPONENT LOCATION - 3 OF 9

 

ITEM	DESCRIPTION
1	Fuel pressure control valve
2	Mass Air Flow and Temperature (MAFT) sensor - Vehicles with mono turbocharger
3	Exhaust Gas Recirculation (EGR) outlet temperature sensor - North American Specification (NAS) market vehicles only
4	Crankcase pressure sensor - North American Specification (NAS) market vehicles only
5	Fuel Rail Pressure (FRP) sensor
6	Fuel temperature sensor
7	Fuel metering valve
8	Crankshaft Position (CKP) sensor
9	Heated Oxygen Sensor (HO2S)
10	Exhaust gas temperature sensor
11	Fuel injector - 6 off

COMPONENT LOCATION - 4 OF 9 - VEHICLES WITH TWIN TURBOCHARGER

 

ITEM	DESCRIPTION
1	Mass Air Flow and Temperature (MAFT) sensor
2	Turbocharger - Secondary
3	Charge air solenoid
4	Turbine intake shut-off valve solenoid
5	Variable Geometry Turbocharger (VGT) - Primary
6	Mass Air Flow (MAF) sensor
7	Charge air intake valve

COMPONENT LOCATION - 5 OF 9 - EU4 MARKET VEHICLES ONLY

 

ITEM	DESCRIPTION
1	Right Exhaust Gas Recirculation (EGR) cooler and valve housing
2	Left Exhaust Gas Recirculation (EGR) cooler and valve housing

COMPONENT LOCATION - 6 OF 9 ALL MARKETS, EXCEPT EU4

 

ITEM	DESCRIPTION
1	Right Exhaust Gas Recirculation (EGR) cooler and valve housing
2	Left Exhaust Gas Recirculation (EGR) cooler and valve housing

COMPONENT LOCATION - 7 OF 9

 

ITEM	DESCRIPTION
1	Charge air temperature sensor
2	Water In Fuel (WIF) sensor
3	Oil pump solenoid

COMPONENT LOCATION - 8 OF 9 - ALL MARKETS, EXCEPT EU4

NOTE:

Mono turbocharger exhaust system shown, twin turbocharger exhaust system is similar.

 

ITEM	DESCRIPTION
1	Diesel Particulate Filter (DPF) inlet temperature sensor
2	Differential pressure sensor
3	Exhaust pressure control valve
4	Diesel Particulate Filter (DPF) outlet temperature sensor

COMPONENT LOCATION - 9 OF 9 - EU6 AND NORTH AMERICAN SPECIFIC MARKET VEHICLES

NOTE:

Mono turbocharger exhaust system shown, twin turbocharger exhaust system is similar.

 

ITEM	DESCRIPTION
1	Diesel Exhaust Fluid (DEF) injector
2	Pre Selective Catalyst Reduction (SCR) Nitrogen Oxide (NOx) sensor and module
3	Pre catalyst exhaust gas temperature sensor - North American Specification (NAS) market vehicles only
4	Post Selective Catalyst Reduction (SCR) Nitrogen Oxide (NOx) sensor and module
5	Post Selective Catalyst Reduction (SCR) soot sensor - North American Specification (NAS) market vehicles only

 

OVERVIEW

The TDV6 3.0L Diesel engine has an Engine Management System (EMS) controlled by an Powertrain Control Module (PCM) which monitors, adapts and precisely controls the fuel injection. The PCM uses multiple sensor inputs and precision control of actuators to achieve optimum performance during all driving conditions.

 

DESCRIPTION

POWERTRAIN CONTROL MODULE

NOTE:

Left Hand Drive (LHD) shown, Right Hand Drive (RHD) Powertrain Control Module (PCM) is located on opposite side.

The Powertrain Control Module (PCM) is installed in the rear left corner of the engine compartment, behind the secondary bulkhead panel. The PCM is attached to brackets on the wheel housing and the fender outer support panel.

The PCM connected to the vehicle harnesses via two connectors. The PCM contains data processors and memory microchips. The output signals to the actuators are in the form of ground paths provided by driver circuits within the PCM. Some sensors receive a regulated voltage supplied by the PCM. This avoids incorrect signals caused by voltage drop during cranking.

The PCM is connected to the engine sensors which allow it to monitor the engine operating conditions. The PCM processes these signals and decides the actions necessary to maintain optimum engine performance in terms of driveability, fuel efficiency and exhaust emissions. The memory of the PCM is programmed with instructions for how to control the engine. The memory also contains data in the form of maps which the PCM uses as a basis for fueling and emission control. By comparing the information from the sensors to the data in the maps, the PCM is able to calculate the various output requirements. The PCM contains an adaptive strategy which updates the system when components vary due to production tolerances or ageing.

The PCM is connected to other system control modules and receives data from these modules on the FlexRay bus system and the High Speed (HS) Controller Area Network (CAN) chassis systems bus to enable precise engine control under all vehicle operating conditions.

The PCM receives and processes information from the following input sources:

• Crankshaft Position (CKP) sensor
• Camshaft Position (CMP) sensor
• Mass Air Flow and Temperature (MAFT) sensor
• Manifold Absolute Pressure (MAP) sensor
• Throttle Position Sensor (TPS)
• Engine Coolant Temperature (ECT) sensor
• Cylinder head temperature sensor
• Accelerator Pedal Position (APP) sensor
• Charge air temperature sensor
• Ambient Air Temperature (AAT) sensor
• Heated Oxygen Sensor (HO2S)
• Oil pressure switch
• Variable Geometry Turbocharger (VGT) vane position sensor
• Oil level and temperature sensor
• Active grille air shutter motor - If equipped
• Transmission Control Switch (TCS)
• Transmission Control Module (TCM)
• Terrain Response (TR) switchpack
• Exhaust pressure control valve - Position sensor - if equipped
• Exhaust gas temperature sensor
• Diesel Exhaust Fluid (DEF) tank module - All markets, except EU4
• DEF heater control unit - All markets, except EU4
• Water In Fuel (WIF) sensor
• Automatic Temperature Control Module (ATCM)
• Restraints Control Module (RCM)
• Turbine intake shut-off valve position sensor - Vehicles with twin turbocharger only
• The following brake system components:
  • Anti-lock Brake System (ABS) control module
  • Brake pedal switch
  • Brake vacuum sensor (Stop/start system vehicles only).
• The following fuel system components:
  • Fuel Rail Pressure (FRP) sensor
  • Fuel temperature sensor.
• The following Exhaust Gas Recirculation (EGR) system components:
  • EGR valve position sensor - High Pressure (HP)
  • EGR valve position sensor - Low Pressure (LP) - All markets, except EU4
  • LP EGR outlet temperature sensor - All markets, except EU4
  • LP EGR differential pressure sensor - All markets, except EU4.
• The following catalytic converter and Diesel Particulate Filter (DPF) system components:
  • Pre Selective Catalyst Reduction (SCR) Nitrogen Oxide (NOx) sensor - North America Specification (NAS) market vehicles only
  • Post SCR NOx sensor
  • Post SCR soot sensor - NAS market vehicles only
  • Differential pressure sensor
  • DPF inlet temperature sensor
  • DPF outlet temperature sensor

The PCM outputs controlling signals to the following sensors and actuators:

• Throttle actuator
• Oil pump control solenoid
• PCM cooling fan - if equipped
• Diesel Exhaust Fluid (DEF) tank module
• DEF heater control unit
• DEF Injector
• Transmission Control Switch (TCS)
• Automatic Temperature Control Module (ATCM)
• Anti-lock Braking System (ABS) control module
• Active engine mount solenoid
• Variable Geometry Turbocharger (VGT) vane actuator
• Glow plug control module
• Transmission Control Module (TCM)
• Instrument Cluster (IC)
• Exhaust pressure control valve actuator - if equipped
• Turbine intake shut-off valve solenoid - Vehicles with twin turbocharger only
• Charge air solenoid - Vehicles with twin turbocharger only
• Charge air recirculation solenoid - Vehicles with twin turbocharger only
• The following cooling system components:
  • Variable coolant pump
  • Engine cooling fan control modules
  • Active grille air shutter motor - if equipped
  • Charge air coolant pump.
• The following fuel system actuators:
  • Fuel injector - 6 off
  • Fuel pressure control valve
  • Fuel metering valve.
• The following Exhaust Gas Recirculation (EGR) system components:
  • EGR cooler bypass valve solenoid
  • EGR High Pressure (HP) valve motor
  • EGR Low Pressure (LP) valve motor - All markets, except EU4.

CRANKSHAFT POSITION SENSOR

The Crankshaft Position (CKP) sensor is located on the left side of the crankshaft rear oil seal housing. The sensor lead passes through a cover in the side of the cylinder block. The sensor tip is aligned with a reluctor ring on the rear flange of the crankshaft. The sensor produces a square wave signal, the frequency of which is proportional to engine speed.

The Powertrain Control Module (PCM) monitors the CKP sensor signal and can detect engine over-speed. The PCM counteracts engine over-speed by gradually fading out speed synchronized functions. The CKP is a Hall effect sensor. The sensor measures the magnetic field variation induced by the reluctor ring.

The reluctor ring has a 60 minus two pole pattern. The missing poles provide a reference point for the angular position of the crankshaft. When the space with the two missing poles passes the sensor tip, a gap in the signal is produced which the PCM uses to determine the crankshaft position.

The PCM uses the signal from the CKP sensor for the following functions:

• Synchronization
• Determine fuel injection timing
• Produce an engine speed signal which is broadcast on the High Speed (HS) Controller Area Network (CAN) chassis system bus for use by other systems.

The CKP sensor receives a 5 V supply from the PCM. Two further connections to the PCM provide ground and signal output.

CAMSHAFT POSITION SENSOR

The Camshaft Position (CMP) sensor is located on the front face of the bank two cylinder head. The sensor tip protrudes through an aperture in the front face of the cylinder head to pick up on a reluctor ring behind the camshaft pulley.

The CMP sensor is a Hall effect sensor which is used by the Powertrain Control Module (PCM) at engine start-up to synchronize the PCM with the Crankshaft Position (CKP) sensor signal. The PCM does this by using the CMP sensor signal to identify the stroke of the piston in number one cylinder to ensure the correct injector timing. Once the PCM has established the injector timing, the CMP sensor signal is no longer used.

The CMP sensor receives a 5 V supply from the PCM. Two further connections to the PCM provide ground and signal output.

If a fault occurs, an error is registered in the PCM.

Two types of failure can occur:

• No CMP sensor signal
• A synchronization error of the CMP and CKP sensors.

The error recorded by the PCM can also relate to a total failure of the crankshaft signal or crankshaft signal dynamically implausible. Both components should be checked to determine the cause of the fault.

If a fault occurs with the CMP sensor when the engine is running, the engine will continue to run but the PCM will deactivate charge air pressure control. Once the engine is switched off, the engine will crank but will not restart while the fault is present.

MASS AIR FLOW AND TEMPERATURE SENSOR - VEHICLES WITH MONO TURBOCHARGER

The air filter housing is located in left front corner of the engine compartment. The Mass Air Flow and Temperature (MAFT) sensor is attached to the air cleaner outlet. The MAFT sensor provides the mass air flow and temperature signal for the Powertrain Control Module (PCM).

The PCM checks the calculated air mass against the engine speed. If the calculated air mass is not plausible, the PCM uses a default air mass figure which is derived from the average engine speed compared to a stored characteristic map. The air mass value will be corrected using values for charge air pressure, ambient air pressure and ambient air temperature. 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 MAFT sensor receive a 12 V supply from the PCM relay in the Engine Junction Box (EJB) and a ground connection via the PCM. If the MAFT sensor fail the PCM implements the default strategy based on engine speed.

In the event of a MAFT sensor signal failure, the following symptoms may be observed:

• Exhaust Gas Recirculation (EGR) system off
• Delayed engine response
• Reduced engine performance.

MASS AIR FLOW SENSOR AND MASS AIR FLOW AND TEMPERATURE SENSOR - VEHICLES WITH TWIN TURBOCHARGER

 

ITEM	DESCRIPTION
1	Mass Air Flow And Temperature (MAFT) sensor
2	Mass Air Flow (MAF) sensor

An air filter housing is located in each front corner of the engine compartment. The air outlet connection of each air filter housing incorporates either a Mass Air Flow (MAF) sensor and a Mass Air Flow and Temperature (MAFT) sensor. 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).

MANIFOLD ABSOLUTE PRESSURE SENSOR

The Manifold Absolute Pressure (MAP) sensor is installed in the outlet of the electric throttle, to measure the pressure of the air entering the intake manifolds. The sensor is a semi-conductor type sensor which responds to pressure acting on a membrane within the sensor, altering the output voltage.

The sensor receives a 5 V reference voltage and a ground from the Powertrain Control Module (PCM) and returns a signal of between 0.5 - 4.5 V to the PCM. A Low Pressure (LP) returns a low voltage signal to the PCM and a High Pressure (HP) returns a high voltage. The signal is used in conjunction with the Mass Air Flow and Temperature (MAFT) sensor signals to calculate the injection period.

The PCM monitors the engine MAP sensor for faults and can store fault related codes. These can be retrieved using Land Rover approved diagnostic equipment. If the sensor fails, the PCM uses the MAFT sensor signal as a substitute. 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).

ELECTRIC THROTTLE

 

ITEM	DESCRIPTION
1	Throttle actuator
2	Right Exhaust Gas Recirculation (EGR) pipe connection
3	Right intake manifold connection
4	Manifold Absolute Pressure (MAP) sensor
5	Left intake manifold connection
6	Left Exhaust Gas Recirculation (EGR) pipe connection - if equipped
7	Air intake

The electric throttle is installed at the front of the engine, between the cylinder heads.

There is no mechanical linkage between the accelerator pedal and the butterfly valve with electronic throttle control. Instead, the position of the butterfly valve is fully controlled by the Powertrain Control Module (PCM) via an Direct Current (DC) electric motor. The Throttle Position Sensor (TPS) is continually read and then the PCM makes appropriate adjustments to reach the desired amount of engine power. This method allows a precisely controlled amount of air into the intake manifold. 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 PCM has five connections with the electric throttle motor:

• A ground and two 12 V feeds to operate the motor in each direction to open or close the throttle plate
• A 5 V reference connection and a signal connection with the TPS in the motor, for closed loop control.

CHARGE AIR TEMPERATURE SENSOR

The charge air temperature sensor is located in the charge air duct connection with the electric throttle. The sensor is used to measure the intake air temperature from the turbochargers in order to calculate the required amount of fueling.

The charge air temperature sensor incorporates a Negative Temperature Coefficient (NTC) thermistor in a voltage divider circuit. The sensor receives a 5 V reference voltage from the Powertrain Control Module (PCM). The resistance of the NTC thermistor decreases as temperature increases. So a low intake air temperature produces a high resistance value, and a high temperature produces a low resistance value. The PCM uses the voltage output to help in determining air/fuel mixture, spark timing and idle control. 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).

If the charge air temperature sensor fails the PCM uses a default charge air temperature of -5°C (23°F).

In the event of a charge air temperature sensor failure, any of the following symptoms may be observed:

• Over fueling, resulting in black smoke emitting from the exhaust
• Poor performance
• Hard starting
• Idle speed control inoperative.

ENGINE COOLANT TEMPERATURE SENSOR

The Engine Coolant Temperature (ECT) sensor is located in the Exhaust Gas Recirculation (EGR) cooler intake hose, at the front of the engine.

The Powertrain Control Module (PCM) uses the temperature information for the following functions:

• Fueling calculations
• Limit engine operation if engine coolant temperature becomes too high
• Electric cooling fan operation
• Glow plug activation time.

The Instrument Cluster (IC) uses the temperature information for generation of engine temperature messages. The ECT signal is also transmitted on the High Speed (HS) Controller Area Network (CAN) chassis systems bus by the IC for use by other systems.

The ECT sensor circuit consists of an internal voltage divider circuit which incorporates a Negative Temperature Coefficient (NTC) thermistor. The PCM compares the signal voltage to stored values and adjusts fuel delivery to ensure optimum driveability at all times.

The input to the sensor is a 5 V reference voltage supplied from the voltage divider circuit within the PCM. The ground from the sensor is also connected to the PCM which measures the returned current and calculates a resistance figure for the sensor which relates to the coolant temperature.

If the ECT sensor fails, the following symptoms may be observed:

• Difficult cold start
• Difficult hot start
• Engine performance compromised
• Temperature gauge inoperative or inaccurate reading.

In the event of ECT sensor signal failure, the PCM applies a default value of 80°C (176°F) coolant temperature for fueling purposes. The PCM will also permanently operate the cooling fan at all times when the ignition is switched on, to protect the engine from overheating. For additional information, refer to:Engine Cooling (303-03A Engine Cooling - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Description and Operation).

VARIABLE COOLANT PUMP

NOTE:

There is still a thermostat for conventional thermal transient operation.

The variable coolant pump has a shroud mechanism which can be used to create zero flow in the engine coolant circuit to enable accelerated engine warm-up. The only control from the Powertrain Control module (PCM) is a signal when the engine is cold telling the pump to move the shroud to a ‘no coolant flow’ position. Once the engine is approaching running temperature, the PCM removes this signal, the shroud retracts and full coolant flow is resumed. For additional information, refer to:Engine Cooling (303-03A Engine Cooling - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Description and Operation).

CHARGE AIR COOLANT PUMP

The charge air coolant pump is an electric pump attached to the rear left side of the engine cooling fan shroud.

Electrical power for the charge air coolant pump is supplied from the Powertrain Control Module (PCM) relay, located in the Engine Junction Box (EJB). Operation of the charge air coolant pump is controlled by the PCM with a Pulse Width Modulation (PWM) signal. When the charge air coolant pump is running, coolant flows from the pump outlet through the charge air cooler, the charge air radiator and back to the pump inlet connection. For additional information, refer to:Engine Cooling (303-03A Engine Cooling - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Description and Operation).

ENGINE COOLING FAN CONTROL MODULE

 

ITEM	DESCRIPTION
1	Engine cooling fan control module - auxiliary
2	Engine cooling fan control module - main

Each electric cooling fan is operated by a control module, integrated into their electric motor, which is controlled by the Powertrain Control Module (PCM).

The PCM determines when to operate the cooling fan from the Engine Coolant Temperature (ECT) sensors input and/or a cooling fan request from the Automatic Temperature Control Module (ATCM). The PCM also adjusts the fan speed to compensate for the ram effect of vehicle speed.

The control module of each electric cooling fan is provided with:

• A battery power supply from the Auxiliary Junction Box (AJB)
• An ignition signal from the PCM relay in the Engine Junction Box (EJB)
• A Pulse Width Modulation (PWM) signal from the PCM
• A ground.

The cooling fan control module monitors for over and under input voltage, a stalled motor and a partially stalled motor. If it detects any of these faults the cooling fan control module temporarily pulls the PWM signal to ground to notify the fault to the PCM. The length of time the PWM signal is pulled to ground varies between two and eight seconds, depending on the fault. The cooling fan control module repeats the notification process at five second intervals until the fault is cleared. If there is more than one fault, only the highest priority fault is notified to the PCM. Fault priorities, in descending order, are over voltage, under voltage, stalled motor and partially stalled motor. The PCM records a related Diagnostic Trouble Code (DTC) for faults notified by the fan control module and signals the Instrument Cluster (IC) on the High Speed (HS) Controller Area Network (CAN) comfort systems bus to display a warning message. For additional information, refer to:Engine Cooling (303-03A Engine Cooling - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Description and Operation).

CYLINDER HEAD TEMPERATURE SENSOR

The cylinder head temperature sensor is located in a threaded boss in the front of the left hand cylinder head, adjacent to the oil filter housing and electric throttle.

The sensor is a Negative Temperature Coefficient (NTC) sensor with a two pin connection; one pin receives a 5 V reference from the Powertrain Control Module (PCM) and the other provides a signal feedback to the PCM.

OIL PRESSURE SWITCH

The oil pressure switch is located in a threaded port in the bank 2 cylinder head. The switch is connected directly to the Body Control Module/Gateway Module (BCM/GWM) assembly.

The switch is not connected to the Powertrain Control module (PCM) but is supplied with a reference voltage from the BCM/GWM. The switch ground is through the switch body and the engine. When the oil pressure falls to below a predetermined threshold, the switch contacts close, completing a circuit from the BCM/GWM. This circuit is sensed by the BCM/GWM which displays and appropriate warning message and warning lamp to alert the driver.

OIL LEVEL AND TEMPERATURE SENSOR

The TDV6 3.0L Diesel engine is not fitted with a conventional dipstick. The dipstick is replaced with an ultrasonic oil level and temperature sensor which is located on three studs in the underside of the oil pan and secured with 3 locknuts. A link lead connects the sensor to the engine harness at the right side of the oil pan.

The sensor uses ultrasonic pulses to determine the oil level in the oil pan. The sensor converts the results into a Pulse Width Modulation (PWM) signal to the Powertrain Control module (PCM) which converts the frequency of the signal into a oil level height.

The sensor uses an Negative Temperature Coefficient (NTC) type sensor to determine the oil temperature. The sensor measures the oil temperature and converts the sensor signal into a PWM signal to the PCM which converts the frequency of the signal into an oil temperature.

OIL PUMP CONTROL SOLENOID

The oil pump control solenoid is located at the front of the oil pump, and connected to the Powertrain Control module (PCM) via hardwired connection. The oil pump control solenoid receives a 12 V power supply from the Engine Junction Box (EJB). The PCM controls the operation of the solenoid valve by controlling the ground path for the solenoid. When the PCM energizes the control solenoid at low engine speed and low engine loads, the oil pump switches to the low pressure mode. This method provides to reduce pumping losses within the oil pump, and optimize fuel economy. 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).

EXHAUST GAS RECIRCULATION COOLER BYPASS VALVE SOLENOID

The Exhaust Gas Recirculation (EGR) cooler bypass valve solenoid is located on a bracket at the rear of the engine, adjacent to the vacuum pump.

The EGR cooler bypass solenoid valve receives a 12 V supply from the Engine Junction Box (EJB). The Powertrain Control module (PCM) controls the operation of the solenoid valve by controlling the ground path for the solenoid. The controlled solenoid turns vacuum on or off to the actuator. For additional information, 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).

VARIABLE GEOMETRY TURBOCHARGER - PRIMARY TURBOCHARGER

 

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

The Variable Geometry Turbocharger (VGT) is attached to the left exhaust manifold and secured to three studs on a flange on the manifold with nuts. This is the primary turbocharger.

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 Powertrain Control Module (PCM). The VGT vane actuator also provides the PCM 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. For additional information, refer to:Turbocharger (303-04B Fuel Charging and Controls - Turbocharger - TDV6 3.0L Diesel, Description and Operation).

SECONDARY TURBOCHARGER - VEHICLES WITH TWIN TURBOCHARGER ONLY

 

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

The secondary turbocharger is attached to the right exhaust manifold and is secured to three studs on a flange on the manifold with nuts.

Attached to the rear of the turbocharger is a turbine intake shut-off valve operated by a vacuum actuator. The Powertrain Control Module (PCM) 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 PCM to monitor the shut-off valve for correct operation. For additional information, refer to:Turbocharger (303-04B Fuel Charging and Controls - Turbocharger - TDV6 3.0L Diesel, Description and Operation).

CHARGE AIR INTAKE VALVE - VEHICLES WITH TWIN TURBOCHARGER ONLY

 

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 Powertrain Control Module (PCM) 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 Engine Junction Box (EJB) and a ground connection with the PCM. 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 Manifold Absolute Pressure (MAP) sensor which detects the increase in pressure. The PCM registers the signals from the MAP sensor and operates the turbochargers in mono-turbo mode with restricted engine torque and Diagnostic Trouble Code (DTC) recorded. For additional information, refer to:Turbocharger (303-04B Fuel Charging and Controls - Turbocharger - TDV6 3.0L Diesel, Description and Operation).

VACUUM CONTROL SOLENOIDS - VEHICLES WITH TWIN TURBOCHARGER ONLY

 

ITEM	DESCRIPTION
1	Charge air solenoid
2	Turbine intake shut-off valve solenoid

The turbine intake shut-off valve and charge air solenoids are installed on a bracket attached to the front of the bank two cylinder head. The Powertrain Control Module (PCM) operates the solenoids to apply and release the vacuum in the vacuum actuators of the turbine intake shut-off valve and the charge air shut-off valve. For additional information, refer to:Turbocharger (303-04B Fuel Charging and Controls - Turbocharger - TDV6 3.0L Diesel, Description and Operation).

EXHAUST GAS RECIRCULATION LOW PRESSURE COMPONENTS

 

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

The Low Pressure (LP) Exhaust Gas Recirculation (EGR) valve and LP EGR cooler are located on the left side of the engine. The EGR cooler is secured to a bracket on the intake manifold with two bolts and to the left hand cylinder head with one bolt.

The LP EGR valve is a solenoid operated valve which is controlled by the Powertrain Control Module (PCM). The PCM uses the LP EGR valve to control the amount of exhaust gas being re-circulated from the catalytic converter and Diesel Particulate Filter (DPF) assembly in order to further reduce exhaust emissions. The LP EGR valve is enabled when the engine is at normal operating temperature and under cruising conditions.

In the event of a failure of the LP EGR valve, the LP EGR function will become inoperative. The PCM can monitor the LP EGR valve solenoid for short circuits and store fault codes in the event of failure. The LP EGR valve can also be activated for testing using an approved diagnostic system. For additional information, 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).

Differential Pressure Sensor - Low Pressure Exhaust Gas Recirculation

The LP EGR differential pressure sensor is located to a bracket which is attached to the LP EGR valve. The sensor is secured to the bracket with a screw.

The LP EGR differential pressure sensor is used by the PCM to monitor exhaust gas passing into the LP EGR cooler. The PCM compares it with exhaust gas/clean air passing though the LP EGR valve into the turbocharger.

EXHAUST GAS RECIRCULATION HIGH PRESSURE COMPONENTS

 

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

The Exhaust Gas Recirculation (EGR) system comprises an EGR cooler and valve housing assembly bolted to the cylinder head, above the exhaust manifold. The EGR assembly incorporates an EGR valve and motor, an EGR cooler, and a cooler bypass valve and actuator.

On the 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 turbocharger. For additional information, 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).

WATER IN FUEL SENSOR

The Water In Fuel (WIF) sensor is located in the base of the fuel filter and is hardwired to the Powertrain Control Module (PCM). The sensor operates on the principle of differing resistance values to the transmission of current through water and fuel. When the volume of water in the fuel reaches 85 cm³ or more, the sensor value is sensed by the PCM. The PCM transmits a message on the High Speed (HS) Controller Area Network (CAN) powertrain systems bus to the Instrument Cluster (IC) which displays a message in the message center. For additional information, refer to:Fuel Tank and Lines (310-01A Fuel Tank and Lines - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Description and Operation).

FUEL INJECTORS

CAUTION:

Each injection event is controlled by a charge and discharge cycle allowing energy to dissipate in, and recover from, the injector. Never disconnect the wiring connector when the vehicle is running. The injector may remain open thus causing engine damage.

Six fuel injectors are located through a hole in the camshaft carrier. Each injector is sealed by a seat in the cylinder head and held in position by a clamp. The clamp is secured to the camshaft carrier with a bolt which passes through the carrier into the cylinder head.

Each injector is supplied with pressurized fuel from the fuel rail and delivers finely atomized fuel directly into the combustion chambers. Each injector is individually controlled by the Powertrain Control Module (PCM) which operates each injector in the firing order and controls the injector opening period. Each injector receives a 12 V supply from the PCM and, using programmed injection/timing maps and sensor signals, determines the precise pilot and main injector timing for each cylinder. If battery voltage falls to between 6 and 9 volts, fuel injector operation is restricted, affecting emissions, engine speed range and idle speed. For additional information, refer to:Fuel Charging and Controls (303-04A Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Description and Operation).

The PCM can monitor the injector operation by monitoring both connections to the injector. Each injector can be diagnosed by the PCM and Diagnostic Trouble Codes (DTC) stored.

In the event of a failure of a fuel injector, the following symptoms may be observed:

• Engine misfire
• Idle irregular
• Reduced engine performance
• Reduced fuel economy
• Difficult starting
• Increased smoke emissions.

