Range Rover Sport / L494 2017 GENERAL ENGINE INFORMATION ALL ENGINES USER MANUAL

ENGINE SYSTEM - GENERAL INFORMATION

Range Rover Sport / L494 2017 User Manual GENERAL ENGINE INFORMATION ALL ENGINES

ENGINE - TDV6 3.0L DIESEL (G1883208)

DIAGNOSIS AND TESTING
 
 
PRINCIPLE OF OPERATION

For a detailed description of the 3.0L Diesel engine, refer to the relevant Description and Operation section in the workshop manual. REFER to:Engine (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Diagnosis and Testing).

 
INSPECTION AND VERIFICATION
  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection

MECHANICAL ELECTRICAL
  • Coolant level
  • Coolant leaks
  • Oil level
  • Oil leaks
  • Visibly damaged or worn parts
  • Loose or missing nuts or bolts
  • Vacuum system leaks
  • Left active engine mount
  • Right active engine mount
  • Wiring harness
  • Electrical connector(s)
  • Injectors
  • Glow plugs
  • 5 volt sensor supply
  • Sensor(s)
  • Cooling fan control module and motor
  • Powertrain Control Module (PCM)
  • Active engine mount 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 concern is not visually evident, verify the symptom and refer to the relevant Symptom Chart. Symptom Charts have been separated into Leaks and Noise, Vibration and Harshness (NVH) for ease of use. Alternatively, check for Diagnostic Trouble Codes (Diagnostic trouble code(s)) and refer to the relevantDiagnostic Trouble Code(s) (DTC) Index.
 
SYMPTOM CHARTS

Symptom Chart, Leaks

SYMPTOM POSSIBLE CAUSE ACTION
External coolant leaks
  • Damaged hose(s)
  • Damaged expansion tank
  • Damaged radiator
  • Leaking seals/gaskets
  • Cracked/damaged casings
  • For cooling system checks, 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, Diagnosis and Testing).
Internal coolant leaks Note: This may be indicated by the production of white smoke from the exhaust
  • Leaking seals/gaskets
  • Cracked/damaged casings
  • For cooling system checks, 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, Diagnosis and Testing).
Engine overheats
  • Insufficient coolant
  • Insufficient oil
  • Pressure cap fault
  • Thermostat not opening
  • Coolant pump failure
  • Cooling fan failure
  • For cooling system checks, 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, Diagnosis and Testing).
Engine takes too long to reach operating temperature
  • Thermostat stuck open
  • For cooling system checks, 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, Diagnosis and Testing).
External oil leaks
  • Gaskets
  • Inlet manifold / Camshaft cover
  • Seals
  • Oil pipes
  • Oil filter
  • Damaged/cracked casings
  • Crankcase ventilation system
NOTE:

Do not assume where oil is visible on the engine that is the source of the oil leak. For example, oil may be visible around the sump gasket, but the source of the leak is likely to be from a gasket or seal higher up on the engine. Always check for other leaking components before condemning the sump gasket.

  • Clean the area around the relevant gasket and confirm if a leak is present. Visually check the condition of all gaskets around the area of the leak. If the leak can be confirmed as coming from a failed gasket, replace as required
  • Clean the area around the inlet manifold / camshaft cover to cylinder head and confirm if a leak is present. Visually check the condition of the inlet manifold / camshaft cover to cylinder head gasket. If the leak can be confirmed as coming from the inlet manifold / camshaft cover to cylinder head gasket, replace as required
  • NOTES:

    • Care should be taken when diagnosing a rear crankshaft oil seal leak. Oil leaks from other parts of the engine may run down on to the rear crankshaft oil seal.

    • The gasket joint between the camshaft cover and cylinder head are a known leak area. Always check for a leak from the camshaft cover gasket before diagnosing a failed oil seal.

    Clean the area around the relevant oil seals and confirm if a leak is present. Visually check the condition of all visible oil seals around the area of the leak. If the leak can be confirmed as coming from a failed oil seal, replace as required
  • Clean the oil pipes and unions and confirm if a leak is present. Visually check the condition of the oil pipes and unions. If the leak can be confirmed as coming from the oil pipes or unions, replace as required
  • Clean the oil filter housing and confirm if a leak is present. Visually check the condition of the oil filter housing. If the leak can be confirmed as coming from the oil filter housing, replace as required
  • Clean all casings and confirm if a leak is present. Visually check the condition of the casing components. If the leak can be confirmed as coming from a damaged or cracked casing component, replace as required
  • Check the crankcase ventilation system for damage and/or loose joints. Complete a compression test, GO to Pinpoint TestA.
Internal oil leaks (leaks into coolant or combustion chamber) Note: This may be indicated by the production of blue smoke from the exhaust
  • Gaskets
  • Seals
  • Damaged/cracked casings
  • Worn valve guides
  • Worn cylinder bores/pistons
  • Broken piston rings
  • Check for traces of oil in the coolant. Check for evidence of oil in the combustion chambers (deposits on the glow plugs, etc). Confirm oil consumption and vehicle usage with the owner/driver. Complete an oil consumption test, GO to Pinpoint TestB.

Symptom ChartNVH

NOTES:

  • Where possible please complete a back to back test with a similar specification vehicle to confirm the issue in not a characteristic of the engine.

  • As the checks suggested here are open to interpretation, they should be used as a guide only. Descriptions of noises, etc, are in general terms, so depend on a degree of experience on the part of the technician.

SYMPTOM POSSIBLE CAUSE ACTION
Rattle/ticking from top of engine
  • Valve gear noise
  • Camshaft bearing noise
  • Camshaft chain noise
  • Tensioner noise
  • Vacuum pump noise
  • High pressure fuel pump noise
  • Check the engine oil pressure, GO to Pinpoint TestC. . Check the function of the hydraulic tappets and the camshaft condition. Check the camshaft bearings, chains and tensioners. Check the vacuum pump, and high pressure fuel pump
Growl from top of engine
  • High pressure fuel pump belt noise
  • High pressure fuel pump belt tensioner noise
  • Check the high pressure fuel pump belt and tensioner
Squeaking/Creaking/Squeal from front of engine
  • Front End Accessory Drive (FEAD) belt
  • FEAD belt tensioner
  • Driven components on FEAD belt
  • Check the FEAD belt and driven components,
Whine/Slap/Growl from front of engine
  • Front End Accessory Drive (FEAD) belt
  • FEAD belt tensioner
  • Driven components on FEAD belt
  • Timing belt noise
  • Timing belt tensioner noise
  • Check the FEAD belt and driven components. Check the timing belt and tensioners
Knock from lower half of engine (often worse with a cold engine)
  • Piston slap
  • Gudgeon pin noise
  • Connecting rod bearing noise
  • Check the engine oil pressure, GO to Pinpoint TestC. . Check piston, cylinder bore, gudgeon pin and connecting rod bearing for excess wear
Knock/Rumble from lower half of engine (often worse on overrun)
  • Main bearing noise
  • Check the engine oil pressure, GO to Pinpoint TestC. . Check connecting rod bearing for excess wear
Misfire/Rough running
  • Engine management system
  • Fuel charging and controls
  • Exhaust gas recirculation system
  • Burnt/sticking valves
  • Worn valve guides
  • Worn cylinder bores/pistons
  • Broken piston rings
  • Damaged/cracked casings
  • For engine management system tests, refer to section 303-14. For fuel charging and controls systems tests, refer to section 303-04. For exhaust gas recirculation system tests, refer to section 303-08. Complete a compression test, GO to Pinpoint TestA. Check for excess wear in engine components
Excessive vibration of the vehicle when stationary with the engine at idle
  • Active engine mount system vacuum lines damaged or leaking
  • Left active engine mount failure
  • Right active engine mount failure
  • Active engine mount system solenoid circuit, short circuit to ground, short circuit to power, open circuit, high resistance
  • Active engine mount system solenoid internal failure
  • Check the active engine mount system: GO to Pinpoint TestD.
  • Inspect electrical connectors for signs of water ingress, and pins for damage and/or corrosion
 
PINPOINT TESTS
NOTE:

Where reference is made to 'suitable equipment', this refers to standard workshop equipment. Refer to the operating instructions for your own equipment when performing any tests.

 

PINPOINT TEST A : CHECK THE CYLINDER COMPRESSIONS
WARNING:

Only compression testers able to read the higher compression pressures found in diesel engines should be used. Failure to follow this instruction may result in personal injury.
NOTE:

Where possible, compression testing should be completed on an engine at operating temperature.
A1: COMPLETE A DRY CYLINDER COMPRESSION TEST
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 
1
Make sure the parking brake is applied and that the selector lever is in park.
 
2
Set the ignition status to OFF.
 
3
Remove the starter relay.
 
4
Disconnect the starter motor solenoid connector.
 
5
Connect a suitable remote starter device to the starter motor solenoid.
 
6
Remove the glow plugs.
 
7
Install adapter 303-1131 in place of the glow plug in the first cylinder to be tested.
 
8
Connect a suitable compression tester to the adapter. See warning above.
 
9
Using the remote starter device, crank the engine a minimum of five revolutions.
 
10
Record the compression figure and the number of revolutions taken to reach it.
 
11
Repeat steps 7 - 10 above for the remaining cylinders, cranking the engine for a similar number of revolutions each time.
 
12
Compare the compression figures across all the cylinders.

 
Are the compression figures within 10% of each other?
Yes
Unless the compression figures are universally very low (experience will indicate this), check for other causes for the customer complaint.
No
GO toA2.
A2: COMPLETE A WET CYLINDER COMPRESSION TEST
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
CAUTION:

If engine oil is introduced into the cylinders, run the engine at 2,000 rpm for a minimum of ten minutes after completing testing to prevent damage to the catalytic converters. Failure to follow this instruction may result in damage to the vehicle.
NOTE:

There is a combustion chamber in the top of each piston. Make sure that the oil is not allowed to run into this chamber.
 
1
Using a suitable oil can with a flexible spout, introduce a small amount of clean engine oil into the cylinder just before testing, such that the oil is able to run between the piston and the cylinder bore.
 
2
Repeat steps 7 - 10 from the test above, introducing oil into each cylinder just before testing.
 
3
Compare the compression figures across all the cylinders.

 
Is the compression figure higher than the dry test?
Yes
A higher figure following the introduction of oil may indicate a worn or damaged cylinder bore, piston and/or piston rings. Disassembly would be required to confirm this.
No
If the compression figure is unaffected by the introduction of oil, but the figure is still less than 90% of the other cylinders, this may indicate a burnt and/or sticking valve, leaking head gasket, etc. Disassembly would be required to confirm this.
Clear any Diagnostic trouble code(s) which may have been induced by the test.

 

PINPOINT TEST B : OIL CONSUMPTION TEST
NOTE:

Oil consumption will vary, depending on a number of factors. New engines will normally use more oil than 'run-in' engines, although a guideline would be to expect 16,000 Km (10,000 miles) per liter.
B1: CHECK FOR EXCESSIVE OIL CONSUMPTION
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 
1
Start the engine and allow it to run until it reaches normal operating temperature.
 
2
Make sure the vehicle is parked on a level surface and set ignition status to OFF.
 
3
Allow to settle for at least five minutes.
 
4
Check the oil level.
 
5
Correct the level, if necessary, and record the reading and mileage in the vehicle history.
 
6
Make sure that the owner/driver is aware that a test is being completed, and that they should not top-up their oil level for the duration of the test, but should check the level every 160-240 Km (100-150 miles).
 
7
When the oil level reaches the ADD mark, the customer should bring the vehicle in to be checked.
 
8
Top-up the oil to the level at the beginning of the test and record the amount of oil needed to do so, and the mileage covered in the course of the test.
 
9
From this, the consumption can be calculated, and a decision made as to if or not the consumption is considered excessive.

 
Is the consumption excessive for the mileage and/or use?
Yes
Disassembly will be required to check the components indicated in the symptom chart.
No
No further action is required.

 

PINPOINT TEST C : CHECK THE ENGINE OIL PRESSURE
NOTES:

  • Check and, if necessary, top-up the engine oil level before beginning this test.

  • Where reference is made to 'suitable equipment', this refers to standard workshop equipment. Refer to the operating instructions for your own equipment when performing any tests.
NOTE:

Where reference is made to 'suitable equipment', this refers to standard workshop equipment. Refer to the operating instructions for your own equipment when performing any tests.
C1: CHECK FOR LOW ENGINE OIL PRESSURE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 
1
Remove the oil pressure sensor.
 
2
Connect a suitable oil pressure gauge in place of the oil pressure sensor.
 
3
Start the engine and check for leaks at the gauge connection.
 
4
Allow the engine to idle and monitor the oil pressure.
 
5
Raise the engine speed to 2,500 rpm and monitor the oil pressure.

 
Is the oil pressure less than 0.50 bar (7.25 psi) between idle and 2,500 rpm?
Yes
GO toC2.
No
GO toC3.
C2: CHECK FOR LOW ENGINE OIL PRESSURE AT ENGINE SPEEDS GREATER THAN 2,500
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 
1
Raise the engine speed to above 2,500 rpm and monitor the oil pressure.

 
Is the oil pressure less than 1.0 bar (14.5 psi) at engine speeds greater than 2,500 rpm?
Yes
Pressure this low may indicate a problem with: oil pump, filtering, clearances within the engine. Check if there are any other indications of engine faults (noise, etc), refer to the symptom chart above.
No
GO toC3.
C3: CHECK FOR HIGH ENGINE OIL PRESSURE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 
1
Monitor the engine oil pressure at varying engine speeds.

 
Does the oil pressure reach 4.0 bar (58 psi)?
Yes
Pressure this high may indicate a blockage in the lubrication system. If this is not resolved, high oil pressure will lead to engine oil leaks and other failures.
No
If the oil pressure stays in the band between 0.50 bar (7.25 psi) and 1.0 bar (14.5 psi) this would be considered normal.

 

PINPOINT TEST D : ACTIVE ENGINE MOUNT TEST
D1: ACTIVE ENGINE MOUNT VACUUM LINES VISUAL CHECKS
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 
1
Inspect all the vacuum lines for correct connection and for any damage

 
Are all the vacuum lines correctly connected and free from damage?
Yes
GO toD2.
No
Reconnect or replace damaged vacuum lines as required and retest
D2: ACTIVE ENGINE MOUNT VACUUM LINES VACUUM CHECKS
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 
1
Disconnect the vacuum lines from the solenoid
 
2
Using the Jaguar Land Rover approved vacuum testing equipment, connect to the vacuum system and check it can hold a vacuum

 
Did the vacuum system hold a constant vacuum when tested?
Yes
GO toD3.
No
Systematically check each vacuum line until the fault is identified. Repair or replace the faulty line as necessary and retest
D3: CHECK ACTIVE ENGINE MOUNT SWITCH POSITION
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
E222279
1
Inspect the left and right active engine mount switch positions as shown in the image

 
Is the active engine mount switch clearly visible as shown in the image?
Yes
The active engine mount may still be serviceable even if the switch is clearly visible. GO toD4. and perform a vacuum test of the engine mount. Only install a new engine mount if the vacuum test fails
No
GO toD4.
D4: ACTIVE ENGINE MOUNT VACUUM CHECKS
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 
1
Disconnect the vacuum lines directly from the left and right active engine mounts
E188328
  
E199106
  
 
2
Using the Jaguar Land Rover approved vacuum testing equipment, connect to each active engine mount and check it is holding vacuum. The engine mount should switch before 0.4 bar of vacuum is pulled and then be able to hold the vacuum for 30 seconds

 
Did the engine mount hold the vacuum for 30 seconds?
Yes
GO toD5.
No
The active engine mount is faulty, replace only the faulty active engine mount and retest
D5: ACTIVE ENGINE MOUNT SOLENOID ELECTRICAL CHECKS
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 
1
Refer to the electrical circuit diagrams and check the active engine mount solenoid circuit for short circuit to ground, open circuit, high resistance. Repair circuit as required and retest. Check vacuum is present at the end of the lines

 
Did the check and repair of the active engine mount solenoid circuit resolve the issue?
Yes
No further action is required
No
Check and install a new active engine mount solenoid as required and retest. If the fault persists, reconfirm the customer symptoms
 
DIAGNOSTIC TROUBLE CODE INDEX

For a complete list of all Diagnostic Trouble Codes (Diagnostic trouble code(s)) 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).

CYLINDER PRESSURES CHECK USING DIAGNOSTIC EQUIPMENT (G2369884)

DIAGNOSIS AND TESTING
 

SPECIAL TOOL(S)

E179225
 

JLR-CF54

Jaguar Land Rover (JLR) approved diagnostic equipment

E179226
 

BSU2

JLR approved battery support unit

E243739
 

JLR-IDU2

IDU 2 Kit

E243740
 

IDU06

Petrol Compression Test Cable

E243741
 

IDU06C

Diesel Compression Test Cable

NOTE:

The Jaguar Land Rover (JLR) approved diagnostic equipment will read the Vehicle Identification Number (VIN) for the vehicle.

  1. Connect the Jaguar Land Rover (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 the 'Diagnosis' Session Type.
    2. Select any of the following symptoms:
      • Powertrain-Engine System-Engine Performance
      • Powertrain-Engine System-Starting System
      • Electrical-Instruments-Warning Lamps-Engine Malfunction Lamp
    3. Run Inline diagnostic unit 2, relative compression test - XXXX
    4. When all of the tasks are complete, exit the session.
  1. Disconnect the JLR approved diagnostic equipment and the JLR approved battery support unit.

  2. CYLINDER HEAD DISTORTION (G1676086)

    GENERAL PROCEDURES
     
    • 01.01.34
    • CYLINDER HEAD - DISTORTION MEASUREMENT
    • ALL DERIVATIVES
    • 0.10
    • USED WITHINS
     
    CHECK
     
      1. E160359
        Using a suitable metallic straight edge and feeler gauge, measure the cylinder head face in the areas illustrated. Note the maximum value.
     
    1. CAUTION:

      Machine the minimum thickness of material from the cylinder head to meet specification. If a selection of cylinder head gaskets are available, increase the thickness of the cylinder head gasket by one size.

      NOTES:

      • Prior to having the cylinder head machined, prior approval is required by Jaguar or Land Rover engineering.

      • If the cylinder head requires machining, this must be carried out by a local engineering company.

      If the cylinder head exceeds the maximum value, the cylinder head must be machined.
      Refer to:Specifications (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Specifications).
      Refer to:Specifications (303-01B Engine - V6 S/C 3.0L Petrol, Specifications).
      Refer to:Specifications (303-01C Engine - V8 S/C 5.0L Petrol, Specifications).
      Refer to:Specifications (303-01C Engine - V8 S/C 5.0L Petrol, Specifications).

 

CYLINDER HEAD GASKET SELECTION - TDV6 3.0L DIESEL (G1453873)

GENERAL PROCEDURES
 

SPECIAL TOOL(S)

E86886
 

303-979

Measuring Bridge, Piston Protusion

 
CHECK
NOTE:

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


 
    1. CAUTION:

      Make sure that the surface is clean and free of foreign material.

      E87024
      Zero the gauge on the cylinder block machined face.
      Special Tool(s): 303-979
 
    1. CAUTION:

      Make sure that the surface is clean and free of foreign material.

      NOTE:

      Note the dial gauge readings.

      E87025
      Take 2 measurements on each piston crown.
 
  1. Use the average piston protrusion measurement (taken from all piston measurements), to select the correct thickness cylinder head gasket.
    Refer to:Specifications (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Specifications).

CYLINDER COMPRESSION TEST - TDV6 3.0L DIESEL (G1716424)

GENERAL PROCEDURES
 
  • 12.25.01
  • CYLINDER PRESSURES - CHECK
  • 3000 CC, TDV6
  • 1.60
  • USED WITHINS

GENERAL EQUIPMENT

EQUIPMENT NAME
Compression tester (petrol/diesel)
 
CHECK
CAUTION:

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

NOTES:

  • Removal steps in this procedure may contain installation details.

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

  • The vehicle battery must be in good condition and fully charged before carrying out this procedure.


 
    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. Refer to:Intake Air Shutoff Throttle (303-04A Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Refer to:Oil Filter Element (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Refer to:Crankcase Vent Oil Separator (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. E162866
      Torque: 10Nm
 
    1. E144252
      Torque: 10Nm
 
    1. NOTE:

      Some components shown removed for clarity.

      E163237
 
    1. NOTE:

      Some components shown removed for clarity.

      E163238
 
    1. CAUTION:

      Make sure the fuel injection system is disabled before carrying out a cylinder compression test. Failure to follow this step may result in damage to the vehicle.

      NOTE:

      Some components shown removed for clarity.

      E163239
 
    1. CAUTION:

      Make sure the fuel injection system is disabled before carrying out a cylinder compression test. Failure to follow this step may result in damage to the vehicle.

      NOTE:

      Some components shown removed for clarity.

      E163240
 
    1. E163241
      Torque: 10Nm
 
    1. E163242
      Torque: 10Nm
 
    1. CAUTION:

      Take extra care not to damage the component.

      E112579
 
    1. CAUTIONS:

      • Take care when handling the components.

      • Fixings must be started by hand to avoid damaging threads.

      • If accidentally dropped or knocked install a new glow plug.

      E163243
      Remove the glow plugs.
      Torque: 10Nm
 
    1. E163234
      Install the oil filter element and housing.
      Torque: 28Nm
 
    1. CAUTION:

      Make sure the fuel injection system is disabled before carrying out a cylinder compression test. Failure to follow this step may result in damage to the vehicle.

      Crank the engine for approximately five seconds to remove any remaining fuel in the cylinders.
 
    1. CAUTION:

      Make sure the correct adaptors are used.

      E224218
      Install the compression tester (K00825).
      General Equipment: Compression tester (petrol/diesel)
      Torque: 10Nm
 
    1. NOTES:

      • This step requires the aid of another technician.

      • Print graphic number E163867 in Step 22. Use this graphic to record each cylinder compression figure.

      • The vehicle battery must be in good condition and fully charged before carrying out this procedure.

      E163948
      Crank the engine for 10 seconds and record the figure displayed on the compression test gauge. Make sure the pressure is released from the compression test gauge after each cylinder recording. Repeat the process for all cylinders.
 
    1. E163867
 
    1. To install, reverse the removal procedure.
 
    1. The minimum cylinder compression reading recorded must be within 10% of the maximum cylinder compression reading recorded. If the difference across the cylinders is higher than 10% please contact dealer technical support (DTS) for further assistance.
 
  1. Using the Land Rover approved diagnostic equipment, read and clear any diagnostic trouble codes (DTCs).

303-01A: Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2

ENGINE - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1950015)

DESCRIPTION AND OPERATION
 
 
COMPONENT LOCATION

EXTERNAL VIEWS

E169818
 
OVERVIEW

The TDV6 3.0L Diesel engine is a V6 configuration unit with two banks of three cylinders arranged at 60 degrees to each other. There are four valves per cylinder, which are operated by two overhead camshafts per cylinder bank.

The cylinder block is coupled with a cast oil pan to provide a lightweight, compact and very stiff bottom end. The cylinder heads are fitted with integrated intake manifold and camshaft covers. The exhaust manifolds are unique for each cylinder head. An acoustic cover is fitted over the upper engine to absorb engine-generated noise.

Depending on the market, there are two variants of the TDV6 3.0L Diesel engine:

  • Single turbocharger variant
  • Twin turbocharger variant.

The single turbocharger variant uses a Variable Geometry Turbocharger (VGT), the twin turbocharger variant uses two turbochargers. The twin turbocharger variant comprises a VGT as a primary turbocharger, and a fixed vane type as a secondary turbocharger.

A low compression ratio of 16:1 contributes to improved emissions quality, quieter combustion and compatibility with the engine’s unique forced induction 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 low compression ratio also means less heat build-up in the piston bowl and more efficient fuel burn, resulting in the production of lower levels of pollutants. It also assists with cold starting allowing a faster cranking speed.

 
DESCRIPTION

ENGINE STRUCTURE

E120983
 
ITEM DESCRIPTION
1 Cylinder heads
2 Cylinder block
3 Oil pan

CYLINDER BLOCK COMPONENTS

The cylinder block is a single cast construction with a hollow beam structure. This type of construction provides outstanding strength and durability and reduces engine weight and length.

Lubrication oil is distributed through the cylinder block, via a main oil gallery and channels bored in the block, to all critical moving parts. These channels divert oil to the main and connecting rod bearings via holes machined into the crankshaft.

A tapping at the rear of the cylinder block connects a pipe to the turbochargers by means of banjo connections. Oil is supplied, under pressure via this tapping, from the oil pump to provide lubrication for the bearings of the turbochargers.

Cylinder cooling is achieved by coolant circulating through chambers in the cylinder block casting.

Two hollow dowels are used to locate the cylinder heads to the cylinder block, one on each side at the rear of the unit.

A port is included at the right and left side of the cylinder block, below each of the turbochargers, to connect the turbochargers oil return pipe to the oil pan.

Two coolant drain plugs are installed in the cylinder block. One is fitted in the rear right side, and the other is fitted in the middle of the cylinder block on the left side.

PISTON COOLING JETS

E152112
 
ITEM DESCRIPTION
1 Bolt
2 Cooling jet

Jets located in the cylinder block provide piston and gudgeon pin lubrication and cooling. These jets spray oil on to the inside of the piston, the oil then flows through 2 internal wave shaped channels to help cool each piston crown.

CYLINDER NUMBERING

DIN standard cylinder numbering
NOTE:

Front of engine is at cylinder 1

E163885
 
ITEM DESCRIPTION
A Engine rear

DIN standard cylinder firing order: 1,4,2,5,3,6

 

Engine Serial Number
E120570

Engine serial number is stamped on the right side of the cylinder block.

CRANKSHAFT

E152113
 
ITEM DESCRIPTION
1 Oil pump drive
2 Main bearing journal
3 Connecting rod bearing journal
4 Rear drive flange
5 Rear oil seal location
6 Reluctor ring location

The crankshaft runs in four bearings with clamped two layer bearing shells. The upper and lower shells of bearing number 4 are flanged, which limits the end float of the crankshaft. The main bearing caps are double bolted and cross bolted to increase the strength and rigidity of the engine block.

The main bearings are selective split plain bearings. An oil groove in the top half of each bearing transfers oil into the crankshaft for lubrication of the connecting rod bearings.

Crankshaft Rear Oil Seal

E152122
 
ITEM DESCRIPTION
1 Crankshaft reluctor ring
2 Crankshaft rear seal retainer
3 Crankshaft rear seal
4 Bolt (10 of)

The crankshaft rear seal and retainer assembly is a one-piece unit and is supplied with its own fitting sleeve. The seal and retainer have two locating dowels, ten fixing bolts and a seal. In addition, the retainer has a location for the Crankshaft Position Sensor (CKP). 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).

Crankshaft Reluctor Ring

E152123
 
ITEM DESCRIPTION
1 Special tool
2 Reluctor ring
3 Crankshaft

The crankshaft reluctor ring is located on the rear of the crankshaft. It is pressed onto the crankshaft using a special tool, which also precisely aligns the reluctor ring for crankshaft position and timing.

The crankshaft reluctor ring consists of 60 magnets minus 2 for Powertrain Control Module (PCM) crankshaft position reference and synchronization. The magnets cannot be seen on the reluctor ring, which therefore can only be positioned using the special tool.

If the reluctor ring is removed for any reason, then a new reluctor ring must be fitted.

Crankshaft Pulley/Mass Damper

The crankshaft pulley/mass damper is bolted to the front of the crankshaft to provide the drive for the engine accessory components. For additional information, refer to:Accessory Drive (303-05A Accessory Drive - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Description and Operation).

OIL PAN COMPONENTS

E112394
 
ITEM DESCRIPTION
1 Oil scavenge reservoir
2 Oil level and temperature sensor
3 Oil pick-up pipe
4 Oil level and temperature sensor connector

The structural oil pan is fitted to the lower cylinder block to stiffen the base structure of the engine, helping to reduce Noise,Vibration and Harshness (NVH). The oil pan also incorporates an oil baffle plate to reduce oil foaming and splash.

The oil pan is secured to the cylinder block with two dowels, two locator pins for the gasket and 18 retaining bolts.

Three different lengths of bolts are used:

  • M8 x 20 (9 of).
  • M8 x 75 (1 of).
  • M6 x 105 (8 of).

A gasket seals the joint between the oil pan and the cylinder block.

An oil pick-up pipe with integral strainer locates in the oil pan to provide oil to the crankshaft driven oil pump.

An oil level and temperature sensor provides an electronic indication of the oil level. This removes the requirement for the mechanical dipstick. An advantage in comparison with the static 'dipstick' method is that all marginal influences, for example vehicle being on a slope, lateral and longitudinal acceleration, are compensated for by averaging.

The values determined can be used to signal that the minimum oil level has been reached or to display the current oil level if required.

The sensor is mounted inside the oil pan where it sends an ultrasonic pulse vertically upward, it then measures the time for the pulse to be reflected back from the top surface of the oil.

PISTON AND CONNECTING ROD ASSEMBLY

E152118
 
ITEM DESCRIPTION
1 Circlip
2 Piston
3 Gudgeon pin
4 Circlip
5 Connecting rod identification
6 Connecting rod bolts (2 of)
7 Connecting rod bearings (2 of)
8 Connecting rod

The connecting rods have fracture-split bearing caps. The bearing caps are produced by fracturing the opposing sides of the connecting rod at the bearing horizontal center-line. As well as being easier to manufacture, when reassembled the fractured surfaces interlock to form a strong seamless joint. The cylinder position is etched on adjoining sides of the joint to identify matching connecting rods and bearing caps. The connecting rod bearings are selective split plain bearings. The connecting rod bearing is 'bismuth coated tri-metal', which is a manufacturing process that layers the bearing material to produce a higher load capacity for improved durability.

NOTE:

The connecting rods are not selective.

Piston And Connecting Rod Orientation

E152111
 
ITEM DESCRIPTION
1 Piston and connecting rod assembly, cylinders 4-6
2 Piston and connecting rod assembly, cylinders 1-3
3 Connecting rod bearing cap (6 of)
4 Bolts (12 of)
5 Connecting rod lower bearing (6 of)

When installing a connecting rod, ensure the back of the connecting rod faces the center of the 'vee'.

The pistons are fitted with three rings. The piston crown incorporates a pronounced bowl. This forms the combustion chamber, which promotes swirl and turbulence necessary for good combustion and improved emissions. In addition, the piston skirt has a molybdenum-coated surface, which counteracts scoring of the cylinder bore and piston.

The piston also incorporates a double wave gallery within the piston crown to enhance piston cooling. The pistons are supplied oil by means of spray jets located in the cylinder block oil gallery. These jets ensure optimum piston cooling to counteract the high temperatures generated by the combustion process.

Each piston is installed on a gudgeon pin located in a bushing in the connecting rod.

PISTON RINGS ORIENTATION

E152119
 
ITEM DESCRIPTION
1 Ring gap - Oil control ring
2 Ring gap - Upper compression ring
3 Spiral joint - Oil control ring
4 Upper compression ring
5 Lower compression ring
6 Oil control ring
7 Ring gap - Lower compression ring

When installing pistons ensure the arrows on the piston crowns all point to the front of the engine. All pistons are common single grade/single part number for all engines.

The piston top ring is a taper type and is fitted with the taper to the top of the piston. All rings marked 'top' are assembled with 'top' uppermost. All rings must be spaced evenly around the piston before installing. The circumference gap of the double beveled oil control ring must be opposite the spiral control joint.

CAMSHAFT TIMING COMPONENTS - PRIMARY DRIVE

E152121
 
ITEM DESCRIPTION
1 Bolt
2 Bolt (3 off)
3 Right camshaft timing pulley
4 Camshaft hub
5 Exhaust camshaft - Bank 1
6 Secondary timing chain tensioner - Bank 1
7 Secondary timing chain - Bank 1
8 Intake camshaft - Bank 1
9 Intake camshaft - Bank 2
10 Exhaust camshaft - Bank 2
11 Secondary timing chain tensioner - Bank 2
12 Secondary timing chain - Bank 2
13 Camshaft hub
14 Left camshaft timing pulley
15 Bolt (3 of)
16 Bolt
17 Bolt
18 Crankshaft drive gear
19 Bolt
20 Timing belt
21 Timing belt tensioner
22 Bolt
23 Bolt
24 Idler pulley
25 Idler pulley

Primary drive is provided by a toothed timing belt from the crankshaft to the exhaust camshaft gears of each cylinder bank via two idler pulleys and a tensioner.

Timing belt adjustment is carried out by the eccentric type tensioner mounted on the right front face of the cylinder block.

The primary drive cover is secured to the front of the cylinder block, cylinder heads, intake manifolds and oil pump housing. The cover is sealed with a gasket. A bridge piece closes the back of the cover in between the cylinder heads.

CAMSHAFT TIMING COMPONENTS - SECONDARY DRIVE

NOTE:

Bank 1 cylinder head installation shown, Bank 2 is similar.

E152125
 
ITEM DESCRIPTION
1 Tensioner firing pin
2 Secondary timing chain
3 Bolt (2 of)
4 Intake camshaft
5 Exhaust camshaft
6 Timing chain tensioner

Secondary drive is provided by two short secondary timing chains, which transfer drive from the exhaust camshaft sprockets to the intake camshaft sprockets. The secondary drives are located at the rear of the Bank 1 cylinder head and the front of the Bank 2 cylinder head. This allows for a much shorter and simpler run for the timing belt at the front of the engine.

Each secondary timing chain is tensioned via an automatic chain tensioner, which acts directly on the chains via a guide rail. The tensioners are located between the exhaust and intake camshafts at the front or rear of the cylinder head, depending on the cylinder bank.

The tensioner firing pin holds the automatic chain tensioner in a compressed state to aid installation.

CYLINDER HEAD COMPONENTS

NOTE:

Bank 2 cylinder head shown, Bank 1 cylinder head is similar.

E152115
 
ITEM DESCRIPTION
1 Bolt (4 of)
2 Front lifting eye
3 Rear lifting eye
4 Bolt (4 of)
5 Camshaft cover stud (6 of)
6 Camshaft cover bolt (7 of)
7 Intake manifold camshaft cover assembly
8 Gasket
9 Cylinder head
10 Plug (coolant)
11 Plug (oil port)
12 Camshaft bearing cap (7 of)
13 Bolts (18 of)
14 Camshaft bearing cap and seal housing (2 of)
15 Intake camshaft
16 Seal
17 Cylinder head bolts (8 of)
18 Exhaust camshaft
19 Secondary timing chain
20 Seal
21 Cylinder head gasket
22 Plug (oil port)
23 Plug (coolant)
24 Plug (oil port)
Cylinder Heads
E152114
 
ITEM DESCRIPTION
1 Blanking plug - coolant (2 of)
2 Cylinder head bolt (8 of)
3 Exhaust manifold stud (6 of)
4 Cylinder head dowel
5 Cylinder head dowel

The cylinder heads are unique to each cylinder bank. Eight deep-seated bolts help reduce distortion and secure each cylinder head to the cylinder block. The cylinder head bolts are located beneath the camshafts, four under the intake camshaft and four under the exhaust camshaft. Two hollow dowels align each cylinder head with the cylinder block.

NOTE:

The cylinder heads cannot be reworked.

The cylinder head gasket is available in five different thicknesses. The choice of gasket thickness is dependent on the maximum piston protrusion. Gasket thickness is identified by serrations cut into the front end of the gasket. 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 cylinder head has four ports machined at each cylinder location, two exhaust ports and two intake ports. One of the intake ports is helical and functions as a swirl port, the other is arranged laterally as a tangential port and functions as a charge port.

The camshafts are of a hollow tube construction, with pressed on lobes. Each camshaft is retained by caps, five for the exhaust camshafts and four for the intake camshafts. Location letters, A to I for the intake camshaft and R to Z for the exhaust camshaft, are marked on the outer faces of the caps for each cylinder head.

High Pressure (HP) Fuel Pump Drive
E152120
 
ITEM DESCRIPTION
1 Bolt
2 Camshaft gear
3 Toothed belt
4 Left cylinder head exhaust camshaft
5 High Pressure (HP) fuel pump
6 High Pressure (HP) fuel pump gear
7 Nut
8 Bolt
9 Tensioner
10 Bolts

 

The left cylinder bank exhaust camshaft is machined to accept a rear camshaft gear. The rear camshaft gear provides drive for the High Pressure (HP) fuel pump.

The HP fuel pump drive incorporates the following main components:

  • Camshaft gear
  • HP fuel pump gear
  • Toothed belt
  • Tensioner.

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 exhaust camshaft gear of the Bank 2 cylinder head also incorporates a reluctor ring, which is used in conjunction with the Camshaft Position Sensor (CMP) to measure engine position. 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 Bank 1 cylinder head exhaust camshaft is machined at the rear end to provide a drive connection for the vacuum and oil scavenge pump.