FUEL PRESSURE CONTROL VALVE

The fuel pressure control valve is located in a threaded port in the forward end of the fuel rail for the left cylinder bank. The Powertrain Control Module (PCM) controls the fuel rail pressure by operating the control valve solenoid using a Pulse Width Modulation (PWM) signal.

The PCM controls the operation of the control valve using the following information to determine the required fuel pressure:

• Fuel rail pressure
• Engine load
• Accelerator Pedal Position (APP) sensor position
• Engine coolant temperature
• Engine speed.

In the event of a total failure of the fuel pressure control valve, the engine will not start. In the event of a partial failure of the fuel pressure control valve, the PCM will activate the solenoid with the minimum PWM duty cycle which results in the injection quantity being limited. For additional information, refer to:Fuel Charging and Controls (303-04A Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Description and Operation).

FUEL RAIL PRESSURE SENSOR

The Fuel Rail Pressure (FRP) sensor is located in a threaded port in the forward end of the fuel rail for the right cylinder bank.

The sensor measures the fuel pressure in the fuel rail which is supplied from the High Pressure (HP) fuel pump.

The FRP sensor is a piezo resistor type sensor. The sensor receives a 5 V reference voltage supplied through a resistor within the Powertrain Control Module (PCM). The sensor produces an analogue signal of between 0 and 5 V depending on the pressure sensed. Low Pressure (LP) gives a low voltage output and consequently HP gives a higher voltage output. The PCM uses this pressure signal to monitor the fuel pressure in the fuel rail and adjust the fuel metering valve to control the fuel pressure.

The PCM monitors the FRP sensor for faults and can store fault related Diagnostic Trouble Codes (DTC). These can be retrieved using an approved diagnostic system. For additional information, refer to:Fuel Charging and Controls (303-04A Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Description and Operation).

FUEL TEMPERATURE SENSOR AND FUEL METERING VALVE

 

ITEM	DESCRIPTION
1	Fuel temperature sensor
2	Fuel metering valve

The fuel temperature sensor is located in a threaded port in the High Pressure (HP) fuel pump.

The Powertrain Control Module (PCM) monitors the fuel temperature constantly. If the fuel temperature exceeds 85°C (185°F), the PCM invokes an engine 'derate' strategy. This reduces the amount of fuel delivered to the injectors in order to allow the fuel to cool. When this occurs, the driver may notice a loss of performance.

The wires to the fuel temperature sensor are monitored by the PCM for short and open circuit. The PCM also monitors the 5 V supply. If a failure occurs a fault is recorded in the PCM memory and the PCM uses a default fuel pressure value.

The fuel metering valve is located on the top of the HP fuel pump. The valve is sealed to the HP fuel pump body with an O-ring seal and secured with two screws.

The fuel metering valve is a variable position solenoid-operated valve that is controlled by the PCM with a Pulse Width Modulation (PWM) signal.

The fuel metering valve controls the quantity of fuel delivered to the HP fuel pump from the Low Pressure (LP) fuel pump module in the fuel tank. The valve returns unwanted fuel back to the fuel tank. This avoids unused fuel being pressurized by the HP stage of the pump, only to be returned back to return system by the fuel pressure control valve. For additional information, refer to:Fuel Charging and Controls (303-04A Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Description and Operation).

GLOW PLUG CONTROL MODULE

The glow plug control module is located in the right front side of the engine compartment.

There are three phases of glow plug heating:

• Pre heating
• Crank heating
• Post heating.

The Powertrain Control Module (PCM) determines the power levels for each phase and heating times from the coolant temperature.

When the stop/start switch is operated to start the engine, the PCM calculates any required heating times and, if heating is required, sends a Local Interconnect Network (LIN) bus signal to the glow plug control module. The glow plug control module energizes the glow plugs with the required power levels. If required by the PCM, the glow plug control module keeps the glow plugs energized during cranking and for the duration of any post heating phase.

The glow plug control module monitors the drive circuit of the glow plugs for plausibility of operation, continuity, and short and open circuits. If a fault is detected, the glow plug control module sends a signal to the PCM, which then stores a related fault code. For additional information, refer to:Glow Plug System (303-07C Glow Plug System - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Description and Operation).

DIFFERENTIAL PRESSURE SENSOR

The Diesel Particulate Filter (DPF) differential pressure sensor is located on the end of the transmission. The sensor is located on a bracket which is attached to the end of the transmission casing.

The differential pressure sensor is used by the DPF software in the Powertrain Control Module (PCM) to monitor the condition of the DPF. Two pipe connections on the sensor are connected by pipes to the inlet and outlet ends of the DPF. The pipes allow the sensor to measure the inlet and outlet pressures of the DPF. By measuring the pressure difference between the DPF inlet and outlet and the DPF temperature, the DPF software can determine if the DPF is becoming blocked and requires regeneration. For additional information, refer to:Diesel Particulate Filter (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Description and Operation).

The DPF software performs the following checks using the DPF differential pressure sensor:

• Plausibility check
• DPF efficiency
• DPF overloaded
• DPF clogged
• Monitoring of the maximum regeneration attempts in the lower load range.

HEATED OXYGEN SENSOR

The Heated Oxygen Sensor (HO2S) is a wide band type oxygen sensor that allows the Powertrain Control Module (PCM) to provide closed loop control of the air fuel mixture. The sensor is installed in the downpipe of the exhaust system, immediately after the connection with the turbocharger outlet.

Power for the heater element of the HO2S is provided by a battery voltage supply from the PCM relay in the Engine Junction Box (EJB). The circuit through the heater element is completed by a connection with the PCM. The PCM regulates the current flow through the heater element to control the heating of the sensor. The heater element is operated immediately after each engine start and during low load conditions when the temperature of the exhaust gases is insufficient to maintain the required sensor temperature.

The HO2S has four further connections with the PCM, two for the Nernst (oxygen measuring) cell and two for the pump cell. The PCM adjusts the current of the pump cell circuit as necessary to maintain a constant signal from the oxygen measuring cell. The PCM then relates the current of the pump cell circuit to the lambda ratio of the exhaust gases.

If the HO2S fails the PCM defaults to open loop fueling and the emissions content of the exhaust gases increases. With a failed HO2S, the engine will suffer from unstable operation and reduced performance.

EXHAUST PRESSURE CONTROL VALVE - ALL MARKETS, EXCEPT EU4

 

ITEM	DESCRIPTION
1	Exhaust pressure control valve
2	Exhaust pressure control valve actuator
3	Electrical connection

The exhaust pressure control valve is located in the front of the exhaust system rear section. The assembly comprises a flap valve which is welded to the exhaust pipe and an actuator which is secured to the valve with four screws. The actuator is controlled by the Powertrain Control Module (PCM). The valve controls the quantity of the exhaust gas that is redirected through the Low Pressure (LP) Exhaust Gas Recirculation (EGR) valve. For additional information, 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).

ACCELERATOR PEDAL POSITION SENSOR

NOTE:

Right Hand Drive (RHD) pedal shown, Left Hand Drive (LHD) is similar.

The Accelerator Pedal Position (APP) sensor allows the Powertrain Control Module (PCM) to determine the driver requests for vehicle speed, acceleration and deceleration. The PCM uses this information to determine the torque demand from the engine via injection control.

The APP sensor consists of a twin track rotary potentiometer integrated into the mounting bracket of the accelerator pedal. The APP sensor receives two separate electrical supplies and generates two different outputs. Both tracks are analogue output signals connected to the PCM. Both signals contain the same positional information, but the secondary track has half the voltage output of the primary track.

If there is a fault with the primary track, the secondary track is used and the vehicle/engine response to pedal demand will be sluggish. If both analogue signals have a fault, the engine adopts a constant engine speed of 1300 Revolutions Per Minute (RPM) to allow the vehicle to move. Torque application and reduction of engine speed back to normal idle speed can be subsequently controlled via brake pedal switch operation. For additional information, refer to:Speed Control (310-03A Speed Control - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Description and Operation).

The PCM constantly checks the range and plausibility of the two signals and stores a Diagnostic Trouble Code (DTC) if it detects a fault.

BRAKE PEDAL SWITCH

NOTE:

Right Hand Drive (RHD) pedal shown, Left Hand Drive (LHD) is similar.

The brake pedal switch is located on the pedal box and is operated by the brake pedal. The two pole switch has a normally open circuit switch connected to battery voltage which closes the circuit when the driver has depressed the brake pedal. When the driver depresses the brake pedal then a normally closed circuit which is connected to ground. The switch contacts are connected directly to the Powertrain Control Module (PCM) and the PCM also receives a brake pressure signal on the FlexRay systems bus from the Anti-lock Brake System (ABS) control module. For additional information, refer to:Braking Control System (206-11 Brake Controls, Description and Operation).

AMBIENT AIR TEMPERATURE SENSOR

The Ambient Air Temperature (AAT) sensor is a Negative Temperature Coefficient (NTC) thermistor that allows the Powertrain Control Module (PCM) to monitor the temperature of the air around the vehicle. The PCM uses the AAT input for a number of functions, including engine cooling fan control. The PCM also transmits the ambient temperature on the High Speed (HS) Controller Area Network (CAN) chassis systems bus for use by other control modules.

The AAT sensor is installed in the left exterior mirror, with the bulb of the sensor positioned over a hole in the bottom of the mirror casing.

The PCM supplies the sensor with a 5 V reference voltage and a ground, and translates the return signal voltage into a temperature.

If there is a fault with the AAT sensor, the PCM adopts a default ambient temperature of 20°C (68°F).

EXHAUST GAS TEMPERATURE SENSORS

The exhaust gas temperature sensor is used by the Powertrain Control Module (PCM) to monitoring the exhaust gas temperature. The PCM constantly checks the range and the high temperatures can be an indicator of dangerous conditions that can lead to catastrophic engine failure. Excessively high exhaust gas temperatures are the result of a rich air/fuel ratio.

EXHAUST GAS RECIRCULATION OUTLET TEMPERATURE SENSOR - ALL MARKETS, EXCEPT EU4

The Exhaust Gas Recirculation (EGR) outlet temperature sensor is used to measure the actual temperature of the exhaust gas exiting the EGR cooler.

The Powertrain Control Module (PCM) uses three temperature sensors to determine EGR flow rate. The temperature sensors measure the charge air temperature, the manifold air temperature and the EGR outlet temperature. The PCM can calculate EGR flow rate using these three temperatures. For additional information, 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).

DIESEL EXHAUST FLUID TANK MODULE

The Diesel Exhaust Fluid (DEF) tank module is located at the bottom of the DEF tank. The DEF tank module includes a DEF level and temperature sensor and a heater element to defrost the DEF in extreme cold climates.

The DEF level sensor is an ultrasonic device located in the DEF tank module, which sends the DEF level value to the Powertrain Control Module (PCM) via Pulse Width Modulation (PWM) signals. The Negative Temperature Coefficient (NTC) temperature sensor measures the temperature of the fluid in the DEF tank. The DEF temperature sensor transmits the initial temperature signal to an evaluation unit in the tank module, where the signal is converted into a PWM signal and sent to the PCM for processing. For additional information, refer to:Selective Catalyst Reduction (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Description and Operation).

DIESEL EXHAUST FLUID HEATER CONTROL UNIT

The Diesel Exhaust Fluid (DEF) heater control unit is located on the right side of the luggage compartment, behind the side trim panel. The heater system provides an adequate quantity of defrosted DEF that is available at all operating points. As a result, this enables rapid Selective Catalyst Reduction (SCR) system operation in the event of frozen DEF. The DEF heater control unit has a switched power supply from the Rear Junction Box (RJB), which is controlled by the Powertrain Control Module (PCM).

The DEF heater control unit has hardwired connections to the DEF tank module and the DEF line heater element. If the ambient air temperature is below -5°C (23°F), the PCM switches on the DEF heater control unit via the private Controller Area Network (CAN) bus. The DEF heater control unit energizes the heater elements, located in the DEF tank module and in the DEF line. The DEF heater control unit has on-board diagnostics to detect and report faults to the PCM via the private CAN bus. For additional information, refer to:Selective Catalyst Reduction (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Description and Operation).

PRE CATALYST EXHAUST GAS TEMPERATURE SENSOR - NORTH AMERICAN SPECIFICATION MARKET VEHICLES ONLY

The pre catalyst exhaust gas temperature sensor measures the temperature of exhaust gas exiting the turbocharger and before it passes through the catalyst converter and Diesel Particulate Filter (DPF). The sensor provides the information needed to calculate the DPF temperature. For additional information, refer to:Exhaust System (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Description and Operation).

DIESEL PARTICULATE FILTER SENSORS - ALL MARKETS, EXCEPT EU4

 

ITEM	DESCRIPTION
1	Diesel Particulate Filter (DPF) outlet temperature sensor
2	Diesel Particulate Filter (DPF) inlet temperature sensor
3	Differential pressure sensor

The Diesel Particulate Filter (DPF) is located in the exhaust system, downstream of the catalytic converter. Its function is to trap particulate matter in the exhaust gases leaving the engine. A major feature of the DPF is its ability for regeneration. Regeneration is the burning of particulates trapped by the filter to prevent obstruction to the free flow of exhaust gasses. The regeneration process takes place at calculated intervals and is not noticeable by the driver of the vehicle.

The DPF temperature sensors are used to provide exhaust gas temperature feedback to the Powertrain Control Module (PCM) in order to control engine conditions and to effectively monitor and control emissions.

The DPF temperature sensors information is sent to the PCM using a 0 to 5 V signal. The information is used, in conjunction with other data, to estimate the amount of accumulated particulates and to control the DPF temperature. For additional information, refer to:Diesel Particulate Filter (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Description and Operation).

DIESEL EXHAUST FLUID INJECTOR - EU6 AND NORTH AMERICAN SPECIFICATION MARKET VEHICLES ONLY

The Diesel Exhaust Fluid (DEF) injector is located in the exhaust system, downstream of the Diesel Particulate Filter (DPF) and delivers a metered amount of DEF into the exhaust pipe.

The DEF injector works at high pressures to provide complete atomization of the injected DEF. This ensures the Selective Catalyst Reduction (SCR) catalytic converter performs at its optimum performance.

The DEF injector is activated by a Pulse Width Modulation (PWM) signal, controlled by the Powertrain Control Module (PCM). A signal duty cycle of 3.33 - 4 Hz determines the opening duration of the injector. The injector is designed to operate at a nominal operating pressure of 4.4 and 8.6 bar (64 and 125 psi). Heat, generated by the exhaust system, is dissipated through the injector by cooling fins built into the body of the injector. For additional information, refer to:Selective Catalyst Reduction (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Description and Operation).

SELECTIVE CATALYST REDUCTION COMPONENTS

 

ITEM	DESCRIPTION
1	Post Selective Catalyst Reduction (SCR) soot sensor and module - North American Specification (NAS) market vehicles only
2	Post Selective Catalyst Reduction (SCR) Nitrogen Oxide (NOx) sensor and module
3	Pre Selective Catalyst Reduction (SCR) Nitrogen Oxide (NOx) sensor and module - North American Specification (NAS) market vehicles only

On North American Specification (NAS) market vehicles only, there is a pre Selective Catalyst Reduction (SCR) Nitrogen Oxide (NOx) sensor module and a pre SCR NOx sensor located in the exhaust system before the SCR catalytic converter.

EU6 and NAS markets there is a post SCR NOx sensor module and a post SCR NOx sensor located in the exhaust system after the SCR catalytic converter.

The NOx sensor comprises an integrated heater and sensor control module. The sensor is used to measure the O2 and the NOx concentration in the exhaust gas of a diesel engine. The sensor and the control module are replaced as an assembly.

The NOx sensor control module sends a message via a private Controller Area Network (CAN) bus to the Powertrain Control Module (PCM) for monitoring the effectiveness of the SCR System.

Failure of a NOx sensor or the NOx emissions fail to reach a pre-determined threshold, the PCM will record a fault, messages will be displayed to the driver in the Instrument cluster (IC) and the Malfunction Indicator Lamp (MIL) will be illuminated.

Selective Catalyst Reduction Soot Sensor and Module - NAS market vehicles only

The post Selective Catalyst Reduction (SCR) soot sensor is located in the exhaust system after the SCR catalytic converter.

The soot sensor comprises a sensor and sensor control module. The sensor measures the soot particles in the exhaust to evaluate the Diesel Particulate Filter (DPF) functionality. The sensor and the control module are replaced as an assembly.

The absorbed soot particles form conductive paths between the electrode combs in the sensor element. The control module measures the resistance between the electrode combs and sends a message via a private Controller Area Network (CAN) bus to the PCM to evaluate the DPF functionality. For additional information, refer to:Selective Catalyst Reduction (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Description and Operation).

CRANKCASE PRESSURE SENSOR - NORTH AMERICAN SPECIFICATION MARKET VEHICLES ONLY

The crankcase pressure sensor is attached to a bracket which located on the right suspension top mount. The sensor is a pressure sensor containing a piezo-resistive pressure element and amplification circuitry.

The purpose of the crankcase pressure sensor is to detect when a crankcase vent pipe is disconnected. Under normal operating conditions the sensor should detect a negative pressure value. When a pipe is disconnected and opened to atmospheric pressure, then a reduced amount of negative pressure or positive pressure will be detected by the Powertrain Control Module (PCM), signaling an error state with the crankcase ventilation system. For additional information, 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).

ACTIVE ENGINE MOUNT SOLENOID

The active engine mount system comprises:

• Two engine mounts
• Active engine mount solenoid
• Connecting vacuum pipes.

Active engine mounts optimally dampen and isolate the vibrations and noises generated by the engine in every combustion engine operating mode. This noticeably enhances comfort for the vehicle occupants.

The Powertrain Control Module (PCM) controls the vacuum operated engine mounts via an active engine mount solenoid. The active engine mount solenoid is operated at idle speed, and are switched off when the engine speed goes above a predetermined threshold. The threshold is engine speed dependant. The active engine mounts are switched off when the engine speed increases to 1250 Revolutions Per Minute (RPM).

ACTIVE GRILLE AIR SHUTTER - IF EQUIPPED

The active grille air shutter is installed behind the radiator grille and attached to the front end carrier.

The active grille air shutter incorporates moveable vanes that control the air flow into the top half of the upstream main duct attached to the front of the cooling pack. The vanes are installed in a housing in two groups of four and operated by an electric motor.

Operation of the motor is controlled by the Powertrain Control Module (PCM), which communicates with the motor on a Local Interconnect Network (LIN) bus connection. Power for the motor is provided by a power supply from the PCM relay in the Engine Junction Box (EJB). For additional information, refer to:Engine Cooling (303-03A Engine Cooling - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Description and Operation).

 

OPERATION

The TDV6 3.0L Diesel engine management system is controlled by the Powertrain Control Module (PCM) and is able to monitor, adapt and precisely control the fuel injection and electric throttle. The PCM uses multiple sensor inputs and precision control of actuators to achieve optimum performance during all driving conditions.

The PCM controls fuel delivery to all six cylinders via a common rail injection system. The common rail system uses a fuel rail to accumulate highly pressurized fuel and feed the six, electronically controlled injectors. The fuel rail is located in close proximity to the injectors, which assists in maintaining full system pressure at each injector at all times.

The PCM uses the drive by wire principle for acceleration control. There are no control cables or physical connections between the accelerator pedal and the engine. Accelerator pedal demand is communicated to the PCM by two potentiometers located in the Accelerator Pedal Position (APP) sensor. The PCM uses the two signals to determine the position, rate of movement and direction of movement of the pedal. The PCM then uses this data, along with other engine information from other sensors, to achieve the optimum engine response.

The PCM performs self-diagnostic routines and stores fault codes in its memory. These fault codes and diagnostics can be accessed using Land Rover approved diagnostic equipment. If the PCM is to be replaced, the new PCM is supplied 'blank' and must be configured to the vehicle using Land Rover approved diagnostic equipment. A 'flash' electrically erasable programmable read only memory allows the PCM to be externally configured, using Land Rover approved diagnostic equipment, with market specific or new tune information. The current engine tune data can be accessed and read using Land Rover approved diagnostic equipment.

When a new PCM is equipped, it must also be synchronized to other system control modules using Land Rover approved diagnostic equipment. PCM's cannot be 'swapped' between vehicles as they must be 'matched' with security information to other system modules.

 

CONTROL DIAGRAM

CONTROL DIAGRAM - 1 OF 6

 

A = HARDWIRED; O = LOCAL INTERCONNECT NETWORK (LIN) BUS; AC = DIAGNOSTIC; AL = PULSE WIDTH MODULATION (PWM); AY = HIGH SPEED (HS) CONTROLLER AREA NETWORK (CAN) POWER MODE ZERO SYSTEMS BUS; AM = HIGH SPEED (HS) CONTROLLER AREA NETWORK (CAN) CHASSIS SYSTEMS BUS; AN = HIGH SPEED (HS) CONTROLLER AREA NETWORK (CAN) POWERTRAIN SYSTEMS BUS; AP = MIDDLE SPEED (MS) CONTROLLER AREA NETWORK (CAN) COMFORT SYSTEMS BUS; AW = ETHERNET; AX = FLEXRAY BUS.

ITEM	DESCRIPTION
1	Powertrain Control Module (PCM)
2	Automatic Temperature Control Module (ATCM)
3	Instrument Cluster (IC)
4	Body Control Module/Gateway Module (BCM/GWM) assembly
5	Diagnostic connector (J1962)
6	Transmission Control Module (TCM)
7	Transmission Control Switch (TCS)
8	Terrain Response (TR) switchpack
9	Anti-lock Brake System (ABS) control module
10	Active grille air shutter motor - if equipped
11	Glow plug control module
12	Engine cooling fan control module - main
13	Charge air coolant pump
14	Engine cooling fan control module - auxiliary
15	Fuel pressure control valve
16	Fuel metering valve
17	Throttle actuator
18	Variable Geometry Turbocharger (VGT) vane actuator
19	Heated Oxygen sensor (HO2S)
20	Ground
21	Power supply
22	Oil level and temperature sensor
23	Variable Geometry Turbocharger (VGT) vane position sensor
24	Throttle Position Sensor (TPS)
25	Restraints Control Module (RCM)
26	Engine Coolant Temperature (ECT) sensor
27	Camshaft Position (CMP) sensor
28	Crankshaft Position (CKP) sensor
29	Heated Oxygen sensor (HO2S)
30	Accelerator Pedal Position (APP) sensor
31	Mass Air Flow and Temperature (MAFT) sensor
32	Brake pedal switch
33	Brake vacuum sensor

CONTROL DIAGRAM - 2 OF 6

 

A = HARDWIRED.

ITEM	DESCRIPTION
1	Powertrain Control Module (PCM)
2	Oil pump control solenoid
3	Powertrain Control Module (PCM) cooling fan - if equipped
4	Active engine mount solenoid
5	Fuel injector - 6 off
6	Variable coolant pump
7	Ground
8	Power supply
9	Pre catalyst exhaust gas temperature sensor - North American Specification (NAS) market vehicles only
10	Diesel Particulate Filter (DPF) outlet temperature sensor - All markets, except EU4
11	Diesel Particulate Filter (DPF) inlet temperature sensor - All markets, except EU4
12	Oil pressure switch
13	Ambient Air Temperature (AAT) sensor
14	Cylinder head temperature sensor
15	Charge air temperature sensor
16	Water In Fuel (WIF) sensor
17	Fuel Rail Pressure (FRP) sensor
18	Manifold Absolute Pressure (MAP) sensor
19	Exhaust gas temperature sensor
20	Fuel temperature sensor

CONTROL DIAGRAM - 3 OF 6 - VEHICLES WITH TWIN TURBOCHARGER

 

A = HARDWIRED.

ITEM	DESCRIPTION
1	Powertrain Control Module (PCM)
2	Turbine intake shut-off valve solenoid
3	Charge air solenoid
4	Charge air recirculation solenoid
5	Ground
6	Power supply
7	Turbine intake shut-off valve position sensor

CONTROL DIAGRAM - 4 OF 6 - SELECTIVE CATALYST REDUCTION SYSTEM

 

A = HARDWIRED; AL = PULSE WIDTH MODULATION (PWM); U = PRIVATE CONTROLLER AREA NETWORK (CAN) BUS.

ITEM	DESCRIPTION
1	Powertrain Control Module (PCM)
2	Diesel Exhaust Fluid (DEF) heater control unit
3	Diesel Exhaust Fluid (DEF) tank module
4	Diesel Exhaust Fluid (DEF) line
5	Diesel Exhaust Fluid (DEF) injector
6	Diesel Exhaust Fluid (DEF) injection pump
7	Ground
8	Power supply
9	Diesel Exhaust Fluid (DEF) tank module
10	Post Selective Catalyst Reduction (SCR) Nitrogen Oxide (NOx) sensor
11	Post Selective Catalyst Reduction (SCR) soot sensor - North American Specification (NAS) market vehicles only
12	Pre Selective Catalyst Reduction (SCR) Nitrogen Oxide (NOx) sensor - North American Specification (NAS) market vehicles only

CONTROL DIAGRAM - 5 OF 6 - EXHAUST GAS RECIRCULATION SYSTEM - EU4 MARKET VEHICLES

 

A = HARDWIRED.

ITEM	DESCRIPTION
1	Powertrain Control Module (PCM)
2	Right Exhaust Gas Recirculation (EGR) valve motor
3	Left Exhaust Gas Recirculation (EGR) valve motor
4	Exhaust Gas Recirculation (EGR) cooler bypass valve solenoid
5	Ground
6	Power supply
7	Left Exhaust Gas Recirculation (EGR) valve position sensor
8	Right Exhaust Gas Recirculation (EGR) valve position sensor

CONTROL DIAGRAM - 6 OF 6 EXHAUST GAS RECIRCULATION SYSTEM - EU5, EU6 AND NORTH AMERICAN SPECIFICATION MARKET VEHICLES

 

A = HARDWIRED.

ITEM	DESCRIPTION
1	Powertrain Control Module (PCM)
2	High Pressure (HP) Exhaust Gas Recirculation (EGR) cooler bypass valve solenoid
3	High Pressure (HP) Exhaust Gas Recirculation (EGR) valve motor
4	Low Pressure (LP) Exhaust Gas Recirculation (EGR) valve motor
5	Exhaust pressure control valve actuator
6	Ground
7	Power supply
8	Exhaust pressure control valve position sensor
9	Low Pressure (LP) Exhaust Gas Recirculation (EGR) valve position sensor
10	High Pressure (HP) Exhaust Gas Recirculation (EGR) valve position sensor
11	Differential pressure sensor - Low Pressure (LP) Exhaust Gas Recirculation (EGR) valve
12	Crankcase pressure sensor - North American Specification (NAS) market vehicles only

 

Diagnosis and Testing

 

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G2718641)

DIAGNOSIS AND TESTING

 

 

PRINCIPLES OF OPERATION

For a detailed description of the Electronic Engine Controls, refer to the relevant Description and Operation section in the workshop manual. 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).

 

INSPECTION AND VERIFICATION

WARNINGS:

• Wait at least 30 seconds after the engine stops before commencing any repair to the high-pressure fuel injection system. Failure to follow this instruction may result in personal injury.

• Place the vehicle in a well ventilated, quarantined, area and arrange "No Smoking/Fuel Fumes" signs about the vehicle. Failure to follow this instruction may result in personal injury.

• Before any work is completed on the fuel system, ground the vehicle to earth and maintain the ground connection until the work is complete. Failure to follow this instruction may result in personal injury.

• Do not complete any repairs to the fuel injection system with the engine running. The fuel pressure within the system can be as high as 2000 bar. 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 vapours are always present and may ignite. Failure to follow these instructions may result in personal injury.

• If taken internally do not induce vomiting, seek immediate medical attention. Failure to follow these instructions may result in personal injury.

• If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek medical attention. Failure to follow this instruction may result in personal injury.

• Wash hands thoroughly after handling fuel, as prolonged contact may cause irritation. Should irritation develop, seek medical attention. Failure to follow this instruction 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:

• 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 fit blanking plugs to any open orifices or lines.