The fuel injection nozzles are centrally mounted above each cylinder. 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 glow plugs are arranged centrally on the intake side of the cylinder heads, between the two intake ports of each cylinder. 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).

The engine lifting eyes are bolted to the cylinder head, one at the front and two at the rear of the engine, one per cylinder head.

 

Camshaft Covers
NOTE:

Bank 1 installation shown, Bank 2 is similar.

E152126
 
ITEM DESCRIPTION
1 Camshaft cover stud (8 of)
2 Camshaft cover - intake manifold assembly
3 Oil filler cap
4 Camshaft cover bolt (5 of)

The Bank 1 camshaft cover incorporates an outlet for the full load engine breather and the engine oil filler cap. The Bank 2 camshaft cover incorporates an outlet for the part load engine breather. 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).

In-groove gaskets seal the joints between the camshaft covers and the cylinder heads. Together with spacers and seals on the camshaft cover fasteners, the gaskets are isolate the covers from direct contact with the cylinder heads, to reduce noise.

 

Intake And Exhaust Valves
NOTE:

Bank 1 installation shown, Bank 2 is similar.

E152155
 
ITEM DESCRIPTION
1 Valve spring collet - 24 of (12 per cylinder head)
2 Valve spring retainer - 24 of (12 per cylinder head)
3 Valve spring - 24 of (12 per cylinder head)
4 Valve stem seal - 24 of (12 per cylinder head)
5 Exhaust valve - 12 of (6 per cylinder head)
6 Intake valve - 12 of (6 per cylinder head)

Each cylinder head incorporates two overhead camshafts operating four valves per cylinder via rocker arms with hydraulic valve tappets.

Rocker Arms And Hydraulic Valve Tappets
E152124
 
ITEM DESCRIPTION
1 Hydraulic valve tappet - 24 of (12 per cylinder head)
2 Rocker arm - 24 of (12 per cylinder head)

The lightweight valve gear provides good economy and noise levels. Valve head diameters are 31 mm (1.220 in) for the exhaust and 35 mm (1.378 in) for the intake. All valves have 5 mm (0.197 in) diameter stems supported in seats and guide inserts. Valve spring collets, collars seats locate single valve springs on both intake and exhaust valves. Valve stem seals are integrated into the valve spring seats.

VACUUM AND OIL SCAVENGE PUMP

E149083
 
ITEM DESCRIPTION
1 Vacuum pipe connections
2 Torx bolt (2 of)
3 Nut
4 Bracket (emission hose)
5 Stud

The vacuum and oil scavenge pump is located at the rear of the Bank 1 cylinder head and driven from the exhaust camshaft. The pump provides the vacuum used by the Exhaust Gas Recirculation (EGR), turbocharger and brake booster systems, and scavenges oil from the turbochargers.

EXHAUST MANIFOLDS

NOTE:

Left exhaust manifold is shown, right exhaust manifold is similar.

E169819
 
ITEM DESCRIPTION
1 Cylinder head
2 Connecting pipe
3 Bolt (3 of)
4 Nut (3 of)
5 Exhaust manifold
6 Turbocharger (primary turbocharger shown)
7 Manifold rear heat shield
8 Bolt
9 Bolt (2 of)
10 Manifold heat shield
11 Gasket

The exhaust manifolds are cast from an iron alloy with a high nickel content giving excellent heat and corrosion resistance properties. They are sealed to the cylinder head by means of a steel gasket. Sacrificial plastic sleeves are used to align the manifolds. These sleeves must be changed when refitting the manifolds. Spacers on the securing bolts allow the manifolds to expand and retract with changes of temperature while maintaining the clamping loads.

The Bank 1 exhaust manifold has a connection for the High Pressure (HP) Exhaust Gas Recirculation (EGR) valve.

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

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

LUBRICATION SYSTEM

NOTE:

Twin turbocharger variant shown, single turbocharger variant is similar.

E169820
 
ITEM DESCRIPTION
1 Intake camshaft
2 Exhaust camshaft
3 Turbocharger oil supply
4 Primary turbocharger
5 Crankshaft and connecting rods
6 Oil level and temperature sensor
7 Oil pan
8 Oil pump
9 Oil cooler and filter assembly
10 Piston cooling jets
11 Secondary turbocharger

Oil is drawn from the oil pan and pressurized by the oil pump. The output from the oil pump is then filtered and distributed through internal oil passageways.

All moving parts are lubricated by pressure or splash oil. Pressurized oil is also provided for operation of the hydraulic valve tappets and the timing gear chain tensioners.

 

Oil Cooler And Filter Assembly
E169821
 
ITEM DESCRIPTION
1 Filter housing
2 O-ring seal
3 Filter element
4 Retaining bolt (6 of)
5 Coolant outlet connection
6 Oil cooler assembly

The engine is lubricated by a force-feed oil circulation system with a full flow oil filter. The oil cooler forms a unit with the oil filter, which is mounted centrally in the middle of the cylinder block between the two banks of cylinders. The engine oil is cooled using the engine cooling system. 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).

Oil returns to the oil pan under gravity. Large drain holes through the cylinder heads and cylinder block ensure the quick return of the oil, reducing the volume of oil required and enabling an accurate check of the contents soon after the engine stops.

System replenishment is through the oil filler cap on the right camshaft cover.

The oil pick-up is immersed in the oil reservoir to provide a supply to the oil pump during all normal vehicle attitudes. A mesh screen in the intake prevents debris from entering the oil system.

 

Oil Pump
E169823

The oil pump is a G-rotor two stage pressure pump with solenoid control to switch between low and high pressure modes depending on engine speed and load to optimize fuel economy.

It is bolted to the front of the cylinder block. It is sealed by means of a gasket, which is recessed into the oil pump housing. The pump intake and outlet ports align with oil passages in the cylinder block.

The pumping element is an eccentric rotor, which is directly driven by flats on the crankshaft. An integral pressure relief valve regulates pump outlet pressure at 4.5 bar (65.25 lb/in²).

The front crankshaft oil seal is housed in the oil pump casing and is fitted such that its front face is 1 mm (0.04 in) under flush with the machined front face of the oil pump.

NOTE:

The seal is not to be pushed all the way into the bore as this will block the seal drains.

 

Oil Pan
E169822
 
ITEM DESCRIPTION
1 Primary turbocharger
2 Turbocharger oil feed pipes
3 Vacuum and oil scavenge pump
4 Oil scavenge pipe
5 Oil extraction tube
6 Secondary turbocharger - If equipped
7 Secondary turbocharger oil return tube - If equipped
8 Drain plug
9 Secondary reservoir
10 Primary turbocharger oil return tube

Due to the wide range of inclines Land Rover vehicles operate across, the geometry of the oil pan has been configured to guarantee oil pick-up across all operating angles. An oil scavenge system has been developed to guarantee excellent oil flow through the turbochargers on severe side-slopes. At extreme angles there is a risk the turbochargers may be below the oil level in the oil pan, restricting oil return flow.

 

To overcome this, the engine uses:

  • The oil pump to supply oil to the turbocharger bearings from the main reservoir of the oil pan.
  • A secondary reservoir in the oil pan, sealed off from the main reservoir, to receive oil from the turbocharger bearings.
  • The vacuum and oil scavenge pump to assist the oil flow from the turbocharger bearings by scavenging oil from the secondary reservoir into the right camshaft cover.

For service, a drain plug and an oil extraction tube are installed to drain the main body of the oil pan.

OIL LEVEL CHECK

The engine oil level can be displayed in the message center on the Instrument Cluster (IC).

For accuracy, oil level checks should be performed with the vehicle on level ground when the oil is hot. The vehicle needs to stand for approximately 10 minutes, after the engine is switched off, to allow the oil to drain back into the sump and the oil level to stabilize. The oil level system will not give a reading until the oil level has stabilized.

The method of checking the oil level can be found in the oil draining and filling procedures.

For additional information, refer to:(303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2)

 

 
OPERATION

Operation of the engine is controlled by the Powertrain Contol Module (PCM).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).

ENGINE - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G2094377)

SPECIFICATIONS
 

Engine Data - Low Flow Fuel Injection System

ENGINE DESCRIPTION ENGINE CAPACITY MAXIMUM ENGINE TORQUE (EEC) (SAE) MAXIMUM ENGINE POWER (EEC) (SAE) COMPRESSION RATIO BORE STROKE
60° "Vee" • 6 Cylinder • 24 Valves 2993 ccm 600 Nm at 2000 RPM 190 kW at 4000 RPM 16.1:1 ± 0.5 84 90

Engine Data - Standard Flow Fuel Injection System

ENGINE DESCRIPTION ENGINE CAPACITY MAXIMUM ENGINE TORQUE (EEC) (SAE) MAXIMUM ENGINE POWER (EEC) (SAE) COMPRESSION RATIO BORE STROKE
60° "Vee" • 6 Cylinder • 24 Valves 2993 ccm 600 Nm at 2000 RPM 223 kW at 4000 RPM 16.1:1 ± 0.5 84 90

Engine Firing Order

FIRING ORDER
1:4:2:5:3:6

Glow Plug

SPECIFICATION
9X2Q-6M090-AC

Lubricants, Fluids, Sealers and Adhesives

DESCRIPTION SPECIFICATION
Engine oil - Vehicles with diesel particulate filter SAE 5W30 STJLR.03.5005
Engine oil - Vehicles without diesel particulate filter SAE 5W30 STJLR.03.5003
Sealant WSE–M4G323–A5
Core plug and stub pipe retainer WSK-M2G349-A7
Cooling system fluid Havoline Extended Life Coolant (XLC)

Capacities

DESCRIPTION LITERS
Engine oil initial fill 6.75
Engine oil service fill with oil filter change 5.9

Cylinder Head and Valve Train

ITEM SPECIFICATION
Valve guide inner diameter (mm) 5.980 ± 0.010
Intake valve effective length (mm) (tip to gauge line) 94.99mm +/- 0.15
Exhaust valve effective length (mm) (tip to gauge line) 94.45mm +/-0.15
Valve stem to guide clearance intake diametrical (mm) 0.027 - 0.063
Valve stem to guide clearance exhaust diametrical (mm) 0.037 - 0.073
Valve head diameter intake (mm) 27.8mm +/-0.1
Valve head diameter exhaust (mm) 25.2mm +/-0.1
Intake valve face angle (degrees) 44 deg 52 min +/-7min30sec
Exhaust valve face angle (degrees) 44 deg 52 min +/-7min30sec
Valve stem diameter intake (mm) 5.935±0.008
Valve stem diameter exhaust (mm) 5.925±0.008
Valve spring free length (mm) - inlet 38.9mm
Valve spring free length (mm) - exhaust 38.9mm
Valve spring installed height (mm) - inlet 31.22mm
Valve spring installed height (mm) - exhaust 31.22mm
Camshaft lobe max lift intake (mm) 3.75187mm
Camshaft lobe max lift exhaust (mm) 3.80999mm
Camshaft journal to cylinder head bearing surface clearance diametrical (mm) 0.040-0.090
Camshaft journal diameter - all positions 26.015±0.015
Bearing diameter - all positions 25.950±0.010
Camshaft journal maximum run out limit (mm) 0.030mm
Camshaft journal maximum out of round (mm) - all journals 0.010mm
Cylinder head maximum permitted warp (mm) flatness specification 0.2mm (0.008 in)
Cylinder block maximumpermitted warp (flatness specification) 0.2mm (0.008 in)

Cylinder Head Gasket

IDENTIFICATION GASKET THICKNESS (MM) PISTON PROTRUSION (MM)
2 1.17 0.552 - 0.603
3 1.22 0.604 - 0.655
4 1.27 0.656 - 0.707
5 1.32 0.708 - 0.760

Torque Specification

NOTE:

A = refer to procedure for correct torque sequence

DESCRIPTION NM LB-FT LB-IN
Piston cooling nozzle 10 7 -
Engine coolant drain plug 18 13 -
Cylinder head retaining bolts A - -
Oil filter housing retaining bolts 10 7 -
Fuel injection pump cradle retaining bolts 23 17 -
Fuel injection pump to cradle retaining bolts 23 17 -
Fuel injection pump bracket to cradle retaining bolts 10 7 -
Fuel injection pump to bracket retaining bolts 10 7 -
Oil pump retaining bolts 10 7 -
Crankshaft rear oil seal housing retaining bolts 10 7 -
Oil pan retaining bolts M6 10 7 -
Oil pan retaining bolts M8 23 17 -
Oil pump pick up pipe retaining bolts 10 7 -
Engine oil level sensor retaining nuts 10 7 -
Crankshaft timing belt pulley retaining bolt A - -
Crankshaft position sensor (CKP) retaining bolt 5 - 44
Timing chain tensioner retaining bolts 10 7 -
Camshaft bearing cap retaining bolts A - -
Timing belt idler pulley retaining bolt 45 33 -
Fuel injection pump belt rear cover retaining bolts 10 7 -
Fuel injection pump sprocket retaining nut 50 37 -
Coolant outlet pipe retaining bolts 10 7 -
Coolant pump retaining bolts 10 7 -
Timing belt tensioner retaining bolt 26 19 -
Engine lifting eye bolts 23 17 -
Camshaft rear end accessory drive (READ) pulley hub retaining bolt Stage 1 - 80 Stage 2 - 80 degrees Stage 1 - 59 Stage 2 - 80 degrees -
Camshaft front timing pulley hub retaining bolt 80 + 80° 59 + 80 ° -
Camshaft READ pulley retaining bolt 23 17 -
Camshaft front timing pulley retaining bolt 23 17 -
Fuel injection pump timing belt tensioner bolt 23 17 -
Camshaft position sensor (CMP) retaining bolt 10 7 -
Intake manifold / camshaft cover retaining bolts 10 7 -
Brake vacuum pump retaining bolts 23 17 -
Engine oil pressure (EOP) switch 14 10 -
Glow plug 11 8 -
Fuel rail retaining bolts 23 17 -
Fuel rail bracket retaining bolts 23 17 -
Fuel injector retaining bolts A - -
High pressure fuel line union nuts A - -
High pressure fuel line bracket retaining bolts 9 - 80
Turbocharger assembly to exhaust manifold retaining nuts 24 18 -
Exhaust manifold to cylinder head retaining nuts A - -
Exhaust manifold heatshield retaining bolts 11 8 -
Turbocharger heatshield retaining bolts 11 8 -
Exhaust gas recirculation (EGR) valve retaining bolts M6 10 7 -
Accessory drive belt idler pulley bracket retaining bolts 83 61 -
Timing belt covers retaining bolts 10 7 -
Engine mount bracket to engine retaining bolts 115 85 -
Engine mount bracket to engine mounting 130 96 -
Engine mounting to subframe bolts. A - -
Exhaust cross over pipe retaining nuts 24 18 -
Engine coolant inlet pipe retaining bolts 10 7 -
Coolant pump pulley retaining bolts 25 18 -
Crankshaft pulley/vibration damper retaining bolts 25 18 -
Throttle body retaining threaded stud 10 7 -
Wiring harness retaining nuts 10 7 -
Vacuum hose assembly retaining bolts 10 7 -
Drive plate retaining bolts A - -
Accessory drive component bracket retaining bolts 23 17 -
Generator retaining bolts 47 35 -
Accessory drive belt tensioner retaining bolt 47 35 -
Accessory drive belt idler pulley retaining bolt 47 35 -
Air conditioning compressor bracket retaining bolts 23 17 -
Air conditioning compressor retaining bolts 23 17 -
 

Description and Operation

ENGINE - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1950015)

DESCRIPTION AND OPERATION
 
 
COMPONENT LOCATION

EXTERNAL VIEWS

E169818
 
OVERVIEW

The TDV6 3.0L Diesel engine is a V6 configuration unit with two banks of three cylinders arranged at 60 degrees to each other. There are four valves per cylinder, which are operated by two overhead camshafts per cylinder bank.

The cylinder block is coupled with a cast oil pan to provide a lightweight, compact and very stiff bottom end. The cylinder heads are fitted with integrated intake manifold and camshaft covers. The exhaust manifolds are unique for each cylinder head. An acoustic cover is fitted over the upper engine to absorb engine-generated noise.

Depending on the market, there are two variants of the TDV6 3.0L Diesel engine:

  • Single turbocharger variant
  • Twin turbocharger variant.

The single turbocharger variant uses a Variable Geometry Turbocharger (VGT), the twin turbocharger variant uses two turbochargers. The twin turbocharger variant comprises a VGT as a primary turbocharger, and a fixed vane type as a secondary turbocharger.

A low compression ratio of 16:1 contributes to improved emissions quality, quieter combustion and compatibility with the engine’s unique forced induction 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 low compression ratio also means less heat build-up in the piston bowl and more efficient fuel burn, resulting in the production of lower levels of pollutants. It also assists with cold starting allowing a faster cranking speed.

 
DESCRIPTION

ENGINE STRUCTURE

E120983
 
ITEM DESCRIPTION
1 Cylinder heads
2 Cylinder block
3 Oil pan

CYLINDER BLOCK COMPONENTS

The cylinder block is a single cast construction with a hollow beam structure. This type of construction provides outstanding strength and durability and reduces engine weight and length.

Lubrication oil is distributed through the cylinder block, via a main oil gallery and channels bored in the block, to all critical moving parts. These channels divert oil to the main and connecting rod bearings via holes machined into the crankshaft.

A tapping at the rear of the cylinder block connects a pipe to the turbochargers by means of banjo connections. Oil is supplied, under pressure via this tapping, from the oil pump to provide lubrication for the bearings of the turbochargers.

Cylinder cooling is achieved by coolant circulating through chambers in the cylinder block casting.

Two hollow dowels are used to locate the cylinder heads to the cylinder block, one on each side at the rear of the unit.

A port is included at the right and left side of the cylinder block, below each of the turbochargers, to connect the turbochargers oil return pipe to the oil pan.

Two coolant drain plugs are installed in the cylinder block. One is fitted in the rear right side, and the other is fitted in the middle of the cylinder block on the left side.

PISTON COOLING JETS

E152112
 
ITEM DESCRIPTION
1 Bolt
2 Cooling jet

Jets located in the cylinder block provide piston and gudgeon pin lubrication and cooling. These jets spray oil on to the inside of the piston, the oil then flows through 2 internal wave shaped channels to help cool each piston crown.

CYLINDER NUMBERING

DIN standard cylinder numbering
NOTE:

Front of engine is at cylinder 1

E163885
 
ITEM DESCRIPTION
A Engine rear

DIN standard cylinder firing order: 1,4,2,5,3,6

 

Engine Serial Number

E120570

Engine serial number is stamped on the right side of the cylinder block.

CRANKSHAFT

E152113
 
ITEM DESCRIPTION
1 Oil pump drive
2 Main bearing journal
3 Connecting rod bearing journal
4 Rear drive flange
5 Rear oil seal location
6 Reluctor ring location

The crankshaft runs in four bearings with clamped two layer bearing shells. The upper and lower shells of bearing number 4 are flanged, which limits the end float of the crankshaft. The main bearing caps are double bolted and cross bolted to increase the strength and rigidity of the engine block.

The main bearings are selective split plain bearings. An oil groove in the top half of each bearing transfers oil into the crankshaft for lubrication of the connecting rod bearings.

Crankshaft Rear Oil Seal

E152122
 
ITEM DESCRIPTION
1 Crankshaft reluctor ring
2 Crankshaft rear seal retainer
3 Crankshaft rear seal
4 Bolt (10 of)

The crankshaft rear seal and retainer assembly is a one-piece unit and is supplied with its own fitting sleeve. The seal and retainer have two locating dowels, ten fixing bolts and a seal. In addition, the retainer has a location for the Crankshaft Position Sensor (CKP). 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).

Crankshaft Reluctor Ring

E152123
 
ITEM DESCRIPTION
1 Special tool
2 Reluctor ring
3 Crankshaft

The crankshaft reluctor ring is located on the rear of the crankshaft. It is pressed onto the crankshaft using a special tool, which also precisely aligns the reluctor ring for crankshaft position and timing.

The crankshaft reluctor ring consists of 60 magnets minus 2 for Powertrain Control Module (PCM) crankshaft position reference and synchronization. The magnets cannot be seen on the reluctor ring, which therefore can only be positioned using the special tool.

If the reluctor ring is removed for any reason, then a new reluctor ring must be fitted.

Crankshaft Pulley/Mass Damper

The crankshaft pulley/mass damper is bolted to the front of the crankshaft to provide the drive for the engine accessory components. For additional information, refer to:Accessory Drive (303-05A Accessory Drive - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Description and Operation).

OIL PAN COMPONENTS

E112394
 
ITEM DESCRIPTION
1 Oil scavenge reservoir
2 Oil level and temperature sensor
3 Oil pick-up pipe
4 Oil level and temperature sensor connector

The structural oil pan is fitted to the lower cylinder block to stiffen the base structure of the engine, helping to reduce Noise,Vibration and Harshness (NVH). The oil pan also incorporates an oil baffle plate to reduce oil foaming and splash.

The oil pan is secured to the cylinder block with two dowels, two locator pins for the gasket and 18 retaining bolts.

Three different lengths of bolts are used:

  • M8 x 20 (9 of).
  • M8 x 75 (1 of).
  • M6 x 105 (8 of).

A gasket seals the joint between the oil pan and the cylinder block.

An oil pick-up pipe with integral strainer locates in the oil pan to provide oil to the crankshaft driven oil pump.

An oil level and temperature sensor provides an electronic indication of the oil level. This removes the requirement for the mechanical dipstick. An advantage in comparison with the static 'dipstick' method is that all marginal influences, for example vehicle being on a slope, lateral and longitudinal acceleration, are compensated for by averaging.

The values determined can be used to signal that the minimum oil level has been reached or to display the current oil level if required.

The sensor is mounted inside the oil pan where it sends an ultrasonic pulse vertically upward, it then measures the time for the pulse to be reflected back from the top surface of the oil.

PISTON AND CONNECTING ROD ASSEMBLY

E152118
 
ITEM DESCRIPTION
1 Circlip
2 Piston
3 Gudgeon pin
4 Circlip
5 Connecting rod identification
6 Connecting rod bolts (2 of)
7 Connecting rod bearings (2 of)
8 Connecting rod

The connecting rods have fracture-split bearing caps. The bearing caps are produced by fracturing the opposing sides of the connecting rod at the bearing horizontal center-line. As well as being easier to manufacture, when reassembled the fractured surfaces interlock to form a strong seamless joint. The cylinder position is etched on adjoining sides of the joint to identify matching connecting rods and bearing caps. The connecting rod bearings are selective split plain bearings. The connecting rod bearing is 'bismuth coated tri-metal', which is a manufacturing process that layers the bearing material to produce a higher load capacity for improved durability.

NOTE:

The connecting rods are not selective.

Piston And Connecting Rod Orientation

E152111
 
ITEM DESCRIPTION
1 Piston and connecting rod assembly, cylinders 4-6
2 Piston and connecting rod assembly, cylinders 1-3
3 Connecting rod bearing cap (6 of)
4 Bolts (12 of)
5 Connecting rod lower bearing (6 of)

When installing a connecting rod, ensure the back of the connecting rod faces the center of the 'vee'.

The pistons are fitted with three rings. The piston crown incorporates a pronounced bowl. This forms the combustion chamber, which promotes swirl and turbulence necessary for good combustion and improved emissions. In addition, the piston skirt has a molybdenum-coated surface, which counteracts scoring of the cylinder bore and piston.

The piston also incorporates a double wave gallery within the piston crown to enhance piston cooling. The pistons are supplied oil by means of spray jets located in the cylinder block oil gallery. These jets ensure optimum piston cooling to counteract the high temperatures generated by the combustion process.

Each piston is installed on a gudgeon pin located in a bushing in the connecting rod.

PISTON RINGS ORIENTATION

E152119
 
ITEM DESCRIPTION
1 Ring gap - Oil control ring
2 Ring gap - Upper compression ring
3 Spiral joint - Oil control ring
4 Upper compression ring
5 Lower compression ring
6 Oil control ring
7 Ring gap - Lower compression ring

When installing pistons ensure the arrows on the piston crowns all point to the front of the engine. All pistons are common single grade/single part number for all engines.

The piston top ring is a taper type and is fitted with the taper to the top of the piston. All rings marked 'top' are assembled with 'top' uppermost. All rings must be spaced evenly around the piston before installing. The circumference gap of the double beveled oil control ring must be opposite the spiral control joint.

CAMSHAFT TIMING COMPONENTS - PRIMARY DRIVE

E152121
 
ITEM DESCRIPTION
1 Bolt
2 Bolt (3 off)
3 Right camshaft timing pulley
4 Camshaft hub
5 Exhaust camshaft - Bank 1
6 Secondary timing chain tensioner - Bank 1
7 Secondary timing chain - Bank 1
8 Intake camshaft - Bank 1
9 Intake camshaft - Bank 2
10 Exhaust camshaft - Bank 2
11 Secondary timing chain tensioner - Bank 2
12 Secondary timing chain - Bank 2
13 Camshaft hub
14 Left camshaft timing pulley
15 Bolt (3 of)
16 Bolt
17 Bolt
18 Crankshaft drive gear
19 Bolt
20 Timing belt
21 Timing belt tensioner
22 Bolt
23 Bolt
24 Idler pulley
25 Idler pulley

Primary drive is provided by a toothed timing belt from the crankshaft to the exhaust camshaft gears of each cylinder bank via two idler pulleys and a tensioner.

Timing belt adjustment is carried out by the eccentric type tensioner mounted on the right front face of the cylinder block.

The primary drive cover is secured to the front of the cylinder block, cylinder heads, intake manifolds and oil pump housing. The cover is sealed with a gasket. A bridge piece closes the back of the cover in between the cylinder heads.

CAMSHAFT TIMING COMPONENTS - SECONDARY DRIVE

NOTE:

Bank 1 cylinder head installation shown, Bank 2 is similar.

E152125
 
ITEM DESCRIPTION
1 Tensioner firing pin
2 Secondary timing chain
3 Bolt (2 of)
4 Intake camshaft
5 Exhaust camshaft
6 Timing chain tensioner

Secondary drive is provided by two short secondary timing chains, which transfer drive from the exhaust camshaft sprockets to the intake camshaft sprockets. The secondary drives are located at the rear of the Bank 1 cylinder head and the front of the Bank 2 cylinder head. This allows for a much shorter and simpler run for the timing belt at the front of the engine.

Each secondary timing chain is tensioned via an automatic chain tensioner, which acts directly on the chains via a guide rail. The tensioners are located between the exhaust and intake camshafts at the front or rear of the cylinder head, depending on the cylinder bank.

The tensioner firing pin holds the automatic chain tensioner in a compressed state to aid installation.

CYLINDER HEAD COMPONENTS

NOTE:

Bank 2 cylinder head shown, Bank 1 cylinder head is similar.

E152115
 
ITEM DESCRIPTION
1 Bolt (4 of)
2 Front lifting eye
3 Rear lifting eye
4 Bolt (4 of)
5 Camshaft cover stud (6 of)
6 Camshaft cover bolt (7 of)
7 Intake manifold camshaft cover assembly
8 Gasket
9 Cylinder head
10 Plug (coolant)
11 Plug (oil port)
12 Camshaft bearing cap (7 of)
13 Bolts (18 of)
14 Camshaft bearing cap and seal housing (2 of)
15 Intake camshaft
16 Seal
17 Cylinder head bolts (8 of)
18 Exhaust camshaft
19 Secondary timing chain
20 Seal
21 Cylinder head gasket
22 Plug (oil port)
23 Plug (coolant)
24 Plug (oil port)
Cylinder Heads

E152114
 
ITEM DESCRIPTION
1 Blanking plug - coolant (2 of)
2 Cylinder head bolt (8 of)
3 Exhaust manifold stud (6 of)
4 Cylinder head dowel
5 Cylinder head dowel

The cylinder heads are unique to each cylinder bank. Eight deep-seated bolts help reduce distortion and secure each cylinder head to the cylinder block. The cylinder head bolts are located beneath the camshafts, four under the intake camshaft and four under the exhaust camshaft. Two hollow dowels align each cylinder head with the cylinder block.

NOTE:

The cylinder heads cannot be reworked.

The cylinder head gasket is available in five different thicknesses. The choice of gasket thickness is dependent on the maximum piston protrusion. Gasket thickness is identified by serrations cut into the front end of the gasket. 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 cylinder head has four ports machined at each cylinder location, two exhaust ports and two intake ports. One of the intake ports is helical and functions as a swirl port, the other is arranged laterally as a tangential port and functions as a charge port.

The camshafts are of a hollow tube construction, with pressed on lobes. Each camshaft is retained by caps, five for the exhaust camshafts and four for the intake camshafts. Location letters, A to I for the intake camshaft and R to Z for the exhaust camshaft, are marked on the outer faces of the caps for each cylinder head.

High Pressure (HP) Fuel Pump Drive

E152120
 
ITEM DESCRIPTION
1 Bolt
2 Camshaft gear
3 Toothed belt
4 Left cylinder head exhaust camshaft
5 High Pressure (HP) fuel pump
6 High Pressure (HP) fuel pump gear
7 Nut
8 Bolt
9 Tensioner
10 Bolts

 

The left cylinder bank exhaust camshaft is machined to accept a rear camshaft gear. The rear camshaft gear provides drive for the High Pressure (HP) fuel pump.

The HP fuel pump drive incorporates the following main components:

  • Camshaft gear
  • HP fuel pump gear
  • Toothed belt
  • Tensioner.

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 exhaust camshaft gear of the Bank 2 cylinder head also incorporates a reluctor ring, which is used in conjunction with the Camshaft Position Sensor (CMP) to measure engine position. 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 Bank 1 cylinder head exhaust camshaft is machined at the rear end to provide a drive connection for the vacuum and oil scavenge pump.

The fuel injection nozzles are centrally mounted above each cylinder. 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 glow plugs are arranged centrally on the intake side of the cylinder heads, between the two intake ports of each cylinder. 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).

The engine lifting eyes are bolted to the cylinder head, one at the front and two at the rear of the engine, one per cylinder head.

 

Camshaft Covers
NOTE:

Bank 1 installation shown, Bank 2 is similar.

E152126
 
ITEM DESCRIPTION
1 Camshaft cover stud (8 of)
2 Camshaft cover - intake manifold assembly
3 Oil filler cap
4 Camshaft cover bolt (5 of)

The Bank 1 camshaft cover incorporates an outlet for the full load engine breather and the engine oil filler cap. The Bank 2 camshaft cover incorporates an outlet for the part load engine breather. 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).

In-groove gaskets seal the joints between the camshaft covers and the cylinder heads. Together with spacers and seals on the camshaft cover fasteners, the gaskets are isolate the covers from direct contact with the cylinder heads, to reduce noise.

 

Intake And Exhaust Valves
NOTE:

Bank 1 installation shown, Bank 2 is similar.

E152155
 
ITEM DESCRIPTION
1 Valve spring collet - 24 of (12 per cylinder head)
2 Valve spring retainer - 24 of (12 per cylinder head)
3 Valve spring - 24 of (12 per cylinder head)
4 Valve stem seal - 24 of (12 per cylinder head)
5 Exhaust valve - 12 of (6 per cylinder head)
6 Intake valve - 12 of (6 per cylinder head)

Each cylinder head incorporates two overhead camshafts operating four valves per cylinder via rocker arms with hydraulic valve tappets.

Rocker Arms And Hydraulic Valve Tappets

E152124
 
ITEM DESCRIPTION
1 Hydraulic valve tappet - 24 of (12 per cylinder head)
2 Rocker arm - 24 of (12 per cylinder head)

The lightweight valve gear provides good economy and noise levels. Valve head diameters are 31 mm (1.220 in) for the exhaust and 35 mm (1.378 in) for the intake. All valves have 5 mm (0.197 in) diameter stems supported in seats and guide inserts. Valve spring collets, collars seats locate single valve springs on both intake and exhaust valves. Valve stem seals are integrated into the valve spring seats.

VACUUM AND OIL SCAVENGE PUMP

E149083
 
ITEM DESCRIPTION
1 Vacuum pipe connections
2 Torx bolt (2 of)
3 Nut
4 Bracket (emission hose)
5 Stud

The vacuum and oil scavenge pump is located at the rear of the Bank 1 cylinder head and driven from the exhaust camshaft. The pump provides the vacuum used by the Exhaust Gas Recirculation (EGR), turbocharger and brake booster systems, and scavenges oil from the turbochargers.

EXHAUST MANIFOLDS

NOTE:

Left exhaust manifold is shown, right exhaust manifold is similar.

E169819
 
ITEM DESCRIPTION
1 Cylinder head
2 Connecting pipe
3 Bolt (3 of)
4 Nut (3 of)
5 Exhaust manifold
6 Turbocharger (primary turbocharger shown)
7 Manifold rear heat shield
8 Bolt
9 Bolt (2 of)
10 Manifold heat shield
11 Gasket

The exhaust manifolds are cast from an iron alloy with a high nickel content giving excellent heat and corrosion resistance properties. They are sealed to the cylinder head by means of a steel gasket. Sacrificial plastic sleeves are used to align the manifolds. These sleeves must be changed when refitting the manifolds. Spacers on the securing bolts allow the manifolds to expand and retract with changes of temperature while maintaining the clamping loads.

The Bank 1 exhaust manifold has a connection for the High Pressure (HP) Exhaust Gas Recirculation (EGR) valve.

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

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

LUBRICATION SYSTEM

NOTE:

Twin turbocharger variant shown, single turbocharger variant is similar.

E169820
 
ITEM DESCRIPTION
1 Intake camshaft
2 Exhaust camshaft
3 Turbocharger oil supply
4 Primary turbocharger
5 Crankshaft and connecting rods
6 Oil level and temperature sensor
7 Oil pan
8 Oil pump
9 Oil cooler and filter assembly
10 Piston cooling jets
11 Secondary turbocharger

Oil is drawn from the oil pan and pressurized by the oil pump. The output from the oil pump is then filtered and distributed through internal oil passageways.

All moving parts are lubricated by pressure or splash oil. Pressurized oil is also provided for operation of the hydraulic valve tappets and the timing gear chain tensioners.

 

Oil Cooler And Filter Assembly

E169821
 
ITEM DESCRIPTION
1 Filter housing
2 O-ring seal
3 Filter element
4 Retaining bolt (6 of)
5 Coolant outlet connection
6 Oil cooler assembly

The engine is lubricated by a force-feed oil circulation system with a full flow oil filter. The oil cooler forms a unit with the oil filter, which is mounted centrally in the middle of the cylinder block between the two banks of cylinders. The engine oil is cooled using the engine cooling system. 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).

Oil returns to the oil pan under gravity. Large drain holes through the cylinder heads and cylinder block ensure the quick return of the oil, reducing the volume of oil required and enabling an accurate check of the contents soon after the engine stops.

System replenishment is through the oil filler cap on the right camshaft cover.

The oil pick-up is immersed in the oil reservoir to provide a supply to the oil pump during all normal vehicle attitudes. A mesh screen in the intake prevents debris from entering the oil system.

 

Oil Pump

E169823

The oil pump is a G-rotor two stage pressure pump with solenoid control to switch between low and high pressure modes depending on engine speed and load to optimize fuel economy.

It is bolted to the front of the cylinder block. It is sealed by means of a gasket, which is recessed into the oil pump housing. The pump intake and outlet ports align with oil passages in the cylinder block.

The pumping element is an eccentric rotor, which is directly driven by flats on the crankshaft. An integral pressure relief valve regulates pump outlet pressure at 4.5 bar (65.25 lb/in²).

The front crankshaft oil seal is housed in the oil pump casing and is fitted such that its front face is 1 mm (0.04 in) under flush with the machined front face of the oil pump.

NOTE:

The seal is not to be pushed all the way into the bore as this will block the seal drains.

 

Oil Pan

E169822
 
ITEM DESCRIPTION
1 Primary turbocharger
2 Turbocharger oil feed pipes
3 Vacuum and oil scavenge pump
4 Oil scavenge pipe
5 Oil extraction tube
6 Secondary turbocharger - If equipped
7 Secondary turbocharger oil return tube - If equipped
8 Drain plug
9 Secondary reservoir
10 Primary turbocharger oil return tube

Due to the wide range of inclines Land Rover vehicles operate across, the geometry of the oil pan has been configured to guarantee oil pick-up across all operating angles. An oil scavenge system has been developed to guarantee excellent oil flow through the turbochargers on severe side-slopes. At extreme angles there is a risk the turbochargers may be below the oil level in the oil pan, restricting oil return flow.

 

To overcome this, the engine uses:

  • The oil pump to supply oil to the turbocharger bearings from the main reservoir of the oil pan.
  • A secondary reservoir in the oil pan, sealed off from the main reservoir, to receive oil from the turbocharger bearings.
  • The vacuum and oil scavenge pump to assist the oil flow from the turbocharger bearings by scavenging oil from the secondary reservoir into the right camshaft cover.