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

• Do not disconnect an injector wiring connector when the engine is running. The fuel injectors are operated by piezo elements controlled by an electrical signal, they can latch open if disconnected when the engine is running. Failure to observe this caution may result in severe engine damage.

• The low pressure fuel system bleeding procedure must be completed before this procedure is completed, or the engine is attempted to be started, following removal or replacement of any low pressure fuel system component. Failure to follow this instruction may result in damage to the fuel injection pump.

• 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 tested and/or the donor vehicle.

NOTES:

• If a control module or a component is at fault and the vehicle remains under manufacturer warranty, refer to the Warranty Policy and Procedures manual, or determine if any prior approval program is in operation, prior to the installation of a new module/component.

• When performing voltage or resistance tests, always use a digital multimeter that has the resolution ability to view 3 decimal places. For example, on the 2 volts range can measure 1 mV or 2 kΩ range can measure 1 Ω. When testing resistance always take the resistance of the digital multimeter leads into account.

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

1. Verify the customer concern

1. Visually inspect for obvious signs of damage and system integrity

Visual Inspection

MECHANICAL	ELECTRICAL
Engine oil level Coolant level Fuel level Fuel contamination/grade/quality Fuel leaks Air ingress into fuel system Fuel filter Accessory drive belt Air filter and induction hoses Boost air circuit and charge air cooler Exhaust system including oxidation catalyst and particulate filter Primary turbocharger vane control linkage	Fuses Wiring harnesses and connectors Powertrain control module Sensor(s) Actuator(s)

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 and refer to the Diagnostic Trouble Code(s) (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 CHART

SYMPTOM	POSSIBLE CAUSES	ACTION
Engine does not crank	Starting procedure incorrect Transmission control switch not set to Park or Neutral Security system/immobilizer armed Battery/charging system fault Telematics control module (TCU)fault (where fitted)/Controller Area Network (CAN) fault Engine system fault Starting system fault Power distribution fault Transmission control switch system fault Engine seized/hydraulically locked	Refer to the owner's handbook and check that the correct starting procedure is being adhered to Set the transmission control switch to Park or Neutral and retest Check that the security system/immobilizer is disarmed Refer to the relevant section of the workshop manual and check the battery and charging system. Rectify as necessary When a start request is made, the telematics control module (where fitted) must transmit a secure ID message to the powertrain control module over the CAN bus to authorise cranking. Check the telematics control module for related DTCs and refer to the relevant DTC index. Check the CAN circuit between the telematics control module and the powertrain control module and repair the wiring harness as necessary Using the Jaguar Land Rover approved diagnostic equipment, check the powertrain control module for related DTCs and refer to the relevant DTC index Refer to the relevant section of the workshop manual and check the starting system. Rectify as necessary Check the integrity of the battery terminal clamps. Check the fusible links and fuses. Check the wiring harnesses and ground fixings. Rectify as necessary Using the Jaguar Land Rover approved diagnostic equipment, check the transmission control switch for related DTCs and refer to the relevant DTC index Check the engine is not seized or hydraulically locked. Rectify as necessary
Engine cranks but does not start	Engine system fault Camshaft position sensor / crankshaft position sensor power circuit short circuit to ground, short circuit to power, open circuit, high resistance Battery/charging system fault Starting system fault Fuel level low Fuel contaminated Air ingress to fuel Low pressure fuel system restricted/leaking/damaged Fuel filter restricted/leaking/damaged Fuel volume control valve blocked/contaminated Fuel pressure control valve blocked/contaminated High pressure fuel pump internal failure Glow plugs system fault Fuel injection pump belt failure	Using the Jaguar Land Rover approved diagnostic equipment, check the powertrain control module for related DTCs and refer to the relevant DTC index Refer to the electrical circuit diagrams and check the camshaft position sensor / crankshaft position sensor power circuit for short circuit to ground, short circuit to power, open circuit, high resistance. Repair the wiring harness as necessary Refer to the relevant section of the workshop manual and check the battery and charging system. Rectify as necessary Refer to the relevant section of the workshop manual and check the starting system. Rectify as necessary Check the fuel level. Rectify as necessary Check the fuel for contamination. Rectify as necessary Check the low pressure fuel system for air ingress (air bubbles may be visible passing through the transparent fuel pipes). Rectify as necessary Check the low pressure fuel system for restrictions, leaks and damage. Rectify as necessary Check the fuel filter for restrictions, leaks and damage. Rectify as necessary Check the fuel volume control valve for blockages and contamination. Rectify as necessary Check the fuel pressure control valve for blockages and contamination. Rectify as necessary Check the high pressure fuel pump. Rectify as necessary Refer to the relevant section of the workshop manual and check the glow plugs. Rectify as necessary Check the integrity of the fuel injection pump belt. Rectify as necessary
Engine stops, will crank, but will not start. No DTCs set in the powertrain control module	Camshaft position sensor / crankshaft position sensor power circuit short circuit to ground, short circuit to power, open circuit, high resistance	Refer to the electrical circuit diagrams and check the camshaft position sensor / crankshaft position sensor power circuit for short circuit to ground, short circuit to power, open circuit, high resistance. Repair the wiring harness as necessary
Difficult to start	Glow plugs system fault Fuel level low Fuel contaminated Intake system leaking or restricted Low pressure fuel system restricted/leaking/damaged Fuel filter restricted/leaking/damaged Fuel volume control valve blocked/contaminated Fuel pressure control valve blocked/contaminated Exhaust gas recirculation system fault	Refer to the relevant section of the workshop manual and check the glow plugs. Rectify as necessary Check the fuel level. Rectify as necessary Check the fuel for contamination. Rectify as necessary Check the intake system for leaks and restrictions. Rectify as necessary Check the low pressure fuel system for restrictions, leaks and damage. Rectify as necessary Check the fuel filter for restrictions, leaks and damage. Rectify as necessary Check the fuel volume control valve for blockages and contamination. Rectify as necessary Check the fuel pressure control valve for blockages and contamination. Rectify as necessary Refer to the relevant section of the workshop manual and check the exhaust gas recirculation system. Rectify as necessary
Rough idle	Intake system leaking or restricted Glow plugs system fault Fuel level low Fuel contaminated Air ingress to fuel Low pressure fuel system restricted/leaking/damaged Fuel filter restricted/leaking/damaged Fuel volume control valve blocked/contaminated Fuel pressure control valve blocked/contaminated Exhaust gas recirculation system fault	Check the intake system for leaks and restrictions. Rectify as necessary Refer to the relevant section of the workshop manual and check the glow plugs. Rectify as necessary Check the fuel level. Rectify as necessary Check the fuel for contamination. Rectify as necessary Check the low pressure fuel system for air ingress (air bubbles may be visible passing through the transparent fuel pipes). Rectify as necessary Check the low pressure fuel system for restrictions, leaks and damage. Rectify as necessary Check the fuel filter for restrictions, leaks and damage. Rectify as necessary Check the fuel volume control valve for blockages and contamination. Rectify as necessary Check the fuel pressure control valve for blockages and contamination. Rectify as necessary Refer to the relevant section of the workshop manual and check the exhaust gas recirculation system. Rectify as necessary
Lack of power when accelerating	Fuel level low Fuel level sensor fault Low pressure fuel system restricted/leaking/damaged Fuel filter restricted/leaking/damaged Fuel volume control valve blocked/contaminated Fuel pressure control valve blocked/contaminated Intake system leaking or restricted Exhaust system restricted Exhaust gas recirculation system fault Turbocharger system fault	Check the fuel level. Rectify as necessary Refer to the relevant section of the workshop manual and check the fuel level sensors. Rectify as necessary Check the low pressure fuel system for restrictions, leaks and damage. Rectify as necessary Check the fuel filter for restrictions, leaks and damage. Rectify as necessary Check the fuel volume control valve for blockages and contamination. Rectify as necessary Check the fuel pressure control valve for blockages and contamination. Rectify as necessary Check the intake system for leaks and restrictions. Rectify as necessary Check the exhaust system for restrictions. Rectify as necessary Refer to the relevant section of the workshop manual and check the exhaust gas recirculation system. Rectify as necessary Refer to the relevant section of the workshop manual and check the turbocharger system. Rectify as necessary
Engine stops/stalls	Fuel level low Fuel level sensor fault Fuel contaminated Air ingress to fuel Low pressure fuel system restricted/leaking/damaged Fuel filter restricted/leaking/damaged Fuel volume control valve blocked/contaminated Fuel pressure control valve blocked/contaminated High pressure fuel system leaking Exhaust gas recirculation system fault	Check the fuel level. Rectify as necessary Refer to the relevant section of the workshop manual and check the fuel level sensors. Rectify as necessary Check the fuel for contamination. Rectify as necessary Check the low pressure fuel system for air ingress (air bubbles may be visible passing through the transparent fuel pipes). Rectify as necessary Check the low pressure fuel system for restrictions, leaks and damage. Rectify as necessary Check the fuel filter for restrictions, leaks and damage. Rectify as necessary Check the fuel volume control valve for blockages and contamination. Rectify as necessary Check the fuel pressure control valve for blockages and contamination. Rectify as necessary Check the high pressure fuel system for leaks. Rectify as necessary Refer to the relevant section of the workshop manual and check the exhaust gas recirculation system. Rectify as necessary
Engine judders	Fuel level low Fuel level sensor fault Fuel contaminated Air ingress to fuel Low pressure fuel system restricted/leaking/damaged Fuel filter restricted/leaking/damaged Fuel volume control valve blocked/contaminated Fuel pressure control valve blocked/contaminated High pressure fuel system leaking High pressure fuel pump failure Fuel injector failure	Check the fuel level. Rectify as necessary Refer to the relevant section of the workshop manual and check the fuel level sensors. Rectify as necessary Check the fuel for contamination. Rectify as necessary Check the low pressure fuel system for air ingress (air bubbles may be visible passing through the transparent fuel pipes). Rectify as necessary Check the low pressure fuel system for restrictions, leaks and damage. Rectify as necessary Check the fuel filter for restrictions, leaks and damage. Rectify as necessary Check the fuel volume control valve for blockages and contamination. Rectify as necessary Check the fuel pressure control valve for blockages and contamination. Rectify as necessary Check the high pressure fuel system for leaks. Rectify as necessary Check the high pressure fuel pump. Rectify as necessary Check the fuel injectors. Rectify as necessary
Excessive fuel consumption	Tire pressures are incorrect Brakes binding Low pressure fuel system leaking High pressure fuel system leaking Fuel volume control valve blocked/contaminated Fuel pressure control valve blocked/contaminated Fuel injector failure Exhaust gas recirculation system fault Intake system leaking or restricted Exhaust system restricted Turbocharger system fault	Check the tire pressures. Rectify as necessary Check the brakes for binding. Rectify as necessary Check the low pressure fuel system for leaks. Rectify as necessary Check the high pressure fuel system for leaks. Rectify as necessary Check the fuel volume control valve for blockages and contamination. Rectify as necessary Check the fuel pressure control valve for blockages and contamination. Rectify as necessary Check the fuel injectors. Rectify as necessary Refer to the relevant section of the workshop manual and check the exhaust gas recirculation system. Rectify as necessary Check the intake system for leaks and restrictions. Rectify as necessary Check the exhaust system for restrictions. Rectify as necessary Refer to the relevant section of the workshop manual and check the turbocharger system. Rectify as necessary
OBD II monitor readiness status incomplete	The vehicle has not been driven enough for the monitors to complete their cycles	Refer to section 'Diesel OBD II Monitors and Readiness Status'

 

DIESEL OBD II MONITORS AND READINESS STATUS

OVERVIEW

The engine management system uses a number of monitors to check for fault conditions. Any detected faults are reported through Diagnostic Trouble Codes. In order for the complete range of monitors to run, the engine must be operated at various speeds, loads, temperatures, etc.

Each group of monitors has a readiness status. When the readiness status is 'Complete' (or 'Set'), the necessary operating conditions to run every monitor in the group have been achieved. When the readiness status is 'Incomplete', the necessary operating conditions have not been achieved and this means that one or more undetected faults may be present.

The readiness status of each group of monitors will change to 'Incomplete' after the following events:

• Disconnecting/reconnecting the vehicle battery.
• Clearing the DTCs.
• Re-configuring the powertrain control module.
• Installing a new powertrain control module.

A vehicle may fail the state Inspection and Maintenance (I/M) test if one or more of the readiness status is 'Incomplete'.

Each readiness status will achieve 'Complete' status automatically during normal driving but this may take some time and distance.

A vehicle may fail the state Inspection and Maintenance (I/M) test if one or more of the readiness status is 'Incomplete'.

READINESS STATUS ROUTINE

The current readiness status of each group of monitors may be read using the Jaguar Land Rover approved diagnostic equipment. Perform routine - OBD II Readiness Tests. If the readiness status for every group of monitors is 'Complete', no further action is necessary. If any readiness status is 'Incomplete', perform the relevant drive cycle.

 

DRIVE CYCLE: BOOST PRESSURE MONITORS

GENERAL INFORMATION

WARNINGS:

• This procedure must not be attempted without assistance. Failure to comply with this instruction may result in personal injury or death.

• Diagnostic equipment must not be operated when driving. Failure to comply with this instruction may result in personal injury or death.

• Take additional care when driving on public roads. Always observe local speed restrictions and traffic regulations when performing this procedure. Failure to comply with this instruction may result in personal injury or death.

Read and understand all steps before commencing the drive cycle.

ENTRY CONDITIONS

• Ambient temperature greater than 41°F (5°C).
• Altitude less than 8,000 ft (2,438 m) above sea level.
• Engine coolant temperature greater than 167°F (75°C).

If necessary, the engine coolant temperature may be raised by increasing the engine speed to approximately 1500 Revolutions Per Minute (RPM) or by driving.

TEST PROCEDURE

1. Using the Jaguar Land Rover approved diagnostic equipment, perform routine - OBD II Readiness Tests.

1. Start the engine.

1. Drive the vehicle steadily at a speed of approximately 50 mph (80 km/h) for a minimum of 10 minutes.

1. Using the Jaguar Land Rover approved diagnostic equipment, check the readiness status of the boost pressure monitors.

INTERPRETATION OF RESULTS

If the readiness status of the boost pressure monitors is displayed as 'Incomplete', perform the boost pressure monitors drive cycle again.

If the readiness status of the boost pressure monitors is displayed as 'Complete', no further action is necessary.

 

DRIVE CYCLE: COMPREHENSIVE COMPONENT MONITORS

No drive cycle necessary. The readiness status for comprehensive component monitors should always be displayed as 'Complete'.

 

DRIVE CYCLE: EXHAUST GAS RECIRCULATION (EGR) / VARIABLE VALVE TIMING (VVT) MONITORS

Perform the generic drive cycle.

 

DRIVE CYCLE: EXHAUST GAS SENSOR MONITORS

GENERAL INFORMATION

WARNINGS:

• This procedure must not be attempted without assistance. Failure to comply with this instruction may result in personal injury or death.

• Diagnostic equipment must not be operated when driving. Failure to comply with this instruction may result in personal injury or death.

• Take additional care when driving on public roads. Always observe local speed restrictions and traffic regulations when performing this procedure. Failure to comply with this instruction may result in personal injury or death.

Read and understand all steps before commencing the drive cycle.

ENTRY CONDITIONS

• Ambient temperature greater than 41°F (5°C).
• Altitude less than 8,000 ft (2,438 m) above sea level.
• Engine coolant temperature greater than 167°F (75°C).

If necessary, the engine coolant temperature may be raised by increasing the engine speed to approximately 1500 RPM or by driving.

TEST PROCEDURE - STAGE 1 (URBAN)

1. Using the Jaguar Land Rover approved diagnostic equipment, perform routine - OBD II Readiness Tests.

1. Start the engine and run at idle speed for 1 minute.

1. Drive the vehicle for a minimum of 10 minutes in an urban environment.

NOTE:

If a gear shift occurs during this step, the step must be repeated. To avoid gear shifts, manual gear selections or 3rd or 4th gear may be used.

1. Perform three or more sharp accelerations, followed by fuel cut off:
   1. Accelerate using greater than 50% throttle for a minimum of three seconds.
   2. Release the accelerator pedal to trigger fuel cut off. Do not press the accelerator pedal or brake pedal for a duration of 5 seconds.

TEST PROCEDURE - STAGE 2 (HIGHWAY)

1. Continue to drive the vehicle for a minimum of 30 minutes in a highway environment. The ideal speed is between 50 mph (80 km/h) and 65 mph (104 km/h).

NOTE:

If a gear shift occurs during this step, the step must be repeated. This step will be easier to achieve when traveling downhill.

1. Perform 3 or more fuel cut offs:
   1. Drive at a speed of approximately 55 mph (88 km/h).
   2. Downshift to 4th gear.
   3. Accelerate gently and then release the accelerator pedal to trigger fuel cut off. Do not press the accelerator pedal or brake pedal for a duration of 5 seconds.

1. Using the Jaguar Land Rover approved diagnostic equipment, check the readiness status of the exhaust gas sensors monitor.

INTERPRETATION OF RESULTS

If the readiness status of the exhaust gas sensor monitors is displayed as 'Incomplete', perform the exhaust gas sensor monitors drive cycle again.

If the readiness status of the exhaust gas sensor monitors is displayed as 'Complete', no further action is necessary.

 

DRIVE CYCLE: FUEL SYSTEM MONITORS

GENERAL INFORMATION

WARNINGS:

• This procedure must not be attempted without assistance. Failure to comply with this instruction may result in personal injury or death.

• Diagnostic equipment must not be operated when driving. Failure to comply with this instruction may result in personal injury or death.

• Take additional care when driving on public roads. Always observe local speed restrictions and traffic regulations when performing this procedure. Failure to comply with this instruction may result in personal injury or death.

Read and understand all steps before commencing the drive cycle.

ENTRY CONDITIONS

• Ambient temperature greater than 41°F (5°C).
• Altitude less than 8,000 ft (2,438 m) above sea level.
• Engine coolant temperature less than 104°F (40°C).

TEST PROCEDURE

1. Using the Jaguar Land Rover approved diagnostic equipment, perform routine - OBD II Readiness Tests.

1. Start the engine and run at idle speed for a minimum of 10 minutes.

1. Using the Jaguar Land Rover approved diagnostic equipment, check the readiness status of the fuel system monitor.

INTERPRETATION OF RESULTS

If the readiness status of the fuel system monitors is displayed as 'Incomplete', perform the fuel system monitors drive cycle again after making sure that the entry conditions are satisfied.

If the readiness status of the fuel system monitors is displayed as 'Complete', no further action is necessary.

 

DRIVE CYCLE: NON-METHANE HYDROCARBONS (NMHC) MONITORS

All of the non-methane hydrocarbons monitors require the successful completion of two active regenerations of the diesel particulate filter before they will commence. This would require an unfeasibly long drive cycle. It is recommended that these monitors are allowed to achieve readiness automatically during normal driving by the customer.

 

DRIVE CYCLE: MISFIRE MONITORS

GENERAL INFORMATION

WARNINGS:

• This procedure must not be attempted without assistance. Failure to comply with this instruction may result in personal injury or death.

• Diagnostic equipment must not be operated when driving. Failure to comply with this instruction may result in personal injury or death.

• Take additional care when driving on public roads. Always observe local speed restrictions and traffic regulations when performing this procedure. Failure to comply with this instruction may result in personal injury or death.

Read and understand all steps before commencing the drive cycle.

ENTRY CONDITIONS

• Ambient temperature greater than 41°F (5°C).
• Altitude less than 8,000 ft (2,438 m) above sea level.

TEST PROCEDURE

1. Using the Jaguar Land Rover approved diagnostic equipment, perform routine - OBD II Readiness Tests.

1. Start the engine and run at idle speed for a minimum of 10 minutes.

1. Using the Jaguar Land Rover approved diagnostic equipment, check the readiness status of the misfire monitor.

INTERPRETATION OF RESULTS

If the readiness status of the misfire monitors is displayed as 'Incomplete', perform the misfire monitors drive cycle again.

If the readiness status of the misfire monitors is displayed as 'Complete', no further action is necessary.

 

DRIVE CYCLE: NITROGEN OXIDES (NOX) / SELECTIVE CATALYST REDUCTION (SCR) CATALYST MONITORS

Perform the generic drive cycle.

 

DRIVE CYCLE: PARTICULATE MATTER (PM) SENSOR MONITORS

GENERAL INFORMATION

WARNINGS:

• This procedure must not be attempted without assistance. Failure to comply with this instruction may result in personal injury or death.

• Diagnostic equipment must not be operated when driving. Failure to comply with this instruction may result in personal injury or death.

• Take additional care when driving on public roads. Always observe local speed restrictions and traffic regulations when performing this procedure. Failure to comply with this instruction may result in personal injury or death.

Read and understand all steps before commencing the drive cycle.

Some of the particulate matter sensor monitors require the successful completion of two active regenerations of the diesel particulate filter before they will commence. This would require an unfeasibly long drive cycle. If the readiness status of the particulate matter sensor monitors remains 'Incomplete' after performing this drive cycle, it is recommended that these monitors are allowed to achieve readiness automatically during normal driving by the customer.

ENTRY CONDITIONS

• Ambient temperature greater than 41°F (5°C).
• Altitude less than 8,000 ft (2,438 m) above sea level.
• Engine coolant temperature greater than 167°F (75°C).

If necessary, the engine coolant temperature may be raised by increasing the engine speed to approximately 1500 RPM or by driving.

TEST PROCEDURE

1. Using the Jaguar Land Rover approved diagnostic equipment, perform routine - OBD II Readiness Tests.

1. Drive the vehicle steadily at a speed of approximately 50 mph (80 km/h) for a minimum of 10 minutes.

NOTE:

If a gear shift occurs during this step, the step must be repeated. To avoid gear shifts, manual gear selections or 3rd or 4th gear may be used.

1. Perform three or more sharp accelerations, followed by fuel cut off:
   1. Drive the vehicle at a speed of approximately 55 mph (88 km/h) and select 4th gear.
   2. Accelerate gently and then release the accelerator pedal to trigger fuel cut off. Do not press the accelerator pedal or brake pedal for a duration of 5 seconds.

1. Using the Jaguar Land Rover approved diagnostic equipment, check the readiness status of the exhaust gas sensors monitor.

INTERPRETATION OF RESULTS

If the readiness status of the particulate matter sensor monitors is displayed as 'Incomplete', it is recommended that these monitors are allowed to achieve readiness automatically during normal driving by the customer.

If the readiness status of the particulate matter sensor monitors is displayed as 'Complete', no further action is necessary.

 

DRIVE CYCLE: GENERIC

GENERAL INFORMATION

WARNINGS:

• This procedure must not be attempted without assistance. Failure to comply with this instruction may result in personal injury or death.

• Diagnostic equipment must not be operated when driving. Failure to comply with this instruction may result in personal injury or death.

• Take additional care when driving on public roads. Always observe local speed restrictions and traffic regulations when performing this procedure. Failure to comply with this instruction may result in personal injury or death.

NOTES:

• This procedure will not produce the driving conditions necessary to run the Non-Methane Hydrocarbons (NMHC) monitors.

• This procedure will not produce the driving conditions necessary to run all of the Particulate Matter (PM) sensor monitors.

Read and understand all steps before commencing the drive cycle.

ENTRY CONDITIONS

• Ambient temperature greater than 41°F (5°C).
• Altitude less than 8,000 ft (2,438 m) above sea level.
• Engine cold (not started for a minimum of 8 hours and engine coolant temperature less than 104°F (40°C).

TEST PROCEDURE - STAGE 1 (URBAN)

1. Using the Jaguar Land Rover approved diagnostic equipment, perform routine - OBD II Readiness Tests.

1. Start the engine and run at idle speed for 1 minute.

1. Drive the vehicle for a minimum of 10 minutes in an urban environment.

NOTE:

If a gear shift occurs during this step, the step must be repeated. To avoid gear shifts, manual gear selections or 3rd or 4th gear may be used.

1. Perform three or more sharp accelerations, followed by fuel cut off:
   1. Accelerate using greater than 50% throttle for a minimum of three seconds.
   2. Release the accelerator pedal to trigger fuel cut off. Do not press the accelerator pedal or brake pedal for a duration of 5 seconds.

TEST PROCEDURE - STAGE 2 (HIGHWAY)

1. Continue to drive the vehicle for a minimum of 30 minutes in a highway environment. The ideal speed is between 50 mph (80 km/h) and 65 mph (104 km/h).

NOTE:

If a gear shift occurs during this step, the step must be repeated. This step will be easier to achieve when traveling downhill.

1. Perform 3 or more fuel cut offs:
   1. Drive at a speed of approximately 55 mph (88 km/h).
   2. Downshift to 4th gear.
   3. Accelerate gently and then release the accelerator pedal to trigger fuel cut off. Do not press the accelerator pedal or brake pedal for a duration of 5 seconds.

TEST PROCEDURE - STAGE 3 (URBAN)

1. Continue to drive the vehicle for a minimum of 10 minutes in an urban environment.

1. Stop the vehicle and run the engine at idle speed for 1 minute.

1. Using the Jaguar Land Rover approved diagnostic equipment, check the readiness status of the monitors.

INTERPRETATION OF RESULTS

If the readiness status of any group of monitors (excluding the particulate matter sensor monitors and the non-methane hydrocarbons monitors) is displayed as 'Incomplete', perform the generic drive cycle again after making sure that the entry conditions are satisfied.

If the readiness status of the particulate matter sensor monitors is displayed as 'Incomplete', it is recommended that these monitors are allowed to achieve readiness automatically during normal driving by the customer.

If the readiness status of the non-methane hydrocarbons monitors is displayed as 'Incomplete', it is recommended that these monitors are allowed to achieve readiness automatically during normal driving by the customer.

If the readiness status of every group of monitors is displayed as 'Complete', no further action is necessary.

 

MALFUNCTION INDICATOR LAMP IS ILLUMINATED ON THE INSTRUMENT CLUSTER (IC) WITH DIAGNOSTIC TROUBLE CODES P0030-29 AND/OR P2251-13 STORED

Affected Vehicle Range

MODEL:	MODEL YEAR:	VEHICLE IDENTIFICATION NUMBER (VIN):	ASSEMBLY PLANT:	APPLICABILITY:
Range Rover Sport (LW)	2016	542165-599999	Solihull	TDV6 3.0L Diesel /TDV8 4.4L Diesel
Range Rover Sport (LW)	2016-2018	100003-189788	Solihull	TDV6 3.0L Diesel /TDV8 4.4L Diesel/INGENIUM I4 2.0L Diesel
Range Rover Sport (LW)	2016-2018	630154-699492	Solihull	TDV6 3.0L Diesel /INGENIUM I4 2.0L Diesel
Range Rover (LG)	2016-2018	243372-388449	Solihull	TDV6 3.0L Diesel /TDV8 4.4L Diesel
Discovery (LR)	2017-2018	000004-055735	Solihull	TDV6 3.0L Diesel /INGENIUM I4 2.0L Diesel
Range Rover Velar (LY)	2018	700004-752401	Solihull	INGENIUM I4 2.0L Diesel

 

CONDITION SUMMARY

Situation:

A customer may express a concern that the Malfunction Indicator Lamp is illuminated on the Instrument Cluster (IC) with Diagnostic Trouble Codes P0030-29 and/or P2251-13 stored in the Powertrain Control Module (PCM).

Cause:

Component fault.

Action:

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

 

PARTS:

DESCRIPTION	QUANTITY
Heated Oxygen Sensor (HO2S)	1
Gasket - TDV6 3.0L Diesel	1
Gasket - TDV6 3.0L Diesel - Twin turbocharger vehicles only	1
Gasket - TDV6 3.0L Diesel - Except Eu4 non Diesel Particulate Filter (DPF) emission vehicles	1

 

SERVICE INSTRUCTION:

NOTE:

Normal Warranty procedures apply.

1. Inspect the HO2S wiring for a short/open circuit condition, (see TOPIx Electrical Information: Electrical Wiring Diagrams - 303-14 - Electronic Engine Controls).
   1. If a short/open circuit condition is found, repair before continuing with this procedure, (see Topix Workshop Manual section 418-02: General Procedures - Wiring Harness Repair). Continue to the diagnostic procedure.
   2. If a fault is not found when checking wiring, continue to step 2.