For service, a drain plug and an oil extraction tube are installed to drain the main body of the oil pan.

OIL LEVEL CHECK

The engine oil level can be displayed in the message center on the Instrument Cluster (IC).

For accuracy, oil level checks should be performed with the vehicle on level ground when the oil is hot. The vehicle needs to stand for approximately 10 minutes, after the engine is switched off, to allow the oil to drain back into the sump and the oil level to stabilize. The oil level system will not give a reading until the oil level has stabilized.

The method of checking the oil level can be found in the oil draining and filling procedures.

For additional information, refer to:(303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2)

 

 
OPERATION

Operation of the engine is controlled by the Powertrain Contol Module (PCM).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).

Diagnosis and Testing

LONG/STRIPPED ENGINE ASSEMBLY RENEW - TDV6 3.0L DIESEL - GEN 2 - TWIN TURBOCHARGER (G2357394)

 
PART(S)
ALL VEHICLES
 
Name Quantity Part Number
Camshaft position sensor 1 LR013458
Camshaft sprocket bolt 1 LR010530
Circlip 1 TDL500030
Coolant pump inlet O-ring seal 1 1336551
Driveshaft flange bolts 1, 2 4 TYG500130
Driveshaft flange bolts 1, 2 6 TYG500141
EGR cooler to EGR valve gasket 1 LR078958
Engine compartment brace bolts 8 LR037935
Engine coolant outlet upper O-ring seal 2 LR018829
Engine coolant pump gasket 1 LR079619
Exhaust manifold cross-over pipe gaskets 2 LR072304
Exhaust manifold cross-over pipe nuts 6 LR106277
Exhaust manifold cross-over pipe studs 6 LR113358
Exhaust manifold gasket 2 1336543
Exhaust manifold studs 12 1357627
Front halfshaft nut 1 LR024151
Front suspension upper arm ball joint to wheel knuckle bolt (s) 1 KYG000230
Front suspension upper arm ball joint to wheel knuckle nut (s) 1 FY110056
Fuel injector refit kit - cylinder(s) 2,5 or 6 3 LR017437
Fuel injector refit kit - cylinder(s) 3 or 4 2 LR017438
Fuel injector refit kit - cylinder 1 1 LR017436
Fuel pump drive belt kit 1 LR069054
Fuel rail balance pipe 1 LR013482
Intake air shutoff throttle front seal(s) 1 LR008353
Intake air shutoff throttle rear seal(s) 2 1316152
Left exhaust downpipe gasket 1 LR016619
Oil pan scavenge reservoir tube O-ring seal(s) 1 LR018460
Oil scavenge pipe gasket 1 1331076
Retaining clip 1 1311338
Right exhaust downpipe gasket 1 LR016621
Right fuel rail supply pipe 1 LR013481
Shock absorber to yoke bolt 1 LR000094
Stabilizer bar link retaining nut(s) 1 FY114056
Steering column lower shaft lower bolt 1 QYG500090
Tie-rod end nut 1 LR026275
Torque converter bolts 4 LR038661
Transmission fluid cooler tubes to transmission O-ring seals 2 LR049457
Turbocharger coolant pipes to turbocharger gasket 1 LR062102
Turbocharger oil feed pipe banjo bolt washers 2 1372726
Turbocharger oil return pipe lower gasket 1 LR013234
Turbocharger oil return pipe upper gasket 1 LR013235
Turbocharger oil supply pipe 1 LR038163
Yoke to lower arm bolt (s) 1 LR034230
Yoke to lower arm nut 1 LR038809
Yoke to shock absorber nut (s) 1 FN112056
17MY ONWARDS
 
Name Quantity Part Number VIN range from VIN range to
Driveshaft flange bolts 6 LR092696 HA151411  
Driveshaft flange bolts 6 TYP500180 HA000001 HA151410
ENGINE
 
Name Quantity Part Number VIN range from
Engine 1 LR035100  
Engine 1 LR106166 FA000001
Engine 1 LR048136  
Engine 1 LR127427 FA000001
SINGLE HIGH PRESSURE EGR VALVE
 
Name Quantity Part Number
EGR valve outlet pipe gasket (vehicles without EGR cooler) 1 LR078915
TWIN HIGH PRESSURE EGR VALVES
 
Name Quantity Part Number
EGR valve outlet pipe gasket (vehicles without EGR cooler) 2 LR038333
VIN SPECIFIC
 
Name Quantity Part Number VIN range from VIN range to
Diesel exhaust fluid injector clamp kit 1 LR138592 LA580625  
Diesel exhaust fluid injector clamp kit 1 LR069697   LA580624
Exhaust manifold nuts 12 LR004057   JA193550
Exhaust manifold nuts 12 LR106277 JA193551  
Exhaust manifold to EGR valve gasket 2 LR031488   FA999999
Exhaust manifold to EGR valve gasket 2 LR075627 GA000001 LR031488
Flexplate bolts 8 1406665   HA146684
Flexplate bolts 8 LR096833 HA146685  
Left fuel rail supply pipe 1 LR013480   DA999999
Left fuel rail supply pipe 1 LR059808 EA000001  
Secondary turbocharger oil return pipe 1 LR044556   EA299999
Secondary turbocharger oil return pipe 1 LR044556   FA516687
Secondary turbocharger oil return pipe 1 LR078522 EA300000 FA520408
Secondary turbocharger oil return pipe 1 LR078522 FA516688 FA520408
Secondary turbocharger oil return pipe 1 LR078875 FA520409 FA611880
Secondary turbocharger oil return pipe 1 LR087351 FA611881  
Secondary turbocharger oil return pipe upper gasket 1 LR078880 FA516470 GA999999
Secondary turbocharger oil return pipe upper gasket 1 LR087348 HA000001  
Secondary turbocharger oil return pipe upper gasket 1 LR013235   FA516469
Turbocharger coolant pipe 1 LR061986 FA000001 GA110589
Turbocharger coolant pipe 1 LR092499 GA110590  
Turbocharger coolant pipe 1 LR061985 FA000001 GA587522
Turbocharger coolant pipe 1 LR092500 GA587523  
 
SPECIAL TOOL(S)
ALL VEHICLES
 
Adapter, Wrench 1, 2
303-1069
 E53727
Adaptor, Cooling System Vacuum Refill Kit
JLR-303-1634
 E166365
Ball Joint Splitter
JLR-204-793A
 E177036
Coolant System Vacuum Refill Kit
HU-919
 E169995
Cutter, Exhaust Pipe 1, 2
100-051
 E130266
Engine lifting bracket - Rear 1, 2
303-1141-01
 E193494
Engine lifting kit 1, 2
303-1141
 E193495
Engine support bracket 1, 2
303-021
 303021
Installer, Oil Seal
308-598
 E50941
Post Selective Catalyst Reduction Soot Sensor - Remover/Installer
JLR-303-1646
 E193856
Remover, Driveshaft
205-932
 E117586
Remover, Input and Output Seal
308-375
 308375
Remover/Installer, Driveshaft Nut
JLR-205-993
 E144020
Remover/Installer, Halfshaft
204-506/1
 E49618
Remover/Installer, Halfshaft Screw Thread
204-506/3
 E49620
Remover/Installer, Halfshaft Spacer
204-506/2
 E49619
Remover/Installer, NOx/Oxygen Sensor
JLR-303-1666
 E213446
Retainers, Halfshaft tools
204-506/5
 E49621
Slide Hammer 1, 2
100-012
 E54135
Slide Hammer Adapter
100-012-01
 10001201
Splitter, Damper
JLR-204-802
 E145965
Splitter, Upper Arm
JLR-204-803
 E145966
Viscous Coupling Wrench
303-1142
 E46076
Wrench, H02S
310-121
 E53465
Wrench, Transmission Filler Plug
307-452
 307452
Fuel Injector Removal Adapter
310-213
 E116924
Locking Tool, Flywheel 1, 2
303-1123
 E54546
Rear End Accessory Drive (READ) belt Timing Tool
310-212
 E116926
Remover/Installer, Camshaft Rear Pulley 1, 2
JLR-303-1523
 E123916

REPAIR
 
 
Long/Stripped Engine Assembly Renew - TDV6 3.0L Diesel - Gen 2 - Twin Turbocharger (303-01A DISASSEMBLY G2194109)
 

PUBLISHED: 28-OCT-2019

2017.0 RANGE ROVER SPORT (LW), 303-01A

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

LONG/STRIPPED ENGINE ASSEMBLY RENEW - TDV6 3.0L DIESEL - GEN 2 - TWIN TURBOCHARGER (G2194109)

DISASSEMBLY
 
  • 12.41.02
  • STRIPPED ENGINE - REMOVE ENGINE, CHANGE OVER ANCILLARY EQUIPMENT AND REFIT
  • 3000 CC, TDV6, TWIN TURBOCHARGER FITTED, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FL
  • 15.90
  • USED WITHINS
 
DISASSEMBLY

SPECIAL TOOL(S)

E54135
 

100-012

Slide Hammer

 
E54546
 

303-1123

Locking Tool, Flywheel

 
E116924
 

310-213

Fuel Injector Removal Adapter

 
E123916
 

JLR-303-1523

Remover/Installer, Camshaft Rear Pulley

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.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. Remove the engine.
      Refer to:Engine (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal).
 
    1. E194637
      Install the special tool.
      Install the Special Tool(s): 303-1123
 
    1. E194638
      • Remove and discard the 8 drive plate bolts.
      • Remove the drive plate.
 
    1. E194637
      Remove the special tool.
      Remove the Special Tool(s): 303-1123
 
    1. E245313
      • Remove the 3 bolts.
      • Remove the heatshield.
 
    1. E245314
      • Remove the 2 bolts.
      • Remove the heatshield.
 
    1. E245315
      • Remove and discard the bolt.
      • Remove and discard the 2 nuts.
 
    1. E245316
      • Remove and discard the 3 nuts.
      • Remove the exhaust manifold crossover pipe.
      • Remove and discard the 2 gaskets.
 
    1. E245320
      Remove and discard the 2 studs.
 
    1. E245321
      Remove and discard the 3 studs.
 
  1. E242232
    • Disconnect the electrical connector.
    • Release the 2 clips.

 

 

The following step(s) applies to:
1 high pressure EGR valve & 1 Low pressure EGR valve

 

 
  1. E242231
    • Remove the 3 bolts.
    • Release the clip.
    • Remove the pipe assembly.

 

 

The following step(s) applies to:
2 High pressure EGR valves

 

 
    1. E241759
      • Remove the 3 bolts.
      • Release the clip.
      • Remove the pipe assembly.
 
  1. E241293
    • Disconnect the vacuum hose.
    • Release the 2 clips.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. E241925
      • Disconnect the 2 electrical connectors.
      • Release the 3 clips.
 
    1. E241292
      • Disconnect the vacuum hose.
      • Remove the nut.
      • Release the vacuum solenoid.
 
    1. E241294
      Disconnect the 2 vacuum hoses.
 
    1. E242143
      • Release the 2 clips.
      • Disconnect the 2 electrical connectors.
      • Remove the 2 bolts.
 
    1. E242144
      Remove the vacuum hose assembly.
 
  1. NOTE:

    Repeat this step for the other side.

    E241298
    Remove the Noise, Vibration and Harshness (NVH) material.

 

 

The following step(s) applies to:
1 high pressure EGR valve & 1 Low pressure EGR valve

 

 
  1. E242233
    • Disconnect the electrical connector.
    • Release the 2 hose clips.
    • Remove the 2 bolts.
    • Release the clip.

 

 

The following step(s) applies to:
2 High pressure EGR valves

 

 
    1. E241398
      • Remove the 3 bolts.
      • Remove the EGR outlet pipe.
      • Remove and discard the gasket.
 
  1. E241927
    • Disconnect the electrical connector.
    • Release the 2 hose clips.
    • Remove the bolt.
    • Release the clip.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. E241928
      • Release the hose clip.
      • Remove the coolant hose.
 
    1. E241929
      • Remove the 3 bolts.
      • Remove the bracket.
 
  1. E241761
    • Disconnect the 4 electrical connectors.
    • Release the 3 clips.

 

 

The following step(s) applies to:
1 high pressure EGR valve & 1 Low pressure EGR valve

 

 
  1. E242234
    • Disconnect the 5 electrical connectors.
    • Release the 4 clips.

 

 

The following step(s) applies to:
2 High pressure EGR valves

 

 
  1. E241300
    • Disconnect the 3 electrical connectors.
    • Release the 3 clips.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. E241301
      • Disconnect the 4 electrical connectors.
      • Release the 3 clips.
 
    1. E241302
      • Disconnect the electrical connector.
      • Release the 2 clips.
 
    1. E241303
      • Disconnect the 2 electrical connectors.
      • Release the 2 clips.
 
    1. E241304
      • Disconnect the 3 electrical connectors.
      • Release the 5 clips.
 
    1. E241930
      • Disconnect the 2 electrical connectors.
      • Release the 2 clips.
 
    1. E241931
      • Remove the bolt.
      • Remove the nut.
 
    1. E241932
      Remove the engine wiring harness.
 
    1. CAUTION:

      Be prepared to collect escaping oil.

      E196875
      • Disconnect the connector.
      • Remove the 2 bolts.
      • Remove the nut.
      • Remove the oil extraction pipe.
 
    1. E191572
      • Remove the 5 bolts.
      • Remove the EGR valve.
      • Remove and discard the gasket.
 
    1. E242518
      • Remove the 2 bolts.
      • Remove the heatshield.
 
    1. E196879
      • Remove the 4 bolts.
      • Remove and discard the gasket.
      • Remove and discard the sealing washers.
      • Remove and discard the O-ring seal.
 
  1. E242245
    • Remove and discard the 6 nuts.
    • Remove the 2 mounting bolts.
    • Remove the exhaust manifold and turbocharger assembly.
    • Remove and discard the gasket.

 

 

The following step(s) applies to:
1 high pressure EGR valve & 1 Low pressure EGR valve

 

 
    1. E242235
      • Remove the 3 bolts.
      • Remove the EGR cooler.
 
  1. E242237
    • Remove the 3 bolts.
    • Remove the heatshield.

 

 

The following step(s) applies to:
2 High pressure EGR valves

 

 
    1. E241402
      • Remove the 5 bolts.
      • Remove the EGR valve.
      • Remove and discard the gasket.
 
  1. E242246
    • Remove the 3 bolts.
    • Remove the heatshield.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. E242238
      • Release the electrical connector.
      • Remove the 4 bolts.
      • Remove the mounting bracket.
 
    1. E242474
      • Remove the 4 bolts.
      • Remove and discard the 2 gaskets.
 
    1. E256788
      • Remove the bolt.
      • Remove and discard the 2 sealing washers.
 
    1. E242240
      • Remove the 4 bolts.
      • Remove and discard the 2 gaskets.
 
    1. E242242
      • Remove and discard the 6 nuts.
      • Remove the exhaust manifold and turbocharger assembly.
      • Remove and discard the gasket.
 
    1. E178339
      • Remove the 2 bolts.
      • Remove and discard the turbocharger coolant pipes.
 
    1. CAUTION:

      Be prepared to collect escaping oil.

      E196876
      • Remove the 4 bolts.
      • Remove the oil pipe.
      • Remove and discard the gasket.
      • Remove and discard the O-ring.
 
    1. CAUTION:

      Be prepared to collect escaping oil.

      E196890
      • Remove the bolt.
      • Remove oil supply pipe.
      • Remove and discard the sealing washers.
 
    1. E196882
      • Remove the 5 bolts.
      • Remove the bracket.
 
    1. E196891
      • Remove the 2 bolts.
      • Remove the bracket.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E241403
      • Disconnect the 4 fuel line connectors.
      • Release the 4 clips.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E241404
      • Disconnect the fuel line connector.
      • Release the 2 clips.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E241405
      • Disconnect the 3 fuel line connectors.
      • Release the clip.
 
    1. E241481
      Remove the fuel lines.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E241510
      Remove the 2 bolts.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E196893
      • Release the bracket bolt.
      • Release the 7 fuel line unions.
      • Remove and discard the 3 fuel lines.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E196894
      • Release the 2 fuel line bracket bolts.
      • Release the 7 fuel line unions.
      • Remove and discard the 4 fuel lines.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E196896
      • Release the 2 fuel line unions.
      • Remove the 3 bolts.
      • Remove the fuel rail assembly.
      • Remove and discard the fuel line.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E196898
      • Release the 2 fuel line unions.
      • Remove the 2 bolts.
      • Remove the fuel rail assembly.
      • Remove and discard the fuel line.
 
    1. NOTE:

      Repeat this step for the other side.

      E241923
      Remove the 6 bolts.
 
    1. NOTE:

      Repeat this step for the remaining injectors.

      E241924
      • Install the special tools.
        Install the Special Tool(s): 310-213, 100-012
      • Remove the injector assembly.
 
    1. NOTE:

      Repeat this step for the remaining injectors.

      E130725
      • Remove and discard the 2 O-ring seals.
      • Remove and discard the sealing washer.
 
    1. E241512
      • Release the 2 clips.
      • Remove the Rear End Accessory Drive (READ) cover.
 
    1. CAUTION:

      Only rotate the crankshaft clockwise.

      E116628
      Rotate the crankshaft until the mark on the rear camshaft pulley is in the illustrated position.
 
    1. E130870
      Using a suitable cutting tool, remove the READ belt.
 
    1. E126058
      • Remove the bolt.
      • Remove and discard the READ belt tensioner.
 
    1. E241665
      • Remove the 2 bolts.
      • Remove the cover.
 
    1. E241669
      • Remove the upper engine vent oil separator.
      • Remove and discard the seals.
 
    1. E241666
      Remove the 3 bolts.
 
    1. E241667
      Remove the 2 bolts.
 
    1. E241668
      Remove the fuel pump assembly.
 
    1. E241672
      Install the special tool.
      Install the Special Tool(s): JLR-303-1523
      Torque: 10Nm
 
    1. E241673
      • Install the special tool.
        Install the Special Tool(s): JLR-303-1523
      • Remove and discard the camshaft sprocket bolt.
 
    1. Remove the special tool.
      Remove the Special Tool(s): JLR-303-1523
 
    1. E123934
      Remove the camshaft pulley.
 
    1. E241671
      • Remove the 2 bolts.
      • Remove the cover.
 
    1. E241670
      • Remove the 4 bolts.
      • Remove the bracket and the lower engine vent oil separator.
 
    1. E196899
      • Remove the 3 bolts.
      • Remove the bracket.
 
    1. E242139
      • Remove the 3 bolts.
      • Remove the coolant pump.
      • Remove and discard the O-ring seal.
 
    1. E242140
      • Remove the bolt cover.
      • Remove the bolt.
      • Remove the pulley.
 
    1. E178681
      • Remove the 6 bolts.
      • Remove the crankshaft damper pulley.
 
    1. E241756
      • Remove the 2 bolts.
      • Remove the coolant inlet pipe.
      • Remove and discard the O-ring seal.
 
    1. E241757
      • Remove the 4 bolts.
      • Remove the coolant outlet assembly.
      • Remove and discard the 2 seals.
 
    1. E241764
      Remove the cover.
 
    1. E241765
      • Remove the bolt.
      • Remove the Crankshaft Position (CKP) sensor.
 
    1. NOTE:

      Repeat this step for the other side.

      E194797
      Remove the NVH material.
 
    1. E194798
      Remove the 2 mountings.
 
    1. E194799
      • Remove the 2 nuts.
      • Remove the bracket.
 
    1. NOTE:

      Repeat this step for the other side.

      E194861
      • Remove the 2 bolts.
      • Remove the bracket.
 
    1. E194858
      • Remove the 2 bolts.
      • Remove the bracket.
 
    1. E194859
      • Remove the 2 mountings.
 
  1. E194860
    • Remove the 2 nuts.
    • Remove the bracket.

LONG/STRIPPED ENGINE ASSEMBLY RENEW - TDV6 3.0L DIESEL - GEN 2 - TWIN TURBOCHARGER (G2357394)

 
PART(S)
ALL VEHICLES
 
Name Quantity Part Number
Camshaft position sensor 1 LR013458
Camshaft sprocket bolt 1 LR010530
Circlip 1 TDL500030
Coolant pump inlet O-ring seal 1 1336551
Driveshaft flange bolts 1, 2 4 TYG500130
Driveshaft flange bolts 1, 2 6 TYG500141
EGR cooler to EGR valve gasket 1 LR078958
Engine compartment brace bolts 8 LR037935
Engine coolant outlet upper O-ring seal 2 LR018829
Engine coolant pump gasket 1 LR079619
Exhaust manifold cross-over pipe gaskets 2 LR072304
Exhaust manifold cross-over pipe nuts 6 LR106277
Exhaust manifold cross-over pipe studs 6 LR113358
Exhaust manifold gasket 2 1336543
Exhaust manifold studs 12 1357627
Front halfshaft nut 1 LR024151
Front suspension upper arm ball joint to wheel knuckle bolt (s) 1 KYG000230
Front suspension upper arm ball joint to wheel knuckle nut (s) 1 FY110056
Fuel injector refit kit - cylinder(s) 2,5 or 6 3 LR017437
Fuel injector refit kit - cylinder(s) 3 or 4 2 LR017438
Fuel injector refit kit - cylinder 1 1 LR017436
Fuel pump drive belt kit 1 LR069054
Fuel rail balance pipe 1 LR013482
Intake air shutoff throttle front seal(s) 1 LR008353
Intake air shutoff throttle rear seal(s) 2 1316152
Left exhaust downpipe gasket 1 LR016619
Oil pan scavenge reservoir tube O-ring seal(s) 1 LR018460
Oil scavenge pipe gasket 1 1331076
Retaining clip 1 1311338
Right exhaust downpipe gasket 1 LR016621
Right fuel rail supply pipe 1 LR013481
Shock absorber to yoke bolt 1 LR000094
Stabilizer bar link retaining nut(s) 1 FY114056
Steering column lower shaft lower bolt 1 QYG500090
Tie-rod end nut 1 LR026275
Torque converter bolts 4 LR038661
Transmission fluid cooler tubes to transmission O-ring seals 2 LR049457
Turbocharger coolant pipes to turbocharger gasket 1 LR062102
Turbocharger oil feed pipe banjo bolt washers 2 1372726
Turbocharger oil return pipe lower gasket 1 LR013234
Turbocharger oil return pipe upper gasket 1 LR013235
Turbocharger oil supply pipe 1 LR038163
Yoke to lower arm bolt (s) 1 LR034230
Yoke to lower arm nut 1 LR038809
Yoke to shock absorber nut (s) 1 FN112056
17MY ONWARDS
 
Name Quantity Part Number VIN range from VIN range to
Driveshaft flange bolts 6 LR092696 HA151411  
Driveshaft flange bolts 6 TYP500180 HA000001 HA151410
ENGINE
 
Name Quantity Part Number VIN range from
Engine 1 LR035100  
Engine 1 LR106166 FA000001
Engine 1 LR048136  
Engine 1 LR127427 FA000001
SINGLE HIGH PRESSURE EGR VALVE
 
Name Quantity Part Number
EGR valve outlet pipe gasket (vehicles without EGR cooler) 1 LR078915
TWIN HIGH PRESSURE EGR VALVES
 
Name Quantity Part Number
EGR valve outlet pipe gasket (vehicles without EGR cooler) 2 LR038333
VIN SPECIFIC
 
Name Quantity Part Number VIN range from VIN range to
Diesel exhaust fluid injector clamp kit 1 LR138592 LA580625  
Diesel exhaust fluid injector clamp kit 1 LR069697   LA580624
Exhaust manifold nuts 12 LR004057   JA193550
Exhaust manifold nuts 12 LR106277 JA193551  
Exhaust manifold to EGR valve gasket 2 LR031488   FA999999
Exhaust manifold to EGR valve gasket 2 LR075627 GA000001 LR031488
Flexplate bolts 8 1406665   HA146684
Flexplate bolts 8 LR096833 HA146685  
Left fuel rail supply pipe 1 LR013480   DA999999
Left fuel rail supply pipe 1 LR059808 EA000001  
Secondary turbocharger oil return pipe 1 LR044556   EA299999
Secondary turbocharger oil return pipe 1 LR044556   FA516687
Secondary turbocharger oil return pipe 1 LR078522 EA300000 FA520408
Secondary turbocharger oil return pipe 1 LR078522 FA516688 FA520408
Secondary turbocharger oil return pipe 1 LR078875 FA520409 FA611880
Secondary turbocharger oil return pipe 1 LR087351 FA611881  
Secondary turbocharger oil return pipe upper gasket 1 LR078880 FA516470 GA999999
Secondary turbocharger oil return pipe upper gasket 1 LR087348 HA000001  
Secondary turbocharger oil return pipe upper gasket 1 LR013235   FA516469
Turbocharger coolant pipe 1 LR061986 FA000001 GA110589
Turbocharger coolant pipe 1 LR092499 GA110590  
Turbocharger coolant pipe 1 LR061985 FA000001 GA587522
Turbocharger coolant pipe 1 LR092500 GA587523  
 
SPECIAL TOOL(S)
ALL VEHICLES
 
Adapter, Wrench 1, 2
303-1069
 E53727
Adaptor, Cooling System Vacuum Refill Kit
JLR-303-1634
 E166365
Ball Joint Splitter
JLR-204-793A
 E177036
Coolant System Vacuum Refill Kit
HU-919
 E169995
Cutter, Exhaust Pipe 1, 2
100-051
 E130266
Engine lifting bracket - Rear 1, 2
303-1141-01
 E193494
Engine lifting kit 1, 2
303-1141
 E193495
Engine support bracket 1, 2
303-021
 303021
Installer, Oil Seal
308-598
 E50941
Post Selective Catalyst Reduction Soot Sensor - Remover/Installer
JLR-303-1646
 E193856
Remover, Driveshaft
205-932
 E117586
Remover, Input and Output Seal
308-375
 308375
Remover/Installer, Driveshaft Nut
JLR-205-993
 E144020
Remover/Installer, Halfshaft
204-506/1
 E49618
Remover/Installer, Halfshaft Screw Thread
204-506/3
 E49620
Remover/Installer, Halfshaft Spacer
204-506/2
 E49619
Remover/Installer, NOx/Oxygen Sensor
JLR-303-1666
 E213446
Retainers, Halfshaft tools
204-506/5
 E49621
Slide Hammer 1, 2
100-012
 E54135
Slide Hammer Adapter
100-012-01
 10001201
Splitter, Damper
JLR-204-802
 E145965
Splitter, Upper Arm
JLR-204-803
 E145966
Viscous Coupling Wrench
303-1142
 E46076
Wrench, H02S
310-121
 E53465
Wrench, Transmission Filler Plug
307-452
 307452
Fuel Injector Removal Adapter
310-213
 E116924
Locking Tool, Flywheel 1, 2
303-1123
 E54546
Rear End Accessory Drive (READ) belt Timing Tool
310-212
 E116926
Remover/Installer, Camshaft Rear Pulley 1, 2
JLR-303-1523
 E123916

REPAIR
 
 
Long/Stripped Engine Assembly Renew - TDV6 3.0L Diesel - Gen 2 - Twin Turbocharger (303-01A DISASSEMBLY G2194109)
 

PUBLISHED: 28-OCT-2019

2017.0 RANGE ROVER SPORT (LW), 303-01A

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

LONG/STRIPPED ENGINE ASSEMBLY RENEW - TDV6 3.0L DIESEL - GEN 2 - TWIN TURBOCHARGER (G2194109)

DISASSEMBLY
 
  • 12.41.02
  • STRIPPED ENGINE - REMOVE ENGINE, CHANGE OVER ANCILLARY EQUIPMENT AND REFIT
  • 3000 CC, TDV6, TWIN TURBOCHARGER FITTED, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FL
  • 15.90
  • USED WITHINS
 
DISASSEMBLY

SPECIAL TOOL(S)

E54135
 

100-012

Slide Hammer

 
E54546
 

303-1123

Locking Tool, Flywheel

 
E116924
 

310-213

Fuel Injector Removal Adapter

 
E123916
 

JLR-303-1523

Remover/Installer, Camshaft Rear Pulley

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.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. Remove the engine.
      Refer to:Engine (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal).
 
    1. E194637
      Install the special tool.
      Install the Special Tool(s): 303-1123
 
    1. E194638
      • Remove and discard the 8 drive plate bolts.
      • Remove the drive plate.
 
    1. E194637
      Remove the special tool.
      Remove the Special Tool(s): 303-1123
 
    1. E245313
      • Remove the 3 bolts.
      • Remove the heatshield.
 
    1. E245314
      • Remove the 2 bolts.
      • Remove the heatshield.
 
    1. E245315
      • Remove and discard the bolt.
      • Remove and discard the 2 nuts.
 
    1. E245316
      • Remove and discard the 3 nuts.
      • Remove the exhaust manifold crossover pipe.
      • Remove and discard the 2 gaskets.
 
    1. E245320
      Remove and discard the 2 studs.
 
    1. E245321
      Remove and discard the 3 studs.
 
  1. E242232
    • Disconnect the electrical connector.
    • Release the 2 clips.

 

 

The following step(s) applies to:
1 high pressure EGR valve & 1 Low pressure EGR valve

 

 
  1. E242231
    • Remove the 3 bolts.
    • Release the clip.
    • Remove the pipe assembly.

 

 

The following step(s) applies to:
2 High pressure EGR valves

 

 
    1. E241759
      • Remove the 3 bolts.
      • Release the clip.
      • Remove the pipe assembly.
 
  1. E241293
    • Disconnect the vacuum hose.
    • Release the 2 clips.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. E241925
      • Disconnect the 2 electrical connectors.
      • Release the 3 clips.
 
    1. E241292
      • Disconnect the vacuum hose.
      • Remove the nut.
      • Release the vacuum solenoid.
 
    1. E241294
      Disconnect the 2 vacuum hoses.
 
    1. E242143
      • Release the 2 clips.
      • Disconnect the 2 electrical connectors.
      • Remove the 2 bolts.
 
    1. E242144
      Remove the vacuum hose assembly.
 
  1. NOTE:

    Repeat this step for the other side.

    E241298
    Remove the Noise, Vibration and Harshness (NVH) material.

 

 

The following step(s) applies to:
1 high pressure EGR valve & 1 Low pressure EGR valve

 

 
  1. E242233
    • Disconnect the electrical connector.
    • Release the 2 hose clips.
    • Remove the 2 bolts.
    • Release the clip.

 

 

The following step(s) applies to:
2 High pressure EGR valves

 

 
    1. E241398
      • Remove the 3 bolts.
      • Remove the EGR outlet pipe.
      • Remove and discard the gasket.
 
  1. E241927
    • Disconnect the electrical connector.
    • Release the 2 hose clips.
    • Remove the bolt.
    • Release the clip.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. E241928
      • Release the hose clip.
      • Remove the coolant hose.
 
    1. E241929
      • Remove the 3 bolts.
      • Remove the bracket.
 
  1. E241761
    • Disconnect the 4 electrical connectors.
    • Release the 3 clips.

 

 

The following step(s) applies to:
1 high pressure EGR valve & 1 Low pressure EGR valve

 

 
  1. E242234
    • Disconnect the 5 electrical connectors.
    • Release the 4 clips.

 

 

The following step(s) applies to:
2 High pressure EGR valves

 

 
  1. E241300
    • Disconnect the 3 electrical connectors.
    • Release the 3 clips.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. E241301
      • Disconnect the 4 electrical connectors.
      • Release the 3 clips.
 
    1. E241302
      • Disconnect the electrical connector.
      • Release the 2 clips.
 
    1. E241303
      • Disconnect the 2 electrical connectors.
      • Release the 2 clips.
 
    1. E241304
      • Disconnect the 3 electrical connectors.
      • Release the 5 clips.
 
    1. E241930
      • Disconnect the 2 electrical connectors.
      • Release the 2 clips.
 
    1. E241931
      • Remove the bolt.
      • Remove the nut.
 
    1. E241932
      Remove the engine wiring harness.
 
    1. CAUTION:

      Be prepared to collect escaping oil.

      E196875
      • Disconnect the connector.
      • Remove the 2 bolts.
      • Remove the nut.
      • Remove the oil extraction pipe.
 
    1. E191572
      • Remove the 5 bolts.
      • Remove the EGR valve.
      • Remove and discard the gasket.
 
    1. E242518
      • Remove the 2 bolts.
      • Remove the heatshield.
 
    1. E196879
      • Remove the 4 bolts.
      • Remove and discard the gasket.
      • Remove and discard the sealing washers.
      • Remove and discard the O-ring seal.
 
  1. E242245
    • Remove and discard the 6 nuts.
    • Remove the 2 mounting bolts.
    • Remove the exhaust manifold and turbocharger assembly.
    • Remove and discard the gasket.

 

 

The following step(s) applies to:
1 high pressure EGR valve & 1 Low pressure EGR valve

 

 
    1. E242235
      • Remove the 3 bolts.
      • Remove the EGR cooler.
 
  1. E242237
    • Remove the 3 bolts.
    • Remove the heatshield.

 

 

The following step(s) applies to:
2 High pressure EGR valves

 

 
    1. E241402
      • Remove the 5 bolts.
      • Remove the EGR valve.
      • Remove and discard the gasket.
 
  1. E242246
    • Remove the 3 bolts.
    • Remove the heatshield.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. E242238
      • Release the electrical connector.
      • Remove the 4 bolts.
      • Remove the mounting bracket.
 
    1. E242474
      • Remove the 4 bolts.
      • Remove and discard the 2 gaskets.
 
    1. E256788
      • Remove the bolt.
      • Remove and discard the 2 sealing washers.
 
    1. E242240
      • Remove the 4 bolts.
      • Remove and discard the 2 gaskets.
 
    1. E242242
      • Remove and discard the 6 nuts.
      • Remove the exhaust manifold and turbocharger assembly.
      • Remove and discard the gasket.
 
    1. E178339
      • Remove the 2 bolts.
      • Remove and discard the turbocharger coolant pipes.
 
    1. CAUTION:

      Be prepared to collect escaping oil.

      E196876
      • Remove the 4 bolts.
      • Remove the oil pipe.
      • Remove and discard the gasket.
      • Remove and discard the O-ring.
 
    1. CAUTION:

      Be prepared to collect escaping oil.

      E196890
      • Remove the bolt.
      • Remove oil supply pipe.
      • Remove and discard the sealing washers.
 
    1. E196882
      • Remove the 5 bolts.
      • Remove the bracket.
 
    1. E196891
      • Remove the 2 bolts.
      • Remove the bracket.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E241403
      • Disconnect the 4 fuel line connectors.
      • Release the 4 clips.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E241404
      • Disconnect the fuel line connector.
      • Release the 2 clips.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E241405
      • Disconnect the 3 fuel line connectors.
      • Release the clip.
 
    1. E241481
      Remove the fuel lines.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E241510
      Remove the 2 bolts.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E196893
      • Release the bracket bolt.
      • Release the 7 fuel line unions.
      • Remove and discard the 3 fuel lines.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E196894
      • Release the 2 fuel line bracket bolts.
      • Release the 7 fuel line unions.
      • Remove and discard the 4 fuel lines.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E196896
      • Release the 2 fuel line unions.
      • Remove the 3 bolts.
      • Remove the fuel rail assembly.
      • Remove and discard the fuel line.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E196898
      • Release the 2 fuel line unions.
      • Remove the 2 bolts.
      • Remove the fuel rail assembly.
      • Remove and discard the fuel line.
 
    1. NOTE:

      Repeat this step for the other side.

      E241923
      Remove the 6 bolts.
 
    1. NOTE:

      Repeat this step for the remaining injectors.

      E241924
      • Install the special tools.
        Install the Special Tool(s): 310-213, 100-012
      • Remove the injector assembly.
 
    1. NOTE:

      Repeat this step for the remaining injectors.

      E130725
      • Remove and discard the 2 O-ring seals.
      • Remove and discard the sealing washer.
 
    1. E241512
      • Release the 2 clips.
      • Remove the Rear End Accessory Drive (READ) cover.
 
    1. CAUTION:

      Only rotate the crankshaft clockwise.

      E116628
      Rotate the crankshaft until the mark on the rear camshaft pulley is in the illustrated position.
 
    1. E130870
      Using a suitable cutting tool, remove the READ belt.
 
    1. E126058
      • Remove the bolt.
      • Remove and discard the READ belt tensioner.
 
    1. E241665
      • Remove the 2 bolts.
      • Remove the cover.
 
    1. E241669
      • Remove the upper engine vent oil separator.
      • Remove and discard the seals.
 
    1. E241666
      Remove the 3 bolts.
 
    1. E241667
      Remove the 2 bolts.
 
    1. E241668
      Remove the fuel pump assembly.
 
    1. E241672
      Install the special tool.
      Install the Special Tool(s): JLR-303-1523
      Torque: 10Nm
 
    1. E241673
      • Install the special tool.
        Install the Special Tool(s): JLR-303-1523
      • Remove and discard the camshaft sprocket bolt.
 
    1. Remove the special tool.
      Remove the Special Tool(s): JLR-303-1523
 
    1. E123934
      Remove the camshaft pulley.
 
    1. E241671
      • Remove the 2 bolts.
      • Remove the cover.
 
    1. E241670
      • Remove the 4 bolts.
      • Remove the bracket and the lower engine vent oil separator.
 
    1. E196899
      • Remove the 3 bolts.
      • Remove the bracket.
 
    1. E242139
      • Remove the 3 bolts.
      • Remove the coolant pump.
      • Remove and discard the O-ring seal.
 
    1. E242140
      • Remove the bolt cover.
      • Remove the bolt.
      • Remove the pulley.
 
    1. E178681
      • Remove the 6 bolts.
      • Remove the crankshaft damper pulley.
 
    1. E241756
      • Remove the 2 bolts.
      • Remove the coolant inlet pipe.
      • Remove and discard the O-ring seal.
 
    1. E241757
      • Remove the 4 bolts.
      • Remove the coolant outlet assembly.
      • Remove and discard the 2 seals.
 
    1. E241764
      Remove the cover.
 
    1. E241765
      • Remove the bolt.
      • Remove the Crankshaft Position (CKP) sensor.
 
    1. NOTE:

      Repeat this step for the other side.

      E194797
      Remove the NVH material.
 
    1. E194798
      Remove the 2 mountings.
 
    1. E194799
      • Remove the 2 nuts.
      • Remove the bracket.
 
    1. NOTE:

      Repeat this step for the other side.

      E194861
      • Remove the 2 bolts.
      • Remove the bracket.
 
 
    1. E194859
      • Remove the 2 mountings.
 
  1. E194860
    • Remove the 2 nuts.
    • Remove the bracket.

General Procedures

ENGINE OIL DRAINING AND FILLING (G1509133)

GENERAL PROCEDURES
 
  • 12.60.05
  • ENGINE OIL DRAINING AND FILLING
  • 3000 CC, TDV6
  • 0.80
  • USED WITHINS

PART(S)

STEP PART NAME QUANTITY
Filling Step 1 Oil pan drain plug 1
Filling Step 5 Oil filter 1
Filling Step 5 Oil filter and O-ring seal kit 1
 
DRAINING
WARNING:

The spilling of hot engine oil is unavoidable during this procedure, care must be taken to prevent scalding.

CAUTION:

Make sure the engine is warm.

NOTE:

Engine oil vacuum draining and filling is the recommended procedure for engine oil change during a scheduled service. Scheduled service labour times are calculated using this method.


 
    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. E113950
      • Rotate the oil filter element housing six complete turns counter-clockwise.
      • Allow the engine oil to drain from the oil filter element housing for two minutes.
      • Remove the oil filter element housing.
 
    1. E195968
      • Remove and discard the O-ring seals.
      • Remove and discard the engine oil filter element.
 
    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. WARNING:

    Observe due care when draining engine oil as the oil can be very hot.

    CAUTIONS:

    • Be prepared to collect escaping oil.

    • Discard the bolt.

    • Allow at least 10 minutes for the engine oil to drain.

    E121163
    Drain the engine oil.
 
FILLING
 
    1. CAUTIONS:

      • Make sure that the component is clean, free of foreign material and lubricant.

      • Make sure that a new bolt is installed.

      E121164
      Renew Part: Oil pan drain plug Quantity: 1.
      Torque: 23Nm
 
    1. Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).
 
    1. Lower the vehicle.
 
    1. CAUTION:

      Make sure the engine oil filter housing center tube is installed to the engine oil filter housing before installing the new engine oil filter, as shown in the illustration. Failure to do this will cause low engine oil pressure when starting the engine, resulting in premature engine wear.

      E262835
      Check the position of the center tube.
 
    1. E195968
      • Install the new engine oil filter element.
        Renew Part: Oil filter Quantity: 1.
      • Lubricate the O-ring seal with clean engine oil.
 
    1. E113950
      Torque: 25Nm
 
    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. E163155
      Fill the engine with the recommended oil to the correct level.
      Refer to:Specifications (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Specifications).
 
    1. Clean any residual engine oil from the oil filler cap area.
 
    1. E163155
 
    1. CAUTION:

      Make sure that the vehicle has been left for 5 minutes from filling with oil.

      • Start the engine and allow to run for 10 minutes, stop the engine.
      • Check for leaks.
 
    1. CAUTIONS:

      • Make sure that the selector lever is in the park (P) position.

      • Make sure that the hood is open.

      • Set the ignition to the ON position.
 
    1. E147435
      • Press the left-hand OK buton to access the Instrument Cluster (IC) Main Menu.
 
    1. E147186
      • Press the left-hand directional button and select Service Menu.
 
    1. E147184
      • Press the left-hand OK button.
 
    1. E147185
      • Press the left-hand directional button and select the Oil Level display.
 
    1. E147183
      • Press the left-hand OK button to access the Oil Level display.
 
    1. CAUTION:

      Make sure that the hood is open.

      E147181
      • Press the speed control cancel button twice within 2 seconds while being on the oil level display.
 
    1. E147272
      • The message center displays the actual oil level in service mode.
      • Only after having started and run the engine for 10 minutes (as indicated in Step 10), switch off the engine, then stabilizing for 10 minutes, take a reading from the oil level display and, if necessary top up with engine oil.
 
    1. Set the ignition to the OFF position.
 
    1. Allow 10 minutes for the engine oil level to stabilize if there has been additional oil top up.
NOTE:

The following steps are to update the average oil level value.

 
    1. Repeat step 11 to 17 to access the oil level display in service mode.
 
    1. NOTE:

      The actual volume displayed on the bar graph will be written into the electronic control unit as a new value.

      E147187
      • Press and hold the speed control cancel button for more than 5 seconds.
      • The message center display the current oil level.
NOTE:

Close the hood.

 
    1. Set the ignition to the OFF position.
 
    1. Set the ignition to the ON position.
 
    1. NOTE:

      The following steps are to check the current oil level in a customer mode.

      E147435
      • Press the left-hand OK button to access the Instrument Cluster (IC) Main Menu.
 
    1. E147186
      • Press the left-hand directional button and select Service Menu.
 
    1. E147184
      • Press the left-hand OK button.
 
    1. E147185
      • Press the left-hand directional button and select the Oil Level display.
 
  1. E147182
    • Press the left-hand OK button and follow the instructions.
    • NOTE:

      If the message shows "Not available” wait for further 10 mins to allow the oil level to stabilize.

      Make sure that the average oil level value has now been updated.

ENGINE OIL VACUUM DRAINING AND FILLING (G1509134)

GENERAL PROCEDURES
 
  • 12.60.99
  • ENGINE OIL VACUUM DRAIN / REFILL INCLUDING OIL FILTER - RENEW
  • 3000 CC, TDV6
  • 0.50
  • USED WITHINS

SPECIAL TOOL(S)

E129630
 

JLR-303-1644

Oil Extraction Kit

PART(S)

STEP PART NAME QUANTITY
Filling Step 2 Oil filter 1
Filling Step 2 Oil filter O-ring seal(s) 1
 
DRAINING
WARNING:

The spilling of hot engine oil is unavoidable during this procedure, care must be taken to prevent scalding.

CAUTION:

Make sure the engine is warm.

NOTE:

Engine oil vacuum draining and filling is the recommended procedure for engine oil change during a scheduled service. Scheduled service labour times are calculated using this method.


 
    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. E121161
 
    1. E121162
 
    1. E113950
      • Rotate the oil filter element housing six complete turns counter-clockwise.
      • Allow the engine oil to drain from the oil filter element housing for two minutes.
      • Remove the oil filter element housing.
 
    1. E195968
      • Remove and discard the O-ring seals.
      • Remove and discard the engine oil filter element.
 
    1. NOTE:

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

      E233837
      Using the oil vacuum pump drain the oil out through the oil extraction tube.
      Special Tool(s): JLR-303-1644
 
  1. Remove the oil vacuum pump.
 
FILLING
 
    1. CAUTION:

      Make sure the engine oil filter housing center tube is installed to the engine oil filter housing before installing the new engine oil filter, as shown in the illustration. Failure to do this will cause low engine oil pressure when starting the engine, resulting in premature engine wear.

      E262835
      Check the position of the center tube.
 
    1. E195968
      • Clean the components.
      • Install a new oil filter element to the oil filter cover.
        Renew Part: Oil filter Quantity: 1.
      • Lubricate the O-ring seal with clean engine oil.
 
    1. E113950
      Torque: 28Nm
 
    1. E121162
 
    1. E121161
      • Fill the engine with the recommended oil to the correct level.
        Refer to:Specifications (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Specifications).
      • Clean any residual engine oil from the oil filler cap area.
 
    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. E163155
 
    1. CAUTION:

      Make sure that the vehicle has been left for 5 minutes from filling with oil.

      • Start the engine and allow to run for 10 minutes, stop the engine.
      • Check for leaks.
 
    1. CAUTIONS:

      • Make sure that the selector lever is in the park (P) position.

      • Make sure that the hood is open.

      • Set the ignition to the ON position.
 
    1. E147435
      • Press the left-hand OK button to access the Instrument Cluster (IC) Main Menu.
 
    1. E147186
      • Press the left-hand directional button and select Service Menu.
 
    1. E147184
      • Press the left-hand OK button.
 
    1. E147185
      • Press the left-hand directional button and select the Oil Level display.
 
    1. E147183
      • Press the left-hand OK button to access the Oil Level display.
 
    1. CAUTION:

      Make sure that the hood is open.

      E147181
      • Press the speed control cancel button twice within 2 seconds while being on the oil level display.
 
    1. E147272
      • The message center displays the actual oil level in service mode.
      • Only after having started and run the engine for 10 minutes (as indicated in Step 7), switch off the engine, then stabilizing for 10 minutes, take a reading from the oil level display and, if necessary top up with engine oil.
 
    1. Set the ignition to the OFF position.
 
    1. Allow 10 minutes for the engine oil level to stabilize if there has been additional oil top up.
NOTE:

The following steps are to update the average oil level value.

 
    1. Repeat step 8 to 14 to access the oil level display in service mode.
 
    1. NOTE:

      The actual volume displayed on the bar graph will be written into the electronic control unit as a new value.

      E147187
      • Press and hold the speed control cancel button for more than 5 seconds.
      • The message center display the current oil level.
NOTE:

Close the hood.

 
    1. Set the ignition to the OFF position.
 
    1. Set the ignition to the ON position.
 
    1. NOTE:

      The following steps are to check the current oil level in a customer mode.

      E147435
      • Press the left-hand OK button to access the Instrument Cluster (IC) Main Menu.
 
    1. E147186
      • Press the left-hand directional button and select Service Menu.
 
    1. E147184
      • Press the left-hand OK button.
 
    1. E147185
      • Press the left-hand directional button and select the Oil Level display.
 
  1. E147182
    • Press the left-hand OK button and follow the instructions.
    • NOTE:

      If the message shows "Not available” wait for further 10 mins to allow the oil level to stabilize.

      Make sure that the average oil level value has now been updated.

 

ACTIVE ENGINE MOUNT - VACUUM CHECK (G2782711)

GENERAL PROCEDURES
 
  • 12.45.50
  • ACTIVE ENGINE MOUNT - VACUUM CHECK
  • 3000 CC, TDV6
  • 0.70
  • USED WITHINS

GENERAL EQUIPMENT

EQUIPMENT NAME
Jaguar Land Rover approved battery support unit
Jaguar Land Rover approved diagnostic equipment
 
CHECK
 
      • If the engine management lamp ON, continue to step 1 of the repair section of this procedure.
      • If the engine management lamp is NOT ON, continue to step 2.
 
    1. Raise and support the vehicle on a suitable 2 post lift.
      Refer to:Jacking and Lifting (100-02, Description and Operation).
 
    1. Open the hood.
 
    1. E276185
      Remove the vac pipe active engine mount solenoid.
 
    1. E276186
      • Using the Jaguar Land Rover approved vacuum testing equipment, connect to the vacuum pipe and check that the active engine mounts hold vacuum. The engine mounts should generate a vacuum of 0.4 bar and then be able to hold the vacuum for 30 seconds.
      • If the active engine mount holds vacuum for 30 seconds, continue to step 1 of the repair section of this procedure.
      • If the active engine mounts does not hold vacuum for 30 seconds, continue to step 6.
 
    1. Remove the engine undershield.
      Refer to:Engine Undershield (501-02, Removal and Installation).
 
    1. NOTE:

      Check the vacuum pipe(s) and connections are tight and there are no signs of leakage.

      E264119
      Disconnect the vacuum line directly from the right active engine mount.
 
    1. E222279
      • Inspect the right active engine mount switch positions.
      • If the right active engine mount switch clearly is not visible as shown in illustration E222279, continue to step 9.
      • If the right active engine mount switch is clearly visible as shown in illustration E222279, replace the right active engine mount and continue to step 11.
        Refer to:Right Engine Mount (303-01A, Removal and Installation).
 
    1. E264120
      • Using the Jaguar Land Rover approved vacuum testing equipment, connect to the right active engine mount and check that the active engine mount holds vacuum. The engine mount should generate a vacuum of 0.4 bar and then be able to hold the vacuum for 30 seconds.
      • If the right active engine mount holds vacuum for 30 seconds, continue to step 10.
      • If the right active engine mount does not hold vacuum for 30 seconds, replace the right active engine mount and continue to step 11.
        Refer to:Right Engine Mount (303-01A, Removal and Installation).
 
    1. NOTE:

      Check the vacuum pipe(s) and connections are tight and there are no signs of leakage.

      E264119
      Reconnect the vacuum line directly from the right active engine mount.
 
    1. NOTE:

      Check the vacuum pipe(s) and connections are tight and there are no signs of leakage.

      E276189
      • Disconnect the vacuum line.
      • Connect the Jaguar Land Rover approved vacuum testing equipment to the left vacuum pipe.
      • Using the Jaguar Land Rover approved vacuum testing equipment, check that the left active engine mount holds vacuum. The engine mount should generate a vacuum of 0.4 bar and then be able to hold the vacuum for 30 seconds.
      • If the left active engine mount holds vacuum for 30 seconds, continue to step 12.
      • If the left active engine mount does not hold vacuum for 30 seconds, replace the right active engine mount and vacuum pipe and continue to step 13.
        Refer to:Right Engine Mount (303-01A, Removal and Installation).
 
    1. NOTE:

      Check the vacuum pipe(s) and connections are tight and there are no signs of leakage.

      E276189
      • Remove the Jaguar Land Rover approved vacuum testing equipment from the left vacuum pipe.
      • Reconnect the vacuum pipe.
 
    • Install the engine undershield.
      Refer to:Engine Undershield (501-02, Removal and Installation).
    • Lower the vehicle
    • The active engine mount vacuum check is complete and the active engine mounts have passed, continue to step 1 of the repair section of this procedure if fault is still persisting.
 
REPAIR
 
    1. NOTE:

      Check the vacuum pipe(s) and connections are tight and there are no signs of leakage.

      E264332
      Disconnect the vacuum pipe from the active engine mount solenoid valve.
 
    1. E264333
      Disconnect the active engine mount solenoid electrical connector and remove the bolt.
 
      • Connect the Jaguar Land Rover (JLR) approved battery support unit.
        General Equipment: Jaguar Land Rover approved battery support unit
      • Connect the JLR approved diagnostic equipment.
        General Equipment: Jaguar Land Rover approved diagnostic equipment
      • Read the Diagnostic Trouble Code(s) (DTC) in the Powertrain Control Module (PCM).
 
    1. E264864
      • If DTC P0A14-13 Engine Mount "A" Control Circuit/Open - Circuit open, continue to step 26.
      • If DTC P0A15-11 Engine Mount "A" Control Circuit Low - Circuit short to ground, continue to step 27.
      • If DTC P0A16-12 Engine Mount "A" Control Circuit High - Circuit short to battery, continue to step 28.
      • If DTC P0A16-4B Engine Mount "A" Control Circuit High - Over temperature, continue to step 29.
      • If none of the above DTC are present, continue to step 30 and replace the active engine mount solenoid.
 
    1. E264860
      • Illustration E264864 shows the connector pin number location. Using a multi meter connect the positive probe to the back of pin 1 connector C1E925-1 and the negative probe to body ground
      • If a fault is present refer to wiring diagram 303-14 Electronic Engine Controls. Check the wiring between connectors C1E925-1 and C1BB03AD-7, then check the wring between connectors C1E925-2 and connector C1E116BD-91. Repair wiring harness, clear the DTC and retest.
        Refer to:Wiring Harness Overlay (418-02 Wiring Harnesses, Description and Operation).
      • If there is not a fault with the wiring continue step 30 and replace the active engine mount solenoid.
 
    1. E264861
      • Illustration E264864 shows the connector pin number location. Using a multi meter connect the positive probe to the back of pin 1 connector C1E925-1 and the negative probe to body ground.
      • If a fault is present refer to wiring diagram 303-14 Electronic Engine Controls. Check the wiring between connector C1E925-1 and C1BB03AD-7, then check the wiring between connectors C1E925-2 and C1E116BD-91. Repair the wiring harness, clear the DTC and retest.
        Refer to:Wiring Harness Overlay (418-02 Wiring Harnesses, Description and Operation).
      • If there is not a fault with the wiring continue step 9 and replace the active engine mount solenoid.
 
    1. E264862
      • Illustration E264864 shows the connector pin number location. Using a multi meter connect the positive probe to the back of connector C1E925-2 pin 2 and the negative probe to the connector pin terminal C1E116BD-91 and check for voltage .
      • If a fault is present refer to wiring diagram 303-14 Electronic Engine Controls. Check the wiring between connectors C1E925-1 and C1BB03AD-7, then check the wiring between connectors C1E925-2 and C1E116BD-91. Repair the wiring harness, clear the DTC and retest.
        Refer to:Wiring Harness Overlay (418-02 Wiring Harnesses, Description and Operation).
      • If there is not a fault with the wiring continue step 9 and replace the active engine mount solenoid.
 
    1. E264863
      • Illustration E264864 shows the connector pin number location. Using a multi meter connect the positive probe to the back of pin 2 C1E925-2 and the negative probe to body ground. .
      • If a fault is present refer to wiring diagram 303-14 Electronic Engine Controls. Check the wiring between connectors C1E925-1 and C1BB03AD-7, then check the wiring between connectors C1E925-2 and C1E116BD-91. Repair the wiring harness, clear theDTC and retest.
        Refer to:Wiring Harness Overlay (418-02 Wiring Harnesses, Description and Operation).
      • If there is not a fault with the wiring continue step 9 and replace the active engine mount solenoid.
 
    1. E264333
      • Install the new active engine mount solenoid.
      • Install the bolt.
        Torque: 12Nm
      • Connect the active engine mount solenoid electrical connector.
 
  1. E264332
    • Connect the vacuum pipe to the active engine mount solenoid valve.

Removal and Installation

LEFT CAMSHAFT (G1509135)

REMOVAL AND INSTALLATION
 
  • 12.13.21
  • CAMSHAFTS - LH BANK - RENEW
  • 3000 CC, TDV6
  • 8.80
  • USED WITHINS
 

SPECIAL TOOL(S)

E54549
 

303-1124

Holding Tool, Camshaft Front Pulley

 
E60429
 

303-1145/2

Remover, Camshaft Rear Pulley Bolt

 
E123916
 

JLR-303-1523

Remover/Installer, Camshaft Rear Pulley

PART(S)

STEP PART NAME QUANTITY
Installation Step 4 Camshaft seal 1
Installation Step 15 Camshaft sprocket bolt 1
 
REMOVAL
 
    1. Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).
 
    1. Refer to:Rear End Accessory Drive (303-05A Accessory Drive - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Refer to:Timing Belt (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E123893
      Install the special tool.
      Special Tool(s): JLR-303-1523
 
    1. E123894
      Install the special tool.
      Special Tool(s): JLR-303-1523
 
    1. E123895
      Using the special tool, remove and discard the rear camshaft pulley retaining bolt.
      Special Tool(s): 303-1145/2
 
    1. Remove the special tools.
 
    1. E123934
 
    1. E116771
 
    1. E116772
 
    1. E116773
      Install the special tool.
      Special Tool(s): 303-1124
 
    1. E116774
 
    1. E116775
      Remove the special tool.
 
    1. E116776
 
    1. E116777
      • Reposition the secondary timing chain tensioner.
      • Retain the secondary timing chain tensioner plunger.
 
    1. E116778
      Remove the camshaft bearing caps evenly.
 
    1. E116779
 
    1. CAUTION:

      Discard the seals.

      E116780
 
    1. E116781
 
    1. E116782
 
  1. E116783
    Remove the secondary timing chain from the camshafts.
 
INSTALLATION
 
    1. E86461
      Install the secondary timing chain onto the camshafts.
 
    1. E116782
      Install the secondary timing chain tensioner assembly.
 
    1. CAUTION:

      Make sure that the dots on the camshafts are aligned at the 12 o'clock position. Failure to follow this instruction may result in damage to the engine.

      NOTES:

      • Lubricate the camshafts and the camshaft bearing caps with oil meeting Jaguar specification prior to installation.

      • Use hypoid oil to lubricate the camshafts.

      E116781
      Install the camshafts.
 
    1. NOTE:

      Install new seals.

      E116780
      Renew Part: Camshaft seal Quantity: 1.
 
    1. E116779
      Torque: 10Nm
 
    1. E116784
      • Apply Loctite 518 sealant to the exhaust camshaft seal bearing caps.
      • Apply Loctite 518 sealant, 2 mm wide, to the LH rear and RH front camshaft bearing caps.
      • Apply Loctite 518 sealant, 7 mm diameter, to the LH front and RH rear camshaft bearing caps.
 
    1. NOTE:

      Tighten the bolts in the indicated sequence.

      E116785
      • Install the camshaft bearing caps in their original positions.
      • Stage 1: Bolts 1 to 14, 1 Nm.
      • Stage 2: Bolts 1 to 14, 5 Nm.
      • Stage 3: Bolts 1 to 14, 10 Nm.
      • Stage 4: Bolts 15 to 18, 1 Nm.
      • Stage 5: Bolts 15 to 18, 5 Nm.
      • Stage 6: Bolts 15 to 18, 10 Nm.
 
    1. E116786
      Remove the secondary timing chain tensioner retaining pin.
 
    1. E116776
 
    1. E116775
      Install the special tool.
 
    1. E116774
      Torque
      Stage1: 80Nm
      Stage2: 80°
 
    1. E116773
      Remove the special tool.
 
    1. CAUTION:

      Only tighten the bolt finger-tight at this stage.

      E116772
 
    1. E116771
      Torque: 10Nm
 
    1. CAUTIONS:

      • Install a new bolt.

      • Only tighten the bolt finger-tight at this stage.

      E123958
      Install the rear camshaft pulley.
      Renew Part: Camshaft sprocket bolt Quantity: 1.
 
    1. CAUTION:

      Failure to use special tool JLR-303-1523 might result in engine damage/failure.

      E123893
      Install the special tool.
      Special Tool(s): JLR-303-1523
 
    1. E123894
      Install the special tool.
      Special Tool(s): JLR-303-1523
 
    1. CAUTION:

      Make sure the torque wrench setting procedure is followed correctly. Failure to follow this instruction may result in damage to the vehicle.

      E37107
      • Calculate the setting for the torque wrench:
      • Stage 1: Multiply the required torque by the effective length of the torque wrench (1).
      • Stage 2: Add the effective length of the special tool (2) to the effective length of the torque wrench.
      • Stage 3: Divide the total of stage 1 by the total of stage 2.
      • Stage 4: Set the torque wrench to the figure arrived at in stage 3.
 
    1. CAUTION:

      Make sure the torque wrench setting procedure is followed correctly. Failure to follow this instruction may result in damage to the vehicle.

      E123895
      • Using the special tool, install the camshaft rear pulley retaining bolt.
      • Stage one: Tighten to 80 Nm (59 lb.ft).
      • Stage two: Tighten a further 80 degrees.
 
    1. Remove the special tools.
 
    1. Refer to:Timing Belt (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Refer to:Rear End Accessory Drive (303-05A Accessory Drive - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
  1. Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).

RIGHT CAMSHAFT (G1509136)

REMOVAL AND INSTALLATION
 
  • 12.13.20
  • CAMSHAFTS - RH BANK - RENEW
  • 3000 CC, TDV6
  • 6.50
  • USED WITHINS
 

SPECIAL TOOL(S)

E54540
 

303-1117

Timing Peg, Automatic Transmission

 
E54549
 

303-1124

Holding Tool, Camshaft Front Pulley

 
E54551
 

303-1126

Timing Peg, Camshaft Pulley

PART(S)

STEP PART NAME QUANTITY
Installation Step 4 Camshaft seal 1
Installation Step 15 Timing belt and tensioner kit 1
Installation Step 25 Timing belt cover gasket 1
Installation Step 26 Engine coolant pump pulley bolts 1
 
REMOVAL
 
    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:Starter Motor (303-06A Starting System - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Refer to:Brake Vacuum Pump - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (206-07 Power Brake Actuation, Removal and Installation).
 
    1. Refer to:Right Valve Cover (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E116629
 
    1. Rotate the crankshaft clockwise to align the crankshaft alignment hole in the flywheel or flexplate with the block aperture.
 
    1. E160262
      Check the camshaft pulley alignment holes are correctly aligned. If the alignment holes are not aligned, rotate the crankshaft one full turn clockwise.
 
    1. E116630
      Install the special tool.
      Special Tool(s): 303-1117
 
    1. E116967
 
    1. CAUTION:

      Discard the bolts.

      E116968
 
    1. NOTE:

      Discard the gasket.

      E116969
 
    1. E116841
 
    1. E116842
      Special Tool(s): 303-1126
 
    1. CAUTION:

      Do not use the special tools to lock the camshafts. Failure to follow this instruction may result in damage to the engine or the special tools.

      NOTE:

      Do not loosen the bolts more than 2 turns.

      E116843
 
    1. CAUTIONS:

      • Discard the component.

      • Discard the bolt.

      E116844
 
    1. CAUTION:

      Discard the component.

      E116845
 
    1. E159958
 
    1. E159956
      Install the special tool.
      Special Tool(s): 303-1124
 
    1. E159955
 
    1. E159957
      Remove the special tool.
      Special Tool(s): 303-1124
 
    1. E159960
 
    1. E116777
      • Reposition the secondary timing chain tensioner.
      • Retain the secondary timing chain tensioner plunger.
 
    1. E159959
      Remove the camshaft bearing caps evenly.
 
    1. E116779
 
    1. CAUTION:

      Discard the seal.

      E123346
 
    1. E116781
      Remove the RH bank camshafts and secondary timing chain tensioner assembly.
 
    1. E116782
      Remove the secondary timing chain tensioner assembly.
 
  1. E116783
    Remove the secondary timing chain from the camshafts.
 
INSTALLATION
 
    1. E86461
      Install the secondary timing chain onto the camshafts.
 
    1. E116782
      Install the secondary timing chain tensioner assembly.
 
    1. CAUTION:

      Make sure that the dots on the camshafts are aligned at the 12 o'clock position. Failure to follow this instruction may result in damage to the engine.

      NOTES:

      • Lubricate the camshafts and the camshaft bearing caps with oil meeting Jaguar specification prior to installation.

      • Use hypoid oil to lubricate the camshafts.

      E116781
      Install the camshafts.
 
    1. NOTE:

      Install a new seal.

      E123381
      Renew Part: Camshaft seal Quantity: 1.
 
    1. E116779
      Torque: 10Nm
 
    1. E116784
      • Apply Loctite 518 sealant to the exhaust camshaft seal bearing caps.
      • Apply Loctite 518 sealant, 2 mm wide, to the LH rear and RH front camshaft bearing caps.
      • Apply Loctite 518 sealant, 7 mm diameter, to the LH front and RH rear camshaft bearing caps.
 
    1. NOTE:

      Tighten the bolts in the indicated sequence.

      E116785
      • Install the camshaft bearing caps in their original positions.
      • Stage 1: Bolts 1 to 14, 1 Nm.
      • Stage 2: Bolts 1 to 14, 5 Nm.
      • Stage 3: Bolts 1 to 14, 10 Nm.
      • Stage 4: Bolts 15 to 18, 1 Nm.
      • Stage 5: Bolts 15 to 18, 5 Nm.
      • Stage 6: Bolts 15 to 18, 10 Nm.
 
    1. E116786
      Remove the secondary timing chain tensioner retaining pin.
 
    1. E159973
 
    1. E159957
      Install the special tool.
      Special Tool(s): 303-1124
 
    1. E159955
      Torque
      Stage1: 80Nm
      Stage2: 80°
 
    1. E159956
      Remove the special tool.
      Special Tool(s): 303-1124
 
    1. CAUTION:

      Only tighten the bolt finger-tight at this stage.

      E159958
 
    1. E116846
 
    1. CAUTIONS:

      • Make sure that a new bolt is installed.

      • Only tighten the bolts finger-tight at this stage.

      E116847
      Renew Part: Timing belt and tensioner kit Quantity: 1.
 
    1. CAUTION:

      Make sure the camshaft pulleys remain in the clockwise position.

      E116848
      • Install the new timing belt.
      • Starting at the crankshaft pulley, install the timing belt in a counter-clockwise direction, in the sequence shown.
      • Stage one: Attach the timing belt to the crankshaft pulley.
      • Stage two: Attach the timing belt to the idler pulley.
      • Stage three: Attach the timing belt to the left-hand camshaft pulley.
      • Stage four: Attach the timing belt to the idler pulley.
      • Stage five: Attach the timing belt to the RH camshaft pulley.
      • Stage six: Attach the timing belt to the timing belt tensioner.
 
    1. CAUTION:

      Make sure the timing belt tensioner window is aligned with the groove as illustrated.

      E116849
      • Tension the timing belt.
      • Rotate the tensioner assembly counter-clockwise.
      • Torque: 26Nm
 
    1. CAUTION:

      Do not use the special tools to lock the camshafts. Failure to follow this instruction may result in damage to the engine or the special tools.

      E116843
      • Using a suitable tool, counterhold the camshaft pulley center retaining bolts.
      • Torque: 23Nm
 
    1. E116842
      Remove the special tool.
      Special Tool(s): 303-1126
 
    1. E116630
      Remove the special tool.
      Special Tool(s): 303-1117
 
    1. CAUTION:

      Only rotate the crankshaft clockwise.

      Rotate the engine two complete turns clockwise.
 
    1. E116630
      Install with the special tool.
      Special Tool(s): 303-1117
 
    1. E116842
      • Install the special tools to the exhaust camshaft pulleys.
        Special Tool(s): 303-1126
      • If the special tool does not fit correctly, repeat the timing belt installation procedure.
      • Remove the special tools from the camshaft pulleys.
 
    1. E116841
      Torque: 80Nm
 
    1. NOTE:

      Install a new gasket.

      E116969
      Renew Part: Timing belt cover gasket Quantity: 1.
      Torque: 10Nm
 
    1. CAUTION:

      Make sure that new bolts are installed.

      E116968
      Renew Part: Engine coolant pump pulley bolts Quantity: 1.
      Torque: 24Nm
 
    1. E116967
      Torque: 25Nm
 
    1. E116630
      Remove the special tool.
      Special Tool(s): 303-1117
 
    1. E116629
 
    1. Refer to:Right Valve Cover (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Refer to:Brake Vacuum Pump - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (206-07 Power Brake Actuation, Removal and Installation).
 
    1. Refer to:Starter Motor (303-06A Starting System - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
  1. Disconnect the battery ground cable.
    Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).

CAMSHAFT FRONT SEAL (G1509137)

REMOVAL AND INSTALLATION
 
  • 12.13.12
  • OIL SEALS - FRONT - CAMSHAFTS - PAIR - RENEW
  • 3000 CC, TDV6
  • 3.10
  • USED WITHINS
 

SPECIAL TOOL(S)

E54541
 

303-1118

Remover, Camshaft Seal

 
E54542
 

303-1119

Installer, Camshaft Seal

 
E54549
 

303-1124

Holding Tool, Camshaft Front Pulley

 
E54551
 

303-1126

Timing Peg, Camshaft Pulley

 
REMOVAL
NOTE:

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


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

      Do not use the special tools to lock the camshafts. Failure to follow this instruction may result in damage to the engine or the special tools.

      E145816
      Special Tool(s): 303-1126
 
    1. E116772
 
    1. E116773
      Special Tool(s): 303-1124
 
    1. E116774
 
    1. E116775
      Special Tool(s): 303-1124
 
    1. E116776
 
    1. CAUTION:

      Make sure the special tool is correctly seated behind the camshaft seal. Failure to follow this instruction may result in damage to the special tool.

      E116719
      Special Tool(s): 303-1118
 
  1. E116720
 
INSTALLATION
 
    1. E116721
      Special Tool(s): 303-1119
 
    1. CAUTIONS:

      • Make sure the seal is installed correctly.

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

      • Do not use any lubricant on the camshaft front seal or the camshaft. Failure to follow this instruction may result in damage to the vehicle.

      NOTE:

      Make sure that the seal is 1mm below the face of the cylinder head.

      E116722
 
    1. E116723
      Special Tool(s): 303-1119
 
    1. E116776
 
    1. E116775
      Special Tool(s): 303-1124
 
    1. E116774
      Torque
      Stage1: 80Nm
      Stage2: 80°
 
    1. E116773
      Special Tool(s): 303-1124
 
    1. CAUTION:

      Only tighten the bolt finger-tight at this stage.

      E116772
 
    1. CAUTION:

      Do not use the special tools to lock the camshafts. Failure to follow this instruction may result in damage to the engine or the special tools.

      E145816
      Special Tool(s): 303-1126
 
    1. Refer to:Timing Belt (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
  1. Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).
REMOVAL AND INSTALLATION
 
  • 12.13.06
  • OIL SEAL - REAR - CAMSHAFT - RENEW
  • 3000 CC, TDV6
  • 3.10
  • USED WITHINS
 

SPECIAL TOOL(S)

E60429
 

303-1145/2

Remover, Camshaft Rear Pulley Bolt

PART(S)

STEP PART NAME QUANTITY
Installation Step 4 Camshaft sprocket bolt 1
 
REMOVAL
NOTE:

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


 
    1. Refer to:Rear End Accessory Drive (303-05A Accessory Drive - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E123893
      Install the special tool.
 
    1. E123894
      Install the special tool.
 
    1. E123895
      Using the special tool, remove and discard the rear camshaft pulley retaining bolt.
      Special Tool(s): 303-1145/2
 
    1. Remove the special tools.
 
    1. E123934
 
    1. CAUTION:

      Make sure the special tool is correctly seated behind the camshaft seal. Failure to follow this instruction may result in damage to the special tool.

      E116803
      Install the special tool.
 
  1. E116804
 
INSTALLATION
 
    1. E116805
      Install with the special tool.
 
    1. CAUTIONS:

      • Make sure the seal is installed correctly.

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

      • Do not use any lubricant on the camshaft rear seal or the camshaft. Failure to follow this instruction may result in damage to the vehicle.

      NOTE:

      Make sure that the seal is 1mm below the face of the cylinder head.

      E116806
 
    1. E116807
      Remove the special tool.
 
    1. CAUTIONS:

      • Install a new bolt.

      • Only tighten the bolt finger-tight at this stage.

      E123958
      Install the rear camshaft pulley.
      Renew Part: Camshaft sprocket bolt Quantity: 1.
 
    1. CAUTION:

      Failure to use special tool JLR-303-1523 might result in engine damage/failure.

      E123893
      Install the special tool.
 
    1. E123894
      Install the special tool.
 
    1. CAUTION:

      Make sure the torque wrench setting procedure is followed correctly. Failure to follow this instruction may result in damage to the vehicle.

      E37107
      • Calculate the setting for the torque wrench.
      • Stage 1: Multiply the required torque by the effective length of the torque wrench (1).
      • Stage 2: Add the effective length of the special tool (2) to the effective length of the torque wrench.
      • Stage 3: Divide the total of stage 1 by the total of stage 2.
      • Stage 4: Set the torque wrench to the figure arrived at in stage 3.
 
    1. CAUTION:

      Make sure the torque wrench setting procedure is followed correctly. Failure to follow this instruction may result in damage to the vehicle.