1. Replace the HO2S, (see TOPIx Workshop Manual section: 303-14 - Electronic Engine Controls - Removal and Installation - Heated Oxygen Sensor).

1. After installing a new HO2S, clear the DTCs and complete a drive cycle, making sure the engine reaches normal operating temperature for the sensor to become active. Then, using the Jaguar Land Rover approved diagnostic equipment, check the DTC has not reset

 

DIAGNOSTIC PROCEDURE

17 Model Year (MY) Vehicles Onwards

CAUTION:

This procedure requires Pathfinder version 205 loaded or a later version.

NOTE:

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

1. Connect the Jaguar Land Rover approved battery support unit.

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

1. Follow the JLR approved diagnostic equipment prompts.

1. Select 'ECU Diagnostics'.

1. Select 'All DTCs'.

1. Select 'Clear all DTCs'.

1. Cycle the ignition 3 times.

1. Using the JLR approved diagnostic equipment read the DTCs.
   1. If DTCs P0030-29 and/or P2251-13 are still present after repairing the wiring replace the HO2S, continue to step 2 of the service instruction.

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.

 

DTC INDEX

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 - Gen 2/TDV6 3.0L Diesel / TDV6 3.0L Diesel - Gen 1.5, DTC: Powertrain Control Module B10A2-07 to P02D7-32.

General Procedures

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

BRAKE PEDAL POSITION SWITCH ADJUSTMENT (G1395342)

GENERAL PROCEDURES

 

 

CHECK

 

1. Remove the brake pedal rubber.

 

1. NOTE:

   Make sure that the dial test indicator (DTI) gauge is in line with the brake pedal movement.

   
   Position the DTI gauge on a suitable mounting block, as illustrated.

 

1. With the aid of another technician, gently press the brake pedal until the stop lamps illuminate.

 

1. NOTE:

   The specification is that the stop lamps should illuminate at between 5.5mm and 8.5mm brake pedal travel.

   Note the measurement of the brake pedal travel from rest position until the stop lamps illuminated.

 

ADJUST

NOTE:

The Brake Pedal Position Switch is self adjusting when removed and installed.

 

1. Remove and install Brake Pedal Position Switch. For additional information, refer to:Stoplamp Switch (417-01 Exterior Lighting, Removal and Installation).

 

1. Check the adjustment of the stop lamp switch by following the Check procedure in this procedure and carry out the Adjust procedure if required.

Removal and Installation

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

CAMSHAFT POSITION SENSOR (G1509551)

REMOVAL AND INSTALLATION

 

• 18.30.24
• CAMSHAFT POSITION SENSOR - RENEW
• 3000 CC, TDV6, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID
• 1.60
• USED WITHINS

 

 

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. Refer to:Left Exhaust Gas Recirculation Valve - TDV6 3.0L Diesel - Gen 2 (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. 

 

1. 

 

1. 
   Torque: 10Nm

 

INSTALLATION

 

1. CAUTIONS:

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

   • The Camshaft position (CMP) sensor tip must rest on one of the three webs on the back of the camshaft pulley. Incorrect installation may result in the CMP sensor being damaged.

   NOTES:

   • Only turn the engine in the normal direction of rotation.

   • Timing belt left hand cover shown removed for clarity.

   
   Turn the engine until one of the three webs on the back of the camshaft pulley is visible through the CMP sensor housing.

 

1. To install, reverse the removal procedure.

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

CRANKSHAFT POSITION SENSOR (G1509552)

REMOVAL AND INSTALLATION

 

• 18.30.12
• CRANKSHAFT POSITION (CKP) SENSOR - RENEW
• 3000 CC, TDV6
• 1.80
• USED WITHINS

 

PART(S)

STEP	PART NAME	QUANTITY
Removal Step 6	Turbocharger oil return pipe to turbocharger gasket	1

 

REMOVAL

NOTE:

Removal steps in this procedure may contain installation details.

 

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. WARNING:

   Make sure to support the vehicle with axle stands.

   Raise and support the vehicle.

 

1. Remove the left-hand front wheel and tire.
   Refer to:Wheel and Tire - INGENIUM I4 2.0L Diesel/TDV6 3.0L Diesel - Gen 2/TDV8 4.4L Diesel/V6 S/C 3.0L Petrol /V8 S/C 5.0L Petrol (204-04 Wheels and Tires, Removal and Installation).

 

1. Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).

 

1. 

 

1. NOTE:

   Remove and discard the gasket.

   
   Renew Part: Turbocharger oil return pipe to turbocharger gasket Quantity: 1.
   Torque: 10Nm

 

1. NOTE:

   Make sure to clean the threads prior to installation.

   
   Torque: 32Nm

 

1. 

 

1. CAUTIONS:

   • Install the CKP sensor correctly into the housing. Failure to follow this instruction may result in damage to the CKP sensor.

   • Before the disconnection or removal of any components, make sure the area around joint faces and connections are clean. Plug any open connections to prevent contamination.

   NOTES:

   • Engine shown removed for clarity.

   • The CKP sensor retaining bolt should not be removed from the CKP sensor.

   
   • Torque: 5Nm

 

1. CAUTION:

   Install the CKP sensor correctly into the housing. Failure to follow this instruction may result in damage to the CKP sensor.

   
   Using the illustration, check the installed position of the CKP sensor as seen through the cylinder block opening. The CKP sensor wiring must point towards the 9 o'clock position and not contact the cylinder block as shown. If the position is not correct repeat the process from step 9 of the removal procedure.

 

INSTALLATION

 

1. To install, reverse the removal procedure.

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

CRANKSHAFT POSITION SENSOR RING (G1509553)

REMOVAL AND INSTALLATION

 

• 18.30.14
• GEAR(S) - TOOTHED - CRANKSHAFT SENSOR - RENEW
• 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
• 6.30
• USED WITHINS

 

SPECIAL TOOL(S)

 

303-1130

Installer - Crankshaft Position (CKP) Sensor Ring

PART(S)

STEP	PART NAME	QUANTITY
Installation Step 1	Crank position sensor ring (CKP)	1

 

REMOVAL

NOTE:

Removal steps in this procedure may contain installation details.

 

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

 

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

 

1. Refer to:Flexplate (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

1. CAUTION:

   Before the disconnection or removal of any components, make sure the area around joint faces and connections are clean. Plug any open connections to prevent contamination.

   NOTE:

   The crankshaft position (CKP) sensor retaining bolt should not be removed from the CKP sensor.

   

 

1. 
   Remove and discard the CKP sensor ring.

 

INSTALLATION

 

1. CAUTION:

   Make sure that the CKP sensor ring is aligned correctly with the special tool pip and that both mating surfaces are fully seated.

   NOTE:

   Make sure a new CKP sensor ring is installed.

   
   Special Tool(s): 303-1130
   Renew Part: Crank position sensor ring (CKP) Quantity: 1.

 

1. 
   Install the special tool.

 

1. 

 

1. 

 

1. 
   Remove the special tool.
   Special Tool(s): 303-1130

 

1. CAUTIONS:

   • Install the CKP sensor correctly into the housing. Failure to follow this instruction may result in damage to the CKP sensor.

   • Before the disconnection or removal of any components, make sure the area around joint faces and connections are clean. Plug any open connections to prevent contamination.

   
   • Torque: 5Nm

 

1. Refer to:Flexplate (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

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

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

DIESEL PARTICULATE FILTER DIFFERENTIAL PRESSURE SENSOR (G1509554)

REMOVAL AND INSTALLATION

 

• 17.50.23
• SENSOR - DIFFERENTIAL PRESSURE - PARTICULATE FILTER - RENEW
• 3000 CC, TDV6
• 0.40
• USED WITHINS

 

 

REMOVAL

WARNING:

Observe due care when working near a hot exhaust system.

NOTE:

Removal steps in this procedure may contain installation details.

 

1. WARNING:

   Make sure to support the vehicle with axle stands.

   Raise and support the vehicle.

 

1. 

 

1. 

 

1. 

 

1. 

 

1. 
   Torque: 20Nm

 

INSTALLATION

 

1. To install, reverse the removal procedure.

 

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

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

ENGINE COOLANT TEMPERATURE SENSOR (G1509555)

REMOVAL AND INSTALLATION

 

• 18.30.10
• ENGINE COOLING TEMPERATURE SENSOR - RENEW
• 3000 CC, TDV6
• 0.10
• USED WITHINS

 

 

REMOVAL

CAUTION:

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

NOTE:

Removal steps in this procedure may contain installation details.

 

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. 

 

1. CAUTIONS:

   • Be prepared to collect escaping fluids.

   • The seal is to be reused unless damaged.

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

   NOTE:

   Release the locking tang to remove the ECT sensor.

   

 

INSTALLATION

 

1. NOTE:

   Make sure that all the component mating faces are clean.

   To install, reverse the removal procedure.

 

1. Check and top up coolant level.

LECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

ENGINE CONTROL MODULE (G1509556)

REMOVAL AND INSTALLATION

 

• 18.30.01
• POWERTRAIN CONTROL MODULE (PCM) - RENEW
• 3000 CC, TDV6
• 0.20
• USED WITHINS

 

GENERAL EQUIPMENT

EQUIPMENT NAME
Jaguar Land Rover approved diagnostic equipment

 

REMOVAL

CAUTION:

Before the disconnection or removal of any components, make sure the area around joint faces and connections are clean. Plug any open connections to prevent contamination.

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

 

1. 
   • Remove the 4 fasteners.
   • Remove the left side cowl panel moulding.

 

1. 
   • Disconnect the 2 electrical connectors.
   • Release the clip.

 

1. 
   • Remove the 2 bolts.
   • Remove the Engine Control Module (ECM) and bracket assembly.

 

1. 
   • Remove the 4 nuts.
   • Remove the ECM.

 

INSTALLATION

 

1. • Install the Engine Control Module (ECM).
   • Install and tighten the 4 nuts.
     Torque: 7Nm

 

1. • Install the ECM and bracket assembly.
   • Install and tighten the 2 bolts.

 

1. • Install the clip.
   • Connect the 2 electrical connectors.

 

1. • Install the left side cowl panel moulding.
   • Install the 4 fasteners.

 

1. Connect the startup battery ground cable.
   Refer to:Specifications (414-01 Battery, Mounting and Cables, Specifications).

 

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

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

ENGINE OIL LEVEL SENSOR (G1509557)

REMOVAL AND INSTALLATION

 

• 12.60.51
• OIL LEVEL SENSOR - RENEW
• 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
• 6.10
• USED WITHINS

 

 

REMOVAL

NOTES:

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

• 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. WARNING:

   Make sure to support the vehicle with axle stands.

   Raise and support the vehicle.

 

1. Remove the oil pan.
   Refer to:Oil Pan (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

1. 
   Torque: 10Nm

 

1. 
   Torque: 10Nm

 

INSTALLATION

 

1. 
   Torque: 10Nm

 

1. 
   Torque: 10Nm

 

1. Install the oil pan.
   Refer to:Oil Pan (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

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

 

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

ENGINE OIL PRESSURE SENSOR (G1509558)

REMOVAL AND INSTALLATION

 

• 12.60.50
• OIL PRESSURE AND TEMPERATURE SENSOR - RENEW
• 3000 CC, TDV6
• 0.10
• USED WITHINS

 

 

REMOVAL

NOTES:

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

• Some components shown removed for clarity.

 

1. Remove the engine cover.
   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. 

 

1. 

 

INSTALLATION

 

1. CAUTION:

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

   
   Torque: 14Nm

 

1. 

 

1. Install the engine cover.
   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).

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

RIGHT EXHAUST GAS TEMPERATURE SENSOR (G1509559)

REMOVAL AND INSTALLATION

 

• 18.31.52
• EXHAUST GAS TEMPERATURE SENSOR - RH - RENEW
• 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
• 1.90
• USED WITHINS

 

 

REMOVAL

NOTE:

Removal steps in this procedure may contain installation details.

 

1. WARNING:

   Make sure to support the vehicle with axle stands.

   Raise and support the vehicle.

 

1. Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

1. CAUTION:

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

   
   Torque: 35Nm

 

INSTALLATION

 

1. CAUTION:

   If accidentally dropped or knocked install a new sensor.

   NOTE:

   If the original sensor is to be installed, apply lubricant meeting specification ESE-M12A4-A to the thread of the sensor.

   To install, reverse the removal procedure.

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

HEATED OXYGEN SENSOR (G2459359)

REMOVAL AND INSTALLATION

 

• 19.22.16
• HEATED OXYGEN SENSOR (HO2S) - RENEW
• 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID
• 2.00
• USED WITHINS

 

SPECIAL TOOL(S)

 

JLR-303-1666

Remover/Installer, NOx/Oxygen Sensor

GENERAL EQUIPMENT

EQUIPMENT NAME
Jaguar Land Rover approved diagnostic equipment

 

REMOVAL

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:Jacking (100-02 Jacking and Lifting, Description and Operation).

 

1. Remove the exhaust system.
   Refer to:Exhaust System - Vehicles Without: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
   Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
   Refer to:Exhaust System - Vehicles With: Diesel Exhaust Fluid (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

1. 
   Remove the Heated Oxygen Sensor (HO2S).
   Special Tool(s): JLR-303-1666

 

INSTALLATION

 

1. CAUTIONS:

   • If accidentally dropped or knocked install a new sensor.

   • Make sure the HO2S wiring harness is not twisted more than 180 degrees and is not in contact with either the exhaust or driveshaft.

   • Make sure the anti-seize compound does not contact the HO2S tip.

   NOTE:

   If the original sensor is to be installed, apply lubricant meeting specification ESE-M12A4-A to the thread of the sensor.

   
   • Install the HO2S.
     Special Tool(s): JLR-303-1666
     Torque: 48Nm

 

1. Install the exhaust system.
   Refer to:Exhaust System - Vehicles Without: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
   Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
   Refer to:Exhaust System - Vehicles With: Diesel Exhaust Fluid (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

1. NOTE:

   If a new HO2S is installed, do the following steps.

   • Using the Jaguar Land Rover (JLR) approved diagnostic equipment, run the 'Oxygen sensor' routine (0x4035).
   • Using the Jaguar Land Rover approved diagnostic equipment, run the 'Diesel fuelling adaption re-initialization' routine (0x402C).
   • Using the JLR approved diagnostic equipment, clear the Diagnostic Trouble Code(s) (DTC) and retest.

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

INTAKE AIR TEMPERATURE SENSOR (G1509561)

REMOVAL AND INSTALLATION

 

• 18.30.09
• SENSOR - INTAKE AIR TEMPERATURE (IAT) - RENEW
• 3000 CC, TDV6
• 0.10
• USED WITHINS

 

 

REMOVAL

NOTE:

Removal steps in this procedure may contain installation details.

 

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. 

 

1. 

 

INSTALLATION

 

1. To install, reverse the removal procedure.

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

MANIFOLD ABSOLUTE PRESSURE SENSOR (G1509562)

REMOVAL AND INSTALLATION

 

• 18.30.56
• MANIFOLD ABSOLUTE PRESSURE AND TEMPERATURE SENSOR - RENEW
• 3000 CC, TDV6
• 0.10
• 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. Remove the engine cover.
   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. 
   • Disconnect the Manifold Absolute Pressure (MAP) electrical connector.
   • Remove the MAP sensor retaining bolt.
   • Remove the MAP sensor.

 

INSTALLATION

 

1. CAUTIONS:

   • Make sure that the MAP (Manifold Absolute Pressure) sensor is held in a downwards position during cleaning to avoid any carbon deposits entering the MAP sensor.

   • Do not use hard or sharp tools to clean the sensor or damage may occur.

   • Do not insert any tooling into the sensing element. Failure to follow this instruction could damage the component.

   NOTE:

   All dirt or contaminants must be removed from the MAP (Manifold Absolute Pressure) sensor.

   
   Using a suitable blunt tool, throughly clean the Manifold Absolute Pressure (MAP) sensor.

 

1. 
   • Install the MAP sensor.
   • Install the MAP sensor retaining bolt.
   • Connect the MAP electrical connector.

 

1. Install the engine cover.
   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).

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

MASS AIR FLOW SENSOR (G1509563)

REMOVAL AND INSTALLATION

 

• 19.22.25
• MASS AIR FLOW SENSOR - RENEW
• 3000 CC, TDV6
• 0.10
• USED WITHINS

 

 

REMOVAL

NOTE:

Removal steps in this procedure may contain installation details.

 

1. 

 

1. 
   Torque: 2Nm

 

INSTALLATION

 

1. To install, reverse the removal procedure.

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

OIL TEMPERATURE SENSOR (G1509564)

REMOVAL AND INSTALLATION

 

• 18.30.41
• SENSOR - OIL TEMPERATURE - RENEW
• 3000 CC, TDV6
• 0.40
• USED WITHINS

 

 

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. WARNING:

   Make sure to support the vehicle with axle stands.

   Raise and support the vehicle.

 

1. Remove the oil pan.
   Refer to:Oil Pan (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

1. 
   Torque: 12Nm

 

1. 
   Torque: 12Nm

 

INSTALLATION

 

1. To install, reverse the removal procedure.

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

POST CATALYTIC CONVERTER TEMPERATURE SENSOR (G1883377)

REMOVAL AND INSTALLATION

 

• 18.31.56
• CATALYST POST TEMPERATURE SENSOR - RENEW
• 3000 CC, TDV6, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID
• 1.90
• USED WITHINS

 

SPECIAL TOOL(S)

 

310-121

Wrench, H02S

 

REMOVAL

NOTES:

• Removal steps in this procedure may contain installation details.

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

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

 

1. WARNING:

   Make sure to support the vehicle with axle stands.

   Raise and support the vehicle.

 

1. 
   • Remove the 10 bolts.
     Torque

     M10: 60Nm

     M6: 10Nm
   • Remove the transmission undershield.

 

1. 
   • Disconnect the electrical connector.
   • Release the 4 wiring harness clips.

 

1. CAUTION:

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

   
   Remove the post catalytic converter temperature sensor.
   Special Tool(s): 310-121
   Torque: 35Nm

 

INSTALLATION

 

1. CAUTION:

   If accidentally dropped or knocked install a new sensor.

   NOTE:

   If the original sensor is to be installed, apply lubricant meeting specification ESE-M12A4-A to the thread of the sensor.

   To install, reverse the removal procedure.

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

POST DPF EXHAUST GAS TEMPERATURE SENSOR (G1509566)

REMOVAL AND INSTALLATION

 

• 18.31.54
• PARTICULATE FILTER POST TEMPERATURE SENSOR - RENEW
• 3000 CC, TDV6
• 0.30
• USED WITHINS

 

 

REMOVAL

WARNING:

Observe due care when working near a hot exhaust system.

NOTE:

Removal steps in this procedure may contain installation details.

 

1. WARNING:

   Make sure to support the vehicle with axle stands.

   Raise and support the vehicle.

 

1. 
   Torque

   M10: 60Nm

   M6: 10Nm

 

1. 

 

1. 

 

1. CAUTION:

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

   
   Torque: 35Nm

 

INSTALLATION

 

1. CAUTION:

   If accidentally dropped or knocked install a new sensor.

   NOTE:

   If the original sensor is to be installed, apply lubricant meeting specification ESE-M12A4-A to the thread of the sensor.

   To install, reverse the removal procedure.

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

PRE CATALYTIC CONVERTER TEMPERATURE SENSOR (G1883378)

REMOVAL AND INSTALLATION

 

• 18.31.55
• CATALYST PRE TEMPERATURE SENSOR - RENEW
• 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
• 1.90
• USED WITHINS

 

 

REMOVAL

NOTE:

• 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. Remove the front driveshaft.
   Refer to:Front Driveshaft - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (205-01 Driveshaft, Removal and Installation).

 

1. 

 

1. 

 

INSTALLATION

 

1. CAUTION:

   • If accidentally dropped or knocked install a new sensor.
   • Make sure that the mating face is clean and free of foreign material.
   NOTE:

   If the original sensor is to be installed, apply lubricant meeting specification ESE-M12A4-A to the thread of the sensor.

   
   Torque: 35Nm

 

1. 

 

1. Install the front driveshaft.
   Refer to:Front Driveshaft - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (205-01 Driveshaft, Removal and Installation).

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

LEFT EXHAUST GAS TEMPERATURE SENSOR (G1879617)

REMOVAL AND INSTALLATION

 

• 18.31.59
• EXHAUST GAS TEMPERATURE SENSOR - LH - RENEW
• 3000 CC, TDV6, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID
• 2.50
• USED WITHINS

 

 

REMOVAL

 

1. Raise and support the vehicle.

 

1. Refer to:Exhaust Manifold Cross-over Pipe (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

1. 

 

1. 
   Torque: 28Nm

 

INSTALLATION

 

1. To install reverse the removal procedure.

ELECTRONIC ENGINE CONTROLS - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

POST SELECTIVE CATALYST REDUCTION NOX SENSOR (G1879624)

REMOVAL AND INSTALLATION

 

• 17.50.46
• SENSOR - NOX - POST SELECTIVE CATALYST REDUCTION - RENEW
• 3000 CC, TDV6
• 0.40
• USED WITHINS

 

SPECIAL TOOL(S)

 

JLR-303-1666

Remover/Installer, NOx/Oxygen Sensor

 

REMOVAL

WARNING:

Observe due care when working near a hot exhaust system.

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. 
   Release the undershield.

 

1. 
   Remove the heatshield.

 

1. 
   • Disconnect the electrical connector.
   • Release the post selective catalyst reduction NOx sensor module.

 

1. 
   Release the wiring harness.

 

1. 
   Using the special tool remove the post selective catalyst reduction NOx sensor.
   Special Tool(s): JLR-303-1666

 

INSTALLATION

 

1. CAUTIONS:

   • If accidentally dropped or knocked install a new sensor.

   • Make sure the HO2S wiring harness is not twisted more than 180 degrees and is not in contact with either the exhaust or driveshaft.

   • Make sure the anti-seize compound does not contact the HO2S tip.

   NOTE:

   If the original sensor is to be installed, apply lubricant meeting specification ESE-M12A4-A to the thread of the sensor.

   Install the post selective catalyst reduction NOx sensor.
   Special Tool(s): JLR-303-1666
   Torque: 48Nm

 

1. Install the wiring harness.

 

1. • Install the post selective catalyst reduction NOx sensor module.
     Torque: 10Nm
   • Connect the wiring harness.

 

1. Install the heatshield.
   Torque: 12Nm

 

1. Install the undershield.

 

307: Automatic Transmission/Transaxle

307-01A: Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD

Description and Operation

 

AUTOMATIC TRANSMISSION/TRANSAXLE - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

TRANSMISSION DESCRIPTION (G2003046)

DESCRIPTION AND OPERATION

 

 

COMPONENT LOCATION

AUTOMATIC TRANSMISSION ZF 8HP70

 

ITEM	DESCRIPTION
1	Emergency Park Release (EPR) lever
2	Automatic transmission
3	Automatic Transmission Fluid (ATF) cooler
4	Transmission Control Switch (TCS)

 

OVERVIEW

The ZF 8HP70 transmission is an electronically controlled, hydraulically operated, eight speed automatic unit.

A single unit known as the Mechatronic valve block is located inside the transmission. The Mechatronic valve block contains the following control components:

• Hydraulic control elements
• Electronic control elements
• TCM.

The ZF 8HP70 transmission has the following features:

• Designed to be maintenance free
• Automatic Transmission Fluid (ATF) is 'fill for life'
• The torque converter features a controlled slip feature with electronically regulated control of lock-up, creating a smooth transition to the fully locked condition
• Shift programs controlled by the TCM
• Adaptive Shift Strategy (ASIS), to provide continuous adaptation of shift changes to suit the driving style of the driver, which can vary from sporting to economical
• Connected to the Powertrain Control Module (PCM) via the FlexRay systems bus for communications
• Default mode if major faults occur
• Diagnostics available from the TCM via the FlexRay systems bus.

The transmission selections are made using the linear Transmission Control Switch (TCS) in the floor console. For additional information, refer to:External Controls - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD (307-05A Automatic Transmission/Transaxle External Controls - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Description and Operation).

On vehicles featured with the stop/start system, the 8HP70 automatic transmission is fitted with a Hydraulic Impulse Storage (HIS) device to ensure pressurized Automatic Transmission Fluid (ATF) is available to the shift elements as quickly as possible when the engine is started.

 

DESCRIPTION

TRANSMISSION

The transmission comprises the main casing which houses all of the transmission components. The main casing also incorporates an integral torque converter housing.

A fluid pan is attached to the lower face of the main casing and is secured with bolts. The fluid pan is sealed to the main casing with a gasket. Removal of the fluid pan allows access to the Mechatronic valve block. The fluid pan has magnets located at the rear which collects any ferrous metallic particles present in the transmission fluid.

A fluid filter is located inside the fluid pan. If the Automatic Transmission Fluid (ATF) becomes contaminated or after any service work, the fluid pan with integral filter must be replaced.

The transmission does not have a Bowden cable for park lock operation. This is initiated electronically when the Transmission Control Switch (TCS) is moved to the 'P' park position. An Emergency Park Release (EPR) mechanism is provided to release the park interlock if a failure occurs.

A feature of the eight speed transmission is decoupling of the transmission when the vehicle is at a standstill. Normally the transmission remains in gear with the torque converter slipping and the vehicle is prevented from moving by applying the brake. The new system disengages one of the transmission clutches and only a minimum rotating load remains. This has the effect of further reducing fuel consumption.

The ATF pump is driven by a simplex chain and two drive gears from the input shaft. The ATF pump is a double stroke vane cell pump which delivers 50 cm³ of ATF per revolution.

The integral torque converter housing provides protection for the torque converter assembly and also provides the attachment for the transmission to the engine. The torque converter is a non-serviceable assembly which also contains the lock-up clutch mechanism.

The main casing contains the following major components:

• Input shaft
• Output shaft
• Mechatronic valve block which contains the solenoids, speed sensors and the Transmission Control Module (TCM)
• Three rotating multiplate drive clutches
• Two fixed multiplate brake clutches
• Four planetary gear trains.

Transmission Sectional View

 

ITEM	DESCRIPTION
1	Transmission casing
2	Gear set 1
3	Gear set 2
4	Gear set 3
5	Gear set 4
6	Output shaft
7	Drain plug
8	Clutch D
9	Clutch C
10	Clutch E
11	Mechatronic valve block
12	Brake B
13	Brake A
14	Fluid filter
15	Fluid pan
16	Automatic Transmission Fluid (ATF) pump
17	Torque converter
18	Input shaft

TORQUE CONVERTER

A torsional damper torque converter is used on 8HP70 transmissions.

The torsional damper enables a more direct engine connection for highly efficient power transmission when starting and shifting. The inner spring set is connected directly to the transmission, the outer spring set responds to torque from the engine via the lock-up clutch. When the lock-up clutch is applied, the hydro-dynamic circuit is by-passed and torque is transferred directly to the transmission input shaft. In comparison to conventional torque converters, the torsional damper applies the lock-up clutch earlier. This improves driving comfort at low engine speeds and increases fuel efficiency by enabling the engine to be operated at lower Revolutions Per Minute (RPM) levels.

When the converter lock-up clutch is not applied, torque is transferred hydro-dynamically. Power from the engine is transmitted via the pump and turbine to the transmission input shaft. When the converter lock-up clutch is applied, the hydro-dynamic circuit is by-passed, torque is transferred directly via the lock-up clutch and the twin spring sets. The turbine inertia is coupled between the two spring sets which improves disengagement, helps reduce wear on the transmission and improve noise insulation.

The torque converter is the coupling element between the engine and the transmission and is located in the torque converter housing, on the engine side of the transmission. The driven power from the engine crankshaft is transmitted hydraulically and mechanically through the torque converter to the transmission. The torque converter is connected to the engine by a drive plate attached to the rear of the crankshaft.

The torque converter comprises a torsional damper, an impeller, a stator and a turbine. The torque converter is a sealed unit with all components located between the converter housing cover and the impeller. The two components are welded together to form a sealed, fluid filled housing. With the impeller brazed to the converter housing cover, the impeller is therefore driven at engine crankshaft speed.

The converter housing drive plate has four threaded bosses, which provide for attachment of the engine drive plate. The threaded bosses also provide for location of special tools which are required to remove the torque converter from the torque converter housing.

 

Lock-Up Clutch

 

The torque converter lock-up clutch is hydraulically controlled by an Electronic Pressure Regulating Solenoid (EPRS), which is controlled by the Transmission Control Module (TCM). This allows the torque converter to have three states of operation as follows:

• Fully engaged
• Controlled slip variable engagement
• Fully disengaged.

The torque converter pressure valve reduces system pressure and guarantees the pressure needed for the torque converter. It also limits the maximum torque converter pressure, to prevent the torque converter from expanding.

The EPRS is operated by Pulse Width Modulation (PWM) signals from the TCM to give full, partial or no lock-up of the torque converter.

The lock-up clutch is a hydro-mechanical device which eliminates torque converter slip, improving fuel consumption. The engagement and disengagement is controlled by the TCM to allow a certain amount of controlled 'slip'. This allows a small difference in the rotational speeds of the impeller and the turbine which results in improved shift quality. The lock-up clutch comprises a piston and a clutch comprising of friction and steel plates.

In the unlocked condition, the oil pressure supplied to the piston chamber is reduced and the pressure in the turbine chamber is allowed to push the piston back. In this condition the clutch plates are released and torque converter slip is permitted.

In the locked condition, the lock-up clutch spool valves are actuated by the EPRS. Pressurized Automatic Transmission Fluid (ATF) is directed into the lock-up clutch piston. The piston moves with the pressure and pushes the clutch plates together. As the pressure increases, the friction between the clutch plates increases, finally resulting in full lock-up of the clutch plates. In this condition there is direct mechanical drive from the engine crankshaft to the transmission planetary gear train.

The Transmission Idle Control feature is a standstill decoupling feature for the eight speed transmission. When the vehicle comes to a standstill with the brakes applied and the Transmission Control Switch (TCS) is in 'D' (Drive) position, the converter is disconnected from the driveline so that only a slight residual load remains. This further reduces fuel consumption. Decoupling is by actuating clutch B in the transmission, and is dependent on load and output speed.

AUTOMATIC TRANSMISSION FLUID PUMP

The Automatic Transmission Fluid (ATF) pump is an integral part of the transmission. The ATF pump is used to supply hydraulic pressure for the operation of the control valves and clutches. The ATF pump also passes the ATF through the transmission cooler and the transmission to lubricate the gears and shafts.

The ZF 8HP70 ATF pump is a double stroke, vane type pump and is located below the transmission input shaft. The pump is driven by a chain drive from a sprocket located on the torque converter. The pump has a delivery rate of 50 cm³ per revolution. The drive sprocket is driven at engine speed through a splined connection in the torque converter shell.

Automatic Transmission Fluid Pump Location

 

ITEM	DESCRIPTION
1	Vane pump
2	Chain drive from torque converter cover

Automatic Transmission Fluid Pump Schematic Diagram

 

ITEM	DESCRIPTION
1	System pressure valve
2	Automatic Transmission Fluid (ATF) pump
3	Intake pipe
4	Oil pan
5	Pressure pipe
6	Recycling of redundant fluid

The Automatic Transmission Fluid (ATF) pump comprises:

• A sprocket
• A rear cover with bearing
• A front cover with bearing
• A cylinder
• A rotor shaft and a rotor with vanes.

A pressure relief valve is fitted in the pressure outlet gallery from the pump, but is not an integral part of the pump itself.

A sprocket is located around the transmission input shaft. Splines on the torque converter nose and the sprocket ensure a positive drive. A simplex chain transmits the rotation of the torque converter cover into rotation of the pump rotor shaft via a second sprocket fitted to the rotor shaft. The gearing of the two sprockets rotates the ATF pump rotor shaft at a speed slightly higher than the Revolutions Per minute (RPM) of the torque converter cover. The torque converter cover is directly connected to the engine crank.

The ATF pump contains seven vanes which are attached to the rotor and rotate within the cam shaped cylinder. As the vanes rotate, the eccentricity of the central hole in the cylinder causes the space between the vanes to increase. This causes a depression between the vanes and fluid is drawn into the space between the vanes via a suction port connected to the fluid pan. The fluid passes through the fluid pan filter before it is drawn into the ATF pump.

As the rotor shaft rotates further, the inlet port is closed by the vanes which have drawn in fluid, trapping the fluid in the space between the vanes. The eccentric hole in the cylinder causes the space between the vanes to decrease and consequentially compresses and pressurizes the fluid trapped between them.

Further rotation of the rotor shaft moves the vanes towards the outlet port. As the vanes pass the outlet port the pressurized fluid passes from the space between the vanes into the pressure gallery to the pressure relief valve.

As the ATF pump is a double stroke vane pump, this sequence is repeated twice per revolution of the rotor shaft.

The pressure relief valve controls the pressure and flow of ATF delivered to the transmission valve block, torque converter and other components. Pressure is controlled by a relief valve which limits the maximum system pressure to 32 bar (464 lbf/in²). The pressure control maintains a constant pressure of ATF irrespective of torque converter input shaft rotational speed. A metering orifice is subject to the pump output pressure. If the pressure in the orifice reaches a predetermined level, a spring loaded ball in the flow control valve is lifted from its seat and pressurized fluid is allowed to recirculate through the pump.

MECHATRONIC VALVE BLOCK

The Mechatronic valve block is located in the bottom of the transmission and is covered by the fluid pan. The valve block houses the following components:

• Transmission Control Module (TCM)
• Electrical actuators
• Speed sensors
• Control valves
• Hydraulic Impulse Storage (HIS) (if fitted).

The above components provide all electro-hydraulic control for all transmission functions.

The Mechatronic valve block comprises the following components:

• TCM
• Seven Electronic Pressure Regulating Solenoids (EPRS)
• Two park lock solenoids
• Twenty one hydraulic spool valves
• Temperature sensor
• Turbine speed sensor
• Output shaft speed sensor
• Hydraulic Impulse Storage (HIS) (if fitted).

 

ITEM	DESCRIPTION
1	Electronic Pressure Regulating Solenoid (EPRS) A - A brake valve
2	EPRS D - D clutch valve
3	EPRS B - B brake valve
4	EPRS E - E clutch valve
5	Magnetic Valve (MV) 2 - magnet-valve 2 for electrical park interlock (hold out of park)
6	MV 1 - pressure reducing valve
7	EPRS SYS - system pressure valve
8	EPRS WK - Torque converter lock-up clutch valve
9	EPRS C - C clutch valve
10	Transmission output shaft speed sensor
11	Hydraulic Impulse Storage (HIS) (if fitted)
12	Electrical connector
13	Transmission Control Module (TCM) - hidden

 

Electronic Pressure Regulator Solenoids

Seven Electronic Pressure Regulator Solenoids (EPRS) are located in the valve block. The solenoids are controlled by Pulse Width Modulation (PWM) signals from the Transmission Control Module (TCM). The solenoids convert the electrical signals into hydraulic control pressure proportional to the signal to actuate the spool valves for precise transmission operation.

EPRS A, B, D, E and WK supply a higher control pressure as the signal amperage increases and can be identified by an orange connector cap. The TCM operates the solenoids using PWM signals. The TCM monitors engine load and clutch slip and varies the solenoid duty cycle accordingly. The solenoids have a 12 V operating voltage and a pressure range of 0 - 4.7 bar (0 - 68 lbf.in²).

EPRS C and SYS supply a lower control pressure as the signal amperage increases and can be identified by a gray connector cap. The TCM monitors engine load and clutch slip and varies the solenoid duty cycle accordingly. The solenoids have a 12 V operating voltage and a pressure range of 4.7 - 0 bar (68 - 0 lbf.in²).

The resistance of the solenoid coil winding for EPRS is 5.05 Ohms at 20 °C (68 °F).

 

Control Solenoid (MV 1)

A shift control solenoid Magnetic Valve 1 (MV1) is located in the valve block. The solenoid is controlled by the Transmission Control Module (TCM) and converts electrical signals into hydraulic control signals to control clutch application.

The shift control solenoid is an open/closed, on/off solenoid which is controlled by the TCM switching the solenoid to earth. The TCM also supplies power to the solenoid. The TCM energizes the solenoid in a programmed sequence for clutch application for gear ratio changes and shift control.

The resistance of the solenoid coil winding for solenoid is between 10 to 11 Ohms at 20 °C (68 °F).

 

Control Solenoid (MV 2)

 

ITEM	DESCRIPTION
A	Solenoid in locked (energized) condition - park lock released
B	Solenoid in unlocked (de-energized) condition - park lock engaged
1	Solenoid
2	Claw - locked
3	Piston
4	Claw - unlocked

A control solenoid Magnetic Valve 2 (MV 2) is located in the valve block. The solenoid is controlled by the Transmission Control Module (TCM) and converts electrical signals into hydraulic control signals to control the electronic park lock function.

The control solenoid is an on/off solenoid which is controlled by the TCM by switching the solenoid to earth.

When the park position is deselected, control solenoid MV2 resets the parking lock valve in the Mechatronic valve block. This is achieved by the TCM providing the ground for the solenoid which is energized, releasing the claws from retaining the park lock piston. Main Automatic Transmission Fluid (ATF) pressure acting on the parking lock piston, pushes the piston back to release the lock.

When the park position is selected, control solenoid MV2 is de-energized. The ATF pressure at the parking lock cylinder piston is vented and the mechanical interlock of the piston is opened. A pre-tensioned torsion spring at the park lock disc pulls the piston into the 'park' position. In the 'park' position the piston engages with the control solenoid claws and is locked in the park position. An emergency release wire cable can be used to release the parking lock manually if an electrical failure occurs.

The resistance of the solenoid coil winding for solenoid is 25 Ohms at 20 °C (68 °F).

When the neutral "N" position is selected and the engine is turned off, the ATF pressure at the park lock cylinder piston is released. The current supply to the control solenoid MV2 remains. The park lock cylinder piston is still held in the unlocked position by the spring force acting on the park lock disc. This prevents the park lock plate from engaging the parking lock. This allows the vehicle to be moved when the engine is not running for a short time. Should the battery voltage fall below the level required to maintain the solenoid in the energized condition, the park lock will be engaged.

 

Sensors

 

Speed Sensors

The turbine speed sensor and the output shaft speed sensor are Hall effect type sensors located in the Mechatronic valve block and are not serviceable items. The Transmission Control Module (TCM) monitors the signals from each sensor to determine the input (turbine) speed and the output shaft speed.

The turbine speed is monitored by the TCM to calculate the slip of the torque converter clutch and internal clutch slip. This signal allows the TCM to accurately control the slip timing during shifts and adjust clutch application or release pressure for overlap shift control.

The output shaft speed is monitored by the TCM and compared to engine speed signals received on the FlexRay system bus from the Powertrain Control Module (PCM). Using a comparison of the two signals the TCM calculates the transmission slip ratio for plausibility and maintains adaptive pressure control.

 

Temperature Sensor

The temperature sensor is also located in the Mechatronic valve block. The Transmission Control Module (TCM) uses the temperature sensor signals to determine the temperature of the transmission fluid. These signals are used by the TCM to control the transmission operation. The TCM uses the temperature signals to promote faster warm-up in cold conditions. The TCM also uses the temperature signal to assist with fluid cooling by controlling the transmission operation when high fluid temperatures are experienced. If the sensor fails, the TCM will use a default value and a fault code will be stored in the TCM.

 

Spool Valves

The valve block contains spool valves which control various functions of the transmission. The spool valves are of conventional design and are operated by Automatic Transmission Fluid (ATF) pressure.

Each spool valve is located in its spool bore and held in a default (unpressurized) position by a spring. The spool bore has a number of ports which allow ATF to flow to other valves and clutches to enable transmission operation. Each spool has a piston which is waisted to allow ATF to be diverted into the applicable ports when the valve is operated.

When ATF pressure moves a spool, one or more ports in the spool bore are covered or uncovered. ATF is prevented from flowing or is allowed to flow around the applicable waisted area of the spool and into another uncovered port. The ATF is either passed through galleries to actuate another spool, operate a clutch or is returned to the fluid pan.

HYDRAULIC IMPULSE STORAGE (IF FITTED)

 

ITEM	DESCRIPTION
1	Solenoid
2	Magnetic core
3	Keeper
4	Balls
5	Piston spring
6	Accumulator cylinder
7	Piston
8	One-way restrictor
9	Inlet/outlet port
10	Piston ATF volume
11	Keeper spring
12	Electrical connector

The Hydraulic Impulse Storage (HIS) system if fitted to vehicles with the auto stop/start system.

The HIS system comprises a cylindrical accumulator which contains an electro-mechanical locking unit, a spring actuated piston and a one-way restrictor. The accumulator is located at the rear of the Mechatronic valve block and is secured in position with three screws and sealed into a port in the transmission casing with an O-ring seal.

The electro-mechanical locking unit comprises a low-current solenoid, a spring loaded keeper incorporating a magnetic core and a number of balls. The keeper has a detent into which the balls locate during filling of the HIS when the engine is running and the Automatic Transmission Fluid (ATF) pump is producing pressure.

The one-way restrictor is located in the inlet/outlet port of the accumulator. The restrictor provides a controlled charging of the HIS, to allow a small volume flow of ATF. This ensures that the operation of the transmission shift elements are not compromised by a sudden drop in ATF pressure. The restrictor allows a charging time for the HIS of approximately 5 seconds. When discharge is required, the restrictor allows full flow from the cylinder.

The filling process for the HIS has several steps:

• When the engine is running and the ATF pump is producing pressure, the one-way restrictor allows a controlled flow of ATF which acts on the piston.
• The ATF pressure moves the piston into the accumulator cylinder. A locking ring on the piston passes over the balls which are at this point located in the keeper detent.
• As the piston continues to move, a spring in the center of the keeper moves the locking cylinder and the magnetic core towards the solenoid windings and into the final fully charged position. The energized solenoid holds the magnetic core and the balls are lifted from the detent by the movement of the keeper, locking the piston in the charged position. The HIS is now electro-mechanically locked and ready for an engine stop to occur.
• When the engine is stopped, the ATF pump also stops and ATF pressure is decayed. The pressure acting on the piston is also decayed and the piston moves to be held in the locked position by the balls. The energy required for hydraulic filling during engine start is now stored in the tensioned piston spring. The solenoid remains energized to hold the keeper in position and the balls out of the detent to lock the piston.

Charging

Charged

Engine start process:

• When the engine is restarted, the solenoid holding current is removed, which starts the unlocking process.
• The magnetic core is released and the keeper is moved towards the piston under spring pressure. The balls fall into the detent in the keeper, releasing the piston.
• The piston is moved under spring pressure, pushing out the volume of ATF. The one-way restrictor opens fully to allow unrestricted flow of ATF from the accumulator cylinder into the transmission housing. The process is completed between 300 and 350 ms.
• Once the engine is started, the ATF pump produces flow and pressure to provide seamless transmission shift element engagement as soon as the engine is started.

Discharging

DRIVE CLUTCHES

Multiplate Clutch or Brake – Typical

 

ITEM	DESCRIPTION
1	Input shaft
2	Main pressure supply port
3	Piston
4	Cylinder – external plate carrier
5	Clutch plate assembly
6	Baffle plate (for clutch, not brake)
7	Diaphragm spring
8	Output shaft
9	Bearing
10	Dynamic pressure equalization chamber
11	Piston chamber
12	Lubrication channel

There are three drive clutches and two brakes used in the transmission. Each clutch comprises a number of friction plates dependent on the output controlled. A typical clutch consists of a number of alternating steel plates and plates with friction material bonded to each face.

The clutch plates are held apart mechanically by a diaphragm spring and hydraulically by dynamic pressure. The pressure is derived from a lubrication channel which supplies fluid to the bearings and clutch cooling. The fluid is passed via a drilling in the input shaft into the chamber between the baffle plate and the piston. To prevent inadvertent clutch application due to pressure build up produced by centrifugal force, the fluid in the dynamic pressure equalization chamber overcomes any centrifugal pressure in the piston chamber and holds the piston off the clutch plate assembly.

When clutch application is required, main pressure from the Automatic Transmission Fluid (ATF) pump is applied to the piston chamber from the supply port. This main pressure overcomes the low pressure fluid present in the dynamic pressure equalization chamber. The piston moves, against the pressure applied by the diaphragm spring, and compresses the clutch plate assembly. When the main pressure falls, the diaphragm spring pushes the piston away from the clutch plate assembly, disengaging the clutch.

PLANETARY GEAR TRAINS

The eight forward gears and the reverse gear are produced by a combination of four simple planetary gear sets, three clutches and two brakes. The front two gear sets share a common sun gear. Power is output always through the planetary carrier of the fourth gearset.

Five shift elements comprising three clutches and two brakes, are responsible for all eight forward and reverse gears. High efficiency is achieved by the use of only two shift elements disengaged in each gear which reduces drag and so increases the efficiency.

 

Planetary Gear Sets 1, 2 and 3

The planetary gear sets 1 and 2 comprise:

• Sunwheel - shared by both gear sets
• Three or four planetary gears per gear set
  • NOTE: Ingenium I4 2.0L Diesel engine fitment has three planetary gears in gearset 2, all other engine variants have four planetary gears.
• Planetary gear carrier (spider) per gear set
• Ring gear per gear set.

The planetary gear set 3 comprises:

• Sunwheel
• Three planetary gears
• Planetary gear carrier (spider)
• Ring gear.

 

ITEM	DESCRIPTION
1	Planetary gears - gear set 1
2	Ring gear - gear set 1
3	Planetary gear carrier (spider)
4	Planetary gears - gear set 2
5	Ring gear - gear set 2
6	Planetary gears - gear set 3
7	Ring gear - gear set 3
8	Sun wheel - gear set 3
9	Sun wheel - joint gear sets 1 and 2

 

Planetary Gear Set 4

The planetary gear set 4 comprises:

• Sunwheel
• Four planetary gears
• Planetary gear carrier (spider) - output shaft
• Ring gear.

 

ITEM	DESCRIPTION
1	Ring gear
2	Planetary gears
3	Output shaft / gear carrier
4	Sun wheel

TRANSMISSION CONTROL MODULE

The Transmission Control Module (TCM) is an integral part of the Mechatronic valve block which is located at the bottom of the transmission, within the fluid pan. The TCM is the main controlling component of the transmission.

The TCM processes signals from the transmission speed and temperature sensors, Powertrain Control Module (PCM) and other vehicle systems. From the received signal inputs and pre-programmed data, the module calculates the correct gear, torque converter clutch setting and optimum pressure settings for gear shift and lock-up clutch control.

 

OPERATION

POWER FLOWS

Operation of the transmission is controlled by the Transmission Control Module (TCM), which electrically activates various solenoids to control the transmission gear selection. The sequence of solenoid activation is based on programmed information in the TCM memory and physical transmission operating conditions such as:

• Vehicle speed
• Throttle position
• Engine load
• Transmission Control Switch (TCS) position.

All gear shifts from 1st to 8th and 8th to 1st are known as 'overlap' shifts. Overlap shifts are during a gear shift one clutch must remain capable of transmitting torque at a reduced main pressure until the other clutch is ready to accept the torque.

Engine torque is transferred, via operation of single or combinations of clutches to the 4 planetary gear trains. All gear trains are controlled by reactionary inputs from brake clutches to produce the eight forward gears and one reverse gear. The ratios are as follows:

GEAR	1ST	2ND	3RD	4TH	5TH	6TH	7TH	8TH	REVERSE
Ratio	4.714	3.143	2.106	1.667	1.285	1.000	0.839	0.667	3.317

Shift Elements

 

ITEM	DESCRIPTION
1	Brake A
2	Brake B
3	Gear set 1
4	Gear set 2
5	Gear set 3
6	Clutch E
7	Clutch C
8	Clutch D
9	Gear set 4

The shift elements, clutches and brakes are actuated hydraulically. Fluid pressure is applied to the required clutch and/or brake, pressing the plates together and allowing drive to be transmitted through the plates. The purpose of the shift elements is to perform power-on shifts with no interruption to traction and smooth transition between gear ratios.

INSTRUMENT CLUSTER

The virtual display Instrument Cluster (IC) is connected to the Body Control Module/Gateway Module (BCM/GWM) on the High Speed (HS) Controller Area Network (CAN) comfort systems bus. The Transmission Control module (TCM) is connected to the BCM/GWM on the FlexRay systems bus.

Automatic transmission status is transmitted from the TCM to the virtual display IC via the BCM/GWM. Transmission status is indicated to the driver by a message in the message center or illumination of a warning indicator. For additional information, refer to:Instrument Cluster (413-01 Instrument Cluster, Description and Operation).

 

The Thin Film Transistor (TFT) display instrument cluster is connected to the TCM via the HS CAN powertrain systems, the BCM/GWM and the FlexRay systems bus. Transmission status is transmitted by the TCM and displayed to the driver in one of two displays in the instrument cluster. For additional information, refer to:Instrument Cluster (413-01 Instrument Cluster, Description and Operation).

 

Malfunction Indicator Lamp

 

The Malfunction Indicator Lamp (MIL) is located in the virtual display Instrument Cluster (IC). Transmission related faults which may affect the vehicle emissions will illuminate the MIL.

The MIL is illuminated by the Powertrain Control Module (PCM) on receipt of a relevant fault message from the Transmission Control Module (TCM) on the FlexRay system bus. The nature of the fault can be diagnosed using approved diagnostic equipment which reads the fault codes stored in the TCM memory.

 

Transmission Status Display

 

The transmission status display is located in the virtual display Instrument Cluster. The display shows the Transmission Control Switch (TCS) or the selected gear when in manual and sport modes.

The following table shows the displays and their descriptions.

SYMBOL	DESCRIPTION
P	Park selected
R	Reverse selected
N	Neutral selected
D*	Drive and temporary manual mode selected (* = current gear)
S*	Sport mode selected (* = current gear)
1	1st gear selected (manual CommandShift mode)
2	2nd gear selected (manual CommandShift mode)
3	3rd gear selected (manual CommandShift mode)
4	4th gear selected (manual CommandShift mode)
5	5th gear selected (manual CommandShift mode)
6	6th gear selected (manual CommandShift mode)
7	7th gear selected (manual CommandShift mode)
8	8th gear selected (manual CommandShift mode)

 

Message Center

 

The message center is located in the virtual display Instrument Cluster (IC). The message center display relays vehicle status and operating information to the driver and can display messages relating to a number of vehicle systems. If a transmission fault occurs, the message GEARBOX FAULT is displayed in the message center. For additional information, refer to:Instrument Cluster (413-01 Instrument Cluster, Description and Operation).

TRANSMISSION CONTROL MODULE

The Transmission Control Module (TCM) outputs signals to control the hydraulic operation of the transmission. Signals are sent to the shift control solenoid valves and the Electronic Pressure Regulating Valve's (EPRS).

The TCM processes signals from the transmission speed and temperature sensors, the Transmission Control Switch (TCS), the Powertrain Control Module (PCM) and other vehicle systems. From the received signal inputs and pre-programmed data, the TCM calculates the:

• Correct gear
• Torque converter clutch setting
• Optimum pressure settings for gear shift and lock-up clutch control.

The PCM supplies the engine management data over the FlexRay systems bus. The TCM requires engine data to efficiently control the transmission operation, for example:

• Flywheel torque
• Engine speed
• Accelerator pedal angle
• Engine temperature.

The steering angle sensor and the Anti-lock Brake System (ABS) control module also supply data to the TCM on the FlexRay systems bus. The TCM uses data from these systems to suspend gear changes when the vehicle is cornering and/or the ABS control module is controlling braking or traction control.

The Body Control Module/Gateway Module (BCM/GWM) supplies steering wheel paddle data over the FlexRay systems bus. The TCM uses this to schedule driver requested upshifts and downshifts.

Using the signal inputs and the memorized data, the TCM control program computes:

• the correct gear and torque converter lock-up clutch setting
• the optimum pressure settings for gear shift and lock-up clutch control.

Special output-side modules (power output stages, current regulator circuits), allow the TCM to control the solenoid valves and pressure regulators. This allows precise control the hydraulics of the automatic transmission. In addition, the amount and duration of engine interventions are supplied to the engine management via the FlexRay systems bus.

The TCM determines the position of the TCS using signals from the TCS via the High Speed (HS) Controller Area Network (CAN) systems bus.

The TCM transmits the position of the TCS and any manual gear selected on the FlexRay systems bus to the BCM/GWM. This information is shown in the gear selector display in the instrument cluster.

Engine Stall

If the engine stalls it will coast down in gear, with the transmission providing drive to the engine. A restart can be attempted at this point and the engine may start and the driver can continue.

If the coast down speed reduces such that the speed of the engine is less than 100 Revolutions Per Minute (RPM), the transmission will go to neutral, D illumination will flash in the instrument cluster. The driver needs to select neutral or park and then press the brake pedal to restart the engine.

If the start/stop switch is pressed when driving, the message ENGINE STOP BUTTON PRESSED is displayed in the message center but there will be no change to the ignition state. If the driver requires to switch off the engine, the start/stop switch must be pressed for a second time. The engine will be stopped and will be back driven by the transmission as the vehicle coasts down.

 

CONTROL DIAGRAM

 

A = HARDWIRED: AN = HIGH SPEED (HS) CONTROLLER AREA NETWORK (CAN) POWERTRAIN SYSTEMS BUS: AP = HS CAN COMFORT SYSTEMS BUS: AX = FLEXRAY SYSTEMS BUS.

ITEM	DESCRIPTION
1	Transmission Control Module (TCM)
2	Transmission Control Switch (TCS)
3	Powertrain Control Module (PCM)
4	Anti-lock Brake System (ABS) control module
5	Body Control Module/Gateway Module (BCM/GWM) assembly
6	Instrument Cluster (IC)
7	Mechatronic valve block
8	TCS
9	Ground
10	Permanent power supply from Engine Junction Box (EJB)
11	Power supply from ignition relay in EJB

 

Diagnosis and Testing

 

DIAGNOSTICS - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD (G2718648)

DIAGNOSIS AND TESTING

 

 

PRINCIPLE OF OPERATION

For a detailed description of the automatic transmission/transaxle system and operation, refer to the relevant Description and Operation sections in the workshop manual. REFER to:Transmission Description (307-01A Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Description and Operation).

 

FLUID LEVEL AND CONDITION CHECK

 

CAUTION:

The vehicle should not be driven if the fluid level is low as this can result in internal damage.

NOTE:

The transmission fluid temperature must not be allowed to exceed 50°C (122°F) when checking level. Should the temperature rise above this figure, abort the check and allow the transmission fluid to cool to below 30°C (86°F).

This vehicle is not equipped with a fluid level indicator. An incorrect level may affect the transmission operation and could result in transmission damage. To check and add fluid to the transmission, refer to the relevant section in the workshop manual. REFER to General Procedures - Transmission Fluid Level Check.

HIGH FLUID LEVEL

A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid from the breather and possible transmission damage. If an overfill condition is identified, with the engine at idle make sure the fluid temperature is within the specified range and allow the excess fluid to drain until a small thread of fluid runs from the filler/level plug hole.

LOW FLUID LEVEL

A low fluid level could result in poor transmission engagement, slipping, or damage. Refer to the oil leak detection process in this document to aid diagnosis.

ADDING FLUID

CAUTION:

The use of any other type of transmission fluid other than that specified can result in transmission damage.

If fluid needs to be added, follow the fill process shown in the relevant section in the workshop manual. REFER to General Procedures - Transmission Fluid Level Check.Do not overfill the fluid.

For fluid type, refer to the Specification section in the workshop manual.

FLUID CONDITION CHECK

1. Check the fluid level. Refer to the relevant section in the workshop manual. REFER to General Procedures - Transmission Fluid Level Check.

1. Observe the color and the odor of the fluid. The color under normal circumstances should be like honey, not dark brown or black.

1. Allow the fluid to drip onto a facial tissue and examine the stain.

1. If evidence of solid material is found, the transmission fluid pan should be removed for further inspection.

NOTE: In the event of a transmission unit replacement for internal failure, the oil cooler and pipes must also be replaced.