      E123895
      • Using the special tool, install the camshaft rear pulley retaining bolt.
      • Stage one: Tighten to 80 Nm (59 lb.ft).
      • Stage two: Tighten a further 80 degrees

        CAMSHAFT REAR SEAL (G1509138)

 
REMOVAL AND INSTALLATION
 
  • 12.13.06
  • OIL SEAL - REAR - CAMSHAFT - RENEW
  • 3000 CC, TDV6
  • 3.10
  • USED WITHINS
 

SPECIAL TOOL(S)

E60429
 

303-1145/2

Remover, Camshaft Rear Pulley Bolt

PART(S)

STEP PART NAME QUANTITY
Installation Step 4 Camshaft sprocket bolt 1
 
REMOVAL
NOTE:

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


 
    1. Refer to:Rear End Accessory Drive (303-05A Accessory Drive - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E123893
      Install the special tool.
 
    1. E123894
      Install the special tool.
 
    1. E123895
      Using the special tool, remove and discard the rear camshaft pulley retaining bolt.
      Special Tool(s): 303-1145/2
 
    1. Remove the special tools.
 
    1. E123934
 
    1. CAUTION:

      Make sure the special tool is correctly seated behind the camshaft seal. Failure to follow this instruction may result in damage to the special tool.

      E116803
      Install the special tool.
 
  1. E116804
 
INSTALLATION
 
    1. E116805
      Install with the special tool.
 
    1. CAUTIONS:

      • Make sure the seal is installed correctly.

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

      • Do not use any lubricant on the camshaft rear seal or the camshaft. Failure to follow this instruction may result in damage to the vehicle.

      NOTE:

      Make sure that the seal is 1mm below the face of the cylinder head.

      E116806
 
    1. E116807
      Remove the special tool.
 
    1. CAUTIONS:

      • Install a new bolt.

      • Only tighten the bolt finger-tight at this stage.

      E123958
      Install the rear camshaft pulley.
      Renew Part: Camshaft sprocket bolt Quantity: 1.
 
    1. CAUTION:

      Failure to use special tool JLR-303-1523 might result in engine damage/failure.

      E123893
      Install the special tool.
 
    1. E123894
      Install the special tool.
 
    1. CAUTION:

      Make sure the torque wrench setting procedure is followed correctly. Failure to follow this instruction may result in damage to the vehicle.

      E37107
      • Calculate the setting for the torque wrench.
      • Stage 1: Multiply the required torque by the effective length of the torque wrench (1).
      • Stage 2: Add the effective length of the special tool (2) to the effective length of the torque wrench.
      • Stage 3: Divide the total of stage 1 by the total of stage 2.
      • Stage 4: Set the torque wrench to the figure arrived at in stage 3.
 
    1. CAUTION:

      Make sure the torque wrench setting procedure is followed correctly. Failure to follow this instruction may result in damage to the vehicle.

      E123895
      • Using the special tool, install the camshaft rear pulley retaining bolt.
      • Stage one: Tighten to 80 Nm (59 lb.ft).
      • Stage two: Tighten a further 80 degrees.
 
    1. Refer to:Rear End Accessory Drive (303-05A Accessory Drive - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).

CRANKSHAFT FRONT SEAL - TDV6 3.0L DIESEL - GEN 2 (G1875415)

REMOVAL AND INSTALLATION
 
  • 12.21.14
  • CRANKSHAFT FRONT OIL SEAL - RENEW
  • 3000 CC, TDV6, GEN 2
  • 2.90
  • USED WITHINS
 

SPECIAL TOOL(S)

E54543
 

303-1120

Remover, Crankshaft Front Seal

 
E52717
 

303-1121A

Installer, Crankshaft Seal

 
E54545
 

303-1122

Installer, Crankshaft Front Seal

 
E54546
 

303-1123

Locking Tool, Flywheel

PART(S)

STEP PART NAME QUANTITY
Installation Step 1 Crankshaft front oil seal 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. Disconnect the battery ground cable.
      Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).
 
    1. Remove the timing belt.
      Refer to:Timing Belt (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
      Refer to:Timing Belt (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E149535
      Install the special tool.
      Special Tool(s): 303-1123
 
    1. Remove the crankshaft pulley.
      Refer to:Crankshaft Pulley - TDV6 3.0L Diesel - Gen 2 (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E178585
      Install the special tool to the crankshaft.
      Special Tool(s): 303-1120
 
    1. E178586
      Install the special tool to the crankshaft, rotate the special tool to engage the crankshaft front oil seal as shown.
      Special Tool(s): 303-1120
 
    1. E178587
      Rotate the special tool release bolt.
      Special Tool(s): 303-1120
 
  1. E178588
    Using the special tool, remove and discard the crankshaft front oil seal.
    Special Tool(s): 303-1120
 
INSTALLATION
 
    1. CAUTION:

      Do not use any lubricant on the crankshaft front seal, special tools or the crankshaft. Failure to follow this instruction may result in damage to the vehicle.

      NOTE:

      Make sure that all the component mating faces are clean.

      E116752
      Install a new crankshaft front seal to the special tool.
      Special Tool(s): 303-1122
      Renew Part: Crankshaft front oil seal Quantity: 1.
 
    1. E116753
      Reposition the crankshaft front seal along the special tool.
      Special Tool(s): 303-1122
 
    1. E178579
      Install the special tool to the crankshaft.
      Special Tool(s): 303-1122
 
    1. E178580
      Remove the special tool.
 
    1. E178581
      Install the special tool to the crankshaft.
      Special Tool(s): 303-1121A
 
    1. NOTES:

      • Make sure the seal is installed correctly.

      • Use the crankshaft bolt with the service tool.

      E178582
      Using the special tool, install the crankshaft front oil seal.
      Special Tool(s): 303-1121A
 
    1. CAUTION:

      Make sure the seal is installed correctly.

      NOTE:

      Wait 10 seconds before removing the crankshaft seal installation tool.

      E178583
      Remove the special tool.
      Special Tool(s): 303-1121A
 
    1. Install the crankshaft pulley.
      Refer to:Crankshaft Pulley - TDV6 3.0L Diesel - Gen 2 (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E149535
      Remove the special tool.
      Special Tool(s): 303-1123
 
    1. Install the timing belt.
      Refer to:Timing Belt (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).
 

CRANKSHAFT PULLEY - TDV6 3.0L DIESEL - GEN 2 (G1875416)

REMOVAL AND INSTALLATION
 
  • 12.21.01
  • CRANKSHAFT PULLEY - RENEW
  • 3000 CC, TDV6, GEN 2
  • 2.90
  • USED WITHINS
 

SPECIAL TOOL(S)

E54540
 

303-1117

Timing Peg, Automatic Transmission

 
E54546
 

303-1123

Locking Tool, Flywheel

 
E64849
 

303-D121

Puller, General Purpose

PART(S)

STEP PART NAME QUANTITY
Installation Step 2 Crankshaft pulley bolt 1
Installation Step 7 Crankshaft mass damper bolt(s) 6
 
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:Lifting (100-02 Jacking and Lifting, Description and Operation).
 
    1. Disconnect the startup battery ground cable.
      Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).
 
    1. Remove the timing belt.
      Refer to:Timing Belt (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E116630
      • Remove the special tool.
 
    1. E116787
      • Install the special tool.
 
    1. E178645
      Loosen, but do not fully remove the bolt.
 
    1. E178646
      • Install the special tool.
 
  1. E178647
    • Remove and discard the bolt.
    • Remove the crankshaft pulley.
 
INSTALLATION
 
    1. CAUTION:

      Make sure that the pulley washer is correctly seated before installing the pulley.

      E178218
 
    1. CAUTIONS:

      • Do not lubricate the components.

      • Make sure that a new bolt is installed.

      NOTE:

      Do not tighten at this stage.

      E178219
      Install crankshaft pulley.
      Renew Part: Crankshaft pulley bolt Quantity: 1.
 
    1. CAUTION:

      Make sure the alignment marks are aligned.

      E178220
 
    1. CAUTION:

      Do not lubricate the components.

      E178219
      Torque
      Stage1: 150Nm
      Stage2: 300Nm
      Stage3: 90°
 
    1. E116787
      • Remove the special tool.
 
    1. E116630
      • Remove the special tool.
 
    1. CAUTION:

      If a new crankshaft pulley has been installed, renew the crankshaft mass damper retaining bolts.

      Install the timing belt.
      Refer to:Timing Belt (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
      Renew Part: Crankshaft mass damper bolt(s) Quantity: 6.
 
  1. Connect the startup battery ground cable.
    Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).

CRANKSHAFT REAR SEAL (G1509141)

REMOVAL AND INSTALLATION
 
  • 12.21.20
  • CRANKSHAFT REAR OIL SEAL - RENEW
  • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
  • 6.50
  • USED WITHINS
 

PART(S)

STEP PART NAME QUANTITY
Installation Step 1 Crankshaft rear seal 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.


 
    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:Crankshaft Position Sensor Ring (303-14A Electronic Engine Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E99329
 
  1. CAUTION:

    Discard the seal.

    E99330
 
INSTALLATION
 
    1. CAUTIONS:

      • Make sure that the crankshaft rear oil seal is correctly located.

      • Make sure the crankshaft seal mating faces are clean and dry.

      E99331
      Apply an 8 mm bead of sealant to the cylinder block in the areas shown.
      Renew Part: Crankshaft rear seal Quantity: 1.
 
    1. E99332
      • Lubricate the oil seal.
 
    1. E99333
      Torque: 10Nm
 
    1. E99334
      Torque: 10Nm
 
    1. E99329
      Torque: 10Nm
 
    1. Refer to:Crankshaft Position Sensor Ring (303-14A Electronic Engine Controls - 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).

LEFT CYLINDER HEAD (G1509142)

REMOVAL AND INSTALLATION
 
  • 12.29.04
  • CYLINDER HEAD - ASSEMBLY - LEFT/ONE ONLY - RENEW
  • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
  • 14.50
  • USED WITHINS
 

PART(S)

STEP PART NAME QUANTITY
Installation Step 2 Cylinder head gasket 1
Installation Step 2 Cylinder head bolts 1
Installation Step 6 Water outlet connection O-ring seals 1
 
REMOVAL
 
    1. Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).
 
    1. WARNING:

      Make sure to support the vehicle with axle stands.

      Raise and support the vehicle.
 
    1. Refer to:Left Camshaft (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Refer to:Glow Plugs (303-07C Glow Plug System - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Refer to:Left Exhaust Manifold (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E116914
 
    1. E116915
 
    1. E116916
 
    1. NOTE:

      Discard the O-ring seals.

      E116917
 
    1. E116919
 
  1. CAUTION:

    Discard the bolts.

    NOTE:

    Discard the gasket.

    E116920
 
INSTALLATION
 
    1. CAUTIONS:

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

      • An acceptable flatness of the cylinder head is 0.2mm.

      E160359
      • Clean and inspect the cylinder head and cylinder block.

RIGHT CYLINDER HEAD (G1715989)

REMOVAL AND INSTALLATION
 
  • 12.29.05
  • CYLINDER HEAD - ASSEMBLY - RIGHT - RENEW
  • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
  • 9.50
  • USED WITHINS
 

PART(S)

STEP PART NAME QUANTITY
Installation Step 2 Cylinder head gasket 1
Installation Step 2 Cylinder head bolts 1
Installation Step 11 Exhaust manifold gasket 1
Installation Step 13 Exhaust manifold cross-over pipe studs 1
Installation Step 14 Exhaust manifold cross-over pipe nuts 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.


 
    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:Right Turbocharger (303-04B Fuel Charging and Controls - Turbocharger - TDV6 3.0L Diesel, Removal and Installation).
 
    1. CAUTION:

      Discard the nuts.

      E147531
 
    1. CAUTION:

      Discard the studs.

      E147532
 
    1. NOTE:

      Discard the gasket.

      E147530
 
    1. E160528
 
    1. E116917
 
    1. E159940
 
    1. E159941
 
    1. Refer to:Right Camshaft (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E159939
 
  1. CAUTION:

    Discard the bolts.

    NOTE:

    Discard the gasket.

    E116920
 
INSTALLATION
 
    1. CAUTIONS:

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

      • An acceptable flatness of the cylinder head is 0.2mm.

      E160359
      • Clean and inspect the cylinder head and cylinder block.
 
    1. CAUTIONS:

      • Only tighten the bolts finger-tight at this stage.

      • Make sure that new bolts are installed.

      • Use care when installing the cylinder head. Damage to the cylinder block, cylinder head or cylinder head gasket may result.

      • The head gasket must be installed over the cylinder block dowels.

      NOTES:

      • Install a new gasket.

      • No additional lubrication to the cylinder head bolts is required.

      E116920
      Renew Part: Cylinder head gasket Quantity: 1.
      Renew Part: Cylinder head bolts Quantity: 1.
 
    1. NOTE:

      Tighten the bolts in the indicated sequence.

      E159942
      • Torque: 80Nm
 
    1. NOTE:

      Tighten the bolts in the indicated sequence.

      E159942
      • Torque: 180°
 
    1. E159939
 
    1. Refer to:Right Camshaft (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E159941
      Torque: 10Nm
 
    1. E159940
 
    1. E116917
      Torque: 10Nm
 
    1. E160528
 
    1. WARNING:

      Make sure that new nuts are installed.

      CAUTION:

      Install the nuts finger tight before final tightening.

      NOTE:

      Install a new gasket.

      E147530
      Renew Part: Exhaust manifold gasket Quantity: 1.
 
    1. NOTE:

      Tighten the bolts in the indicated sequence.

      E159943
      Torque: 28Nm
 
    1. CAUTION:

      Install new studs.

      E147532
      Renew Part: Exhaust manifold cross-over pipe studs Quantity: 1.
      Torque: 13Nm
 
    1. WARNING:

      Make sure that new nuts are installed.

      E147531
      Renew Part: Exhaust manifold cross-over pipe nuts Quantity: 1.
      Torque: 24Nm
 
    1. Refer to:Right Turbocharger (303-04B Fuel Charging and Controls - Turbocharger - TDV6 3.0L Diesel, Removal and Installation).
 
  1. Connect the battery ground cable
    Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).
 
    1. CAUTIONS:

      • Only tighten the bolts finger-tight at this stage.

      • Make sure that new bolts are installed.

      • Use care when installing the cylinder head. Damage to the cylinder block, cylinder head or cylinder head gasket may result.

      • The head gasket must be installed over the cylinder block dowels.

      NOTES:

      • Install a new gasket.

      • No additional lubrication to the cylinder head bolts is required.

      E116920
      Renew Part: Cylinder head gasket Quantity: 1.
      Renew Part: Cylinder head bolts Quantity: 1.
 
    1. NOTE:

      Tighten the bolts in the indicated sequence.

      E116922
      • Torque: 80Nm
 
    1. NOTE:

      Tighten the bolts in the indicated sequence.

      E116922
      • Torque: 180°
 
    1. E116919
      .
 
    1. CAUTION:

      Install the new seals.

      E116917
      Renew Part: Water outlet connection O-ring seals Quantity: 1.
      Torque: 10Nm
 
    1. E116916
      Torque: 10Nm
 
    1. E116915
      Torque: 24Nm
 
    1. E116914
      Torque: 14Nm
 
    1. Refer to:Left Exhaust Manifold (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Refer to:Glow Plugs (303-07C Glow Plug System - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Refer to:Left Camshaft (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
  1. Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).

 

RIGHT CYLINDER HEAD (G1957713)

REMOVAL AND INSTALLATION
 
  • 12.29.05
  • CYLINDER HEAD - ASSEMBLY - RIGHT - RENEW
  • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
  • 9.50
  • USED WITHINS
 

PART(S)

STEP PART NAME QUANTITY
Installation Step 2 Cylinder head bolts 1
Installation Step 2 Cylinder head gasket 1
 
REMOVAL
NOTES:

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

  • Some components shown removed for clarity.

  • 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. Refer to:Right Exhaust Manifold (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E160528
 
    1. E116917
 
    1. E159940
 
    1. E159941
 
    1. Refer to:Right Camshaft (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. NOTE:

      Note the orientation of the components prior to removal.

      E159939
 
  1. CAUTION:

    Discard the bolts.

    NOTE:

    Discard the gasket.

    E116920
 
INSTALLATION
 
    1. CAUTIONS:

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

      • An acceptable flatness of the cylinder head is 0.2mm.

      E160359
      • Clean and inspect the cylinder head and cylinder block.
 
    1. CAUTIONS:

      • Only tighten the bolts finger-tight at this stage.

      • Make sure that new bolts are installed.

      • Use care when installing the cylinder head. Damage to the cylinder block, cylinder head or cylinder head gasket may result.

      • The head gasket must be installed over the cylinder block dowels.

      NOTES:

      • Install a new gasket.

      • No additional lubrication to the cylinder head bolts is required.

      E116920
      Renew Part: Cylinder head bolts Quantity: 1.
      Renew Part: Cylinder head gasket Quantity: 1.
 
    1. E159942
      Tighten the bolts in the indicated sequence.
      Torque
      Stage1: 80Nm
      Stage2: 180°
 
    1. E159939
 
    1. Refer to:Right Camshaft (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E159941
      Torque: 10Nm
 
    1. E159940
 
    1. E116917
      Torque: 10Nm
 
    1. E160528
 
    1. Refer to:Right Exhaust Manifold (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).
 
  1. Refer to:High-Pressure Fuel System Bleeding (310-00 Fuel System - General Information, General Procedures).

LEFT ENGINE MOUNT (G1509143)

REMOVAL AND INSTALLATION
 
  • 12.45.11
  • MOUNTING - LH - RENEW
  • RIGHT HAND DRIVE, 3000 CC, TDV6, DIESEL, IC
  • 3.20
  • USED WITHINS
 
 
REMOVAL
NOTE:
  • Removal steps in this procedure may contain installation details.
  • Some variation in the illustrations may occur, but the essential information is always correct.

 
    1. Disconnect the startup battery ground cable.
      Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).
 
    1. Remove the air conditioning (A/C) compressor.
      Refer to:Air Conditioning Compressor - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (412-01 Climate Control, Removal and Installation).
 
    1. E147606
 
    1. CAUTION:

      Use a wooden block to protect the oil pan when supporting the engine.

      E154006
      Using a suitable hydraulic jack, raise and support the engine.
 
    1. E147608
 
    1. E147607
 
    1. E147610
 
  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.
 
INSTALLATION
 
    1. E147610
 
    1. E147607
      Torque: 32Nm
 
    1. E147608
      • Torque: 115Nm
 
    1. E147606
 
    1. Install the air conditioning (A/C) compressor.
      Refer to:Air Conditioning Compressor - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (412-01 Climate Control, Removal and Installation).
      Refer to:Air Conditioning Compressor - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (412-01 Climate Control, Removal and Installation).
 
  1. Connect the startup battery ground cable.
    Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).

RIGHT ENGINE MOUNT (G1509144)

REMOVAL AND INSTALLATION
 
  • 12.45.12
  • MOUNTING - RH - RENEW
  • RIGHT HAND DRIVE, 3000 CC, TDV6, DIESEL, IC
  • 1.30
  • USED WITHINS
 

PART(S)

STEP PART NAME QUANTITY
Installation Step 10 Steering column lower shaft lower bolt 1
 
REMOVAL
NOTE:

Removal steps in this procedure may contain installation details.


 
    1. Remove the startup battery ground cable.
      Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).
 
    1. Remove the generator.
      Refer to:Generator (414-02A Generator and Regulator - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. NOTE:
      • Make sure to clean the threads prior to installation.
      • Right hand drive only.
      E195428
      Discard the bolt.
 
    1. E147611
 
    1. E147902
 
    1. NOTE:

      Left-hand shown, right-hand similar.

      E147903
 
    1. E155798
 
    1. E158767
 
    1. CAUTION:
      • Support the engine on a jack. The angle may need to be adjusted during this procedure.
      • Use a wooden block to protect the oil pan when supporting the engine.
      E146618
      Using a suitable hydraulic jack, raise and support the engine.
 
    1. E178504
 
    1. E158768
 
  1. E147610
 
INSTALLATION
 
    1. E147610
 
    1. E158768
      Only tighten the bolts finger tight at this stage.
 
    1. E178504
      Torque: 115Nm
 
    1. Lower the engine onto the engine mounting.
 
    1. E158767
      Only tighten the nut finger tight at this stage.
 
    1. E147607
      Torque: 40Nm
 
    1. E158767
      Torque: 130Nm
 
    1. E147606
 
    1. E155798
      Torque: 25Nm
 
    1. E195428
      • Install a new bolt.
      • Torque: 30Nm
 
    1. E147903
      Torque: 10Nm
 
    1. E195429
      Torque: 10Nm
 
    1. E147901
 
    1. Install the generator.
      Refer to:Generator (414-02A Generator and Regulator - 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).

LEFT EXHAUST MANIFOLD (G1509145)

REMOVAL AND INSTALLATION
 
  • 30.15.10
  • EXHAUST MANIFOLD - RENEW
  • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
  • 5.40
  • USED WITHINS
 

PART(S)

STEP PART NAME QUANTITY
Installation Step 1 Exhaust manifold gasket 1
Installation Step 1 Exhaust manifold nuts 6
Installation Step 3 Exhaust manifold cross-over pipe studs 3
Installation Step 4 Exhaust manifold cross-over pipe nuts 3
Installation Step 17 Turbocharger oil return pipe seals 1
Installation Step 18 Turbocharger oil return pipe seals 1
 
REMOVAL
NOTE:

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


 
    1. Remove the left exhaust gas temperature sensor.
      Refer to:Left Exhaust Gas Temperature Sensor (303-14A Electronic Engine Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Remove the left turbocharger.
      Refer to:Left Turbocharger - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5 (303-04B Fuel Charging and Controls - Turbocharger - TDV6 3.0L Diesel, 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. E112567
 
    1. CAUTION:

      Discard the nuts.

      E112568
 
    1. CAUTION:

      Discard the studs.

      E112569
 
  1. CAUTION:

    Discard the nuts.

    NOTE:

    Discard the gasket.

    E112570
 
INSTALLATION
 
    1. WARNING:

      Make sure that new nuts are installed.

      CAUTION:

      Only tighten the bolt finger-tight at this stage.

      NOTE:

      Install a new gasket.

      E112570
      Renew Part: Exhaust manifold gasket Quantity: 1.
      Renew Part: Exhaust manifold nuts Quantity: 6.
 
    1. NOTE:

      Tighten the bolts in the indicated sequence.

      E116354
      Torque: 28Nm
 
    1. CAUTION:

      Install new studs.

      E112569
      Renew Part: Exhaust manifold cross-over pipe studs Quantity: 3.
      Torque: 13Nm
 
    1. WARNING:

      Make sure that new nuts are installed.

      E112568
      Renew Part: Exhaust manifold cross-over pipe nuts Quantity: 3.
      Torque: 24Nm
 
    1. WARNING:

      Make sure that new nuts are installed.

      CAUTIONS:

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

      • Install a new turbocharger to exhaust manifold gasket every time the turbocharger is removed.

      E148200
      Torque: 24Nm
 
    1. WARNING:

      Make sure that a new nut is installed.

      E148089
      Torque: 24Nm
 
    1. CAUTION:

      Apply Loctite 243 to the bolts.

      NOTE:

      Make sure to clean the threads prior to installation.

      E148087
      Torque: 32Nm
 
    1. NOTES:

      • Tighten the bolts in the indicated sequence.

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

      E116354
      Torque: 28Nm
 
    1. E112567
      Torque: 10Nm
 
    1. E148083
 
    1. E148082
 
    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 new sealing washers are installed.

      • Make sure that a new bolt is installed.

      E148202
      Torque: 30Nm
 
    1. CAUTION:

      Install a new gasket.

      E148201
      Torque: 6Nm
 
    1. E148084
      Torque: 10Nm
 
    1. E147941
 
    1. E144605
      Torque: 9Nm
 
    1. CAUTION:

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

      NOTE:

      Install new gaskets.

      E148208
      Renew Part: Turbocharger oil return pipe seals Quantity: 1.
      Torque: 9Nm
 
    1. CAUTION:

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

      NOTE:

      Install a new gasket.

      E148199
      Renew Part: Turbocharger oil return pipe seals Quantity: 1.
      Torque: 9Nm
 
    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 left exhaust gas temperature sensor.
    Refer to:Left Exhaust Gas Temperature Sensor (303-14A Electronic Engine Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).

RIGHT EXHAUST MANIFOLD (G1509146)

REMOVAL AND INSTALLATION
 
  • 30.15.11
  • MANIFOLD - EXHAUST - RH/REAR - RENEW
  • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
  • 3.50
  • USED WITHINS
 

PART(S)

STEP PART NAME QUANTITY
Installation Step 1 Exhaust manifold gasket 1
Installation Step 1 Exhaust manifold nuts 6
Installation Step 3 Exhaust manifold cross-over pipe gaskets 1
Installation Step 3 Exhaust manifold cross-over pipe studs 1
Installation Step 4 Exhaust manifold cross-over pipe nuts 1
Installation Step 11 Turbocharger oil feed pipe banjo bolt washers 1
Installation Step 16 Turbocharger oil return pipe seals 1
Installation Step 17 Turbocharger oil return pipe seals 1
 
REMOVAL
 
    1. Refer to:Right Turbocharger (303-04B Fuel Charging and Controls - Turbocharger - TDV6 3.0L Diesel, Removal and Installation).
 
    1. CAUTION:

      Discard the nuts.

      E147531
 
    1. CAUTION:

      Discard the studs.

      E147532
 
  1. CAUTION:

    Discard the nuts.

    NOTE:

    Remove and discard the gasket.

    E147530
 
INSTALLATION
 
    1. CAUTIONS:

      • Make sure that new nuts are installed.

      • Only tighten the bolts finger-tight at this stage.

      NOTE:

      Install a new gasket.

      E147530
      Renew Part: Exhaust manifold gasket Quantity: 1.
      Renew Part: Exhaust manifold nuts Quantity: 6.
 
    1. NOTE:

      Tighten the bolts in the indicated sequence.

      E147534
      Torque: 28Nm
 
    1. CAUTION:

      Install new studs.

      NOTE:

      Install a new gasket.

      E147532
      Renew Part: Exhaust manifold cross-over pipe gaskets Quantity: 1.
      Renew Part: Exhaust manifold cross-over pipe studs Quantity: 1.
      Torque: 13Nm
 
    1. CAUTION:

      Make sure that new nuts are installed.

      E147531
      Renew Part: Exhaust manifold cross-over pipe nuts Quantity: 1.
      Torque: 24Nm
 
    1. WARNING:

      Make sure that new nuts are installed.

      CAUTIONS:

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

      • Install a new turbocharger to exhaust manifold gasket every time the turbocharger is removed.

      E148212
      Torque: 24Nm
 
    1. CAUTION:

      Apply Loctite 243 to the bolts.

      NOTE:

      Make sure to clean the threads prior to installation.

      E124732
      Torque: 32Nm
 
    1. NOTES:

      • Tighten the bolts in the indicated sequence.

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

      E147534
      Torque: 28Nm
 
    1. E148090
 
    1. E148234
      Torque: 10Nm
 
    1. E124733
 
    1. CAUTIONS:

      • Make sure that new sealing washers are installed.

      • Make sure that a new bolt is installed.

      E124730
      Renew Part: Turbocharger oil feed pipe banjo bolt washers Quantity: 1.
      Torque: 30Nm
 
    1. E124721
 
    1. E124720
 
    1. E148092
      Torque: 11Nm
 
    1. E144608
      Torque: 9Nm
 
    1. NOTE:

      Install new gaskets.

      E148211
      Renew Part: Turbocharger oil return pipe seals Quantity: 1.
      Torque: 9Nm
 
    1. NOTE:

      Install a new gasket.

      E148210
      Renew Part: Turbocharger oil return pipe seals Quantity: 1.
      Torque: 9Nm
 
    1. 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. 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).

RIGHT EXHAUST MANIFOLD (G1957714)

REMOVAL AND INSTALLATION
 
  • 30.15.11
  • MANIFOLD - EXHAUST - RH/REAR - RENEW
  • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
  • 3.50
  • USED WITHINS
 

PART(S)

STEP PART NAME QUANTITY
Removal Step 6 Exhaust manifold cross-over pipe nuts 1
Removal Step 7 Crossover pipe gasket 1
Removal Step 7 Exhaust manifold cross-over pipe studs 1
Removal Step 8 Exhaust manifold gasket 1
Removal Step 8 Exhaust manifold nuts 1
 
REMOVAL
NOTES:

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

  • Some components shown removed for clarity.

  • Removal steps in this procedure may contain installation details.


 
    1. Refer to:Specifications (414-01 Battery, Mounting and Cables, Specifications).
 
    1. CAUTION:

      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. 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: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. E188721
      Torque: 11Nm
 
    1. CAUTION:

      Discard the nuts.

      E188722
      Renew Part: Exhaust manifold cross-over pipe nuts Quantity: 1.
      Torque: 24Nm
 
    1. CAUTION:

      Discard the studs and gasket.

      E188723
      Renew Part: Crossover pipe gasket Quantity: 1.
      Renew Part: Exhaust manifold cross-over pipe studs Quantity: 1.
      Torque: 13Nm
 
  1. CAUTION:

    Discard the nuts and gasket.

    E188724
    Renew Part: Exhaust manifold gasket Quantity: 1.
    Renew Part: Exhaust manifold nuts Quantity: 1.
 
INSTALLATION
 
    1. CAUTIONS:

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

      • Install a new gasket.

      • Make sure a new alignment dowel is installed.

      E188725
      Tighten the exhaust manifold retaining nuts in the sequence shown.
      Torque
      Stage1: 5Nm
      Stage2: 28Nm
 
  1. To install, reverse the removal procedure.

EXHAUST MANIFOLD CROSS-OVER PIPE (G1509147)

REMOVAL AND INSTALLATION
 
  • 30.15.29
  • PIPE - CROSS-OVER - EXHAUST MANIFOLD - RENEW
  • 3000 CC, TDV6, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID
  • 3.40
  • USED WITHINS
 

GENERAL EQUIPMENT

EQUIPMENT NAME
Transmission jack

PART(S)

STEP PART NAME QUANTITY
Installation Step 1 Exhaust manifold cross-over pipe gaskets 1
Installation Step 2 Exhaust manifold cross-over pipe studs 1
Installation Step 3 Exhaust manifold studs 1
Installation Step 5 Exhaust manifold cross-over pipe nuts and bolts 1
 
REMOVAL
CAUTION:

Take care when handling the cross-over pipe as damage to the insulating material may occur.

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 (309-00B Exhaust System - V6 S/C 3.0L Petrol, 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:Transmission Support Crossmember - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (502-02 Full Frame and Body Mounting, Removal and Installation).
 
    1. NOTE:

      The transmission is lowered for access.

      E119345
      • General Equipment: Transmission jack
 
    1. E117369
 
    1. E117316
 
    1. E117299
 
    1. E144608
 
    1. CAUTION:

      Discard the nuts.

      E117311
 
    1. CAUTION:

      Discard the nuts and bolt.

      E124138
 
    1. E117310
 
    1. CAUTION:

      Discard the studs.

      E144610
 
    1. CAUTION:

      Discard the studs.

      E144609
 
  1. NOTE:

    Discard the gasket.

    E124137
 
INSTALLATION
 
    1. NOTE:

      Install new gaskets.

      E124137
      Renew Part: Exhaust manifold cross-over pipe gaskets Quantity: 1.
 
    1. NOTE:

      New exhaust manifold retaining studs must be fitted if the old studs are removed.

      E144609
      Renew Part: Exhaust manifold cross-over pipe studs Quantity: 1.
      Torque: 13Nm
 
    1. NOTE:

      New exhaust manifold retaining studs must be fitted if the old studs are removed.

      E144610
      Renew Part: Exhaust manifold studs Quantity: 1.
      Torque: 13Nm
 
    1. E117310
 
    1. CAUTIONS:

      • New exhaust manifold nuts and bolt must be fitted.

      • Only tighten the nuts finger-tight at this stage.

      E145334
      Renew Part: Exhaust manifold cross-over pipe nuts and bolts Quantity: 1.
 
    1. E145117
      Check for correct alignment.
      Torque: 23Nm
 
    1. E145118
      Check for correct alignment.
      Torque: 23Nm
 
    1. E145119
      Torque: 23Nm
 
    1. E145327
      Torque: 23Nm
 
    1. E145116
 
    1. E144608
      Torque: 11Nm
 
    1. E124166
      General Equipment: Transmission jack
 
    1. Refer to:Transmission Support Crossmember - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (502-02 Full Frame and Body Mounting, Removal and Installation).
 
  1. Refer to:Exhaust System (309-00B Exhaust System - V6 S/C 3.0L Petrol, 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).

FLEXPLATE (G1509148)

REMOVAL AND INSTALLATION
 
  • 12.53.13
  • DRIVE PLATE - AUTOMATIC - RENEW
  • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
  • 6.10
  • USED WITHINS
 

SPECIAL TOOL(S)

E54546
 

303-1123

Locking Tool, Flywheel

PART(S)

STEP PART NAME QUANTITY
Installation Step 1 Flexplate bolts 8
 
REMOVAL
NOTE:

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


 
    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:Starter Motor (303-06A Starting System - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Refer to: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 Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Removal).
 
    1. E116787
      • Install the special tool.
 
  1. CAUTION:

    Discard the bolts.

    NOTE:

    Prevent the flexplate from rotating.

    E116839
 
INSTALLATION
 
    1. CAUTION:

      Make sure that new bolts are installed.

      NOTES:

      • Make sure that all the component mating faces are clean.

      • Loosely install all retaining bolts.

      E116839
      • Prevent the flexplate from rotating.
        Renew Part: Flexplate bolts Quantity: 8.
 
    1. CAUTION:

      Tighten the bolts evenly in the stages shown.

      E100058
      • Stage 1: Tighten to 50 Nm.
      • Stage 2: Tighten to 45 degrees.
      • Stage 3: Tighten to 45 degrees.
 
    1. E116787
      • Remove the special tool.
 
    1. Refer to: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 Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Installation).
 
    1. Refer to:Starter Motor (303-06A Starting System - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
  1. Connect the battery ground cable.
    Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).

OIL FILTER ELEMENT (G1509150)

REMOVAL AND INSTALLATION
 
  • 12.60.02
  • OIL FILTER ELEMENT - RENEW
  • 3000 CC, TDV6
  • 0.10
  • USED WITHINS
 

PART(S)

STEP PART NAME QUANTITY
Installation Step 2 Oil filter and O-ring seal kit 1
 
REMOVAL
CAUTION:

Make sure that the correct tools are used to remove and install the oil filter element cap.

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. E113950
      • Rotate the oil filter element housing six complete turns counter-clockwise.
      • Allow the engine oil to drain from the oil filter element housing for two minutes.
      • Remove the oil filter element housing.
 
  1. E195968
    • Remove and discard the O-ring seals.
    • Remove and discard the engine oil filter element.
 
INSTALLATION
 
    1. CAUTION:

      Make sure the engine oil filter housing center tube is installed to the engine oil filter housing before installing the new engine oil filter, as shown in the illustration. Failure to do this will cause low engine oil pressure when starting the engine, resulting in premature engine wear.

      E262835
 
    1. E195968
      • Install the new engine oil filter element.
      • Lubricate the O-ring seal with clean engine oil.
 
    1. E113950
      Torque: 28Nm
 
    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. Start and run the engine.
 
  1. Check and top-up the engine oil.

OIL PAN (G1671685)

REMOVAL AND INSTALLATION
 
  • 12.60.44
  • OIL PAN - RENEW
  • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
  • 5.90
  • USED WITHINS
 

PART(S)

STEP PART NAME QUANTITY
Removal Step 6 Turbocharger oil return pipe gasket(s) 1
Removal Step 7 Turbocharger oil return pipe gasket(s) 1
Removal Step 11 Turbocharger oil return pipe gasket(s) 1
Removal Step 13 Oil pan gasket 1
Removal Step 16 Oil level gauge O-ring seal 1
Removal Step 17 Oil pick up pipe 1
Removal Step 18 Vent tube 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.


 
    1. Disconnect the battery ground cable.
      Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).
 
    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:Starter Motor (303-06A Starting System - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Refer to:Differential (205-03 Front Drive Axle/Differential, Removal and Installation).
 
    1. E122598
      Torque
      M10: 40Nm
      M8: 24Nm
 
    1. CAUTION:

      A new gasket must be installed.

      NOTE:

      Remove and discard the gasket.

      E147280
      Renew Part: Turbocharger oil return pipe gasket(s) Quantity: 1.
      Torque: 10Nm
 
    1. CAUTION:

      A new gasket must be installed.

      NOTE:

      Remove and discard the gasket.

      E147281
      Renew Part: Turbocharger oil return pipe gasket(s) Quantity: 1.
      Torque: 10Nm
 
    1. E147804
      Torque: 25Nm
 
    1. E122590
      Torque: 24Nm
 
    1. E122595
      Torque: 10Nm
 
    1. CAUTION:

      A new gasket must be installed.

      NOTE:

      Remove and discard the gasket.

      E122597
      Renew Part: Turbocharger oil return pipe gasket(s) Quantity: 1.
      Torque: 10Nm
 
    1. CAUTION:

      Note the position of the bolts, prior to removal.

      E122593
      • Torque
        M8: 23Nm
      • Torque
        M6: 10Nm
 
    1. CAUTION:

      A new gasket must be installed.

      NOTE:

      Remove and discard the gasket.

      E122592
      Renew Part: Oil pan gasket Quantity: 1.
 
    1. NOTE:

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

      E122599
      Torque: 10Nm
 
    1. E122586
      Torque: 10Nm
 
    1. CAUTION:

      A new O-ring seal must be installed.

      NOTE:

      Remove and discard the O-ring seal.

      E122588
      Renew Part: Oil level gauge O-ring seal Quantity: 1.
      Torque: 10Nm
 
    1. NOTE:

      Discard the oil pick up pipe.

      E122594
      Renew Part: Oil pick up pipe Quantity: 1.
      Torque: 10Nm
 
  1. NOTE:

    Discard the breather.

    E122584
    Renew Part: Vent tube Quantity: 1.
    Torque: 10Nm
 
INSTALLATION
 
    1. CAUTIONS:

      • Installation of the oil pan and tightening must be completed within 7 minutes of applying the sealant.

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

      NOTE:

      Right-hand shown, left-hand similar.

      E122585
      Apply sealant WSE-M4G323-A5 in an 8mm bead to the cylinder block in the area illustrated.
 
  1. To install, reverse the removal procedure.

 

ELECTRIC OIL PUMP - TDV6 3.0L DIESEL - GEN 2 (G1875418)

REMOVAL AND INSTALLATION
 
  • 12.60.26
  • OIL PUMP - RENEW
  • 3000 CC, TDV6, DIESEL, GEN 2, IC
  • 4.00
  • USED WITHINS
 

SPECIAL TOOL(S)

E52717
 

303-1121A

Installer, Crankshaft Seal

 
E54545
 

303-1122

Installer, Crankshaft Front Seal

PART(S)

STEP PART NAME QUANTITY
Installation Step 11 Crankshaft front oil seal 1
Installation Step 17 Crankshaft pulley bolt 1
 
REMOVAL
 
    1. Disconnect the battery ground cable.
      Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).
 
    1. Remove the generator.
      Refer to:Generator (414-02A Generator and Regulator - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E144760
 
    1. E144761
 
    1. Refer to:Timing Belt (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Refer to:Crankshaft Pulley - TDV6 3.0L Diesel - Gen 2 (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    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. E144767
 
    1. E178570
      Remove the timing belt cover sealing strips.
 
    1. E178571
 
    1. E178572
 
  1. E145211
    Remove the alignment dowels (if equipped).
 
INSTALLATION
 
 
    1. E178573
 
    1. NOTE:

      Prime the oil pump.

      E178574
      Fill the orifice shown with 20 ml of engine oil.
 
    1. E178575
      Rotate the oil pump drive 2 complete turns.
 
    1. CAUTION:

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

      E144758
      Apply sealant WSE-M4G323-A5 in an 3mm bead to the two areas shown, also apply a smear of sealant to the gasket face as illustrated.
 
    1. CAUTION:

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

      NOTES:

      • Make sure the gasket is installed correctly.

      • Make sure the oil pump locator is installed correctly.

      E178576
      Install the oil pump.
 
    1. NOTE:

      Remove the oil pump locator.

      E178577
      Install two bolts to the oil pump, only finger tighten at this stage.
 
    1. E144767
      Install the oil pump lower retaining bolts.
      Torque: 10Nm
 
    1. NOTE:

      Tighten the bolts in the sequence shown to 10 Nm .

      E178578
      Secure the oil pump.
 
    1. E178570
      Install the timing belt cover sealing strips.
 
    1. CAUTION:

      Do not use any lubricant on the crankshaft front seal, special tools or the crankshaft. Failure to follow this instruction may result in damage to the vehicle.

      NOTE:

      Make sure all component mating faces are clean.

      E116752
      Install a new crankshaft front seal to the special tool.
      Special Tool(s): 303-1122
      Renew Part: Crankshaft front oil seal Quantity: 1.
 
    1. NOTE:

      Remove the sleeve from the special tool.

      E116753
      Reposition the crankshaft front seal along the special tool.
      Special Tool(s): 303-1122
 
    1. E178579
      Install the special tool to the crankshaft.
      Special Tool(s): 303-1122
 
    1. E178580
      Remove the special tool from the crankshaft.
      Special Tool(s): 303-1122
 
    1. E178581
      Install the special tool to the crankshaft.
      Special Tool(s): 303-1121A
 
    1. NOTES:

      • Make sure the seal is installed correctly.

      • Use the crankshaft bolt with the service tool.

      E178582
      Install the special tool to the crankshaft.
      Special Tool(s): 303-1121A
 
    1. NOTES:

      • Make sure the seal is installed correctly.

      • Wait 10 seconds before removing the crankshaft seal installation tool.

      E178583
      Remove and discard the crankshaft pulley retaining bolt.
      Special Tool(s): 303-1121A
      Renew Part: Crankshaft pulley bolt Quantity: 1.
 
    1. E178571
 
    1. Refer to:Crankshaft Pulley - TDV6 3.0L Diesel - Gen 2 (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Refer to:Timing Belt (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E149662
      Tighten the bolts in the sequence shown.
      Torque: 22Nm
 
    1. Install the generator.
      Refer to:Generator (414-02A Generator and Regulator - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E144760
      Torque: 45Nm
 
  1. Connect the battery ground cable.
    Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).

TIMING BELT (G1509153)

REMOVAL AND INSTALLATION
 
  • 12.65.18
  • TIMING BELT - CAMSHAFT - RENEW
  • 3000 CC, TDV6
  • 2.50
  • USED WITHINS
 

SPECIAL TOOL(S)

E54540
 

303-1117

Timing Peg, Automatic Transmission

 
E54551
 

303-1126

Timing Peg, Camshaft Pulley

PART(S)

STEP PART NAME QUANTITY
Installation Step 2 Timing belt and tensioner kit 1
 
REMOVAL
 
    1. Refer to:Timing Cover (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
      Refer to:Timing Cover (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Refer to:Starter Motor (303-06A Starting System - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E116629
 
    1. Rotate the crankshaft clockwise to align the crankshaft alignment hole in the flywheel or flexplate with the block aperture.
 
    1. E145815
      Check the camshaft pulley alignment holes are correctly aligned. If the alignment holes are not aligned, rotate the crankshaft one full turn clockwise.
 
    1. E116630
      Special Tool(s): 303-1117
 
    1. E145816
      Special Tool(s): 303-1126
 
    1. CAUTION:

      Do not use the special tools to lock the camshafts. Failure to follow this instruction may result in damage to the engine or the special tools.

      NOTE:

      Do not loosen the bolts more than 2 turns.

      E145821
 
    1. CAUTIONS:

      • Discard the component.

      • Discard the bolt.

      E145819
 
  1. CAUTION:

    Discard the component.

    E145818
 
INSTALLATION
 
    1. E145820
 
    1. CAUTIONS:

      • Make sure that a new bolt is installed.

      • Only tighten the bolts finger-tight at this stage.

      E145819
      Renew Part: Timing belt and tensioner kit Quantity: 1.
 
    1. CAUTION:

      Make sure the camshaft pulleys remain in the clockwise position.

      E145817
      • Install the new timing belt.
      • Starting at the crankshaft pulley, install the timing belt in a counter-clockwise direction, in the sequence shown.
      • Stage one: Attach the timing belt to the crankshaft pulley.
      • Stage two: Attach the timing belt to the idler pulley.
      • Stage three: Attach the timing belt to the left-hand camshaft pulley.
      • Stage four: Attach the timing belt to the idler pulley.
      • Stage five: Attach the timing belt to the RH camshaft pulley.
      • Stage six: Attach the timing belt to the timing belt tensioner.
 
    1. CAUTION:

      Make sure the timing belt tensioner window is aligned with the groove as illustrated.

      E145814
      • Tension the timing belt.
      • Rotate the tensioner assembly counter-clockwise.
      • Torque
        Stage1: 10Nm
        Stage2: 65°
 
    1. CAUTION:

      Do not use the special tools to lock the camshafts. Failure to follow this instruction may result in damage to the engine or the special tools.

      E145821
      • Using a suitable tool, counterhold the camshaft pulley center retaining bolts.
      • Torque: 23Nm
 
    1. E145816
      Special Tool(s): 303-1126
 
    1. E116630
      Special Tool(s): 303-1117
 
    1. CAUTION:

      Only rotate the crankshaft clockwise.

      Rotate the engine two complete turns clockwise.
 
    1. E116630
      Special Tool(s): 303-1117
 
    1. E145815
      • Install the special tools to the exhaust camshaft pulleys.
      • If the special tool does not fit correctly, repeat the timing belt installation procedure.
      • Remove the special tools from the camshaft pulleys.
 
    1. E116630
      Special Tool(s): 303-1117
 
    1. E116629
 
    1. Refer to:Starter Motor (303-06A Starting System - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
  1. Refer to:Timing Cover (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).

TIMING COVER (G1875417)

REMOVAL AND INSTALLATION
 
  • 12.65.03
  • COVER - CAMSHAFT DRIVE BELT - RENEW
  • 3000 CC, TDV6
  • 1.60
  • USED WITHINS
  • 12.65.03
  • COVER - CAMSHAFT DRIVE BELT - RENEW
  • 3000 CC, TDV6, GEN 2
  • 2.20
  • USED WITHINS
 

PART(S)

STEP PART NAME QUANTITY
Removal Step 13 Engine coolant pump pulley bolts 1
Removal Step 15 Timing belt cover gasket 1
 
REMOVAL
 
    1. Disconnect the battery ground cable.
      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).
      Refer to:Cooling System Partial 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: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:Accessory Drive Belt Pulley (303-05D Accessory Drive - TDV8 4.4L Diesel, Removal and Installation).
      Refer to:Accessory Drive Belt Pulley (303-05A Accessory Drive - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E178673
      Torque: 3Nm
 
    1. E178674
 
    1. E178675
 
    1. E178676
      Torque: 8Nm
 
    1. E144182
      Torque: 4Nm
 
    1. E178677
      Torque: 8Nm
 
    1. E178678
      Torque: 8Nm
 
    1. E178679
      Torque: 4Nm
 
    1. CAUTION:

      Discard the bolts.

      E178680
      • Using a suitable 6mm bar, retain the coolant pump pulley.
 
    1. E178681
      Torque: 25Nm
 
  1. E178682
    Remove and discard the timing belt cover gasket.
    Renew Part: Timing belt cover gasket Quantity: 1.
    Torque: 10Nm
 
INSTALLATION
 
  1. To install, reverse the removal procedure.

LEFT VALVE COVER (G1509155)

REMOVAL AND INSTALLATION
 
  • 12.29.43
  • CAMSHAFT COVER - LEFT - RENEW
  • 3000 CC, TDV6
  • 4.40
  • USED WITHINS
 

SPECIAL TOOL(S)

E54135
 

100-012

Slide Hammer

 
E116924
 

310-213

Fuel Injector Removal Adapter

PART(S)

STEP PART NAME QUANTITY
Installation Step 2 Camshaft cover gasket 1
Installation Step 11 Fuel Injector replacement kits 3
 
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. 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. Partially drain the cooling system.
      Refer to:Cooling System Partial 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. Remove the throttle body.
      Refer to:Intake Air Shutoff Throttle (303-04A Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E193114
      Remove the accessory drive belt.
 
    1. E224281
      • Disconnect the 2 electrical connectors.
      • Release the vacuum harness and position aside.
 
    1. E224295
      • Release the emergency park release assembly and position aside.
 
    1. CAUTION:

      Be prepared to collect escaping engine coolant.

      E224296
      • Disconnect the electrical connector and release the wiring harness from the engine coolant pipe.
      • Release the engine coolant hose from the engine coolant outlet.
      • Remove the 2 bolts.
 
    1. CAUTION:

      Be prepared to collect escaping engine coolant.

      E224297
      • Release the engine coolant hose from the left Exhaust Gas Recirculation (EGR) valve.
      • Remove the engine coolant hose.
 
    1. Always follow the cleaning process before doing any repairs to the fuel injection system components. Failure to follow this instruction may result in damage to the fuel injection system.
      Refer to:Fuel Injection Component Cleaning (303-04A Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, General Procedures).
 
    1. Remove the left fuel rail.
      Refer to:Left Fuel Rail (303-04A Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E144254
      Disconnect and release the fuel injector wiring harness.
 
    1. E144267
      Remove the fuel injector bolts.
 
    1. E144259
      Using the special tools remove the fuel injector.
      Special Tool(s): 100-012, 310-213
 
    1. E130725
      • Remove and discard the O-ring seal.
      • Remove and discard the sealing washer.
 
    1. E144699
      Remove and discard the fuel injector retaining clamp.
 
    1. Repeat steps 14 to 16 for the remaining 2 fuel injectors.
 
    1. E194795
      Disconnect the electrical connector and release the wiring harness.
 
    1. E194796
      Release the wiring harness.
 
    1. E194797
      Remove the Noise, Vibration and Harshness material.
 
    1. E194798
      Remove the pins.
 
    1. E194799
      Remove the left valve cover mounting bracket.
 
    1. E116684
      Release the wiring harness.
 
    1. E194800
      Remove the fuel rail mounting bracket.
 
    1. E224299
      • Remove the engine mounting bracket.
      • Release the coolant pipe from the left valve cover.
 
    1. E224298
      Remove the 6 timing cover bolts.
 
    1. CAUTION:

      Take care not to damage any surrounding components.

      E224300
      • Using a suitable trim tool, release the timing cover from the left valve cover.
      • Loosen the 2 bolts.
 
  1. E224301
    • Loosen the 11 left valve cover bolts.
    • Remove the left valve cover.
    • Remove and discard the left valve cover gasket.
 
INSTALLATION
 
    1. CAUTIONS:

      • Use only a plastic scraper when removing the sealing material.

      • Use lint free cloth.

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

      • Installation of the valve cover and tightening must be carried out within 7 minutes of applying the sealant.

      NOTES:

      • (1) Right valve cover.

      • (2) Left valve cover.

      E249914
      Apply (0.35g) a small amount of gasket sealant (Loctite 5900 or Hylosil sealant) in each location as shown on the illustration. Install the valve cover immediately after applying the sealant.
 
    1. CAUTION:

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

      • Install, but do not fully tighten the 11 left valve cover bolts.
 
    1. CAUTION:

      Take care not to damage any surrounding components.

      • Using a suitable trim tool, release the timing cover from the left valve cover.
      • Install, but do not fully tighten the 2 left valve cover bolts.
 
    1. E230187
      • Tighten the 13 left valve cover bolts in the indicated sequence.
        Torque: 10Nm
 
      • Install the 6 timing cover bolts.
        Torque: 10Nm
 
    1. Install the coolant pipe to the left valve cover.
      Torque: 8Nm
 
    1. Install the engine mounting bracket.
      Torque: 8Nm
 
    1. Install the fuel rail mounting bracket.
      Torque: 23Nm
 
    1. Install the left valve cover mounting bracket.
      Torque: 10Nm
 
      • Install the Noise, Vibration and Harshness material.
      • Install the pins.
      • Install the wiring harness and connect the electrical connectors.
 
      • Install new fuel injector retaining clamps.
      • Install new O-ring seals.
 
    1. Install the fuel injectors.
      Torque: 9Nm
 
    1. Connect the fuel injector wiring harness.
 
    1. Install the left fuel rail.
      Refer to:Left Fuel Rail (303-04A Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
      • Install the Exhaust Gas Recirculation (EGR) engine coolant crossover pipe.
        Torque: 8Nm
      • Connect the electrical connector.
 
    1. Install the emergency park release assembly.
      Torque: 8Nm
 
      • Install the vacuum harness.
      • Connect the electrical connectors.
 
    1. Install the accessory drive belt.
 
    1. Install the throttle body.
      Refer to:Intake Air Shutoff Throttle (303-04A Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Fill the drain the cooling system.
      Refer to:Cooling System Partial 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. Connect the startup battery ground cable.
    Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).

RIGHT VALVE COVER (G1509156)

REMOVAL AND INSTALLATION
 
  • 12.29.44
  • CAMSHAFT COVER - RIGHT - RENEW
  • 3000 CC, TDV6
  • 3.90
  • USED WITHINS
 

SPECIAL TOOL(S)

E54135
 

100-012

Slide Hammer

 
E116924
 

310-213

Fuel Injector Removal Adapter

 
E124125
 

JLR-310-237

Remover, Fuel Injector

PART(S)

STEP PART NAME QUANTITY
Installation Step 2 Camshaft cover gasket 1
Installation Step 9 Fuel Injector replacement kits 3
 
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. 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. Partially drain the cooling system.
      Refer to:Cooling System Partial 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. Remove the throttle body.
      Refer to:Intake Air Shutoff Throttle (303-04A Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E224281
      • Disconnect the 2 electrical connectors.
      • Release the vacuum harness and position aside.
 
    1. Always follow the cleaning process before doing any repairs to the fuel injection system components. Failure to follow this instruction may result in damage to the fuel injection system.
      Refer to:Fuel Injection Component Cleaning (303-04E Fuel Charging and Controls - TDV8 4.4L Diesel, General Procedures).
 
    1. Remove the right fuel rail.
      Refer to:Right Fuel Rail (303-04A Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E201949
      Disconnect and release the fuel injector wiring harness.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E201950
      Release the fuel injector leak off pipes from the injectors.
 
    1. E201951
      Remove the fuel injector bolts.
 
    1. E144260
      Using the special tools remove the fuel injector.
      Special Tool(s): 100-012, 310-213, JLR-310-237
 
    1. E130725
      • Remove and discard the O-ring seal.
      • Remove and discard the sealing washer.
 
    1. E144699
      Remove and discard the fuel injector retaining clamp.
 
    1. Repeat steps 11 to 13 for the remaining 2 fuel injectors.
 
    1. E194855
      Release the vacuum harness.
 
    1. E194856
      Release the wiring harness.
 
    1. E194857
      Remove the Noise, Vibration and Harshness material.
 
    1. E194858
      Remove the pin.
 
    1. E194859
      Remove the plastic fixings.
 
    1. E194860
      Remove the right valve cover mounting bracket.
 
    1. E194861
      Remove the fuel rail mounting bracket.
 
  1. E224435
    • Loosen the 14 left valve cover bolts.
    • Remove the right valve cover.
    • Remove and discard the right valve cover gasket.
 
INSTALLATION
 
    1. CAUTIONS:

      • Use only a plastic scraper when removing the sealing material.

      • Use lint free cloth.

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

      • Installation of the valve cover and tightening must be carried out within 7 minutes of applying the sealant.

      NOTES:

      • (1) Right valve cover.

      • (2) Left valve cover.

      E249914
      Apply (0.35g) a small amount of gasket sealant (Loctite 5900 or Hylosil sealant) in each location as shown on the illustration. Install the valve cover immediately after applying the sealant.
 
    1. CAUTION:

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

      • Install, but do not fully tighten the 14 left valve cover bolts.
 
    1. E230188
      • Tighten the 14 left valve cover bolts in the indicated sequence.
        Torque: 10Nm
 
    1. Install the fuel rail mounting bracket.
      Torque: 23Nm
 
    1. Install the right valve cover mounting bracket.
      Torque: 10Nm
 
    1. Install the plastic fixings.
 
    1. Install the pin.
      Torque: 9Nm
 
      • Install the Noise, Vibration and Harshness material.
      • Install the wiring harness to the right valve cover.
      • Install the vacuum harness.
 
      • Install new fuel injector retaining clamps.
      • Install new O-ring seals.
 
    1. Install the fuel injectors.
      Torque: 9Nm
 
      • Install the fuel injector leak off pipes.
      • Connect the fuel injector wiring harness.
 
    1. Install the right fuel rail.
      Refer to:Right Fuel Rail (303-04A Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
      • Install the vacuum harness.
      • Connect the electrical connectors.
 
    1. Install the throttle body.
      Refer to:Intake Air Shutoff Throttle (303-04A Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Fill the drain the cooling system.
      Refer to:Cooling System Partial 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. Connect the startup battery ground cable
    Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).

 

OIL COOLER (G1879930)

REMOVAL AND INSTALLATION
 
  • 12.60.68
  • OIL COOLER - RENEW
  • 3000 CC, TDV6
  • 4.60
  • USED WITHINS
 

PART(S)

STEP PART NAME QUANTITY
Installation Step 1 Oil cooler O-ring seals 1
Installation Step 2 Engine coolant outlet seal 1
 
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 illustration showing certain components removed to provide extra clarity.


 
    1. Drain the cooling system.
      Refer to:Cooling System Partial 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. Disconnect the startup battery ground cable.
      Refer to:Specifications (414-01 Battery, Mounting and Cables, Specifications).
 
    1. Remove the right valve cover.
      Refer to:Right Valve Cover (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Remove the oil filter.
      Refer to:Oil Filter Element (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Remove the glow plugs.
      Refer to:Glow Plugs (303-07C Glow Plug System - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E204220
      Disconnect the vacuum tubes.
 
    1. E204221
      Remove the vacuum reservoir.
 
    1. CAUTION:

      Be prepared to collect escaping coolant.

      E204222
      Disconnect the coolant hoses.
 
    1. CAUTION:

      Be prepared to collect escaping coolant.

      NOTE:

      Remove and discard the seals.

      E204223
      Remove the engine coolant outlet.
 
  1. NOTE:

    Remove and discard the seals.

    E204219
    Remove the oil cooler.
 
INSTALLATION
 
    1. CAUTION:

      Install new seals.

      Install the oil cooler.
      Renew Part: Oil cooler O-ring seals Quantity: 1.
      Torque: 10Nm
 
    1. CAUTION:

      Install new seals.

      Install the coolant outlet.
      Renew Part: Engine coolant outlet seal Quantity: 1.
      Torque: 10Nm
 
    1. Connect the coolant hoses.
 
    1. Install the vacuum reservoir.
      Torque: 10Nm
 
    1. Connect the vacuum tubes.
 
    1. Install the glow plugs.
      Refer to:Glow Plugs (303-07C Glow Plug System - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Install a new oil filter.
      Refer to:Oil Filter Element (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Install the right valve cover.
      Refer to:Right Valve Cover (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 (414-01 Battery, Mounting and Cables, Specifications).
 
    1. Fill the cooling system.
      Refer to:Cooling System Partial 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. Check and top-up the engine oil.

Removal

ENGINE - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1509157)

REMOVAL
 
  • 12.41.01.99
  • ENGINE AND ANCILLARIES - REMOVE FOR ACCESS AND REFIT
  • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
  • 9.90
  • USED WITHINS
 
REMOVAL

SPECIAL TOOL(S)

303021
 

303-021

Engine support bracket

 
E193495
 

303-1141

Engine lifting kit

 
E193494
 

303-1141-01

Engine lifting bracket - Rear

CAUTION:

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

NOTE:

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


 
    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. Position the hood into the service position.
      Refer to:Specifications (501-02 Front End Body Panels, Specifications).
 
    1. Drain the cooling system.
      Refer to:Cooling System Partial Draining and Vacuum Filling (303-03B Engine Cooling - V6 S/C 3.0L Petrol, General Procedures).
 
    1. Remove the intake air shutoff throttle.
      Refer to:Intake Air Shutoff Throttle (303-04A Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Remove the transmission.
      Refer to: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 Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Removal).
 
    1. Remove the front right halfshaft.
      Refer to:Front Right Halfshaft (205-04 Front Drive Halfshafts, Removal and Installation).
 
    1. NOTE:

      If equipped.

      E145616
      • Remove the 3 bolts.
      • Remove the bracket.
 
    1. E148352
      Remove the bolt.
 
    1. E148353
      • Remove the 4 bolts.
      • Remove the halfshaft support bracket.
 
    1. E159906
      • Disconnect the coolant pipe and reposition away from the coolant hose.
      • Release the 3 clips.
      • Remove the cooling hose.
 
    1. E159902
      • Disconnect the vacuum pipe and reposition away from the engine.
      • Disconnect the pipe.
 
    1. E147490
      Remove the bolt.
 
    1. E159903
      • Release the 3 clamps.
      • Disconnect and reposition the breather pipe away from the air filter outlet pipe.
      • Remove the air filter outlet pipe.
 
    1. E152189
      Disconnect the vacuum pipe.
 
    1. E159901
      • Release the clamp.
      • Reposition the coolant hose away from the thermostat.
 
    1. CAUTION:

      Be prepared to collect escaping coolant.

      E152199
      • Release the coolant hose clip.
      • Reposition the coolant hose away from the engine.
 
    1. E147941
      • Release the 3 clamps.
      • Release the breather hose from the turbocharger intake pipe.
      • Reposition the turbocharger intake pipe away from the turbocharger.
      • Reposition the turbocharger outlet pipe away from the turbocharger.
 
    1. E147940
      • Remove the nut.
      • Remove the turbocharger intake pipe.
 
    1. E152200
      • Release the clamp.
      • Reposition the coolant hose away from the engine.
 
    1. E147939
      • Remove the nut.
      • Remove the turbocharger outlet pipe.
 
    1. CAUTION:

      Be prepared to collect escaping coolant.

      E152202
      • Remove the nut.
      • Remove the bolt.
      • Release the clamp.
      • Remove the coolant pipe.
 
    1. CAUTION:

      Be prepared to collect escaping fluids.

      E147667
      • Release the clip.
      • Disconnect and reposition the 2 pipes away from the transmission oil cooler.
 
    1. CAUTION:

      Be prepared to collect escaping coolant.

      E159277
      • Release the clip.
      • Reposition the coolant pipe away from the cooling module.
 
    1. E147901
      • Release the clamp.
      • Reposition the air filter outlet pipe away from the air filter housing.
 
    1. E147902
      • Remove the bolt.
      • Remove the air filter outlet pipe.
 
    1. E152191
      Disconnect the coolant hose and reposition away from the engine.
 
    1. E152193
      Disconnect the 2 vacuum pipes.
 
    1. E152203
      • Release the clamp.
      • Reposition the hose away from the engine.
 
    1. E152190
      • Release the clip.
      • Release the clamp.
      • Reposition the hose away from the turbocharger bypass valve.
 
    1. CAUTION:

      Be prepared to collect escaping coolant.

      E159325
      • Release the clip.
      • Reposition the coolant hose away from the cooling module.
 
    1. E159262
      Disconnect the 3 electrical connectors.
 
    1. E147481
      Remove the 2 bolts.
 
    1. CAUTION:

      Take extra care not to damage the surrounding components.

      E159900
      • Release the 2 clips.
      • Carefully remove the cooling module.
 
    1. E147668
      Remove the nut.
 
    1. E147669
      Reposition the transmission oil cooler fluid pipes.
 
    1. E147675
      Remove the bolt.
 
    1. Remove the accessory drive belt.
      Refer to:Accessory Drive Belt - Vehicles Without: Dynamic Suspension (303-05A Accessory Drive - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E122697
      • Release clip.
      • Disconnect the 2 electrical connectors.
 
    1. CAUTION:

      The Air Conditioning (A/C) compressor must not be supported by the A/C pipes.

      E118254
      • Remove the 3 bolts.
      • Reposition the Air Conditioning (A/C) compressor away from the engine.
      • Use a suitable strap to tie aside the A/C compressor.
 
    1. E144815
      • Align the steering wheel to the straight ahead position.
      • Remove and discard the bolt.
      • Reposition the lower steering column away form the steering rack.
 
    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. CAUTION:

      Be prepared to collect escaping coolant.

      E144251
      • Release the 4 clamps.
      • Remove the 2 bolts.
      • Remove the coolant bleed pipe.
 
    1. E144252
      • Remove the 2 bolts.
      • Remove the wiring harness cover.
 
    1. E152196
      • Disconnect the 2 electrical connectors.
      • Release wiring harness grommet.
      • Reposition the wiring harness away from the powertrain control module.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E152198
      • Disconnect the 2 fuel pipes from the High Pressure (HP) fuel pump.
      • Disconnect the 2 fuel pipes from the fuel filter.
      • Remove the fuel pipes.
 
    1. E152207
      • Remove the bolt.
      • Remove the vacuum reservoir.
 
    1. E152184
      • Release the 2 vacuum pipe from the 2 clips.
      • Remove the bolt.
 
    1. E152206
      • Remove the 3 studs.
      • Remove the bracket.
 
    1. E152187
      • Disconnect the clip.
      • Disconnect the 2 electrical connectors.
      • Release the 2 connectors from the intake manifolds.
 
    1. E152185
      • Install and tighten the 6 bolts.
      • Install and tighten the 2 studs.
 
    1. E152260
      • Install the special tool.
        Special Tool(s): 303-021
 
    1. E152186
      • Reposition the nut cover.
      • Remove the nut.
      • Reposition the cable away from the engine.
 
    1. E155798
      • Remove the bolt.
      • Reposition the ground cable away from the engine.
 
    1. E152192
      Remove the engine mount nut.
 
    1. E152188
      Remove the engine mount nut.
 
    1. E152260
      • Remove the special tool.
        Special Tool(s): 303-021
 
  1. WARNING:

    This step requires the aid of another technician.

    CAUTION:

    Be prepared to collect escaping fluids.

    E152197
    Carefully and progressively raise and remove the engine.

Disassembly

ENGINE - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1509157)

REMOVAL
 
  • 12.41.01.99
  • ENGINE AND ANCILLARIES - REMOVE FOR ACCESS AND REFIT
  • 3000 CC, TDV6, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FLUID, IC
  • 9.90
  • USED WITHINS
 
REMOVAL

SPECIAL TOOL(S)

303021
 

303-021

Engine support bracket

 
E193495
 

303-1141

Engine lifting kit

 
E193494
 

303-1141-01

Engine lifting bracket - Rear

CAUTION:

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

NOTE:

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


 
    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. Position the hood into the service position.
      Refer to:Specifications (501-02 Front End Body Panels, Specifications).
 
    1. Drain the cooling system.
      Refer to:Cooling System Partial Draining and Vacuum Filling (303-03B Engine Cooling - V6 S/C 3.0L Petrol, General Procedures).
 
    1. Remove the intake air shutoff throttle.
      Refer to:Intake Air Shutoff Throttle (303-04A Fuel Charging and Controls - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. Remove the transmission.
      Refer to: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 Automatic Transmission/Transaxle - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Removal).
 
    1. Remove the front right halfshaft.
      Refer to:Front Right Halfshaft (205-04 Front Drive Halfshafts, Removal and Installation).
 
    1. NOTE:

      If equipped.

      E145616
      • Remove the 3 bolts.
      • Remove the bracket.
 
    1. E148352
      Remove the bolt.
 
    1. E148353
      • Remove the 4 bolts.
      • Remove the halfshaft support bracket.
 
    1. E159906
      • Disconnect the coolant pipe and reposition away from the coolant hose.
      • Release the 3 clips.
      • Remove the cooling hose.
 
    1. E159902
      • Disconnect the vacuum pipe and reposition away from the engine.
      • Disconnect the pipe.
 
    1. E147490
      Remove the bolt.
 
    1. E159903
      • Release the 3 clamps.
      • Disconnect and reposition the breather pipe away from the air filter outlet pipe.
      • Remove the air filter outlet pipe.
 
    1. E152189
      Disconnect the vacuum pipe.
 
    1. E159901
      • Release the clamp.
      • Reposition the coolant hose away from the thermostat.
 
    1. CAUTION:

      Be prepared to collect escaping coolant.

      E152199
      • Release the coolant hose clip.
      • Reposition the coolant hose away from the engine.
 
    1. E147941
      • Release the 3 clamps.
      • Release the breather hose from the turbocharger intake pipe.
      • Reposition the turbocharger intake pipe away from the turbocharger.
      • Reposition the turbocharger outlet pipe away from the turbocharger.
 
    1. E147940
      • Remove the nut.
      • Remove the turbocharger intake pipe.
 
    1. E152200
      • Release the clamp.
      • Reposition the coolant hose away from the engine.
 
    1. E147939
      • Remove the nut.
      • Remove the turbocharger outlet pipe.
 
    1. CAUTION:

      Be prepared to collect escaping coolant.

      E152202
      • Remove the nut.
      • Remove the bolt.
      • Release the clamp.
      • Remove the coolant pipe.
 
    1. CAUTION:

      Be prepared to collect escaping fluids.

      E147667
      • Release the clip.
      • Disconnect and reposition the 2 pipes away from the transmission oil cooler.
 
    1. CAUTION:

      Be prepared to collect escaping coolant.

      E159277
      • Release the clip.
      • Reposition the coolant pipe away from the cooling module.
 
    1. E147901
      • Release the clamp.
      • Reposition the air filter outlet pipe away from the air filter housing.
 
    1. E147902
      • Remove the bolt.
      • Remove the air filter outlet pipe.
 
    1. E152191
      Disconnect the coolant hose and reposition away from the engine.
 
    1. E152193
      Disconnect the 2 vacuum pipes.
 
    1. E152203
      • Release the clamp.
      • Reposition the hose away from the engine.
 
    1. E152190
      • Release the clip.
      • Release the clamp.
      • Reposition the hose away from the turbocharger bypass valve.
 
    1. CAUTION:

      Be prepared to collect escaping coolant.

      E159325
      • Release the clip.
      • Reposition the coolant hose away from the cooling module.
 
    1. E159262
      Disconnect the 3 electrical connectors.
 
    1. E147481
      Remove the 2 bolts.
 
    1. CAUTION:

      Take extra care not to damage the surrounding components.

      E159900
      • Release the 2 clips.
      • Carefully remove the cooling module.
 
    1. E147668
      Remove the nut.
 
    1. E147669
      Reposition the transmission oil cooler fluid pipes.
 
    1. E147675
      Remove the bolt.
 
    1. Remove the accessory drive belt.
      Refer to:Accessory Drive Belt - Vehicles Without: Dynamic Suspension (303-05A Accessory Drive - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
    1. E122697
      • Release clip.
      • Disconnect the 2 electrical connectors.
 
    1. CAUTION:

      The Air Conditioning (A/C) compressor must not be supported by the A/C pipes.

      E118254
      • Remove the 3 bolts.
      • Reposition the Air Conditioning (A/C) compressor away from the engine.
      • Use a suitable strap to tie aside the A/C compressor.
 
    1. E144815
      • Align the steering wheel to the straight ahead position.
      • Remove and discard the bolt.
      • Reposition the lower steering column away form the steering rack.
 
    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. CAUTION:

      Be prepared to collect escaping coolant.

      E144251
      • Release the 4 clamps.
      • Remove the 2 bolts.
      • Remove the coolant bleed pipe.
 
    1. E144252
      • Remove the 2 bolts.
      • Remove the wiring harness cover.
 
    1. E152196
      • Disconnect the 2 electrical connectors.
      • Release wiring harness grommet.
      • Reposition the wiring harness away from the powertrain control module.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E152198
      • Disconnect the 2 fuel pipes from the High Pressure (HP) fuel pump.
      • Disconnect the 2 fuel pipes from the fuel filter.
      • Remove the fuel pipes.
 
    1. E152207
      • Remove the bolt.
      • Remove the vacuum reservoir.
 
    1. E152184
      • Release the 2 vacuum pipe from the 2 clips.
      • Remove the bolt.
 
    1. E152206
      • Remove the 3 studs.
      • Remove the bracket.
 
    1. E152187
      • Disconnect the clip.
      • Disconnect the 2 electrical connectors.
      • Release the 2 connectors from the intake manifolds.
 
    1. E152185
      • Install and tighten the 6 bolts.
      • Install and tighten the 2 studs.
 
    1. E152260
      • Install the special tool.
        Special Tool(s): 303-021
 
    1. E152186
      • Reposition the nut cover.
      • Remove the nut.
      • Reposition the cable away from the engine.
 
    1. E155798
      • Remove the bolt.
      • Reposition the ground cable away from the engine.
 
    1. E152192
      Remove the engine mount nut.
 
    1. E152188
      Remove the engine mount nut.
 
    1. E152260
      • Remove the special tool.
        Special Tool(s): 303-021
 
  1. WARNING:

    This step requires the aid of another technician.

    CAUTION:

    Be prepared to collect escaping fluids.

    E152197
    Carefully and progressively raise and remove the engine.

LONG/STRIPPED ENGINE ASSEMBLY RENEW - TDV6 3.0L DIESEL - GEN 2 - TWIN TURBOCHARGER (G2194109)

DISASSEMBLY
 
  • 12.41.02
  • STRIPPED ENGINE - REMOVE ENGINE, CHANGE OVER ANCILLARY EQUIPMENT AND REFIT
  • 3000 CC, TDV6, TWIN TURBOCHARGER FITTED, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FL
  • 15.90
  • USED WITHINS
 
DISASSEMBLY

SPECIAL TOOL(S)

E54135
 

100-012

Slide Hammer

 
E54546
 

303-1123

Locking Tool, Flywheel

 
E116924
 

310-213

Fuel Injector Removal Adapter

 
E123916
 

JLR-303-1523

Remover/Installer, Camshaft Rear Pulley

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.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. Remove the engine.
      Refer to:Engine (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal).
 