 

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 tested and/or the donor vehicle.

1. Verify the customer concern.

1. Visually inspect for obvious signs of damage and system integrity.

Visual Inspection

MECHANICAL	ELECTRICAL	HYDRAULIC
Damaged/stuck shift mechanism Damaged automatic transmission casing	Blown fuse(s) Damaged, loose or corroded connectors/pins Wiring harness	Fluid level too high/low Poor condition of fluid Fluid leak

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.

1. If the cause is not visually evident check for Diagnostic Trouble Code(s) (DTC)s and refer to the DTC Index.

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

 

VIBRATION FROM TRANSMISSION

Vibration from the transmission may be caused by the installation of incorrect front/rear drive units. Refer to Sections 205-02 and 205-03 for further guidance on how to diagnose and rectify this issue.

 

8-SPEED TRANSMISSION ISSUES - OIL LEAK DETECTION

Symptom Chart

SYMPTOM	POSSIBLE SOURCES	ACTION
Oil leak from underneath the vehicle or a leak is discovered during routine service	Oil leak	Follow the service instruction below

SERVICE INSTRUCTION

NOTE:

Be aware that oil leaks from above the transmission will cause oil to collect on the transmission oil pan for example engine leaks, oil cooler pipe leaks, even diesel fuel leak.

1. Remove the transmission undershield to gain access to the transmission area. REFER to Workshop Manual Section 501-02.

1. Using a suitable degreaser, thoroughly clean the transmission to make sure all oil contamination is removed. Refer to the Oil Leak Inspection section in this document. Make sure all relevant areas are free of oil, contamination before progressing. Make sure there is no residual oil left in bolt holes etc. If necessary, use an air blower to clear and dry the bolt holes on the sump pan.

Oil Leak Inspection

If there is an oil to leak between the automatic transmission and the transfer case, this may be due to internal porosity of the automatic transmission case.

 

Due to capillary action, oil residue may be found in the joint between the transmission case and the oil pan. The potential leak path is shown in the illustration below.

Other potential leak sources are the transmission oil cooler pipe unions. Visually inspect the areas shown in the illustration below.

NOTE:

The bracket securing the transmission oil pipes has been removed to provide extra clarity.

The potential leak path is shown in the illustration below.

NOTE:

Leak detector spray is available to order on the JLR Electronics Parts Catalogue.

1. Thoroughly coat the potential leak locations using a suitable leak detector spray, refer to the illustrations above.

1. Run the vehicle up to operating temperature, raise the ramp and use a suitable inspection lamp to identify the source of the transmission oil leak.

1. Identify the source of the oil leak and take clear, in focus pictures. These may be required to support your warranty claim.

1. When the source of the leak has been identified, refer to the relevant technical bulletin or refer to the relevant section of the workshop manual and repair as necessary. If the source of the leak is not shown in the illustrations above, report using an Electronic Product Quality Report (EPQR). Make sure to attach clear, in focus pictures showing the use of leak detection spray and the exact position of the leak.

 

FLASHING DRIVE (D) LAMP ON THE TRANSMISSION CONTROL SWITCH (TCS) AND/OR INSTRUMENT CLUSTER (IC) FOLLOWING AN AUTO STOP/START EVENT

Affected Vehicle Range

MODEL:	MODEL YEAR:	VEHICLE IDENTIFICATION NUMBER (VIN):	ASSEMBLY PLANT:	APPLICABILITY:
Range Rover Sport (LW)	2017-2018	124031-199999	Solihull	Vehicles With: 8HP70 8-Speed Automatic Transmission All Wheel Drive (AWD)/8HP45 8-Speed Automatic Transmission AWD
Range Rover Sport (LW)	2018	400000-411938	Solihull	Vehicles With: 8HP70 8-Speed Automatic Transmission AWD/8HP45 8-Speed Automatic Transmission AWD
Range Rover Sport (LW)	2017-2018	659468-699999	Solihull	Vehicles With: 8HP70 8-Speed Automatic Transmission AWD/8HP45 8-Speed Automatic Transmission AWD
Range Rover Sport (LW)	2017-2018	800000-806735	Solihull	Vehicles With: 8HP70 8-Speed Automatic Transmission AWD/8HP45 8-Speed Automatic Transmission AWD
Range Rover (LG)	2017-2018	320324-507907	Solihull	Vehicles With: 8HP70 8-Speed Automatic Transmission AWD/8HP45 8-Speed Automatic Transmission AWD
Range Rover Velar (LY)	2018	700000-776521	Solihull	Vehicles With: 8HP70 8-Speed Automatic Transmission AWD/8HP45 8-Speed Automatic Transmission AWD
Discovery (LR)	2017-2018	000001-073283	Solihull	Vehicles With: 8HP70 8-Speed Automatic Transmission AWD/8HP45 8-Speed Automatic Transmission AWD

 

CONDITION SUMMARY

Situation:

A customer may express a concern that the DRIVE (D) lamp will flash on the TCS and/or Instrument Cluster (IC) following an Auto stop/start event. DTCs P0715-64 and P0700-02 may be stored in the Transmission Control Module (TCM). Also, a 'Gearbox Fault' warning message may be displayed on the IC.

Cause:

Software error.

Action:

Should a customer express a concern, follow the diagnostic procedure below.

 

DIAGNOSTIC PROCEDURE

CAUTION:

This procedure requires Pathfinder version 188 loaded or a later version.

NOTE:

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

1. Connect the JLR approved battery support unit.

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

1. Follow the JLR approved diagnostic tool prompts.

1. Select 'ECU Diagnostics'.

1. Select 'All DTCs'.
   1. If the only DTCs stored within the Transmission Control Module (TCM) are P0715-64 and/or P0700-02, continue to step 7.
   2. Any DTCs stored within the TCM, other than P0715-64 and/or P0700-02 must be investigated and rectified, before continuing. Refer to TOPIx workshop manual section 100-00: DTC Index Transmission Control Module (TCM).

1. Select 'Clear all DTCs'.

1. Select 'ECU Diagnostics'.
   1. Select 'Transmission Control Module [TCM]'.
   2. Select 'Update ECU'.
   3. Follow all on-screen instructions to complete the task.

1. If required, reset the vehicle to ‘Transportation mode’.

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.

 

DTC INDEX

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 - DTC: Transmission Control Module (TCM) (100-00 General Information, Description and Operation

AUTOMATIC TRANSMISSION/TRANSAXLE - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

TRANSMISSION OIL COLOR CHART (G2721476)

DIAGNOSIS AND TESTING

 

 

TRANSMISSION OIL COLOR CHART

Transmission Oil Color Chart

8HP / 9HP TRANSMISSION	OK	OK
Oil Inspection Guide	New / Used Oil	New / Used Oil
When assessing oil quality DO NOT use LED work lights. DO NOT use the camera flash when taking photos. LED lights and camera flashes make the oil appear darker than it is, causing an incorrect assessment of the oil condition. Drain a small sample of oil into a clean container, approximately 50 ml (Note: Do not use an old water bottle as this may falsely show water contamination).	ZF 8 and 9 speed transmissions use synthetic transmission oils. These oils discolor and darken with age. New oil is green and turns dark brown as it ages. Discoloration occurs sooner if the transmission operating temperature is higher.	ZF 8 and 9 speed transmissions use synthetic transmission oils. These oils discolor and darken with age. New oil is green and turns dark brown as it ages. Discoloration occurs sooner if the transmission operating temperature is higher.
Visual Inspection - To correctly assess oil color, take the oil sample and pour it over a clean white piece of card. (Take a photo without using the flash) Do not use a white cloth or paper towel as this absorbs the oil.	When viewed over a clean white piece of card the oil should appear green or brown in color and the card should be visible through the oil.	When viewed over a clean white piece of card the oil should appear green or brown in color and the card should be visible through the oil.
Particles in Oil	The presence of small particles in the oil sample or sump of the transmission is not an indication of excessive wear or transmission failure. Particles are generated through the bedding in process and normal wear and tear. Over the life of the transmission these accumulate in the sump and on the magnets.	Sump magnet with a normal build-up of ferrous material.
Oil Smell	New oil has a strong sulphur like smell. Used oil: As the oil ages the smell changes. After approximately 10,000 km the oil develops a sweet smell.	New oil has a strong sulphur like smell. Used oil: As the oil ages the smell changes. After approximately 10,000 km the oil develops a sweet smell.
Action	Do not change the transmission.	Do not change the transmission.

Transmission Oil Color Chart

8HP / 9HP TRANSMISSION	NOK	NOK
Oil Inspection Guide	Burnt Oil	Emulsified Oil
When assessing oil quality DO NOT use LED work lights. DO NOT use the camera flash when taking photos. LED lights and camera flashes make the oil appear darker than it is, causing an incorrect assessment of the oil condition. Drain a small sample of oil into a clean container, approximately 50 ml (Note: Do not use an old water bottle as this may falsely show water contamination).
Visual Inspection - To correctly asses oil color, take the oil sample and pour it over a clean white piece of card. (Take a photo without using the flash) Do not use a white cloth or paper towel as this absorbs the oil.	If the oil appears black in color or the card is not visible the oil may be burnt or contaminated.	Emulsification: Using natural light assess the appearance of the oil. Does it appear milky or cloudy? Emulsified oil caused by water/antifreeze contamination.
Particles in Oil	The presence of small particles in the oil sample or sump of the transmission is not an indication of excessive wear or transmission failure. Particles are generated through the bedding in process and normal wear and tear. Over the life of the transmission these accumulate in the sump and on the magnets.	If suspected large shards of metal are found in the oil, or attached to a magnet, raise a Technical Assistance (TA) with supporting images.
Oil Smell	Burnt oil: When the oil is overheated or there is damage to the clutch plates the oil develops a strong burnt smell. This smells like burnt clutch or brake material.	Should be normal like used oil.
Action	Raise a TA with supporting images.	Raise a TA with supporting images.

 

Repairs

AUTOMATIC TRANSMISSION/TRANSAXLE - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

TRANSMISSION - TDV6 3.0L DIESEL (G2356698)

 

PART(S)

ALL VEHICLES

 

Name	Quantity	Part Number
Driveshaft flange bolts 1, 2	4	TYG500130
Driveshaft flange bolts 1, 2	6	TYG500141
EGR inlet pipe to exhaust gasket	1	LR078958
Engine compartment brace bolts	8	LR037935
Left exhaust downpipe gasket	1	LR016619
Right exhaust downpipe gasket	1	LR016621
Torque converter bolts	4	LR038661
Transfer case input shaft oil seal	1	LR086041
Transmission fluid cooler tubes to transmission O-ring seals	2	LR049457

VIN SPECIFIC

 

Name	Quantity	Part Number	VIN range from	VIN range to
Transmission	1	LR082672	HA000001
Transmission	1	LR082675	HA000001
Transmission	1	LR043325
Transmission	1	LR071402	GA000001	GA999999
Transmission	1	LR075290	GA000001	GA999999
Transmission	1	LR087234	HA000001
Transmission	1	LR062465	FA000001	FA999999
Transmission	1	LR036585		FA999999
Transmission	1	LR078391	GA000001

VIN SPECIFIC - REMANUFACTURED

 

Name	Quantity	Part Number	VIN range from	VIN range to
Transmission	1	LR044435
Transmission	1	LR062464	FA000001	FA999999
Transmission	1	LR036588		FA999999

 

SPECIAL TOOL(S)

ALL VEHICLES

 

Adapter, Wrench 303-1069
Cutter, Exhaust Pipe 1, 2 100-051
Installer, Oil Seal 308-598
Post Selective Catalyst Reduction Soot Sensor - Remover/Installer JLR-303-1646
Remover, Driveshaft 205-932
Remover/Installer, Driveshaft Nut JLR-205-993
Remover/Installer, NOx/Oxygen Sensor JLR-303-1666
Viscous Coupling Wrench 303-1142
Wrench, H02S 310-121
Wrench, Transmission Filler Plug 307-452

REPAIR

 

 

Transmission - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Vehicles With: Twin Speed Transfer Case (307-01A INSTALLATION G1509720)

 

PUBLISHED: 20-APR-2020

2017.0 RANGE ROVER SPORT (LW), 307-01A

AUTOMATIC TRANSMISSION/TRANSAXLE - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

TRANSMISSION - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2, VEHICLES WITH: TWIN SPEED TRANSFER CASE (G1509720)

INSTALLATION

 

• 44.20.01
• AUTOMATIC TRANSMISSION - RENEW
• 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
• 6.10
• USED WITHINS

 

INSTALLATION

SPECIAL TOOL(S)

 

303-1069

Adapter, Wrench

 

 

308-598

Installer, Oil Seal

PART(S)

STEP	PART NAME	QUANTITY
Step 4	Transfer case input shaft oil seal	1
Step 16	Torque converter bolts	4
Step 24	Transmission fluid cooler tubes to transmission O-ring seals	2
Step 37	Rear driveshaft constant velocity joint bolts	6
Step 38	Driveshaft flange bolts	4

NOTES:

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

• Some illustrations may show the transmission removed for clarity.

 

1. NOTE:

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

   
   Remove the torque converter retainer.

 

1. NOTE:

   Make sure that the torque converter is fully engaged to the transmission.

   

 

1. CAUTION:

   Oil seals must be installed dry.

   NOTES:

   • This step is only required if previously removed.

   • Make sure that this component is installed to the noted removal position.

   
   Special Tool(s): 308-598

 

1. NOTE:

   This step is only required if previously removed.

   
   Install a new O-ring seal.
   Renew Part: Transfer case input shaft oil seal Quantity: 1.

 

1. NOTE:

   This step is only required if previously removed.

   
   • Special Tool(s): 303-1069
   • Clean the component mating faces.
   • Lubricate input shaft splines with 'Weicon TL7391' grease.
   • Torque: 45Nm

 

1. CAUTIONS:

   • To prevent water ingress and subsequent transmission damage, make sure that the breather is fully pushed home into the transmission casing. The white line around the circumference of the pipe should not be visible when correctly installed.

   • Remove the blanking plugs.

   NOTE:

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

   

 

1. 

 

1. 
   Torque: 9Nm

 

1. 

 

1. NOTE:

   This step is only required if previously removed.

   
   Torque

   M8: 25Nm

   M6: 10Nm

 

1. NOTE:

   This step is only required if previously removed.

   
   Torque: 10Nm

 

1. WARNING:

   Make sure that the transmission is secured with suitable retaining straps.

   CAUTIONS:

   • Apply grease of the correct specification to the torque converter spigot.

   • Make sure that the torque converter remains in the transmission.

   • Remove and discard the cable ties securing the torque converter.

   NOTE:

   This step requires the aid of other technicians.

   
   Using a suitable hydraulic jack, support the transmission.

 

1. 
   Torque: 40Nm

 

1. 
   Torque: 40Nm

 

1. 

 

1. CAUTION:

   Only rotate the crankshaft clockwise.

   
   Install and tighten 4 new bolts.
   Renew Part: Torque converter bolts Quantity: 4.
   Torque: 63Nm

 

1. 

 

1. 
   Torque: 45Nm

 

1. 
   Torque: 30Nm

 

1. 
   Torque

   M8: 10Nm

   M6: 7Nm

 

1. 

 

1. 

 

1. 
   Torque: 10Nm

 

1. CAUTION:

   Be prepared to collect escaping fluids.

   NOTE:

   Install new O-ring seals.

   
   Renew Part: Transmission fluid cooler tubes to transmission O-ring seals Quantity: 2.
   Torque: 22Nm

 

1. 
   Torque: 25Nm

 

1. NOTE:

   Vehicles with Diesel Particulate Filter (DPF) installed only.

   
   Torque: 25Nm

 

1. NOTE:

   Vehicles without DPF.

   
   Torque: 25Nm

 

1. 
   Torque: 60Nm

 

1. 
   • Torque: 10Nm

 

1. 

 

1. 
   Torque: 9Nm

 

1. 
   Torque: 23Nm

 

1. 
   Torque: 23Nm

 

1. 
   Torque: 23Nm

 

1. 

 

1. CAUTION:

   Only tighten the bolts finger-tight at this stage.

   

 

1. 
   Install new driveshaft bolts.
   Renew Part: Rear driveshaft constant velocity joint bolts Quantity: 6.
   Torque: 73Nm

 

1. NOTE:

   Make sure that the component is installed to the noted removal position.

   
   Install new flange bolts.
   Renew Part: Driveshaft flange bolts Quantity: 4.
   Torque: 150Nm

 

1. 
   Torque: 48Nm

 

1. 
   Torque: 5Nm

 

1. 
   Torque: 5Nm

 

1. Refer to:Front Driveshaft - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (205-01 Driveshaft, Removal and Installation).

 

1. Refer to:Exhaust System - Vehicles Without: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
   Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
   Refer to:Exhaust System - Vehicles With: Diesel Exhaust Fluid (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).

 

1. 
   Remove the jack supporting the transmission.

 

1. Lower the vehicle.

 

1. 
   Torque: 12Nm

 

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. Connect the battery ground cable.
   Refer to:Specifications (414-01 Battery, Mounting and Cables, Specifications).

 

1. Check the transmission fluid leve.
   Refer to:Transmission Fluid Level Check - TDV6 3.0L Diesel /TDV8 4.4L Diesel (307-01A Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, General Procedures).

 

1. • NOTE:

     Vehicles to the end of 17MY.

     If a new Transmission Assembly is installed. The Jaguar Land Rover approved diagnostic equipment must be used to calibrate the module.
   • NOTE:

     Vehicles from introduction of 18MY.

     If a new Transmission Assembly is installed. The Jaguar Land Rover approved diagnostic equipment must be used to calibrate the module.
   • Select 'Transmission Control Module [TCM]'
   • Select 'Replace ECU'
   • Follow all on-screen instructions to complete this task.

General Procedures

AUTOMATIC TRANSMISSION/TRANSAXLE - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

TRANSMISSION FLUID LEVEL CHECK - TDV6 3.0L DIESEL /TDV8 4.4L DIESEL (G1535465)

GENERAL PROCEDURES

 

• 44.24.06
• TRANSMISSION FLUID LEVEL CHECK
• 3000 CC, TDV6
• 0.70
• USED WITHINS

SPECIAL TOOL(S)

 

307-452

Wrench, Transmission Filler Plug

 

CHECK

 

WARNINGS:

• Observe due care when draining, as the fluid can be very hot.

• Observe due care when working near a hot exhaust system.

 

1. • The following steps must be observed before starting the transmission fluid level check.
   • The vehicle must be on a horizontal ramp.
   • Make sure that the electric park brake (EPB) is applied.
   • Make sure the transmission control switch (TCS) is in the Park (P) position.

 

1. CAUTION:

   Using Land Rover approved diagnostic equipment, make sure the transmission temperature is between is 30°C (85°F) and 50°C (122°F) before starting the fluid level check.

   • Connect Land Rover approved diagnostic equipment to the vehicle.
   • Start the engine and allow to idle.
   • Switch off the air conditioning (A/C) system and other electrical components.

 

1. • Make sure that the transmission is not in the default mode, if this is the case, stop and correct the cause first and then restart the fluid level check.

 

1. CAUTION:

   Make sure the hydraulic control system is filled with oil.

   • Apply and hold the brake pedal.
   • Select reverse gear and wait for 10 seconds.
   • Select drive, then manual 1st gear and wait for 10 seconds.
   • Select 2nd gear and wait for 10 seconds.
   • Select Park (P) on the TCS.

 

1. NOTE:

   Make sure the torque converter is completely filled with oil.

   • Raise the engine speed to 2000 rpm and hold for 30 seconds. Then return to idle speed.

 

1. NOTE:

   After completing the preparation, proceed to the actual transmission fluid level check.

   • If the transmission oil temperature is lower than 30°C (86°F). Allow the transmission to warm up above 30°C (86°F) with the engine idling in the P position, then proceed with the transmission fluid level check.
   • If the transmission oil temperature is above 50°C (122°F), switch off the engine and allow the transmission to cool down, then restart the fluid level check.

 

1. CAUTION:

   Only continue with the fluid level check if the transmission temperature is between 30°C (86°F) 50°C (122°F).

   • Start the engine, if not already idling.
   • Maintain the engine idle speed.

 

1. WARNING:

   Make sure to support the vehicle with axle stands.

   Raise and support the vehicle.

 

1. 
    Vehicles with 4.4L diesel engine

 

1. 
    Vehicles with 3.0L diesel engine.

 

1. 

 

1. 
   • Remove the oil filler plug, do not discard.
   • If fluid flows out, proceed to step 14.
   • If fluid does not flow out, proceed to step 13

 

1. CAUTION:

   Make sure the correct specification and quantity of oil is used.

   NOTE:

   Use transmission fluid meeting Land Rover specification.

   
   • Fill oil through the overflow hole until the level inside is high enough that oil starts to trickle back out of the same hole.
     Refer to:Specifications (307-01A Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Specifications).

 

1. 
   • Allow the transmission fluid to drain from the oil filler hole until the flow almost stops to a trickle.

 

1. NOTE:

   Install the original oil filler plug.

   
   • Using the special tool, install the original oil filler plug.
   • Special Tool(s): 307-452

 

1. CAUTION:

   Make sure the transmission fluid fill plug is tightened to the correct specification. Failure to follow this instruction may result in damage to the transmission.

   
   • To make sure the transmission fill plug is torqued to the correct specification. Using the special tool and torque wrench the following calculation steps must be followed.
   • Step 1. Multiply 35 Nm by the effective length of the torque wrench (1).
   • Step 2. Add the effective length of the special tool (2) to the effective length of the torque wrench (1).
   • Step 3. Divide the total of step 1 by the total of step 2.
   • Step 4. Set the torque wrench to the figure arrived at in step 3.
   • Tighten the transmission fluid fill plug to the torque given by the calculation.

 

1. • Remove the special tool.
   • Special Tool(s): 307-452

 

1. CAUTION:

   Clean the area around the filler plug, wipe away any excess fluid.

   Remove the container.

 

1. 
   Torque: 9Nm

 

1. 
   • Vehicles with 3.0L diesel engine
     Torque

     M10: 60Nm

     M6: 10Nm

 

1. 
    Vehicles with 4.4L diesel engine
   Torque: 60Nm

 

1. Lower the vehicle.

 

1. Disconnect the diagnostic tool.

AUTOMATIC TRANSMISSION/TRANSAXLE - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

TRANSMISSION FLUID LEVEL CHECK (G1962079)

GENERAL PROCEDURES

 

• 44.24.06
• TRANSMISSION FLUID LEVEL CHECK
• 3000 CC, TDV6
• 0.70
• USED WITHINS

SPECIAL TOOL(S)

 

307-452

Wrench, Transmission Filler Plug

 

CHECK

WARNINGS:

• Observe due care when draining, as the fluid can be very hot.

• Observe due care when working near a hot exhaust system.

 

1. The following steps must be observed before starting the transmission fluid level check.

 

1. CAUTION:

   Using Land Rover approved diagnostic equipment, make sure the transmission temperature is between is 30°C (85°F) and 50°C (122°F) before starting the fluid level check.

   • Connect Land Rover approved diagnostic equipment to vehicle.
   • Start the engine and allow to idle.
   • Switch off the air conditioning (A/C) system and other electrical components.

 

1. • Make sure that the transmission is not in the default mode, if this is the case, stop and correct the cause first and then restart the fluid level check.

 

1. CAUTION:

   Make sure the hydraulic control system is filled with oil.

   • Apply and hold the brake pedal.
   • Select reverse gear and wait for 10 seconds.
   • Select drive, then manual 1st gear and wait for 10 seconds.
   • Select 2nd gear and wait for 10 seconds.
   • Select Park (P) on the TCS.

 

1. NOTE:

   Make sure the torque converter is completely filled with oil.

   • Raise the engine speed to 2000 rpm and hold for 30 seconds. Then return to idle speed.

 

1. NOTE:

   After completing the preparation, proceed to the actual transmission fluid level check.

   • If the transmission oil temperature is lower than 30°C (86°F). Allow the transmission to warm up above 30°C (86°F) with the engine idling in the P position, then proceed with the transmission fluid level check.
   • If the transmission oil temperature is above 50°C (122°F), switch off the engine and allow the transmission to cool down, then restart the fluid level check.

 

1. CAUTION:

   Only continue with the fluid level check if the transmission temperature is between 30°C (86°C) 50°C (122°).

   • Start the engine, if not already idling.
   • Maintain the engine idle speed.

 

1. WARNING:

   Make sure to support the vehicle with axle stands.

   Raise and support the vehicle.

 

1. NOTE:

   This step requires the aid of another technician.

   

 

1. 
   • Remove the oil filler plug, do not discard.
   • If fluid flows out, proceed to step 13.
   • If fluid does not flow out, proceed to step 12

 

1. 
   • Fill oil through the overflow hole until the level inside is high enough that oil starts to trickle back out of the same hole.

 

1. 
   • Allow the transmission fluid to drain from the oil filler hole until the flow almost stops to a trickle.

 

1. NOTE:

   Install the original oil filler plug.

   
   • Using the special tool, install the original oil filler plug.
   • Special Tool(s): 307-452

 

1. CAUTION:

   Make sure the transmission fluid fill plug is tightened to the correct specification. Failure to follow this instruction may result in damage to the transmission.

   
   • To make sure the transmission fill plug is torqued to the correct specification. Using the special tool and torque wrench the following calculation steps must be followed.
   • Step 1. Multiply 35 Nm by the effective length of the torque wrench (1).
   • Step 2. Add the effective length of the special tool (2) to the effective length of the torque wrench (1).
   • Step 3. Divide the total of step 1 by the total of step 2.
   • Step 4. Set the torque wrench to the figure arrived at in step 3.
   • Tighten the transmission fluid fill plug to the torque given by the calculation.

 

1. • Remove the special tool.
   • Special Tool(s): 307-452

 

1. CAUTION:

   Clean the area around the filler plug, wipe away any excess fluid.

   Remove the container.

 

1. 
   • Torque: 60Nm
   • Torque: 10Nm

 

1. Lower the vehicle.

 

1. Disconnect the diagnostic tool.

AUTOMATIC TRANSMISSION/TRANSAXLE - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

TRANSMISSION FLUID DRAIN AND REFILL - TDV6 3.0L DIESEL /TDV8 4.4L DIESEL (G1535466)

GENERAL PROCEDURES

 

• 44.24.02
• TRANSMISSION FLUID DRAIN AND REFILL
• 3000 CC, TDV6
• 0.60
• USED WITHINS

SPECIAL TOOL(S)

 

307-452

Wrench, Transmission Filler Plug

PART(S)

STEP	PART NAME	QUALIFICATION	QUANTITY
Step 8	Transmission plug service kit	All vehicles	1

 

DRAINING

 

WARNINGS:

• Observe due care when draining, as the fluid can be very hot.

• Observe due care when working near a hot exhaust system.

 

 

The following step(s) applies to:

All vehicles

 

 

1. NOTE:

   The following steps must be observed before starting the transmission drain and refill.

   • Make sure that the electric park brake (EPB) is applied.
   • The vehicle must be on a horizontal ramp.
   • Make sure the transmission control switch (TCS) is in the Park (P) position.
   • Do not start the engine.

 

1. WARNING:

   Make sure to support the vehicle with axle stands.

   Raise and support the vehicle.

 

 

The following step(s) applies to:

Vehicles with 4.4L diesel engine

 

 

1. 

 

 

The following step(s) applies to:

Vehicles with 3.0L diesel engine

 

 

1. 

 

 

The following step(s) applies to:

All vehicles

 

 

1. 

 

1. Place a container under the transmission.

 

1. NOTE:

   Discard the transmission fluid drain plug.

   
   • Allow the fluid to drain in to a container.

 

1. NOTE:

   Install a new transmission drain plug.

   
   Renew Part: Transmission plug service kit Quantity: 1.
   Torque: 8Nm

 

1. NOTE:

   Remove the oil filler plug, do not discard.

   
   Clean the area around the transmission fluid level plug, to prevent foreign material entering the transmission.
   Special Tool(s): 307-452

 

1. 
   • Fill the transmission with the correct specification of fluid. Fill oil through the overflow hole until the level inside is high enough that oil flows back out of the same hole.
     Refer to:Specifications (307-01A Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Specifications).
   • Install the fluid level plug finger tight at this stage.
   • Remove the container from under the transmission to avoid damage.

 

1. • Lower the vehicle.
   • Start the engine, and allow to idle.

 

1. 
   • Raise the vehicle.
   • Place the container under the transmission to catch the overflow oil.
   • Remove the transmission fluid level plug.
   • Fill oil through the overflow hole until the level inside is high enough that oil starts to flow back out of the same hole.

 

1. Raise the engine speed to 2000 rpm and hold for 30 seconds. Then return to idle speed.

 

1. Fill oil through the overflow hole until the level inside is high enough that oil starts to flow back out of the same hole.

 

1. NOTE:

   Vehicles without thermostat

   
   Install the oil filler plug finger tight and proceed to Step 18.
   Special Tool(s): 307-452

 

1. NOTE:

   Vehicles with thermostat.

   
   Install the oil filler plug and proceed to Step 17.
   Special Tool(s): 307-452
   Torque: 20Nm

 

1. • Carry out a road test to open the thermostat and allow the transmission fluid to fill the transmission cooling system.
   • Proceed to the next step.

 

1. NOTE:

   The following steps must be observed before starting the transmission fluid level check.

   • Make sure that the EPB is applied.
   • The vehicle must be on a horizontal ramp.
   • Make sure the TCS is in the P position.

 

1. CAUTION:

   Using Land Rover approved diagnostic equipment, make sure the transmission temperature is between is 30°C (85°F) and 50°C (122°F) before starting the fluid level check.

   • Connect Land Rover approved diagnostic equipment to the vehicle.
   • Start the engine and allow to idle.
   • Switch off the air conditioning (A/C) system and other electrical components.

 

1. • Make sure that the transmission is not in the default mode, if this is the case, stop and correct the cause first and then restart the fluid level check.

 

1. • Apply and hold the brake pedal.
   • Select reverse gear and wait for 10 seconds.
   • Select drive, then manual 1st gear and wait for 10 seconds.
   • Select 2nd gear and wait for 10 seconds.
   • Select P on the TCS.

 

1. Raise the engine speed to 2000 rpm and hold for 30 seconds. Then return to idle speed.

 

1. NOTE:

   After completing the preparation, proceed to the transmission fluid level check.

   • If the transmission oil temperature is lower than 30°C (86°F). Allow the transmission to warm up above 30°C (86°F) with the engine idling in the P position, then proceed with the transmission fluid level check.
   • If the transmission oil temperature is above 50°C (122°F), switch off the engine and allow the transmission to cool down, then restart the fluid level check.

 

1. CAUTION:

   Only continue with the fluid level check if the transmission temperature is between 30°C (86°C) 50°C (122°).

   • Start the engine, if not already idling.
   • Maintain the engine idle speed.

 

1. • Raise the vehicle.

 

1. 
   • Remove the oil filler plug, do not discard.
   • If fluid flows out, proceed to Step 28.
   • If fluid does not flow out, proceed to Step 27.
   • Special Tool(s): 307-452

 

1. CAUTION:

   Use transmission fluid meeting Land Rover specification.

   
   Fill oil through the overflow hole until the level inside is high enough that oil starts to flow back out of the same hole.
   Refer to:Specifications (307-01A Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Specifications).

 

1. 
   Allow the transmission fluid to drain from the oil filler hole until the flow has almost stopped.

 

1. 
   Using the special tool, install the original oil filler plug.
   Special Tool(s): 307-452

 

1. CAUTION:

   Make sure the transmission fluid fill plug is tightened to the correct specification. Failure to follow this instruction may result in damage to the transmission.

   
   • To make sure the transmission fill plug is tightened to the correct specification. Using the special tool and torque wrench the following calculation steps must be followed.
   • Step 1. Multiply 35 Nm by the effective length of the torque wrench (1).
   • Step 2. Add the effective length of the special tool (2) to the effective length of the torque wrench (1).
   • Step 3. Divide the total of step 1 by the total of step 2.
   • Step 4. Set the torque wrench to the figure arrived at in step 3.
   • Tighten the transmission fluid fill plug to the torque given by the calculation.

 

1. CAUTION:

   Clean the area around the filler plug, wipe away any excess fluid.

   Remove the container.

 

1. 
   Torque: 9Nm

 

 

The following step(s) applies to:

Vehicles with 4.4L diesel engine

 

 

1. 
   Torque: 60Nm

 

 

The following step(s) applies to:

Vehicles with 3.0L diesel engine

 

 

1. 
   Torque

   M10: 60Nm

   M6: 10Nm

 

 

The following step(s) applies to:

All vehicles

 

 

1. Lower the vehicle.

 

1. Disconnect the diagnostic tool.

AUTOMATIC TRANSMISSION/TRANSAXLE - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

TRANSMISSION FLUID DRAIN AND REFILL (G1961670)

GENERAL PROCEDURES

 

• 44.24.02
• TRANSMISSION FLUID DRAIN AND REFILL
• 3000 CC, TDV6
• 0.60
• USED WITHINS

SPECIAL TOOL(S)

 

307-452

Wrench, Transmission Filler Plug

WARNINGS:

• Observe due care when draining, as the fluid can be very hot.

• Observe due care when working near a hot exhaust system.

NOTE:

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

 

1. The following steps must be observed before starting the transmission drain and refill.

 

1. WARNING:

   Make sure to support the vehicle with axle stands.

   Raise and support the vehicle.

 

1. 

 

1. Place a container under the transmission.

 

1. WARNING:

   Discard the transmission fluid drain plug.

   
   • Allow the fluid to drain in to a container.

 

1. NOTE:

   Install a new transmission drain plug

   
   Torque: 8Nm

 

1. NOTE:

   Remove the oil filler plug, do not discard.

   
   • Clean the area around the transmission fluid level plug.
   • Special Tool(s): 307-452

 

1. CAUTION:

   Make sure the correct specification and quantity of oil is used.

   NOTE:

   Use transmission fluid meeting Land Rover specification.

   
   • Fill the transmission with the correct specification of fluid. Fill oil through the overflow hole until the level inside is high enough that oil trickles back out of the same hole.
   • Install the fluid level plug, only finger tight at this stage.
   • Remove the container from under the transmission to avoid damage.

 

1. NOTE:

   The following steps require the aid of another technician, due to controlling the engine speed while the visual check is carried out.

   • Lower the vehicle.
   • Start the engine, and allow to idle.

 

1. 
   • Raise the vehicle.
   • Place the container under the transmission to catch the overflow oil.
   • Remove the transmission fluid level plug.
   • Fill oil through the overflow hole until the level inside is high enough that oil starts to trickle back out of the same hole.

 

1. • Increase the engine idle speed to 2000 rpm for 30 seconds, this is to fill the torque converter.
   • Allow the engine to return to idle speed.

 

1. Fill oil through the overflow hole until the level inside is high enough that oil starts to trickle back out of the same hole.

 

1. NOTES:

   • Vehicle without thermostat.

   • Vehicles with thermostat.

   
   • Install the filler plug finger tight and proceed to the transmission fluid check.
   • Install the oil filler plug temporarily and follow Step 15.
   • Special Tool(s): 307-452
   • Torque: 20Nm

 

1. NOTE:

   Vehicles with thermostat.

   • Carry out a road test to open the thermostat and allow the transmission fluid to fill the transmission cooling system.
   • Using Land Rover approved diagnostic equipment, make sure the transmission fluid temperature does not go above the level where the thermostat opens 69°C (156°F).

 

1. NOTE:

   This step is required to complete the procedure.

   Carry out a transmission fluid level check.
   Refer to:Transmission Fluid Level Check (307-01A Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, General Procedures).

Removal and Installation

 

AUTOMATIC TRANSMISSION/TRANSAXLE - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

INPUT SHAFT SEAL (G1961649)

REMOVAL AND INSTALLATION

 

• 44.20.17
• OIL SEAL - INPUT SHAFT - RENEW
• 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
• 5.70
• USED WITHINS

 

SPECIAL TOOL(S)

 

100-012

Slide Hammer

 

 

100-012-01

Slide Hammer Adapter

 

 

307-613

Holding Pins, Torque Converter

 

 

308-375

Remover, Input and Output Seal

 

 

JLR-308-845

Installer, Input Shaft Seal

PART(S)

STEP	PART NAME	QUANTITY
Installation Step 1	Torque converter seal kit	1

 

REMOVAL

 

1. Refer to:Transmission - INGENIUM I4 2.0L Diesel (307-01A Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Removal).

 

1. CAUTION:

   Be prepared to collect escaping fluids.

   
   Special Tool(s): 307-613

 

1. CAUTIONS:

   • Discard the seal.

   • Care must be taken to avoid damage to the seal register and running surface.

   
   Special Tool(s): 100-012, 100-012-01, 308-375

 

INSTALLATION

 

1. CAUTION:

   Install a new seal.

   
   Special Tool(s): JLR-308-845
   Renew Part: Torque converter seal kit Quantity: 1.

 

1. CAUTION:

   Make sure the torque converter is fully located into the oil pump drive.

   

 

1. Install the transmission and transfer gearbox.
   Refer to:Transmission - INGENIUM I4 2.0L Diesel (307-01A Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Removal).

 

1. 
   Carry out a transmission fluid level check.
   Refer to:Transmission Fluid Level Check (307-01A Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, General Procedures).

AUTOMATIC TRANSMISSION/TRANSAXLE - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

EXTENSION HOUSING SEAL (G1961650)

REMOVAL AND INSTALLATION

 

• 44.20.21
• OIL SEAL - OUTPUT SHAFT - RENEW
• 3000 CC, TDV6, DIESEL, SINGLE SPEED TRANSFER CASE, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST
• 2.10
• USED WITHINS

• 44.20.21
• OIL SEAL - OUTPUT SHAFT - RENEW
• 3000 CC, TDV6, DIESEL, TWIN SPEED TRANSFER CASE, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FL
• 2.10
• USED WITHINS

 

SPECIAL TOOL(S)

 

100-012

Slide Hammer

 

 

100-012-01

Slide Hammer Adapter

 

 

307-520

Installer, Output Shaft Seal

 

 

308-375

Remover, Input and Output Seal

 

 

JLR-307-520-01

Adapter, Output Shaft Seal

 

REMOVAL

NOTE:

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

 

1. Refer to:Transmission - INGENIUM I4 2.0L Diesel (307-01A Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Removal).

 

1. CAUTION:

   Care must be taken to avoid damage to the seal register and running surface.

   
   Special Tool(s): 100-012, 100-012-01, 308-375

 

INSTALLATION

 

1. CAUTIONS:

   • Oil seals must be installed dry.

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

   
   Special Tool(s): 307-520, JLR-307-520-01

 

1. Refer to:Transmission - INGENIUM I4 2.0L Diesel (307-01A Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Removal).

 

1. Complete a transmission fluid level check.
   Refer to:Transmission Fluid Level Check (307-01A Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, General Procedures).

AUTOMATIC TRANSMISSION/TRANSAXLE - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

SELECTOR SHAFT SEAL (G1509713)

REMOVAL AND INSTALLATION

 

• 44.15.31
• OIL SEAL - SELECTOR SHAFT - LH - RENEW
• 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
• 2.60
• USED WITHINS

SPECIAL TOOL(S)

 

307-509-1(LRT-44-033/1)

Seal extractor

 

307-509-2(LRT-44-033/2)

Seal extractor

 

307-509-3(LRT-44-033/3)

Seal installer

 

REMOVAL

 

1. WARNING:

   Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

   Raise and support the vehicle.

 

1. 
    TORQUE: 12 Nm

 

1. Release the selector cable and lever.
   • Remove the nut.

 

1. CAUTION:

   Before the disconnection or removal of any components, make sure the area around joint faces and connections are clean. Plug any open connections to prevent contamination.

   
   Remove the selector shaft seal.
   • Install 307-509-1 to the seal.
   • Install 307-509-2 to 307-509-1 and extract the seal.

 

INSTALLATION

 

1. 
   Using 307-509-3, install the selector shaft seal.
   • Clean the components.

 

1. • Secure with the clip.
   • TORQUE: 12 Nm
     
     Install the selector cable and lever.

   AUTOMATIC TRANSMISSION/TRANSAXLE - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

   TRANSMISSION CONTROL MODULE AND MAIN CONTROL VALVE BODY (G1961651)

   REMOVAL AND INSTALLATION

    

   • 44.24.05
   • FLUID PAN GASKET - RENEW
   • 3000 CC, TDV6, DIESEL, IC
   • 0.90
   • USED WITHINS

   • 44.40.01
   • VALVE BODY ASSEMBLY - RENEW
   • 3000 CC, TDV6, DIESEL, IC
   • 1.40
   • USED WITHINS

    

   SPECIAL TOOL(S)

   

    

   JLR-308-844

   Remover/Installer, Transmission Control Module Electrical Connector

    

   REMOVAL

   CAUTION:

   Make sure all suitable safety precautions are taken to protect the TCM and main control valve body electrical connector pins against electrostatic discharge.

   NOTE:

   Removal steps in this procedure may contain installation details.

   
   

    

   1. Remove the transmission fluid pan.
      Refer to:Transmission Fluid Pan, Gasket and Filter (307-01A Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Removal and Installation).

    

   1. CAUTION:

      Take precautions to avoid any electrostatic charging, which could damage this component.

      
      Disconnect the oil accumulator electrical connector.

    

   1. 
      Remove the 3 oil accumulator retaining bolts.

    

   1. 
      Remove the oil accumulator.

    

   1. CAUTION:

      Make sure all suitable safety precautions are taken to protect the Transmission Control Module (TCM) and main control valve body electrical connector pins against electrostatic discharge.

      
      Remove the 3 valve body bracket bolts.

    

   1. 
      Remove the electrical harness bolt.

    

   1. 
      Disconnect the transmission electrical connector.

    

   1. 
      Note the orientation of the component prior to removal.

    

   1. 
      Release the electrical connector retaining clip.

    

   1. 
      Using the special tool, turn the electrical connector 90 degrees clockwise.
      Special Tool(s): JLR-308-844

    

   1. 
      Using a suitable tool, release the electrical connector from the transmission casing.

    

   1. 
      Remove the 14 valve body assembly bolts.

    

   1. NOTES:

      • Note the orientation of the pressure pipes prior to removal.

      • Note the position of the manual park brake release.

      
      Release the linkage and remove the valve body.

    

   INSTALLATION

    

   1. NOTE:

      Steps 1 and 2 are to be completed together.

      
       Make sure that pressure pipe (1) and pressure pipe (2) are installed correctly before installing the valve body assembly.

    

   1. CAUTION:

      Care must be taken when refitting the valve body assembly.

      NOTE:

      Make sure that the component is installed to the noted removal position.

      
      Install the valve body and secure the linkage.

    

   1. NOTE:

      Tighten the retaining bolts evenly and progressively.

      
      Install the valve body bolts in the sequence shown.
      Torque: 8Nm

    

   1. 
      Using the special tool, turn the electrical connector 90 degrees anti clockwise to install.
      Special Tool(s): JLR-308-844

    

   1. Remove the special tool.

    

   1. 
      Make sure that the electrical connector is installed in the correct orientation as noted in the removal step.

    

   1. 
      Secure the electrical connector retaining clip.

    

   1. CAUTION:

      Make sure that the electrical connector is correctly installed.

      
      Connect the transmission electrical connector.

    

   1. 
      Install the electrical harness bolt.
      Torque: 8Nm

    

   1. CAUTION:

      Make sure all suitable safety precautions are taken to protect the Transmission Control Module (TCM) and main control valve body electrical connector pins against electrostatic discharge.

      
      Install the valve body bracket bolts.
      Torque: 8Nm

    

   1. 
      Install the oil accumulator.

    

   1. NOTE:

      Tighten the retaining bolts evenly and progressively.

      
      Install the 3 oil accumulator retaining bolts.
      Torque: 8Nm

    

   1. 
      Connect the oil accumulator electrical connector.

    

   1. Install the transmission fluid pan.
      Refer to:Transmission Fluid Pan, Gasket and Filter (307-01A Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Removal and Installation).

    

   1. Use the Jaguar Land Rover (JRL) approved diagnostic tool to calibrate the main control valve body and the transmission control module (TCM).

   AUTOMATIC TRANSMISSION/TRANSAXLE - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

   TRANSMISSION FLUID PAN, GASKET AND FILTER (G1961652)

   REMOVAL AND INSTALLATION

    

   • 44.24.05
   • FLUID PAN GASKET - RENEW
   • 3000 CC, TDV6, DIESEL, IC
   • 0.90
   • USED WITHINS

    

   PART(S)

   STEP	PART NAME	QUANTITY
   Installation Step 1	Transmission fluid pan, gasket and filter bolts	1

    

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

    

   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 transmission fluid.
      Refer to:Transmission Fluid Drain and Refill (307-01A Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, General Procedures).

    

   1. 
      Remove the transmission support crossmember.
      Refer to:Transmission Support Crossmember (502-02 Full Frame and Body Mounting, Removal and Installation).

    

   1. CAUTION:

      • Make sure that the area around the component is clean and free of foreign material.
      • Be prepared to collect escaping fluids.
      • Make sure that the mating faces are clean and free of foreign material.
      • Discard the components.
      
      Remove the transmission fluid pan.

    

   INSTALLATION

    

   1. 
      Install the transmission fluid pan, gasket and filter.
      Renew Part: Transmission fluid pan, gasket and filter bolts Quantity: 1.
      Torque: 10Nm

    

   1. Install the transmission support crossmember.
      Refer to:Transmission Support Crossmember (502-02 Full Frame and Body Mounting, Removal and Installation).

    

   1. Complete a transmission fluid level check.
      Refer to:Transmission Fluid Level Check (307-01A Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, General Procedures).

   AUTOMATIC TRANSMISSION/TRANSAXLE - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

   TRANSMISSION SUPPORT INSULATOR (G1509716)

   REMOVAL AND INSTALLATION

    

   • 12.45.08
   • MOUNTING - REAR - CENTRE - 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. Disconnect the battery ground cable. For additional information, 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. 
      Using a suitable hydraulic jack, support the transmission.

    

   1. 
       TORQUE: 24 Nm

    

   1. CAUTION:

      Note the fitted position of the component prior to removal.

      

    

   1. 
       TORQUE: 175 Nm

    

   1. 
       TORQUE: 110 Nm

    

   1. 
       TORQUE: 60 Nm

    

   INSTALLATION

    

   1. To install, reverse the removal procedure.

    

    

   Removal

    

   AUTOMATIC TRANSMISSION/TRANSAXLE - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

   TRANSMISSION - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2, VEHICLES WITH: TWIN SPEED TRANSFER CASE (G1509717)

   REMOVAL

    

   • 44.20.01
   • AUTOMATIC TRANSMISSION - RENEW
   • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
   • 6.10
   • USED WITHINS

    

   REMOVAL

   SPECIAL TOOL(S)

   

    

   100-012

   Slide Hammer

    

   

    

   100-012-01

   Slide Hammer Adapter

    

   

    

   303-1069

   Adapter, Wrench

    

   

    

   308-375

   Remover, Input and Output Seal

   NOTES:

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

   • Some illustrations may show the transmission removed for clarity.

   
   

    

   1. Disconnect the battery earth lead.
      Refer to:Specifications (414-01 Battery, Mounting and Cables, Specifications).

    

   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. 

    

   1. Refer to:Exhaust System - Vehicles Without: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
      Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
      Refer to:Exhaust System - Vehicles With: Diesel Exhaust Fluid (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).

    

   1. Refer to:Front Driveshaft - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (205-01 Driveshaft, Removal and Installation).

    

   1. 

    

   1. 

    

   1. CAUTIONS:

      • Mark the position of the driveshaft flange in relation to the drive pinion flange.

      • To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.

      
      Remove and discard the driveshaft bolts.

    

   1. CAUTION:

      To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.

      
      Remove and discard the driveshaft bolts.

    

   1. CAUTION:

      To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.

      
      Using a suitable hammer and drift, make sure that you only hit the corner edges of the special tool to remove the driveshaft.

    

   1. CAUTION:

      Note the position of the component prior to removal.

      

    

   1. 
      Using a transmission jack, support the transmission.

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. NOTE:

      Vehicles with Diesel Particulate Filter (DPF) installed only.

      

    

   1. NOTE:

      Vehicles without DPF.

      

    

   1. 

    

   1. WARNING:

      Be prepared to collect escaping fluids.

      CAUTION:

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

      

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. CAUTION:

      Only rotate the crankshaft clockwise.

      

    

   1. WARNING:

      Make sure that the transmission is secured with suitable retaining straps.

      
      Lower the rear of the transmission for access.

    

   1. 

    

   1. 

    

   1. 

    

   1. WARNINGS:

      • This step requires the aid of another technician.

      • Make sure that the transmission is secured with suitable retaining straps.

      CAUTION:

      Make sure that the torque converter remains in the transmission.

      NOTES:

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

      • Secure the torque converter to the transmission using suitable cable ties.

      

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. CAUTION:

      Always plug any open connections to prevent contamination.

      

    

   1. 
      Special Tool(s): 303-1069

    

   1. CAUTION:

      Do not complete this step if a new transfer case is to be installed.

      

    

   1. CAUTIONS:

      • Care must be taken to avoid damage to the seal and running surface.

      • Do not complete this step if a new transfer case is to be installed.

      • Note the installed position of the component prior to removal.

      
      • Special Tool(s): 100-012, 100-012-01, 308-375

   AUTOMATIC TRANSMISSION/TRANSAXLE - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

   TRANSMISSION - TDV6 3.0L DIESEL , VEHICLES WITH: SINGLE SPEED TRANSFER CASE (G1774413)

   REMOVAL

    

   • 44.20.01
   • AUTOMATIC TRANSMISSION - RENEW
   • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
   • 6.10
   • USED WITHINS

    

   REMOVAL

   SPECIAL TOOL(S)

   

    

   100-012

   Slide Hammer

    

   

    

   100-012-01

   Slide Hammer Adapter

    

   

    

   303-1069

   Adapter, Wrench

    

   

    

   308-375

   Remover, Input and Output Seal

   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. Disconnect the startup battery ground cable.
      Refer to:Specifications (414-01 Battery, Mounting and Cables, Specifications).

    

   1. Remove the secondary bulkhead center panel.
      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. 

    

   1. Remove the exhaust system.
      Refer to:Exhaust System - Vehicles Without: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
      Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
      Refer to:Exhaust System - Vehicles With: Diesel Exhaust Fluid (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).

    

   1. Remove the front driveshaft.
      Refer to:Front Driveshaft - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (205-01 Driveshaft, Removal and Installation).

    

   1. 
      Remove the exhaust heat shield.

    

   1. 
      Remove the exhaust heat shield.

    

   1. CAUTIONS:

      • Mark the position of the driveshaft flange in relation to the drive pinion flange.

      • To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.

      
      Remove and discard the driveshaft bolts.

    

   1. CAUTION:

      To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.

      
      Remove and discard the driveshaft bolts.

    

   1. CAUTION:

      To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.

      
      Using a suitable hammer and drift, make sure that you only hit the corner edges of the special tool to remove the driveshaft.

    

   1. CAUTION:

      Note the position of the component prior to removal.

      
      Remove the driveshaft.

    

   1. 
      Using a transmission jack, support the transmission.

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. 
      • Secure the cable to the floor.

    

   1. 

    

   1. NOTE:

      Vehicles withDiesel Particulate Filter (DPF) installed only.

      

    

   1. NOTE:

      Vehicles without DPF.

      

    

   1. 

    

   1. WARNING:

      Be prepared to collect escaping fluids.

      NOTE:

      Remove and discard the O-ring seals.

      

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. CAUTION:

      Only rotate the crankshaft clockwise.

      

    

   1. WARNING:

      Make sure that the transmission is secured with suitable retaining straps.

      
      Lower the rear of the transmission for access.

    

   1. 

    

   1. 

    

   1. 

    

   1. WARNINGS:

      • This step requires the aid of another technician.

      • Make sure that the transmission is secured with suitable retaining straps.

      CAUTION:

      Make sure that the torque converter remains in the transmission.

      NOTES:

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

      • Secure the torque converter to the transmission using suitable cable ties.

      

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. 

    

   1. 
      Special Tool(s): 303-1069

    

   1. CAUTION:

      Do not complete this step if a new transfer case is to be installed.

      

    

   1. CAUTIONS:

      • Care must be taken to avoid damage to the seal and running surface.

      • Do not complete this step if a new transfer case is to be installed.

      • Note the orientation of the component prior to removal.

      
      • Special Tool(s): 100-012, 100-012-01, 308-375

    

    

   Installation

    

   AUTOMATIC TRANSMISSION/TRANSAXLE - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

   TRANSMISSION - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2, VEHICLES WITH: TWIN SPEED TRANSFER CASE (G1509720)

   INSTALLATION

    

   • 44.20.01
   • AUTOMATIC TRANSMISSION - RENEW
   • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
   • 6.10
   • USED WITHINS

    

   INSTALLATION

   SPECIAL TOOL(S)

   

    

   303-1069

   Adapter, Wrench

    

   

    

   308-598

   Installer, Oil Seal

   PART(S)

   STEP	PART NAME	QUANTITY
   Step 4	Transfer case input shaft oil seal	1
   Step 16	Torque converter bolts	4
   Step 24	Transmission fluid cooler tubes to transmission O-ring seals	2
   Step 37	Rear driveshaft constant velocity joint bolts	6
   Step 38	Driveshaft flange bolts	4

   NOTES:

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

   • Some illustrations may show the transmission removed for clarity.

   
   

    

   1. NOTE:

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

      
      Remove the torque converter retainer.

    

   1. NOTE:

      Make sure that the torque converter is fully engaged to the transmission.

      

    

   1. CAUTION:

      Oil seals must be installed dry.

      NOTES:

      • This step is only required if previously removed.

      • Make sure that this component is installed to the noted removal position.

      
      Special Tool(s): 308-598

    

   1. NOTE:

      This step is only required if previously removed.

      
      Install a new O-ring seal.
      Renew Part: Transfer case input shaft oil seal Quantity: 1.

    

   1. NOTE:

      This step is only required if previously removed.

      
      • Special Tool(s): 303-1069
      • Clean the component mating faces.
      • Lubricate input shaft splines with 'Weicon TL7391' grease.
      • Torque: 45Nm

    

   1. CAUTIONS:

      • To prevent water ingress and subsequent transmission damage, make sure that the breather is fully pushed home into the transmission casing. The white line around the circumference of the pipe should not be visible when correctly installed.

      • Remove the blanking plugs.

      NOTE:

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

      

    

   1. 

    

   1. 
      Torque: 9Nm

    

   1. 

    

   1. NOTE:

      This step is only required if previously removed.

      
      Torque

      M8: 25Nm

      M6: 10Nm

    

   1. NOTE:

      This step is only required if previously removed.

      
      Torque: 10Nm

    

   1. WARNING:

      Make sure that the transmission is secured with suitable retaining straps.

      CAUTIONS:

      • Apply grease of the correct specification to the torque converter spigot.

      • Make sure that the torque converter remains in the transmission.

      • Remove and discard the cable ties securing the torque converter.

      NOTE:

      This step requires the aid of other technicians.

      
      Using a suitable hydraulic jack, support the transmission.

    

   1. 
      Torque: 40Nm

    

   1. 
      Torque: 40Nm

    

   1. 

    

   1. CAUTION:

      Only rotate the crankshaft clockwise.

      
      Install and tighten 4 new bolts.
      Renew Part: Torque converter bolts Quantity: 4.
      Torque: 63Nm

    

   1. 

    

   1. 
      Torque: 45Nm

    

   1. 
      Torque: 30Nm

    

   1. 
      Torque

      M8: 10Nm

      M6: 7Nm

    

   1. 

    

   1. 

    

   1. 
      Torque: 10Nm

    

   1. CAUTION:

      Be prepared to collect escaping fluids.

      NOTE:

      Install new O-ring seals.

      
      Renew Part: Transmission fluid cooler tubes to transmission O-ring seals Quantity: 2.
      Torque: 22Nm

    

   1. 
      Torque: 25Nm

    

   1. NOTE:

      Vehicles with Diesel Particulate Filter (DPF) installed only.