    1. E194637
      Install the special tool.
      Install the Special Tool(s): 303-1123
 
    1. E194638
      • Remove and discard the 8 drive plate bolts.
      • Remove the drive plate.
 
    1. E194637
      Remove the special tool.
      Remove the Special Tool(s): 303-1123
 
    1. E245313
      • Remove the 3 bolts.
      • Remove the heatshield.
 
    1. E245314
      • Remove the 2 bolts.
      • Remove the heatshield.
 
    1. E245315
      • Remove and discard the bolt.
      • Remove and discard the 2 nuts.
 
    1. E245316
      • Remove and discard the 3 nuts.
      • Remove the exhaust manifold crossover pipe.
      • Remove and discard the 2 gaskets.
 
    1. E245320
      Remove and discard the 2 studs.
 
    1. E245321
      Remove and discard the 3 studs.
 
  1. E242232
    • Disconnect the electrical connector.
    • Release the 2 clips.

 

 

The following step(s) applies to:
1 high pressure EGR valve & 1 Low pressure EGR valve

 

 
  1. E242231
    • Remove the 3 bolts.
    • Release the clip.
    • Remove the pipe assembly.

 

 

The following step(s) applies to:
2 High pressure EGR valves

 

 
    1. E241759
      • Remove the 3 bolts.
      • Release the clip.
      • Remove the pipe assembly.
 
  1. E241293
    • Disconnect the vacuum hose.
    • Release the 2 clips.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. E241925
      • Disconnect the 2 electrical connectors.
      • Release the 3 clips.
 
    1. E241292
      • Disconnect the vacuum hose.
      • Remove the nut.
      • Release the vacuum solenoid.
 
    1. E241294
      Disconnect the 2 vacuum hoses.
 
    1. E242143
      • Release the 2 clips.
      • Disconnect the 2 electrical connectors.
      • Remove the 2 bolts.
 
    1. E242144
      Remove the vacuum hose assembly.
 
  1. NOTE:

    Repeat this step for the other side.

    E241298
    Remove the Noise, Vibration and Harshness (NVH) material.

 

 

The following step(s) applies to:
1 high pressure EGR valve & 1 Low pressure EGR valve

 

 
  1. E242233
    • Disconnect the electrical connector.
    • Release the 2 hose clips.
    • Remove the 2 bolts.
    • Release the clip.

 

 

The following step(s) applies to:
2 High pressure EGR valves

 

 
    1. E241398
      • Remove the 3 bolts.
      • Remove the EGR outlet pipe.
      • Remove and discard the gasket.
 
  1. E241927
    • Disconnect the electrical connector.
    • Release the 2 hose clips.
    • Remove the bolt.
    • Release the clip.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. E241928
      • Release the hose clip.
      • Remove the coolant hose.
 
    1. E241929
      • Remove the 3 bolts.
      • Remove the bracket.
 
  1. E241761
    • Disconnect the 4 electrical connectors.
    • Release the 3 clips.

 

 

The following step(s) applies to:
1 high pressure EGR valve & 1 Low pressure EGR valve

 

 
  1. E242234
    • Disconnect the 5 electrical connectors.
    • Release the 4 clips.

 

 

The following step(s) applies to:
2 High pressure EGR valves

 

 
  1. E241300
    • Disconnect the 3 electrical connectors.
    • Release the 3 clips.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. E241301
      • Disconnect the 4 electrical connectors.
      • Release the 3 clips.
 
    1. E241302
      • Disconnect the electrical connector.
      • Release the 2 clips.
 
    1. E241303
      • Disconnect the 2 electrical connectors.
      • Release the 2 clips.
 
    1. E241304
      • Disconnect the 3 electrical connectors.
      • Release the 5 clips.
 
    1. E241930
      • Disconnect the 2 electrical connectors.
      • Release the 2 clips.
 
    1. E241931
      • Remove the bolt.
      • Remove the nut.
 
    1. E241932
      Remove the engine wiring harness.
 
    1. CAUTION:

      Be prepared to collect escaping oil.

      E196875
      • Disconnect the connector.
      • Remove the 2 bolts.
      • Remove the nut.
      • Remove the oil extraction pipe.
 
    1. E191572
      • Remove the 5 bolts.
      • Remove the EGR valve.
      • Remove and discard the gasket.
 
    1. E242518
      • Remove the 2 bolts.
      • Remove the heatshield.
 
    1. E196879
      • Remove the 4 bolts.
      • Remove and discard the gasket.
      • Remove and discard the sealing washers.
      • Remove and discard the O-ring seal.
 
  1. E242245
    • Remove and discard the 6 nuts.
    • Remove the 2 mounting bolts.
    • Remove the exhaust manifold and turbocharger assembly.
    • Remove and discard the gasket.

 

 

The following step(s) applies to:
1 high pressure EGR valve & 1 Low pressure EGR valve

 

 
    1. E242235
      • Remove the 3 bolts.
      • Remove the EGR cooler.
 
  1. E242237
    • Remove the 3 bolts.
    • Remove the heatshield.

 

 

The following step(s) applies to:
2 High pressure EGR valves

 

 
    1. E241402
      • Remove the 5 bolts.
      • Remove the EGR valve.
      • Remove and discard the gasket.
 
  1. E242246
    • Remove the 3 bolts.
    • Remove the heatshield.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. E242238
      • Release the electrical connector.
      • Remove the 4 bolts.
      • Remove the mounting bracket.
 
    1. E242474
      • Remove the 4 bolts.
      • Remove and discard the 2 gaskets.
 
    1. E256788
      • Remove the bolt.
      • Remove and discard the 2 sealing washers.
 
    1. E242240
      • Remove the 4 bolts.
      • Remove and discard the 2 gaskets.
 
    1. E242242
      • Remove and discard the 6 nuts.
      • Remove the exhaust manifold and turbocharger assembly.
      • Remove and discard the gasket.
 
    1. E178339
      • Remove the 2 bolts.
      • Remove and discard the turbocharger coolant pipes.
 
    1. CAUTION:

      Be prepared to collect escaping oil.

      E196876
      • Remove the 4 bolts.
      • Remove the oil pipe.
      • Remove and discard the gasket.
      • Remove and discard the O-ring.
 
    1. CAUTION:

      Be prepared to collect escaping oil.

      E196890
      • Remove the bolt.
      • Remove oil supply pipe.
      • Remove and discard the sealing washers.
 
    1. E196882
      • Remove the 5 bolts.
      • Remove the bracket.
 
    1. E196891
      • Remove the 2 bolts.
      • Remove the bracket.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E241403
      • Disconnect the 4 fuel line connectors.
      • Release the 4 clips.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E241404
      • Disconnect the fuel line connector.
      • Release the 2 clips.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E241405
      • Disconnect the 3 fuel line connectors.
      • Release the clip.
 
    1. E241481
      Remove the fuel lines.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E241510
      Remove the 2 bolts.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E196893
      • Release the bracket bolt.
      • Release the 7 fuel line unions.
      • Remove and discard the 3 fuel lines.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E196894
      • Release the 2 fuel line bracket bolts.
      • Release the 7 fuel line unions.
      • Remove and discard the 4 fuel lines.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E196896
      • Release the 2 fuel line unions.
      • Remove the 3 bolts.
      • Remove the fuel rail assembly.
      • Remove and discard the fuel line.
 
    1. CAUTION:

      Be prepared to collect escaping fuel.

      E196898
      • Release the 2 fuel line unions.
      • Remove the 2 bolts.
      • Remove the fuel rail assembly.
      • Remove and discard the fuel line.
 
    1. NOTE:

      Repeat this step for the other side.

      E241923
      Remove the 6 bolts.
 
    1. NOTE:

      Repeat this step for the remaining injectors.

      E241924
      • Install the special tools.
        Install the Special Tool(s): 310-213, 100-012
      • Remove the injector assembly.
 
    1. NOTE:

      Repeat this step for the remaining injectors.

      E130725
      • Remove and discard the 2 O-ring seals.
      • Remove and discard the sealing washer.
 
    1. E241512
      • Release the 2 clips.
      • Remove the Rear End Accessory Drive (READ) cover.
 
    1. CAUTION:

      Only rotate the crankshaft clockwise.

      E116628
      Rotate the crankshaft until the mark on the rear camshaft pulley is in the illustrated position.
 
    1. E130870
      Using a suitable cutting tool, remove the READ belt.
 
    1. E126058
      • Remove the bolt.
      • Remove and discard the READ belt tensioner.
 
    1. E241665
      • Remove the 2 bolts.
      • Remove the cover.
 
    1. E241669
      • Remove the upper engine vent oil separator.
      • Remove and discard the seals.
 
    1. E241666
      Remove the 3 bolts.
 
    1. E241667
      Remove the 2 bolts.
 
    1. E241668
      Remove the fuel pump assembly.
 
    1. E241672
      Install the special tool.
      Install the Special Tool(s): JLR-303-1523
      Torque: 10Nm
 
    1. E241673
      • Install the special tool.
        Install the Special Tool(s): JLR-303-1523
      • Remove and discard the camshaft sprocket bolt.
 
    1. Remove the special tool.
      Remove the Special Tool(s): JLR-303-1523
 
    1. E123934
      Remove the camshaft pulley.
 
    1. E241671
      • Remove the 2 bolts.
      • Remove the cover.
 
    1. E241670
      • Remove the 4 bolts.
      • Remove the bracket and the lower engine vent oil separator.
 
    1. E196899
      • Remove the 3 bolts.
      • Remove the bracket.
 
    1. E242139
      • Remove the 3 bolts.
      • Remove the coolant pump.
      • Remove and discard the O-ring seal.
 
    1. E242140
      • Remove the bolt cover.
      • Remove the bolt.
      • Remove the pulley.
 
    1. E178681
      • Remove the 6 bolts.
      • Remove the crankshaft damper pulley.
 
    1. E241756
      • Remove the 2 bolts.
      • Remove the coolant inlet pipe.
      • Remove and discard the O-ring seal.
 
    1. E241757
      • Remove the 4 bolts.
      • Remove the coolant outlet assembly.
      • Remove and discard the 2 seals.
 
    1. E241764
      Remove the cover.
 
    1. E241765
      • Remove the bolt.
      • Remove the Crankshaft Position (CKP) sensor.
 
    1. NOTE:

      Repeat this step for the other side.

      E194797
      Remove the NVH material.
 
    1. E194798
      Remove the 2 mountings.
 
    1. E194799
      • Remove the 2 nuts.
      • Remove the bracket.
 
    1. NOTE:

      Repeat this step for the other side.

      E194861
      • Remove the 2 bolts.
      • Remove the bracket.
 
    1. E194858
      • Remove the 2 bolts.
      • Remove the bracket.
 
    1. E194859
      • Remove the 2 mountings.
 
  1. E194860
    • Remove the 2 nuts.
    • Remove the bracket.

SHORT ENGINE ASSEMBLY RENEW - TDV6 3.0L DIESEL - GEN 2 (G2430980)

DISASSEMBLY
 
 
DISASSEMBLY

SPECIAL TOOL(S)

E54546
 

303-1123

Locking Tool, Flywheel

 
E54549
 

303-1124

Holding Tool, Camshaft Front Pulley

 
E54551
 

303-1126

Timing Peg, Camshaft Pulley

GENERAL EQUIPMENT

EQUIPMENT NAME
Engine stand
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. NOTE:

      Do not complete steps 2 - 4 of the procedure. The drive plate needs to remain on the engine.

      Remove the engine and ancillaries.
      Refer to:Long/Stripped Engine Assembly Renew - TDV6 3.0L Diesel - Gen 2 - Mono Turbocharger (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Disassembly).
      Refer to:Long/Stripped Engine Assembly Renew - TDV6 3.0L Diesel - Gen 2 - Twin Turbocharger (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Disassembly).
 
    1. Install the engine assembly on to a suitable engine stand.
      General Equipment: Engine stand
 
    1. E255595
      • Remove the 2 bolts.
      • Remove the brake vacuum pump.
 
    1. E124399
      Remove and discard brake vacuum pump gasket.
 
    1. E255596
      • Remove the 16 bolts.
      • Remove the timing belt cover.
      • Remove and discard seal.
 
    1. CAUTION:

      Do not rotate the crankshaft counter-clockwise, engine damage may occur.

      E255597
      Rotate the crankshaft clockwise until the camshaft pulley alignment holes are aligned.
 
    1. E255598
      Install the 2 camshaft locking pins.
      Install the Special Tool(s): 303-1126
 
    1. CAUTION:

      Do not attempt to loosen the 6 bolts using the special tools to prevent the camshaft pulleys from turning. Failure to follow this instruction may result in damage to the special tools or engine.

      NOTE:

      Do not loosen the 6 bolts more than 2 turns.

      E255599
      Using a suitable tool to prevent the camshaft pulleys from turning, loosen the 6 bolts.
 
    1. E255601
      • Remove the bolt.
      • Remove the timing belt tensioner.
 
    1. E255600
      Remove the timing belt.
 
    1. E255602
      • Remove the 2 bolts.
      • Remove the bracket.
 
    1. E255603
      • Remove the 2 bolts.
      • Remove the 2 timing belt idler pulleys.
      • Remove the cover.
 
    1. E194637
      Install the special tool.
      Install the Special Tool(s): 303-1123
 
    1. E163317
      Loosen, but do not fully remove the crankshaft pulley bolt.
 
    1. E146173
      Using the special tool, release the crankshaft pulley from the cranshaft.
 
    1. E255604
      • Remove the crankshaft pulley bolt.
      • Remove the crankshaft pulley.
 
    1. E145329
      Remove the 2 timing belt cover dowels.
 
    1. E194638
      • Remove the 8 bolts.
      • Remove the drive plate.
 
    1. E194637
      Remove the special tool.
      Remove the Special Tool(s): 303-1123
 
    1. E255605
      Release the 3 electrical connectors.
 
    1. E255611
      • Remove the special tool.
        Remove the Special Tool(s): 303-1126
      • Remove the 3 bolts.
      • Remove the right camshaft drive pulley.
 
    1. E255607
      • Install the special tool.
        Install the Special Tool(s): 303-1124
      • Install the 3 bolts.
        Torque: 20Nm
 
    1. E255608
      Remove the bolt.
 
    1. E255609
      • Remove the 3 bolts.
      • Remove the special tool.
        Remove the Special Tool(s): 303-1124
 
    1. E255610
      Remove the right camshaft pulley.
 
    1. E255612
      • Remove the special tool.
        Remove the Special Tool(s): 303-1126
      • Remove the 3 bolts.
      • Remove the left camshaft drive pulley.
 
    1. E255613
      • Install the special tool.
        Install the Special Tool(s): 303-1124
      • Install the 3 bolts.
        Torque: 20Nm
 
    1. E255614
      Remove the bolt.
 
    1. E255626
      • Remove the 3 bolts.
      • Remove the special tool.
        Remove the Special Tool(s): 303-1124
 
    1. E255627
      Remove the left camshaft pulley.
 
    1. E255606
      • Remove the 13 bolts.
      • Remove the right camshaft cover.
 
    1. E255628
      • Remove the 13 bolts.
      • Remove the left camshaft cover.
 
    1. E116777
      Using a suitable tool, retain the camshaft chain tensioner plunger.
 
    1. CAUTION:

      Note the component location before removal. Make a note of the camshaft cap identification marking and its location on the engine.

      E159959
      • Evenly and progressively remove the 18 camshaft cap bolts.
      • Remove the 9 camshaft caps.
 
    1. E116779
      Remove the 2 camshaft chain tensioner bolts.
 
    1. Repeat steps 32 - 34 for the other side.
 
    1. E123346
      Remove and discard the camshaft seal.
 
    1. E116780
      Remove and discard the 2 camshaft seals.
 
    1. NOTE:

      Note the component location before removal.

      E116781
      Remove the camshaft assembly.
 
    1. E116782
      Remove the camshaft chain tensioner.
 
    1. E116783
      Remove the camshaft chain.
 
    1. NOTE:

      Note the position of the camshaft followers before removal.

      E159939
      Remove the 12 camshaft followers.
 
    1. E116920
      • Remove and discard the 8 cylinder head bolts.
      • Remove the cylinder head.
      • Remove and discard the cylinder head gasket.
 
    1. Repeat steps 38 - 42 for the other side.
 
    1. E255629
      • Remove the 6 bolts.
      • Remove the oil filter and cooler assembly.
      • Remove and discard the 4 o-ring seals.
 
    1. E255630
      • Remove the 18 bolts.
      • Remove the oil pan assembly.
      • Remove and discard the oil pan assembly gasket.
 
    1. E255760
      Remove the breather pipe.
 
    1. E256803
      Remove the bolt.
 
  1. remove the short engine assembly from the engine stand.
    General Equipment: Engine stand

 

Assembly

LONG/STRIPPED ENGINE ASSEMBLY RENEW - TDV6 3.0L DIESEL - GEN 2 - TWIN TURBOCHARGER (G2194110)

ASSEMBLY
 
  • 12.41.02
  • STRIPPED ENGINE - REMOVE ENGINE, CHANGE OVER ANCILLARY EQUIPMENT AND REFIT
  • 3000 CC, TDV6, TWIN TURBOCHARGER FITTED, DIESEL, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FL
  • 15.90
  • USED WITHINS
 
ASSEMBLY

SPECIAL TOOL(S)

E54546
 

303-1123

Locking Tool, Flywheel

 
E116926
 

310-212

Rear End Accessory Drive (READ) belt Timing Tool

 
E123916
 

JLR-303-1523

Remover/Installer, Camshaft Rear Pulley

GENERAL EQUIPMENT

EQUIPMENT NAME
Engine stand

PART(S)

STEP PART NAME QUALIFICATION QUANTITY
Step 11 Engine coolant outlet upper O-ring seal All vehicles 2
Step 12 Coolant pump inlet O-ring seal All vehicles 1
Step 13 Crankshaft mass damper bolt(s) All vehicles 6
Step 15 Engine coolant pump gasket All vehicles 1
Step 19 Camshaft sprocket bolt All vehicles 1
Step 38 Fuel injector refit kit All vehicles 6
Step 44 Fuel rail balance pipe All vehicles 1
Step 57 Turbocharger oil supply pipe All vehicles 1
Step 58 Oil scavenge pipe gasket All vehicles 1
Step 58 Oil pan scavenge reservoir tube O-ring seal(s) All vehicles 1
Step 59 Turbocharger coolant pipes to turbocharger gasket All vehicles 1
Step 60 Exhaust manifold gasket All vehicles 1
Step 60 Exhaust manifold nuts All vehicles 6
Step 62 Turbocharger oil return pipe gasket(s) All vehicles 2
Step 65 Exhaust manifold to EGR valve gasket 2 High pressure EGR valves 1
Step 68 Exhaust manifold gasket All vehicles 1
Step 68 Exhaust manifold nuts All vehicles 6
Step 69 Turbocharger oil return pipe gasket(s) All vehicles 1
Step 69 Turbocharger oil return pipe seals All vehicles 1
Step 71 EGR pipe to exhaust manifold gasket All vehicles 1
Step 73 Camshaft position sensor All vehicles 1
Step 87 EGR valve outlet pipe gasket (vehicles without EGR cooler) 2 High pressure EGR valves 1
Step 99 Exhaust manifold cross-over pipe studs All vehicles 2
Step 100 Exhaust manifold cross-over pipe studs All vehicles 3
Step 101 Exhaust manifold cross-over pipe gaskets All vehicles 2
Step 101 Exhaust manifold cross-over pipe nuts All vehicles 3
Step 102 Exhaust manifold cross-over pipe bolt All vehicles 1
Step 102 Exhaust manifold cross-over pipe nuts All vehicles 2
Step 108 Flexplate bolts All vehicles 8
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.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. Install the engine on to a suitable engine stand.
      General Equipment: Engine stand
 
    1. E194860
      • Install the bracket.
      • Install and tighten the 2 nuts.
        Torque: 9Nm
 
    1. E194859
      • Install and tighten the 2 mountings.
        Torque: 7Nm
 
    1. E194858
      • Install the bracket.
      • Install and tighten the 2 bolts.
        Torque: 7Nm
 
    1. NOTE:

      Repeat this step for the other side.

      E194861
      • Install the bracket.
      • Install and tighten the 2 bolts.
        Torque: 24Nm
 
    1. E194799
      • Install the bracket.
      • Install and tighten the 2 bolts.
        Torque: 10Nm
 
    1. E194798
      Install and tighten the 2 mountings.
      Torque: 5Nm
 
    1. NOTE:

      Repeat this step for the other side.

      E194797
      Install the Noise, Vibration and Harshness (NVH) material.
 
    1. CAUTION:

      Make sure the Crankshaft Position Sensor (CKP) sensor is correctly installed into the housing. Failure to follow this instruction may result in damage to the CKP sensor.

      E241765
      • Install the CKP sensor.
      • Install and tighten the bolt.
        Torque: 5Nm
 
    1. E241764
      Install the cover.
 
    1. E241757
      • Install the coolant outlet assembly.
      • Install and tighten the 4 bolts.
        Torque: 10Nm
 
    1. E241756
      • Install the coolant inlet pipe.
      • Install and tighten the 2 bolts.
        Torque: 10Nm
 
    1. CAUTION:

      New 14 mm bolts must be installed. Failure to install new 14 mm bolts will result in engine damage.

      E178681
      • Install the crankshaft damper pulley.
 
    1. E242140
      • Install the pulley.
      • Install and tighten the bolt.
        Torque: 50Nm
      • Install the cover.
 
    1. E241664
      • Install the coolant pump.
      • Install and tighten the 3 bolts.
        Torque: 10Nm
 
    1. E196899
      • Install the bracket.
      • Install and tighten the 3 bolts.
        Torque: 10Nm
 
    1. E241670
      • Install the bracket and the lower engine vent oil separator.
      • Install and tighten the 4 bolts.
        Torque: 24Nm
 
    1. E241671
      • Install the cover.
      • Install and tighten the 2 bolts.
        Torque: 10Nm
 
    1. E123958
      • Install the camshaft pulley.
 
    1. CAUTION:

      Failure to use special tool JLR-303-1523 might result in engine damage/failure.

      E241672
      Install the special tool.
      Install the Special Tool(s): JLR-303-1523
      Torque: 10Nm
 
    1. E241673
      • Install the special tool.
        Install the Special Tool(s): JLR-303-1523
      • Tighten the camshaft pulley bolt.
        Torque
        Stage1: 80Nm
        Stage2: 80°
 
    1. Remove the special tools.
      Remove the Special Tool(s): JLR-303-1523
 
    1. E241668
      Install the fuel pump assembly.
 
    1. E241667
      Install, but do not fully tighten the 2 bolts.
 
    1. E241666
      Install and tighten the 3 bolts.
      Torque: 23Nm
 
    1. E241667
      Tighten the 2 bolts.
      Torque: 10Nm
 
    1. E241669
      • Install the upper engine vent oil separator.
 
    1. E241665
      • Install the cover.
      • Install and tighten the 2 bolts.
        Torque: 10Nm
 
    1. CAUTION:

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

      NOTE:

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

      E126058
      • Install the Rear End Accessory Drive (READ) belt tensioner.
      • Install and tighten the bolt.
        Torque: 23Nm
 
    1. NOTE:

      Do not loosen the bolts more than 2 turns.

      E116633
      Release the 3 camshaft pulley bolts.
 
    1. NOTES:

      • The camshaft and fuel pump pulleys rotates in a counter-clockwise direction when viewed from the rear of the engine.

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

      E126057
      Install the READ belt.
 
    1. E116634
      Install the special tool.
      Install the Special Tool(s): 310-212
 
    1. NOTE:

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

      E126056
      Check the READ belt is correctly aligned with the timing marks.
 
    1. E116638
      Remove the READ tensioner locking pin.
 
    1. E116639
      Tighten the 3 bolts.
      Torque: 23Nm
 
    1. Remove the special tool.
      Remove the Special Tool(s): 310-212
 
    1. E241512
      • Install the READ cover.
      • Secure the 2 clips.
 
    1. NOTE:

      Repeat this step for the remaining injectors.

      E130725
      • Install the sealing washer.
 
    1. CAUTION:

      Make sure that new components are installed.

      NOTES:

      • Repeat this step for the remaining injectors.

      • A new injector clamp plate is supplied in the injector refit kit.

      E242241
      Install a new injector clamp plate.
 
    1. NOTE:

      Repeat this step for the remaining injectors.

      E144688
      Install the fuel injectors.
 
    1. CAUTION:

      Tighten the bolts evenly to avoid the injector clamp tilting.

      NOTE:

      Repeat this step for the other side.

      E241923
      Install and tighten the 6 bolts.
      Torque: 9Nm
 
    1. CAUTIONS:

      • Only tighten the bolts and unions finger tight at this stage.

      • Make sure that new components are installed.

      E196898
      • Install the fuel rail assembly.
      • Install the 2 bolts.
      • Install a new High Pressure (HP) fuel line.
 
    1. CAUTIONS:

      • Make sure that new components are installed.

      • Only tighten the bolts and unions finger tight at this stage.

      E196896
      • Install fuel rail assembly.
      • Install the 2 bolts.
      • Install a new HP fuel line.
 
    1. CAUTIONS:

      • Make sure that new components are installed.

      • Only tighten the bolts and unions finger tight at this stage.

      NOTE:

      A new HP injector supply fuel line is supplied in the injector refit kit.

      E196894
      Install the HP fuel lines.
      Renew Part: Fuel rail balance pipe Quantity: 1.
 
    1. CAUTIONS:

      • Make sure that new components are installed.

      • Only tighten the bolts and unions finger tight at this stage.

      NOTE:

      A new HP injector supply fuel line is supplied in the injector refit kit.

      E196893
      Install the HP fuel lines.
 
    1. E196898
      • Tighten the 2 bolts.
        Torque: 24Nm
      • Tighten the HP fuel line unions.
        Torque: 15Nm
 
    1. E196896
      • Tighten the 2 fuel rail bolts.
        Torque: 24Nm
      • Tighten the HP fuel line unions.
        Torque: 15Nm
      • Tighten the HP fuel line clip bolt.
        Torque: 9Nm
 
    1. E196894
      • Tighten the HP fuel line unions.
        Torque: 15Nm
      • Tighten the HP fuel line clip bolt.
        Torque: 9Nm
 
    1. CAUTIONS:

      • Make sure that new components are installed.

      • Only tighten the bolts and unions finger tight at this stage.

      NOTE:

      A new HP injector supply fuel line is supplied in the injector refit kit.

      E196893
      Install the HP fuel lines.
 
    1. E196894
      Tighten the HP fuel line unions.
      Torque: 35Nm
 
    1. E196893
      Tighten the HP fuel line unions.
      Torque: 35Nm
 
    1. E242243
      Tighten the HP fuel line unions.
      Torque: 35Nm
 
    1. E241510
      Install and tighten the 2 bolts.
      Torque: 9Nm
 
    1. E196892
      Install the Low Pressure (LP) fuel lines.
 
    1. E196891
      • Install the bracket.
      • Install and tighten the 2 bolts.
        Torque: 23Nm
 
    1. E196882
      • Install the bracket.
      • Install and tighten the 5 bolts.
        Torque: 22Nm
 
    1. CAUTION:

      Make sure that a new component is installed.

      E196890
      • Install and tighten the bolt.
        Torque: 10Nm
 
    1. CAUTION:

      Make sure that new components are installed.

      E196876
      • Install and tighten the 4 bolts.
        Torque: 10Nm
 
    1. CAUTION:

      Make sure that a new component is installed.

      E178339
      • Install the turbocharger coolant pipes.
      • Install and tighten the 2 bolts.
        Torque: 10Nm
 
    1. CAUTION:

      Make sure that new components are installed.

      E191443
      • Install the exhaust manifold and turbocharger assembly.
      • Install and tighten the 6 nuts in the sequence illustrated.
        Renew Part: Exhaust manifold nuts Quantity: 6.
        Torque: 28Nm
 
    1. E242240
      • Install the coolant pipes.
      • Install and tighten the nut and bolt.
        Torque: 10Nm
 
    1. CAUTION:

      Make sure that new components are installed.

      E196883
      • Install and tighten the 4 bolts.
        Torque: 10Nm
      • Install the turbocharger oil supply pipe.
        Torque: 30Nm
 
  1. E242520
    • Install the mounting bracket.
    • Install and tighten the 4 bolts.
      Torque: 32Nm
    • Install the electrical connector.

 

 

The following step(s) applies to:
2 High pressure EGR valves

 

 
    1. E242246
      • Install the heatshield.
      • Install and tighten the 3 bolts.
        Torque: 10Nm
 
  1. CAUTION:

    Make sure that new gasket is installed.

    E241402
    • Install and tighten the 5 bolts.
      Torque: 10Nm

 

 

The following step(s) applies to:
1 high pressure EGR valve & 1 Low pressure EGR valve

 

 
    1. E242237
      • Install the heatshield.
      • Install and tighten the 3 bolts.
        Torque: 10Nm
 
  1. E242235
    • Install the EGR cooler.
    • Install and tighten the 3 bolts.
      Torque: 10Nm

 

 

The following step(s) applies to:
All vehicles

 

 
    1. CAUTION:

      Make sure that new components are installed.

      E242244
      • Install the exhaust manifold and turbocharger assembly.
      • Install and tighten the 6 nuts in the sequence illustrated.
        Renew Part: Exhaust manifold nuts Quantity: 6.
        Torque: 28Nm
      • Install and tighten the 2 mounting bolts.
        Torque: 32Nm
 
    1. CAUTION:

      Make sure that new components are installed.

      E196879
      • Install and tighten the 4 bolts.
      • Install the turbocharger oil supply pipe.
        Torque: 30Nm
 
    1. E196878
      • Install the heatshield.
      • Install and tighten the 3 bolts.
        Torque: 10Nm
 
    1. CAUTION:

      Make sure that a new gasket is installed.

      E191572
      • Install and tighten the 5 bolts.
        Torque: 10Nm
 
    1. CAUTION:

      Be prepared to collect escaping oil.

      E196875
      • Install the oil extraction pipe.
      • Install the connector.
      • Install and tighten the 2 bolts.
        Torque: 9Nm
      • Install and tighten the nut.
        Torque: 9Nm
 
    1. CAUTION:

      The Camshaft Position Sensor (CMP) sensor tip must rest on one of the 3 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 cover shown removed for clarity.

      • Apply light finger pressure to the rear of the CMP sensor when tightening the bolt.

      E242705
      • Rotate the engine until the camshaft pulley hub is visible through the CMP housing.
      • Install the new CMP sensor until it rests on the camshaft pulley hub.
        Renew Part: Camshaft position sensor Quantity: 1.
      • Install and tighten the CMP sensor bolt.
        Torque: 10Nm
 
    1. E241932
      Install the engine wiring harness.
 
    1. E241931
      • Install and tighten the bolt.
        Torque: 10Nm
      • Install and tighten the nut.
        Torque: 10Nm
 
    1. E241930
      • Connect the 2 electrical connectors.
      • Install the 2 clips.
 
    1. E241304
      • Connect the 3 electrical connectors.
      • Install the 5 clips.
 
    1. E241303
      • Connect the 2 electrical connectors.
      • Install the 2 clips.
 
    1. E241302
      • Connect the electrical connector.
      • Install the 2 clips.
 
  1. E241301
    • Connect the 4 electrical connectors.
    • Install the 3 clips.

 

 

The following step(s) applies to:
2 High pressure EGR valves

 

 
  1. E241300
    • Connect the 3 electrical connectors.
    • Install the 3 clips.

 

 

The following step(s) applies to:
1 high pressure EGR valve & 1 Low pressure EGR valve

 

 
  1. E242234
    • Connect the 5 electrical connectors.
    • Install the 4 clips.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. E241761
      • Connect the 4 electrical connectors.
      • Install the 3 clips.
 
    1. E241929
      • Install the bracket.
      • Install and tighten the 3 bolts.
        Torque: 23Nm
 
  1. E241401
    • Install the coolant hose.
    • Install the hose clip.

 

 

The following step(s) applies to:
2 High pressure EGR valves

 

 
    1. E241927
      • Install the 2 hose clips.
      • Install and tighten the bolt.
        Torque: 4Nm
      • Install the clip.
      • Connect the electrical connector.
 
  1. CAUTION:

    Make sure that a new gasket is installed.

    E241398
    • Install and tighten the 2 EGR outlet pipe bolts.
      Torque: 10Nm
    • Install and tighten the mounting bolt.
      Torque: 4Nm

 

 

The following step(s) applies to:
1 high pressure EGR valve & 1 Low pressure EGR valve

 

 
  1. E242233
    • Install the 2 hose clips.
    • Install and tighten the 2 bolts.
      Torque: 4Nm
    • Install the clip.
    • Connect the electrical connector.

 

 

The following step(s) applies to:
All vehicles

 

 
    1. NOTE:

      Repeat this step for the other side.

      E241298
      Install the NVH material.
 
    1. E242144
      Install the vacuum hose assembly.
 
    1. E242143
      • Install and tighten the 2 bolts.
        Torque: 10Nm
      • Connect the 2 electrical connectors.
      • Install the 2 clips.
 
    1. E241294
      Connect the 2 vacuum hoses.
 
    1. E241292
      • Install the vacuum solenoid.
      • Connect the vacuum hose.
      • Install and tighten the nut.
        Torque: 23Nm
 
  1. E241925
    • Connect the 2 electrical connectors.
    • Install the 3 clips.

 

 

The following step(s) applies to:
2 High pressure EGR valves

 

 
    1. E241293
      • Connect the vacuum hose.
      • Install the 2 clips.
 
  1. E241759
    • Install the pipe assembly.
    • Install the clip.
    • Install and tighten the 3 bolts.
      Torque: 10Nm

 

 

The following step(s) applies to:
1 high pressure EGR valve & 1 Low pressure EGR valve

 

 
  1. E242231
    • Install the pipe assembly.
    • Install the clip.
    • Install and tighten the 3 bolts.
      Torque: 10Nm

 

 

The following step(s) applies to:
All vehicles

 

 
    1. E241758
      • Install the 2 clips.
      • Connect the electrical connector.
 
    1. E245321
      Install the new studs.
      Renew Part: Exhaust manifold cross-over pipe studs Quantity: 2.
      Torque: 13Nm
 
    1. E245320
      Install the new studs.
      Renew Part: Exhaust manifold cross-over pipe studs Quantity: 3.
      Torque: 13Nm
 
    1. E245316
      • Install the exhaust manifold crossover pipe.
 
    1. E245315
 
      • Tighten the 5 exhaust manifold cross over pipe nuts.
        Torque: 23Nm
      • Tighten the exhaust manifold cross over pipe bolt.
        Torque: 23Nm
 
    1. E245314
      • Install the heatshield.
      • Install and tighten the 2 bolts.
        Torque: 10Nm
 
    1. E245313
      • Install the heatshield.
      • Install and tighten the 3 bolts.
        Torque: 10Nm
 
    1. Remove the engine from the suitable engine stand.
      General Equipment: Engine stand
 
    1. E194637
      Install the special tool.
      Install the Special Tool(s): 303-1123
 
    1. CAUTION:

      Make sure that new bolts are installed.

      E194638
      • Install the drive plate.
      • Tighten the 8 bolts working diagonally.
      • Tighten the 8 drive plate bolts.
        Torque
        Stage1: 45Nm
        Stage2: 90°
 
    1. E194637
      Remove the special tool.
      Remove the Special Tool(s): 303-1123
 
  1. Install the engine.
    Refer to:Engine (303-01A Engine - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Installation).

SHORT ENGINE ASSEMBLY RENEW - TDV6 3.0L DIESEL - GEN 2 (G2430981)

ASSEMBLY
 
 
ASSEMBLY

SPECIAL TOOL(S)

E54540
 

303-1117

Timing Peg, Automatic Transmission

 
E52717
 

303-1121A

Installer, Crankshaft Seal

 
E54545
 

303-1122

Installer, Crankshaft Front Seal

 
E54546
 

303-1123

Locking Tool, Flywheel

 
E54549
 

303-1124

Holding Tool, Camshaft Front Pulley

 
E54551
 

303-1126

Timing Peg, Camshaft Pulley

GENERAL EQUIPMENT

EQUIPMENT NAME
Engine stand

PART(S)

STEP PART NAME QUANTITY
Step 3 Engine oil pump 1
Step 17 Oil pan dowel 2
Step 20 Oil cooler O-ring seals 4
Step 21 Drive plate bolts 8
Step 24 Crankshaft pulley bolt 1
Step 29 Cylinder head bolts 16
Step 37 Camshaft seal 1
Step 38 Camshaft seal 2
Step 64 Timing belt and tensioner kit 1
Step 65 Timing belt 1
Step 75 Timing belt cover gasket 1
Step 76 Brake vacuum pump gasket 1
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. Install the short engine assembly on to a suitable engine stand.
      General Equipment: Engine stand
 
    1. E256803
      Install and tighten the bolt.
      Torque: 22Nm
 
    1. A new oil pump must be installed.
      Renew Part: Engine oil pump Quantity: 1.
 
    1. CAUTION:

      Failure to follow this step may result in engine component damage.