      
      Torque: 25Nm

    

   1. NOTE:

      Vehicles without DPF.

      
      Torque: 25Nm

    

   1. 
      Torque: 60Nm

    

   1. 
      • Torque: 10Nm

    

   1. 

    

   1. 
      Torque: 9Nm

    

   1. 
      Torque: 23Nm

    

   1. 
      Torque: 23Nm

    

   1. 
      Torque: 23Nm

    

   1. 

    

   1. CAUTION:

      Only tighten the bolts finger-tight at this stage.

      

    

   1. 
      Install new driveshaft bolts.
      Renew Part: Rear driveshaft constant velocity joint bolts Quantity: 6.
      Torque: 73Nm

    

   1. NOTE:

      Make sure that the component is installed to the noted removal position.

      
      Install new flange bolts.
      Renew Part: Driveshaft flange bolts Quantity: 4.
      Torque: 150Nm

    

   1. 
      Torque: 48Nm

    

   1. 
      Torque: 5Nm

    

   1. 
      Torque: 5Nm

    

   1. Refer to:Front Driveshaft - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (205-01 Driveshaft, Removal and Installation).

    

   1. Refer to:Exhaust System - Vehicles Without: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
      Refer to:Exhaust System - Vehicles With: Diesel Particulate Filter (DPF) (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).
      Refer to:Exhaust System - Vehicles With: Diesel Exhaust Fluid (309-00A Exhaust System - TDV6 3.0L Diesel - Gen 2, Removal and Installation).

    

   1. 
      Remove the jack supporting the transmission.

    

   1. Lower the vehicle.

    

   1. 
      Torque: 12Nm

    

   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. Connect the battery ground cable.
      Refer to:Specifications (414-01 Battery, Mounting and Cables, Specifications).

    

   1. Check the transmission fluid leve.
      Refer to:Transmission Fluid Level Check - TDV6 3.0L Diesel /TDV8 4.4L Diesel (307-01A Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, General Procedures).

    

   1. • NOTE:

        Vehicles to the end of 17MY.

        If a new Transmission Assembly is installed. The Jaguar Land Rover approved diagnostic equipment must be used to calibrate the module.
      • NOTE:

        Vehicles from introduction of 18MY.

        If a new Transmission Assembly is installed. The Jaguar Land Rover approved diagnostic equipment must be used to calibrate the module.
      • Select 'Transmission Control Module [TCM]'
      • Select 'Replace ECU'
      • Follow all on-screen instructions to complete this task.

    

   307-02A: Transmission/Transaxle Cooling - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD

    

 

TRANSMISSION/TRANSAXLE COOLING - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD (G1509723)

SPECIFICATIONS

 

Torque Specifications

DESCRIPTION	NM	LB-FT	LB-IN
Transmission fluid cooler bolt	6	-	53
Transmission fluid tube to transmission housing bolt	22	16	-
Transmission fluid tube to engine oil pan nut	9	-	80
Transmission fluid filler plug	35	26	-
Transmission fluid drain plug	8	-	71

NOTE:

INGENIUM I6 3.0L Petrol engine only.

DESCRIPTION	NM	LB-FT	LB-IN
Transmission fluid cooler bolt	10	7	-
Transmission fluid tube to transmission housing bolt	22.5	17	-
Transmission fluid filler plug	35	26	-
Transmission fluid drain plug	8	-	71

 

Description and Operation

TRANSMISSION/TRANSAXLE COOLING - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

TRANSMISSION COOLING (G1728608)

DESCRIPTION AND OPERATION

 

Component Location

 

ITEM	DESCRIPTION
1	Engine cooling radiator
2	Return pipe (To transmission)
3	8HP70 Automatic Transmission
4	Transmission cooling pipe connection
5	Supply pipe (From transmission)
6	Automatic Transmission Fluid (ATF) cooler

 

OVERVIEW

The Automatic Transmission Fluid (ATF) cooler is a separate cooling unit located behind the engine cooling radiator. The unit is attached to the rear of the cooling fan shroud. The transmission is connected to the ATF cooler via flexible hoses and metal pipes.

The ATF cooler is a dedicated cooler which is connected into the engine cooling system circuit. The ATF is cooled by the temperature differential between the ATF and the engine coolant flowing through the ATF cooler.For additional information, refer to:Engine Cooling (303-03A Engine Cooling - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Description and Operation).

Diagnosis and Testing

TRANSMISSION/TRANSAXLE COOLING - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

TRANSMISSION COOLING (G1222465)

DIAGNOSIS AND TESTING

 

 

PRINCIPLE OF OPERATION

For a detailed description of the automatic transmission cooling system, refer to the relevant Description and Operation sections in the workshop manual. REFER to:Transmission Cooling (307-02C Transmission/Transaxle Cooling - Vehicles With: 8HP45 8-Speed Automatic Transmission AWD, Description and Operation).

 

INSPECTION AND VERIFICATION

1. Verify the customer concern by operating the system.

1. Visually inspect for obvious signs of damage and system integrity.

Visual Inspection

MECHANICAL
Feed and return tubes Connections to the automatic transmission and the automatic transmission fluid cooler Automatic transmission fluid level

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

CONDITION	POSSIBLE CAUSES	ACTION
Over heating of the automatic transmission	Obstruction in the automatic transmission fluid cooler	Flush out the automatic transmission fluid cooler with new automatic transmission fluid. If the flushing is unsuccessful, install a new transmission fluid cooler.
Over heating of the automatic transmission	Obstruction in the automatic transmission fluid tubes	Flush out the automatic transmission fluid cooler tubes with new automatic transmission fluid. If the flushing is unsuccessful install new automatic transmission fluid cooler tubes.
Loss of automatic transmission fluid	Connections to the automatic transmission and the automatic transmission fluid cooler	Check the integrity of the tubes, connections and seals. Check the torque of the tube fixings.
Loss of automatic transmission fluid	Leak at oil cooler	Check the integrity of tubes, connections and seals. Check the torque of the tube fixings.

 

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 - DTC: Transmission Control Module (TCM) (100-00 General Information, Description and Operation).

 

Removal and Installation

 

TRANSMISSION FLUID COOLER - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1509724)

REMOVAL AND INSTALLATION

 

• 44.24.10
• TRANSMISSION FLUID COOLER - RENEW
• 3000 CC, TDV6
• 1.80
• USED WITHINS

 

 

REMOVAL

CAUTIONS:

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

• Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

• Be prepared to collect escaping fluids.

NOTE:

Removal steps in this procedure may contain installation details.

 

1. WARNING:

   Make sure to support the vehicle with axle stands.

   Raise and support the vehicle.

 

1. Refer to:Cooling System Partial Draining and Vacuum Filling (303-03 Engine Cooling - TDV6 3.0L Diesel, General Procedures).

 

1. Refer to:Transmission Fluid Level Check - TDV6 3.0L Diesel /TDV8 4.4L Diesel (307-01 Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, General Procedures).

 

1. Refer to:Turbocharger Bypass Valve (303-04B Fuel Charging and Controls - Turbocharger - TDV6 3.0L Diesel, Removal and Installation).

 

1. 
   Torque: 9Nm

 

1. 

 

1. 

 

1. 

 

1. 
   Torque: 6Nm

 

INSTALLATION

 

1. To install reverse the removal procedure.

TRANSMISSION/TRANSAXLE COOLING - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

TRANSMISSION FLUID COOLER PIPES - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1509727)

REMOVAL AND INSTALLATION

 

• 44.24.15
• HOSES/PIPES - OIL/FLUID COOLER - SET - RENEW
• 3000 CC, TDV6
• 1.30
• USED WITHINS

 

PART(S)

STEP	PART NAME	QUANTITY
Removal Step 8	Transmission fluid cooler tubes to transmission O-ring seals	1

 

REMOVAL

NOTES:

• Removal steps in this procedure may contain installation details.

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

• 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. WARNING:

   Make sure to support the vehicle with axle stands.

   Raise and support the vehicle.

 

1. Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).

 

1. Refer to:Front Driveshaft - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (205-01 Driveshaft, Removal and Installation).

 

1. WARNING:

   Be prepared to collect escaping fluids.

   CAUTION:

   Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean and dry. Plug open connections to prevent contamination.

   

 

1. 
   Torque: 9Nm

 

1. 

 

1. CAUTIONS:

   • Be prepared to collect escaping fluids.

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

   • Remove and discard the O-ring seals.

   
   Renew Part: Transmission fluid cooler tubes to transmission O-ring seals Quantity: 1.
   Torque: 22Nm

 

1. 

 

INSTALLATION

 

1. To install, reverse the removal procedure.

 

1. 
   • Check and top-up the transmission fluid level.
   • Torque: 35Nm

 

307-05A: Automatic Transmission/Transaxle External Controls - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD

AUTOMATIC TRANSMISSION/TRANSAXLE EXTERNAL CONTROLS - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD (G1509730)

SPECIFICATIONS

 

Torque Specifications

DESCRIPTION	NM	LB-FT	LB-IN
Transmission Control Switch (TCS) bolts	2	-	18
Emergency Park Release (EPR) lever bracket bolt	9	-	80
EPR cable end bolts	11	8	-
Paddle shifter screw	3	-	27

 

Description and Operation

AUTOMATIC TRANSMISSION/TRANSAXLE EXTERNAL CONTROLS - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

EXTERNAL CONTROLS - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD (G2003048)

DESCRIPTION AND OPERATION

 

 

COMPONENT LOCATION

EXTERNAL CONTROLS ZF 8HP70

 

ITEM	DESCRIPTION
1	Emergency Park Release (EPR) lever and cable assembly
2	Downshift (-) paddle switch
3	Upshift (+) paddle switch
4	Transmission Control Switch (TCS)

 

OVERVIEW

WARNING:

To prevent vehicle roll-away, before operation of the Emergency Park Release (EPR) mechanism the vehicle must be restrained either by use of:

• The Electric Park Brake (EPB)
• Wheel chocks.

The ZF 8HP70 transmission external controls comprise:

• A Transmission Control Switch (TCS)
• Two steering wheel mounted paddle switches
• An Emergency Park Release (EPR) lever and cable.

The linear TCS transmits driver transmission selections to the Transmission Control Module (TCM). The paddle switches allow the driver to initiate gear shifts in all transmission modes:

• Drive (D)
• Sport (S)
• S manual CommandShift.

The EPR system makes sure that the transmission park lock remains disengaged during vehicle recovery operations.

 

DESCRIPTION

TRANSMISSION CONTROL SWITCH

 

ITEM	DESCRIPTION
1	Selector lever
2	Unlock trigger
3	Park (P) switch
4	Light Emitting Diode (LED) display
5	Mounting holes
6	Electrical connector

NOTE:

The Transmission Control Switch (TCS) is not a serviceable component. Repairs to the TCS must not be attempted. The TCS must be replaced as an assembly.

The Transmission Control Switch (TCS) is installed in the floor console and controls the driver transmission selections.

The TCS allows the transmission to be operated as a conventional automatic unit by selecting:

• Park (P)
• Reverse ®)
• Neutral (N)
• Drive (D).

The TCS is fully electronic selector lever type transmission selector with no mechanical connection to the transmission.

Movement of the TCS to any of the four positions, or operation of the P switch is sensed by the TCS. The sensed position is passed to the Transmission Control Module (TCM) via the High Speed (HS) Controller Area Network (CAN) powertrain systems bus. The TCM then reacts according to the new selection request made by the driver. The linear movement of the TCS is sensed by a magnetic system using multiple Hall effect sensors to determine the position of the selector. The TCS P and the unlock trigger use double pole elastomeric switches.

The Sport (S) position selection allows the TCM to operate the transmission using the semi-automatic sequential shift. Gear selections are sensed by the TCM when the driver operates the steering wheel paddle switches or moves the TCS to the '+' or '-' positions.

The TCS allows the driver to operate the transmission similar to a sequential transmission. Once the TCS position is confirmed, the TCM outputs appropriate information on the FlexRay systems bus to the Body Control Module/Gateway Module (BCM/GWM). The information is received by the instrument cluster to display the gear selection information in the message center.

UNLOCK TRIGGER

The TCS unlock trigger must be pressed to select any gear, including Neutral (N) from the Park (P) position.

The unlock trigger must also be pressed to select any driving gear from the Reverse ®), Neutral (N) or Drive (D) positions. Pressing the unlock trigger is not required to select Park.

PADDLE SWITCHES

Two gear change paddle switches are fitted at the rear of the steering wheel. The paddle switches allow the driver to operate the transmission as a semi-automatic manual gearbox using the 'Commandshift' feature.

Each paddle switch has three connections:

• Ground
• Switch illumination Pulse Width Modulation (PWM) supply
• Ground switch signal.

The paddle switches can also be used on a temporary basis when the Transmission Control Switch (TCS) is in the Drive (D) position. This allows the driver to override the automatic gear selection if required.

EMERGENCY PARK RELEASE

 

ITEM	DESCRIPTION
1	Emergency Park Release (EPR) operating lever
2	Cable
3	Bracket
4	M8 nut
5	Park interlock lever
6	Engine mounting bracket
7	Screw driver or suitable tool

If the vehicle requires recovery/transportation, the Emergency Park Release (EPR) mechanism is used to manually disengage the transmission park lock. Operation of the EPR engages the transmission in Neutral (N).

The EPR mechanism consists of an operating lever that is connected to the park interlock lever on the transmission by a cable.

The EPR operating lever is located on a bracket attached to the top of the engine. The park interlock lever is attached to the transmission selector shaft and operated via a cable.

When operated, the EPR mechanism moves the transmission selector shaft to the neutral position.

WARNING:

To prevent vehicle roll-away, before operation of the Emergency Park Release (EPR) mechanism the vehicle must be restrained either by use of:

• The Electric Park Brake (EPB)
• Wheel chocks.

To disengage the park lock:

• Make sure the Electric Park Brake (EPB) is engaged or wheel chocks are in place. This will prevent vehicle roll-away when park lock is disengaged.
• Open the hood to access the engine compartment.
• Remove the engine cover.
• Move the EPR operating lever fully through 90 degrees.
• If additional leverage is required, use a screwdriver or suitable tool and engage the tool in the EPR operating lever.
• Ensure that the EPR lever is locked by the locking tab on the lever bracket.

Moving the operating lever causes the EPR cable to rotate the park interlock lever on the transmission. This disengages the parking pawl in the transmission and engages neutral. This allows the vehicle to freewheel.

EPR Lever Locking Tab Release

 

ITEM	DESCRIPTION
1	Locking tab

To re-engage the park lock:

• Using a suitable tool, release the EPR lever locking tab.
• Move the operating lever through 90 degrees and if used, remove the screwdriver or tool.
• Replace the engine cover.
• Close the hood.

 

OPERATION

Shifting of the Transmission Control Switch (TCS) selector to any of the five positions is sensed by the Transmission Control Module (TCM). Signals from the TCS are passed to the TCM via the High Speed (HS) Controller Area Network (CAN) powertrain systems bus. The TCM then reacts according to the selected position.

The TCS is a magnetic system using Hall effect sensors to determine the position of the selector. The Sport (S) position selection allows the TCM to operate the transmission using the semi-automatic 'Commandshift' system.

Gear selections are sensed by the TCM when the driver operates the steering wheel paddle switches.

Once the TCS position is confirmed, the TCM outputs appropriate information on the FlexRay systems bus to the Body Control Module/Gateway Module (BCM/GWM). The information is received by the Instrument Cluster (IC) to display the gear selection information in the message center. The paddle switches can also be used on a temporary basis when the TCS is in the Drive (D) position to override the automatic gear selection if required.

ROCKING FUNCTION (NOT APPLICABLE TO CHINA MARKET VEHICLES)

The rocking function compliments the neutral lock function. For all changes from a non-driving range to a driving range, it is necessary to press the brake pedal to release the neutral lock.

For use in situations where the driver will require to change the gear selection from Reverse ®) to Drive (D), or from D to R, without brake pedal input. For example:

• Car park manoeuvring
• Multiple point turns
• 'Rocking' the vehicle from a slippery surface.

The rocking function gives a two second lock delay when Neutral (N) is selected on the Transmission Control Switch (TCS) and the brake pedal is not pressed.

PADDLE SWITCHES

The paddle switches are hardwired to the right steering wheel switchpack. Operation of the paddle switch completes a ground path to the right steering wheel switchpack. The right steering wheel switchpack converts the completed ground signal into a Local Interconnect Network (LIN) bus signal. The LIN bus signal is passed via the Steering Wheel Module (SWM) to the Body Control Module/Gateway Module (BCM/GWM). The BCM/GWM converts the signal into a High Speed (HS) Controller Area Network (CAN) powertrain systems bus signal to the Transmission Control Module (TCM).

Pulling the left downshift (-) paddle switch provides down changes. Pulling the right upshift (+) paddle switch provides up changes.

The first operation of either paddle switch, after Sport (S) is selected, puts the transmission into permanent manual Commandshift mode. Moving the Transmission Control Switch (TCS) selector lever back to the Drive (D) position, returns the transmission to conventional automatic operation.

Temporary operation of Commandshift mode can also be operated with the TCS in the D position. Operation of either the upshift (+) or downshift (-) paddle switches activates the manual mode operation.

If the TCS is in D:

• Commandshift will cancel after a time period
• Commandshift can be cancelled by pressing and holding the upshift (+) paddle switch for approximately two seconds.

The temporary operation of the paddle switches in the D position is disabled in North American Specification (NAS) and China markets at delivery. This can be overridden in the Instrument Cluster (IC) menu and the driver can configure the paddle switch operation as 'Active in S only' or 'Active in D and S'.

 

CONTROL DIAGRAM

 

A = HARDWIRED: O = LIN BUS: AN = HIGH SPEED (HS) CONTROLLER AREA NETWORK (CAN) POWERTRAIN SYSTEMS BUS: AX = FLEXRAY SYSTEMS BUS

ITEM	DESCRIPTION
1	Transmission Control Switch (TCS)
2	Body Control Module/Gateway Module (BCM/GWM)
3	Transmission Control Module (TCM)
4	Powertrain Control Module (PCM)
5	Ground
6	Fuse 15A - Engine Junction Box (EJB)
7	Fuse 250A - Auxiliary Junction Box (AJB)
8	Fuse 250A - Battery Junction Box (BJB)
9	Right (+) steering wheel paddle switch
10	Left (-) steering wheel paddle switch
11	Right steering wheel switchpack
12	Steering Wheel Module (SWM)

 

Diagnosis and Testing

AUTOMATIC TRANSMISSION/TRANSAXLE EXTERNAL CONTROLS - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

EXTERNAL CONTROLS (G1763268)

DIAGNOSIS AND TESTING

 

 

PRINCIPLES OF OPERATION

For a detailed description of the automatic transmission/transaxle external controls, refer to the relevant Description and Operation section in the workshop manual. REFER to:External Controls - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD (307-05A Automatic Transmission/Transaxle External Controls - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, 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 tested and/or the donor vehicle.

NOTES:

• If a control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the Warranty Policy and Procedures manual, or determine if any prior approval programme is in operation, prior to the installation of a new module/component.

• When performing voltage or resistance tests, always use a digital multimeter accurate to three decimal places, and with an up-to-date calibration certificate. When testing resistance always take the resistance of the digital multimeter leads into account.

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

1. Verify the customer concern

1. Visually inspect for obvious signs of damage and system integrity

Visual Inspection

MECHANICAL	ELECTRICAL
Transmission control switch	Fuse(s) Loose or corroded electrical connector(s) Transmission control switch

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

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 carry out the recommendations as required.

 

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: Transmission Control Switch (TCS) (100-00 General Information, Description and Operation).

 Removal and Installation

AUTOMATIC TRANSMISSION/TRANSAXLE EXTERNAL CONTROLS - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

EMERGENCY PARK RELEASE LEVER (G1509731)

REMOVAL AND INSTALLATION

 

• 44.15.92
• TRANSMISSION EMERGENCY RELEASE LEVER - RENEW
• 3000 CC, TDV6
• 1.40
• USED WITHINS

 

 

REMOVAL

NOTES:

• Removal steps in this procedure may contain installation details.

• 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. Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).

 

1. 
   Torque

   M10: 60Nm

   M6: 10Nm

 

1. 
   Torque: 10Nm

 

1. CAUTION:

   Care must be taken to avoid damaging the surrounding components.

   

 

1. Refer to:Floor Console Upper Section (501-12 Instrument Panel and Console, Removal and Installation).

 

1. 

 

1. 
   Torque: 3Nm

 

1. 

 

INSTALLATION

NOTE:

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

 

1. 
   To install, reverse the removal procedure.

AUTOMATIC TRANSMISSION/TRANSAXLE EXTERNAL CONTROLS - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

EMERGENCY PARK RELEASE CABLE (G2201773)

REMOVAL AND INSTALLATION

 

 

 

REMOVAL

 

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

 

1. Remove the engine cover.
   Refer to:Engine Cover (501-05, Removal and Installation).

 

1. Remove the left bulkhead panel.
   Refer to:Secondary Bulkhead Left Panel (501-02, Removal and Installation).

 

1. Remove the engine undershield.
   Refer to:Engine Undershield (501-02, Removal and Installation).

 

1. 
   • Remove the 10 bolts.
   • Remove the transmission undershield.

 

1. 
   • CAUTION:

     Use a suitable tool.

     Release the cable.
   • Remove the 2 bolts.
   • Release the cable clip.

 

1. 
   Release the wiring harness clip.

 

1. 
   Remove the bolt.

 

1. NOTE:

   This step requires the aid of another technician.

   
   • Release the 4 clips.
   • Remove the Emergency Park Release (EPR) cable.

 

INSTALLATION

 

1. NOTE:

   This step requires the aid of another technician.

   • Install the Emergency Park Release (EPR) cable.
   • Install the 4 clips.

 

1. • Install and tighten the EPR cable bracket bolt.
     Torque: 9Nm
   • Install the wiring harness clip.

 

1. • Install the cable end.
   • Install and tighten the 2 bolts.
     Torque: 11Nm
   • Install the harness clip.

 

1. • Install the transmission undershield.
   • Install and tighten the 10 bolts.
     Torque

     M10 bolts: 60Nm

     M6 bolts: 10Nm

 

1. Install the engine undershield.
   Refer to:Engine Undershield (501-02, Removal and Installation).

 

1. Install the left bulkhead panel.
   Refer to:Secondary Bulkhead Left Panel (501-02, Removal and Installation).

 

1. Install the engine cover.
   Refer to:Engine Cover (501-05, Removal and Installation).

 

AUTOMATIC TRANSMISSION/TRANSAXLE EXTERNAL CONTROLS - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

TRANSMISSION CONTROL SWITCH (G1606975)

REMOVAL AND INSTALLATION

 

• 44.15.03
• SWITCH - SELECTOR LEVER POSITION - RENEW
• ALL DERIVATIVES
• 0.80
• USED WITHINS

 

GENERAL EQUIPMENT

EQUIPMENT NAME
Land Rover diagnostic equipment

 

REMOVAL

 

1. Remove the floor console upper panel.
   Refer to:Floor Console Upper Section (501-12 Instrument Panel and Console, Removal and Installation).

 

1. 

 

1. 

 

INSTALLATION

 

1. 

 

1. 

 

1. Install the floor console upper panel.
   Refer to:Floor Console Upper Section (501-12 Instrument Panel and Console, Removal and Installation).

 

1. Using the approved Land Rover diagnostic equipment, configure the Transmission Control Switch (TCS).
    

   AUTOMATIC TRANSMISSION/TRANSAXLE EXTERNAL CONTROLS - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

   UPSHIFT PADDLE SWITCH (G1509734)

   REMOVAL AND INSTALLATION

    

   • 44.15.94
   • GEARCHANGE 'UP' PADDLE SWITCH - RENEW
   • ALL DERIVATIVES
   • 0.10
   • USED WITHINS

    

    

   REMOVAL

   NOTE:

   Removal steps in this procedure may contain installation details.

   
   

    

   1. NOTE:

      Make sure that the harness is routed to the position noted on removal.

      
      Torque: 3Nm

    

   INSTALLATION

    

   1. To install, reverse the removal procedure.

   AUTOMATIC TRANSMISSION/TRANSAXLE EXTERNAL CONTROLS - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

   DOWNSHIFT PADDLE SWITCH (G1509735)

   REMOVAL AND INSTALLATION

    

   • 44.15.95
   • GEARCHANGE 'DOWN' PADDLE SWITCH - RENEW
   • ALL DERIVATIVES
   • 0.10
   • USED WITHINS

    

    

   REMOVAL

   NOTE:

   Removal steps in this procedure may contain installation details.

   
   

    

   1. NOTE:

      Make sure that the harness is routed to the position noted on removal.

      
      Torque: 3Nm

    

   INSTALLATION

    

   1. To install, reverse the removal procedure.

   AUTOMATIC TRANSMISSION/TRANSAXLE EXTERNAL CONTROLS - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

   TRANSMISSION CONTROL ACTIVATION SWITCH (G2263247)

   REMOVAL AND INSTALLATION

    

   • 37.27.14
   • TRANSMISSION CONTROL PARK SWITCH - RENEW
   • ALL DERIVATIVES
   • 0.10
   • USED WITHINS

    

    

   REMOVAL

   CAUTION:

   Make sure that the gloves provided with the repair kit are worn throughout this procedure.

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

    

   1. CAUTIONS:

      • Using the trim tool provided with the repair kit.

      • Take care not to damage the leather.

      
       Remove the trim panel.

    

   1. 
      Remove the retaining screw.

    

   1. 
      Release the assembly.

    

   1. NOTE:

      Note the orientation.

      
      Remove the trim.

    

   1. 
      Remove the button.

    

   1. CAUTION:

      Take care not to damage the electrical connector.

      NOTE:

      Remove any broken debris.

      
      • Disconnect the electrical connector.
      • Remove the transmission control activation switch.

    

   INSTALLATION

    

   1. CAUTIONS:

      • Take care not to damage the electrical connector.

      • Make sure that the wires are not trapped on the installation.

      
      • Connect the electrical connector.
      • Install the transmission control activation switch.

    

   1. CAUTION:

      Make sure that the wires are not trapped on the installation.

      
      Install the button.

    

   1. 
      Install the trim.

    

   1. 
      Install the retaining screw.
      Torque: 0.75Nm

    

   1. NOTE:

      Clean the component mating faces.

      
      • Remove the adhesive tape backing.
      • Install the trim panel.

    

   1. 
      Make sure that the trim panel is correctly installed as illustrated.

    

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

    

   1. 
      • Switch the ignition ON.
      • Make sure the gear indicators illuminate correctly when in operation.

   AUTOMATIC TRANSMISSION/TRANSAXLE EXTERNAL CONTROLS - VEHICLES WITH: 8HP70 8-SPEED AUTOMATIC TRANSMISSION AWD

   TRANSMISSION CONTROL SWITCH PARK (P) BUTTON (G2398520)

   REMOVAL AND INSTALLATION

    

   • 44.15.69
   • TRANSMISSION CONTROL SWITCH PARK (P) BUTTON - RENEW
   • ALL DERIVATIVES
   • 0.10
   • USED WITHINS

    

   GENERAL EQUIPMENT

   EQUIPMENT NAME
   Jaguar Land Rover approved diagnostic equipment

    

   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. CAUTION:

      Use a soft material at position A to protect the panel from any damage.

      
      • Use a suitable tool inserted at position B to remove and discard the Park (P) button.

    

   1. 
      Examine the plastic and leather surround for any damage. If any damage is found, replace as required.

    

   1. NOTE:

      Remove and clean any dirt, debris or liquid before fitting the new part.

      
      Check the P button housing for any fragments of the removed button, as the component could be damaged during the removal steps.

    

   INSTALLATION

    

   1. NOTE:

      There is no clear audible click on installation of the Park (P) button.

      • Install the new Park (P) button.
      • To confirm the installation was successful, test the operation of the P button.
      • Operate the P button several times to make sure the P button operates smoothly and returns to the raised position.

    

   1. 
      Make sure that the P button illuminates correctly.

    

   1. Use the approved Jaguar Land Rover diagnostic equipment to read and clear any Diagnostic Trouble Codes (DTCs).