      E144763
      • Fill the orifice shown with 20 ml of engine oil.
      • Rotate the oil pump drive 2 complete turns.
 
    1. NOTE:

      Make sure the oil pump is correctly aligned to the crankshaft.

      E144762
      Install the oil pump.
 
    1. E145210
      • Install, finger tight only, 2 oil pump bolts.
      • Remove the oil pump locator tool.
 
    1. E256802
      Using a straight edge, make sure the oil pump is aligned flush with the engine cylinder block.
 
    1. E178578
      • Install the 8 oil pump bolts.
      • Tighten the 10 oil pump bolts in the sequence shown.
        Torque: 10Nm
 
    1. E116752
      Install the front crankshaft oil seal onto the special tool.
      Special Tool(s): 303-1122
 
    1. E116753
      Reposition the crankshaft front seal along the special tool.
      Special Tool(s): 303-1122
 
    1. E178579
      Install the special tool to the crankshaft.
      Install the Special Tool(s): 303-1122
 
    1. E146179
      Remove the special tool.
      Remove the Special Tool(s): 303-1122
 
    1. E178581
      Install the special tool to the crankshaft.
      Install the Special Tool(s): 303-1121A
 
    1. CAUTION:

      Make sure that the front crankshaft oil seal is seated 1 mm under flush.

      NOTE:

      Use the crankshaft pulley bolt with the special tool.

      E149536
      • Using the special tool. install the front crankshaft oil seal.
        Install the Special Tool(s): 303-1121A
      • Wait 10 seconds before continuing to step 15.
 
    1. Remove the special tool.
      Remove the Special Tool(s): 303-1121A
 
    1. E145329
      Install the 2 timing belt cover seals.
 
    1. E256822
      Install 2 new oil pan location dowels.
      Renew Part: Oil pan dowel Quantity: 2.
 
    1. E255859
      • Install a new oil pan gasket.
      • Install the breather pipe.
 
    1. E255630
      • Install the oil pan assembly.
      • Install and tighten the 18 bolts.
        Torque
        M6 Bolt: 10Nm
        M8 Bolt: 23Nm
 
    1. E255629
      • Install the oil filter and cooler assembly.
      • Install and tighten the 6 bolts.
        Torque: 10Nm
 
    1. E194638
      • Install the drive plate.
 
    1. E194637
      Install the special tool.
      Install the Special Tool(s): 303-1123
 
    1. E194638
      Tighten the 8 bolts working diagonally.
      Torque
      Stage1: 45Nm
      Stage2: 90°
 
    1. E255604
      • Install and tighten the bolt.
        Torque
        Stage1: 150Nm
        Stage2: 300Nm
        Stage3: 90°
 
    1. E194637
      Remove the special tool.
      Remove the Special Tool(s): 303-1123
 
    1. E256821
      • CAUTION:

        Make sure the correct special tool location hole is used, as illustrated.

        Rotate the crankshaft assembly until the special tool can be installed.
      • Install the special tool.
        Install the Special Tool(s): 303-1117
 
    1. CAUTION:

      Only use a plastic scrapper to clean off the old gasket.

      E160359
      • Clean and inspect the cylinder head.
      • Check the cylinder head face for distortion, across the center and from corner to corner. Note the maximum value.
        Refer to:Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).
        Refer to:Specifications (303-01A, Specifications).
      • If the cylinder head requires machining, this must be completed by a local engineering company.
 
    1. CAUTION:

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

      Install the head gaskets supplied with the short block assembly.
 
    1. E116920
      • Install the cylinder head.
 
    1. E116922
      Tighten the 8 bolts in the illustrated sequence.
      Torque
      Stage1: 80Nm
      Stage2: 180°
 
    1. E159939
      Install the 12 camshaft followers to the noted removal positions.
 
    1. E86461
      Install the camshaft chain.
 
    1. E116782
      Install the camshaft chain tensioner.
 
    1. Repeat steps 27 - 33 for the other cylinder head.
 
    1. E256851
      • Lubricate the camshaft journals with clean engine oil prior to installation.
        Refer to:Specifications (303-01 Engine - TDV6 3.0L Diesel - Gen 2/TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5, Specifications).
      • Install the left camshaft assembly.
      • Make sure the camshaft keyways are aligned to the 12 o'clock position.
      • Install and tighten the 2 camshaft chain tensioner bolts.
        Torque: 10Nm
 
    1. E256852
      • Lubricate the camshaft journals with clean engine oil prior to installation.
        Refer to:Specifications (303-01 Engine - TDV6 3.0L Diesel - Gen 2/TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5, Specifications).
      • Install the right camshaft assembly.
      • Make sure the camshaft keyways are aligned to the 12 o'clock position.
      • Install and tighten the 2 camshaft chain tensioner bolts.
        Torque: 10Nm
 
    1. E123381
      Install a new camshaft seal.
      Renew Part: Camshaft seal Quantity: 1.
 
    1. E116780
      Install 2 new camshaft seals.
      Renew Part: Camshaft seal Quantity: 2.
 
    1. E256853
      • Install the 7 left camshaft caps.
      • Install and tighten 14 camshaft cap bolts in the following sequence.
        Torque
        Stage1: Camshaft Cap D: 5Nm
        Stage2: Camshaft Cap C: 5Nm
        Stage3: Camshaft Cap B: 5Nm
        Stage4: Camshaft Cap A: 5Nm
        Stage5: Camshaft Cap F: 5Nm
        Stage6: Camshaft Cap G: 5Nm
        Stage7: Camshaft Cap J: 5Nm
 
    1. E256853
      Tighten 14 camshaft cap bolts in the following sequence.
      Torque
      Stage1: Camshaft Cap D: 10Nm
      Stage2: Camshaft Cap C: 10Nm
      Stage3: Camshaft Cap B: 10Nm
      Stage4: Camshaft Cap A: 10Nm
      Stage5: Camshaft Cap F: 10Nm
      Stage6: Camshaft Cap G: 10Nm
      Stage7: Camshaft Cap J: 10Nm
 
    1. E256854
      • Install the 7 right camshaft caps.
      • Install and tighten the 14 camshaft cap bolts in the following sequence.
        Torque
        Stage1: Camshaft Cap 9: 5Nm
        Stage2: Camshaft Cap 8: 5Nm
        Stage3: Camshaft Cap 7: 5Nm
        Stage4: Camshaft Cap 6: 5Nm
        Stage5: Camshaft Cap 4: 5Nm
        Stage6: Camshaft Cap 3: 5Nm
        Stage7: Camshaft Cap 2: 5Nm
 
    1. E256854
      Tighten 14 camshaft cap bolts in the following sequence.
      Torque
      Stage1: Camshaft Cap 9: 10Nm
      Stage2: Camshaft Cap 8: 10Nm
      Stage3: Camshaft Cap 7: 10Nm
      Stage4: Camshaft Cap 6: 10Nm
      Stage5: Camshaft Cap 4: 10Nm
      Stage6: Camshaft Cap 3: 10Nm
      Stage7: Camshaft Cap 2: 10Nm
 
    1. E116784
      • Apply Loctite 518 sealant to the exhaust camshaft seal bearing caps.
      • Apply Loctite 518 sealant, 2 mm wide, to the left rear and right front camshaft bearing caps.
      • Apply Loctite 518 sealant, 7 mm diameter, to the left front and right rear camshaft bearing caps.
 
    1. E256855
      Install camshaft caps 'E' and 'K', install and tighten the 4 bolts.
      Torque
      Stage1: 5Nm
      Stage2: 10Nm
 
    1. E256856
      Install camshaft caps '1' and '9', install and tighten the 4 bolts.
      Torque
      Stage1: 5Nm
      Stage2: 10Nm
 
    1. NOTE:

      Repeat this step for the other side.

      E116786
      Remove the camshaft chain tensioner plunger retainer.
 
    1. CAUTIONS:

      • Use only a plastic scraper when removing the sealing material.

      • Installation of the valve cover and tightening must be completed within 7 minutes of applying the sealant.

      E249914
      • Clean the mating faces for the left camshaft cover (1) and the camshaft cover (2).
 
    1. E255628
      • Install the left camshaft cover.
      • Install and tighten the 13 bolts.
        Torque: 10Nm
 
    1. E255606
      • Install the right camshaft cover.
      • Install and tighten the 13 bolts.
        Torque: 10Nm
 
    1. E255627
      Install the left camshaft pulley.
 
    1. E255626
      • Install the special tool.
        Install the Special Tool(s): 303-1124
      • Install the 3 bolts.
        Torque: 22Nm
 
    1. E255614
      Install and tighten the bolt.
      Torque
      Stage1: 80Nm
      Stage2: 80°
 
    1. E255613
      • Remove the 3 bolts.
      • Remove the special tool.
        Remove the Special Tool(s): 303-1124
 
    1. CAUTION:

      Do not attempt to tighten the 3 bolts using the special tool to prevent the camshaft pulley from turning. Failure to follow this instruction may result in damage to the special tools or engine.

      E255612
      • Install the left camshaft drive pulley.
      • Install and tighten the 3 bolts.
        Torque: 22Nm
      • Install the special tool.
        Install the Special Tool(s): 303-1126
 
    1. E255610
      Install the right camshaft pulley.
 
    1. E255609
      • Install the special tool.
        Install the Special Tool(s): 303-1124
      • Install the 3 bolts.
        Torque: 22Nm
 
    1. E255608
      Install and tighten the bolt.
      Torque
      Stage1: 80Nm
      Stage2: 80°
 
    1. E255607
      • Remove the 3 bolts.
      • Remove the special tool.
        Remove the Special Tool(s): 303-1124
 
    1. CAUTION:

      Do not attempt to tighten the 3 bolts using the special tool to prevent the camshaft pulley from turning. Failure to follow this instruction may result in damage to the special tools or engine.

      E255611
      • Install the right camshaft drive pulley.
      • Install and tighten the 3 bolts.
        Torque: 22Nm
      • Install the special tool.
        Install the Special Tool(s): 303-1126
 
    1. E255605
      Install the 3 electrical connectors.
 
    1. E255603
      • Install the cover.
      • Install the 2 timing belt idler pulleys.
      • Install and tighten the 2 bolts.
        Torque: 45Nm
 
    1. E255602
      • Install the bracket.
      • Install and tighten the 2 bolts.
        Torque: 80Nm
 
    1. E255833
      Rotate the camshaft pulleys fully clockwise.
 
    1. E255832
      • Install the bolt finger tight only.
 
    1. NOTE:

      A new timing belt is supplied in the timing belt and tensioner kit.

      E255839
      Starting at the crankshaft pulley, install the new timing belt in a counter-clockwise direction, in the sequence shown.
      Renew Part: Timing belt Quantity: 1.
 
    1. E145814
      • Tension the timing belt, rotating the tensioner assembly counter-clockwise.
      • Align the tensioner alignment markings.
      • Tighten the bolt.
        Torque
        Stage1: 20Nm
        Stage2: 55°
 
    1. CAUTION:

      Do not attempt to tighten the 6 bolts using the special tools to prevent the camshaft pulleys from turning. Failure to follow this instruction may result in damage to the special tools or engine.

      E255599
      Tighten the 6 bolts.
      Torque: 22Nm
 
    1. E255598
      Remove the 2 camshaft locking pins.
      Remove the Special Tool(s): 303-1126
 
    1. E255829
      Remove the special tool.
      Remove the Special Tool(s): 303-1117
 
    1. CAUTION:

      Do not rotate the crankshaft counter-clockwise, engine damage may occur.

      E255597
      Rotate the crankshaft clockwise 2 revolutuions, until the camshaft pulley alignment holes are aligned.
 
    1. E255829
      Install the special tool.
      Install the Special Tool(s): 303-1117
 
    1. E255598
      • Install the 2 camshaft locking pins.
        Install the Special Tool(s): 303-1126
      • If the special tools can not be installed, continue to the next step.
      • If the special tools can be installed, continue to step 74.
 
      • If the special tools can not be installed, slacken the camshaft pulley bolts and rotate the camshaft pulley hub until the special tool can be installed.
      • Tighten the camshaft pulley bolts.
        Torque: 22Nm
      • Repeat steps 68 - 72.
 
    1. Remove the special tools.
      Remove the Special Tool(s): 303-1117, 303-1126
 
    1. E255596
      • Install the timing belt cover.
      • Install and tighten the 16 bolts.
        Torque: 10Nm
 
    1. E124399
      Install and new brake vacuum pump gasket.
      Renew Part: Brake vacuum pump gasket Quantity: 1.
 
    1. NOTE:

      The application of sealant must be 10 mm square in the 2 places.

      E116820
      • Apply silicone gasket sealant or equivalent meeting Jaguar Land Rover specification in the 2 areas shown in the illustration.
      • Make sure that the drive coupling is aligned with camshaft coupling.
 
    1. E255595
      • Install the brake vacuum pump.
      • Install and tighten the 2 bolts.
        Torque: 22Nm
 
  1. NOTES:

    • Twin turbocharger - Do not complete steps 111 - 113 of the procedure.

    • Mono turbocharger - Do not complete steps 109 - 111 of the procedure.

    Install the engine and ancillaries.
    Refer to:Long/Stripped Engine Assembly Renew - TDV6 3.0L Diesel - Gen 2 - Twin Turbocharger (303-01 Engine - TDV6 3.0L Diesel - Gen 2/TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5, Assembly).
    Refer to:Long/Stripped Engine Assembly Renew - TDV6 3.0L Diesel - Gen 2 - Mono Turbocharger (303-01 Engine - TDV6 3.0L Diesel - Gen 2/TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5, Assembly).

 

303-03A: Engine Cooling - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2

ENGINE COOLING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1509363)

SPECIFICATIONS
 

Fluid

NOTE:

Coolant must be collected into a clean container and can be reused if not contaminated.

DESCRIPTION SPECIFICATION
Land Rover premium cooling system fluid Havoline XLC
Coolant concentration 50%
Vehicles with block heater coolant concentration 60%

Capacity

ITEM LITRES
Vehicles equipped with 2 zone Air Conditioning (A/C) 9.4
Vehicles equipped with 2 zone A/C and Fuel Fired Booster Heater (FFBH) 9.6
Vehicles equipped with 4 zone A/C 11.2
Vehicles equipped with 4 zone A/C and FFBH 11.4
Hybrid Electric Vehicle (HEV) battery circuit 1.5
DESCRIPTION NM LB-FT LB-IN
Coolant expansion tank bolt 2.8 - 25
Coolant outlet assembly bolts 10 7 -
Coolant pump bolts 10 7 -
Coolant pump pulley bolts 25 18 -
Thermostat housing bracket to fan shroud bolt 5 - 44
Thermostat housing bolts 5 - 44
Radiator drain plug 3.5 - 31
A/C pipes to condenser nuts 8 - 71
A/C pipe to fan shroud bolt 7 - 62
Charge air cooler pipe connector to fan shroud bolt 8 - 71
Charge air cooler hose clamp to fan shroud bolt 7 - 62
Engine cooling module bolts 15 11 -
Cooling fan shroud bolts 7 - 62
Transmission fluid cooler to fan shroud bolt 7 - 62
Coolant bleed screw(s) 3 - 27

 

 
Description and Operation

 

ENGINE COOLING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1950019)

DESCRIPTION AND OPERATION
 
 
COMPONENT LOCATION

COMPONENT LOCATION - 1 OF 3 - FRONT VIEW

E189626
 
ITEM DESCRIPTION
1 Engine Coolant Temperature (ECT) sensor
2 Coolant outlet connector
3 Engine oil cooler
4 Low Pressure (LP) Exhaust Gas Recirculation (EGR) cooler
5 Variable coolant pump
6 Charge air cooler
7 Radiator
8 Charge air radiator
9 Auxiliary radiator

COMPONENT LOCATION - 2 OF 3 - REAR VIEW

E189627
 
ITEM DESCRIPTION
1 Fuel cooler
2 Coolant expansion tank
3 Electric cooling fan - auxiliary
4 Electric cooling fan - main
6 Cooling fan shroud
5 Thermostat
6 High Pressure (HP) Exhaust Gas Recirculation (EGR) cooler
7 Automatic Transmission Fluid (ATF) cooler
8 Charge air coolant pump

COMPONENT LOCATION - 3 OF 3 - ACTIVE GRILLE AIR SHUTTER - IF EQUIPPED

E189628
 
ITEM DESCRIPTION
1 Active grille air shutter
 
OVERVIEW

The engine cooling system maintains the engine within an optimum temperature range under changing ambient and engine operating conditions.

The cooling system also provides:

  • Heating for the passenger compartment. For additional information, refer to:
    Heating and Ventilation (412-01 Climate Control, Description and Operation),
    Auxiliary Climate Control (412-02 Auxiliary Climate Control, Description and Operation).
  • Cooling for the:
    • Engine oil 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).
    • Fuel system 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).
    • Exhaust Gas Recirculation (EGR) 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).
    • Primary turbocharger For additional information, refer to:Turbocharger (303-04B Fuel Charging and Controls - Turbocharger - TDV6 3.0L Diesel, Description and Operation).
    • Automatic Transmission Fluid (ATF) For additional information, refer to:Transmission Cooling (307-02A Transmission/Transaxle Cooling - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Description and Operation) / Transmission Cooling (307-02A Transmission/Transaxle Cooling - Vehicles With: 8HP70 8-Speed Automatic Transmission AWD, Description and Operation).
    • Charge air coolerFor 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).

In some markets, an active grille air shutter is installed to reduce aerodynamic drag and engine warm up time.

 
DESCRIPTION

THERMOSTAT

E145079
 
ITEM DESCRIPTION
1 Heater return hose connection
2 Bypass hose connection
3 Thermostat bracket
4 Lower hose connection
5 Coolant expansion tank return hose connection
6 Coolant pump coolant inlet connection

A pressure relief type thermostat is located behind the radiator, on a bracket attached to the cooling fan shroud. The thermostat body contains a wax element and a spring loaded bypass valve.

The thermostat housing is connected to the following:

  • The radiator lower hose
  • The engine bypass hose
  • The feed hose to the engine coolant pump
  • The heater return hose
  • The coolant expansion tank return hose.

The thermostat allows rapid engine warm-up by preventing coolant flow through the radiator and by limiting coolant flow through the cylinder block when the engine is cold. The thermostat is not a serviceable item and it can be replaced as an assembly.

RADIATOR

E145080
 
ITEM DESCRIPTION
1 Upper mounts
2 Vent hose connection
3 Upper hose connection
4 Lower mount
5 Automatic Transmission Fluid (ATF) cooler hose connection
6 Drain screw
7 Lower hose connection
8 Lower mount

The radiator is a vertical-flow type with an aluminum core and plastic end tanks. The radiator is located in the vehicle by bushes attached to the end tanks. The lower bushes are installed in the front subframe. The upper bushes are installed in the front end carrier.

Upper and lower hose connections are incorporated into the upper and lower end tanks respectively. The lower end tank also incorporates a drain screw, and a connection for the coolant feed hose of the Automatic Transmission Fluid (ATF) cooler. The upper end tank incorporates a connection for a vent hose to the coolant expansion tank. The end tanks also incorporate mounting points for the cooling fan shroud and the Air Conditioning (A/C) condensor.

VARIABLE COOLANT PUMP

E168927

The variable coolant pump has a housing that supports a shaft with an impeller attached to one end and a drive hub at the other. The housing is attached to the front of the cylinder block with the impeller located in a pumping chamber. The variable coolant pump is driven by a pulley attached to the drive hub and driven by the accessory drive belt at engine speed. For additional information, refer to:Accessory Drive (303-05A Accessory Drive - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Description and Operation).

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 operation of the shroud is controlled by the Powertrain Control Module (PCM) through a solenoid valve which is attached to the variable coolant pump housing with a screw. The solenoid valve is connected to the PCM through a hardwired connection. When the engine is cold and the engine speed is between 1900 RPM and 4800 RPM, the PCM activates the solenoid valve and the shroud moves to the 'no coolant flow' position. When the engine approaches the operating temperature the PCM deactivates the solenoid valve and the shroud retracts to its base position. This results full coolant flow from the coolant pump to the engine cooling system.

COOLANT EXPANSION TANK

E145082
 
ITEM DESCRIPTION
1 Filler cap
2 MAX and MIN level markings
3 Mounting lug
4 Supply hose connection
5 Coolant level sensor
6 Mounting lugs
7 Bleed screw
8 Vent hose connection

A pressurized expansion tank system is used which continuously separates the air from the cooling system and replenishes the system through a hose connected between the expansion tank and the thermostat. A continuous vent into the expansion tank, through a hose connected to the radiator, prevents air locks from forming in the cooling system.

The expansion tank is attached to the front end carrier in the front left corner of the engine compartment. A filler cap, bleed screw and level sensor are incorporated into the expansion tank.

The coolant expansion tank provides the following functions:

  • The service fill.
  • Engine coolant expansion during warm up.
  • Air separation during operation.
  • System pressurization by the filler cap.
  • Coolant level sensing.

The coolant expansion tank has an air space of approximately 0.5 to 1 liter (1.06 to 2.11 US pints). The coolant expansion tank allow for the engine coolant expansion if the coolant above the maximum level. Minimum and maximum level markings are molded on the coolant expansion tank body.

The engine coolant level sensor locates in a sealed cavity at the bottom of the coolant expansion tank body. A float with an integral magnet is located inside the coolant expansion tank. The coolant level sensor contains a switch that reacts to the position of the magnetic float. The coolant level sensor is hardwired to the Body Control Module/Gateway Module (BCM/GWM).

The magnetic float is designed to float very close to the bottom of the tank, significantly below the MIN cold fill coolant level. The magnetic float in this position does not indicate float failure, for example sinking or sticking. The float has a travel distance of approximately 15 mm (0.59 in) from the bottom of the tank.

ELECTRIC COOLING FAN

E145153
 
ITEM DESCRIPTION
1 Mounting lug
2 Electric cooling fan - auxiliary
3 Cooling fan shroud
4 Speed flaps
5 Mounting lug
6 Electrical connectors
7 Mounting lug
8 Electric cooling fan - main
9 Mounting lugs
10 Speed flaps

Vehicles have two variable speed electric engine cooling fans to help regulate the coolant temperature. The fan shroud is attached to the rear of the radiator. On vehicles with a single engine cooling fan, a blanking plate is installed in place of the second fan. The shroud incorporates speed flaps, which pivot open to allow engine compartment cooling at speed.

Each electric cooling fan is operated by a control module, integrated into their electric motor, which is controlled by the PCM. Electrical connectors at the right side of the fan shroud provide the interface between the cooling fan harnesses and the vehicle wiring.

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.

To control each electric cooling fan, the PCM varies the duty cycle of the PWM signal. The cooling fan control module translates the duty cycle into a fan target speed and sets the output current to the fan motor accordingly.

CHARGE AIR COOLANT PUMP

E167753
 
ITEM DESCRIPTION
1 Coolant inlet connection
2 Coolant outlet connection
3 Electrical connector

The charge air coolant pump is an electric pump attached to the rear left side of the engine cooling fan shroud. Hoses connect the intake of the charge air coolant pump to the charge air radiator, and the outlet to the charge air cooler. An electrical connector provides the interface between the motor of the charge air coolant pump and the vehicle wiring. Operation of the charge air coolant pump is controlled by a PWM signal from the PCM.

CHARGE AIR COOLER

A charge air cooler is installed on the left side of the cooling pack, behind the left outer air intake in the front bumper. 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).

CHARGE AIR RADIATOR

E180693
 
ITEM DESCRIPTION
1 Coolant expansion hose connection
2 Mounting bracket
3 Charge air radiator
4 Bleed screw
5 Coolant outlet connection
6 Mounting pin
7 Drain screw
8 Coolant inlet connection

The charge air radiator is located between the radiator and the A/C condensor. The charge air radiator is attached to the A/C condensor with two pins at the bottom of the end tanks. Two brackets are attached to the top of the charge air radiator, which are providing the connection to the A/C condensor with two screws.

The right end tank comprises connections to the charge air coolant pump inlet and the engine cooling system. A drain plug is integrated into the bottom of the coolant inlet connection. The connection with the radiator on the top of the right end tank accommodates the thermal expansion and retraction, and enables filling and draining of the coolant in the charge air cooling system. The left end tank comprises a coolant outlet connection to the charge air cooler and a bleed screw.

AUXILIARY RADIATOR

E180692
 
ITEM DESCRIPTION
1 Coolant inlet hose connection
2 Rear air duct
3 Radiator support bracket
4 Front air duct
5 Coolant outlet hose connection
6 Isolator

The auxiliary radiator is located on the right side of the cooling pack, behind the outer air intake in the front bumper. The auxiliary radiator is installed in air ducts attached to the front bumper armature and the front end carrier. The lower end tank of the auxiliary radiator is located in the air duct by a spigot equipped with an isolator bush. The upper end tank of the auxiliary radiator is held in a support bracket in the air duct.

The auxiliary radiator is connected in parallel with the (main) radiator to increase the engine cooling capacity.

ENGINE COOLANT

The coolant is silicate free and must not be mixed with conventional engine coolant.

ACTIVE GRILLE AIR SHUTTER - IF EQUIPPED

E152300
 
ITEM DESCRIPTION
1 Motor
2 Master vane
3 Support bracket
4 Vane - fully open (10 of)
5 Vane - fully closed (10 of)
6 Electrical connector
7 Vane link
8 Housing

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 five and operated by an electric motor. The motor is held in a support bracket in the housing. The inboard hinge pin of one of the vanes (the master vane) is engaged in the output shaft of the motor. A lever on the inboard end of each vane is engaged in a motor link. When the motor turns the master vane, the motor link transfers the movement to the levers of the other nine vanes, which then turn in unison with the master vane.

The design of the vanes equalizes the wind loading on each side of the hinge pin, which reduces the resistance to turning when the vehicle is traveling at speed. A seal along the top edge of each vane provides sealing between adjacent vanes, and between the two upper vanes and the housing. The vanes can be set to one of 14 positions between fully closed and fully open, and have a range of movement of 80 degrees. During normal operation, for the vanes to move from fully closed to fully open takes approximately 30 seconds, and for the vanes to move from fully open to fully closed takes approximately 90 seconds.

Operation of the motor is controlled by the 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 EJB.

 
OPERATION

COOLANT CIRCUIT FLOW

When the engine is running the coolant is circulated around the engine cooling system by the variable coolant pump. From the coolant pump, coolant flows through the cylinder block and the cylinder heads to the coolant outlet connector. Some of the coolant in the cylinder block is diverted through the engine oil cooler before returning to the coolant outlet connector. The primary turbocharger coolant inlet hose is connected to the cylinder block. Some of the coolant from the cylinder block flows through the turbocharger to the Exhaust Gas Recirculation (EGR) cooler outlet hose assembly.

From the coolant outlet connector, the majority of the coolant flows to the thermostat, either directly or through the radiator, depending on the temperature of the coolant and engine speed. The remainder of the coolant flows through the EGR coolers and the heater circuit to the thermostat. From the outlet of the thermostat the coolant flows to the coolant inlet connector on the left side of the cylinder block and back to the coolant pump.

A separate hose from the radiator allows extra-cooled coolant from the radiator to flow through the Automatic Transmission Fluid (ATF) cooler. The coolant from the ATF cooler returns to the system through a connector in the radiator lower hose.

The charge air cooling system is operationally independent of the engine cooling system, but connected to it at the radiator upper end tank. When the charge air coolant pump is running, the coolant flows from the pump outlet through the charge air cooler, the charge air radiator and back to the pump inlet connection.

Schematic Diagram - Coolant Circuit Flow
E190025
 
ITEM DESCRIPTION
1 Charge air radiator
2 Radiator
3 Automatic Transmission Fluid (ATF) cooler
4 Auxiliary radiator
5 Thermostat
6 Static bleed point (5 of)
7 Coolant outlet connection
8 Variable coolant pump
9 Engine oil cooler
10 Cylinder block
11 Cylinder head - Bank 1
12 High Pressure (HP) Exhaust Gas Recirculation (EGR) cooler
13 Heater core - climate control assembly
14 Heater core - auxiliary climate control assembly - If equipped
15 Cylinder head - Bank 2
16 Primary turbocharger
17 Low Pressure (LP) Exhaust Gas Recirculation (EGR) cooler
18 Fuel cooler
19 Coolant expansion tank
20 Charge air cooler
21 Charge air coolant pump

THERMOSTAT

The thermostat is closed at temperatures below approximately 82 °C (179 °F). When the coolant temperature reaches approximately 82 °C (179 °F) the thermostat starts to open and is fully open at approximately 96 °C (204 °F). In this condition the full flow of coolant is directed through the radiator.

COOLANT LEVEL SENSOR

When the coolant level in the coolant expansion tank is sufficient, the magnetic float is in the top position. In this position the magnetic field closes the switch contacts in the coolant level sensor. When the coolant level drops significantly below the MIN cold fill coolant level, the magnetic float descends, thus the switch contacts disconnected. The open circuit is sensed by the Body Control Module/Gateway Module (BCM/GWM), which sends a signal to the Instrument Cluster (IC) to display the "Coolant Level Low" warning message. The message is sent on the High Speed (HS) Controller Area Network (CAN) chassis systems bus.

For additional information, refer to:Information and Message Center (413-08 Information and Message Center, Description and Operation).

ELECTRIC COOLING FAN

The Powertrain Control Module (PCM) determines when to operate the electric cooling fan from the Engine Coolant Temperature (ECT) sensor input and a cooling fan request from the HVAC Control Module. The PCM also adjusts the fan speed to compensate the ram effect of vehicle speed.

The PCM varies the duty cycle of the Pulse Width Modulation (PWM) signal to the engine cooling fan control module between 0 and 100% to operate the fan motor in one of four modes:

  • Off
  • Minimum speed - 750 RPM
  • Linear variable speed between minimum and maximum speeds
  • Maximum speed - 2820 RPM.

Under hot operating conditions, the electric cooling fan may continue to operate for up to 5 minutes after the engine has been switched off.

The engine 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 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 2 and 8 seconds, depending on the fault. The control module repeats the notification process at 5 second intervals until the fault is cleared. If there is more than one fault, only the highest priority fault is notified to the PCM.

The fault priorities in descending order are the following:

  • Over voltage
  • Under voltage
  • Stalled motor
  • Partially stalled motor.

The PCM records a related Diagnostic Trouble Code (DTC) for faults notified by the fan control module and signals the BCM/GWM assembly through the FlexRay bus. The BCM/GWM assembly transmits the signal on the HS CAN chassis systems bus to the IC to display a warning message.

The nominal operating voltage for the engine cooling fans is 9 to 16 Volts. If the input voltage is outside of these limits, the fan control module stops operation of the electric cooling fan and notifies the PCM of the fault. After an under or over voltage occurs, the cooling fan operation is resumed when the input voltage increases to 9.5 Volts, or decreases to 15.5 Volts, respectively.

To check for a stalled motor, each time it supplies power to start the electric cooling fan the control module checks the cooling fan motor speed after 2 seconds. If the speed is zero, the fan control module determines the fan motor is stalled and tries a restart. For a restart, the fan control motor disconnects the power from the fan motor then immediately reconnects it at an increased current level. The fan control module will try up to six restarts of a stalled motor, increasing the output current each time. If the fan motor remains stalled after the sixth restart, the fan control module waits 40 seconds then notifies the PCM of the fault and begins the start process again.

To check for a partially stalled motor, while the fan is running the fan control module monitors the current draw against fan speed. If the current draw is over the limit for more than 10 seconds, the fan control module disconnects the power from the fan motor and notifies the PCM of the fault. After 40 seconds, the fan control module starts the motor again.

The fan control module incorporates a temperature sensor to prevent damage caused by excessive heat at high ambient temperatures. Operation of the fan control module is discontinued if the temperature reaches 135 °C (275 °F). Operation resumes when the temperature decreases to 120 °C (248 °F).

If a fault occurs with the ignition signal or the PWM signal, the fan control module adopts the following fan speeds:

SIGNAL FAULT FAN SPEED
IGNITION ON IGNITION OFF
Pulse Width Modulation (PWM) Duty cycle implausible Maximum Off
Pulse Width Modulation (PWM) Frequency out of range Maximum Off
Pulse Width Modulation (PWM) Open circuit Maximum Off
Pulse Width Modulation (PWM) Short circuit to battery Maximum (provided cooling fan is not damaged) Off
Pulse Width Modulation (PWM) Short circuit to ground Maximum (provided cooling fan is not damaged) Off
Ignition Open circuit Off Off
Ignition Short circuit to battery According to Pulse Width Modulation (PWM) duty cycle Maximum
Ignition Short circuit to ground Off (PCM relay fuse may blow) Off

CHARGE AIR COOLER

Electrical power for the charge air coolant pump is supplied from the PCM relay, located in the Engine Junction Box (EJB). When the relay is energized, it connects power from the battery to the charge air coolant pump. Operation of the charge air coolant pump is controlled by the PCM with a 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.

ACTIVE GRILLE AIR SHUTTER - IF EQUIPPED

During normal driving operation, the PCM determines vane position from the thermal condition of the vehicle, which is an output of the fan control logic.

The vane position depends on the following:

  • The engine coolant temperature
  • The Air Conditioning (A/C) demand
  • The ambient air temperature
  • The fuel temperature
  • The Terrain Response® mode selection.

If vehicle speed reaches 180 km/h (112 mph) the vanes move to the fully open position. The vanes resume a calculated opening position when vehicle speed decreases to 140 km/h (87 mph).

In the case of engine cooling fan after-run, the vanes remain open. When the fan after-run ends, the vanes close and the motor will send a signal to the PCM indicating it is ready to power down.

Calibration Mode

When the PCM shuts down, the motor loses its memory. Therefore a calibration is required every time the ignition is switched on unless the PCM has remained active between ignition off and ignition on, for example engine cooling fan after-run.

Calibration only commences after the engine has started.

The calibration process opens and closes the vanes to find the end stops and range of motion between them. This range of movement is checked and if it is within the specified limits, the cycle is passed. This cycle can take up to 16 seconds.

The software allows for a total of six calibration attempts.

If the first attempt fails, as soon as a position demand exceeds 45%, it will complete the remaining five attempts, one after the other, until they either pass a calibration or fail all six attempts.

If the vanes pass the third calibration, for example the vanes had been frozen for the first two attempts and have since thawed out, the remaining attempts are saved for the rest of the drive cycle.

A 'Calibration Failed Fault' DTC will only be stored if the calibration fails from the first attempt and all attempts are used up.

The vanes will then be commanded to open as much as possible.

If the first calibration passes, then a 'Calibration Failed Fault' DTC cannot be set until the next drive.

NOTE:

The motor is very sensitive to voltage drops from engine cranking and may trigger a further calibration.

Jet Wash Mode

Jet wash mode allows the motor to fully open the vanes and then power down so that the radiator can be cleaned.

To activate jet wash mode:

  1. Start the engine.
  2. Stop the engine and turn the ignition off.
  3. Turn the ignition on (do not start the engine).
  4. Select Terrain Response® sand mode.
  5. Turn the ignition off.

This sequence prevents to enter jet wash mode accidentally when the ignition is turned off in sand mode.

The vanes will default to fully open if the calibration has been completed or not. (See calibration mode section above)

When the position feedback shows that the vanes are fully open, the motor will indicate to the PCM that it is ready to power down.

Fault Diagnosis

If there is a fault with the active grille air shutter, the 'Engine Over Temperature' warning is displayed in the Instrument Cluster (IC) message center. For each fault, a flag is set and after a calibrated de-bounce time, a DTC is stored in the PCM.

The following faults can be detected:

  • Mechanical blockage fault – Motor encounters too much resistance and stalls. Max Torque = 0.7 - 0.8 Nm. When blocked, the motor will try to re-calibrate up to maximum number of attempts as described in the calibration section.
  • Calibration failed fault – Fault stored if all calibration attempts have failed in that drive cycle.
  • Electrical fault – Motor reports an internal electrical fault.
  • Supply voltage fault – Motor supply voltage falls outside the range 7.5 V – 17.5 V.
  • Thermal shutdown fault – Motor circuits exceed their inbuilt temperature threshold.
  • Disconnect fault – Linkage between the motor and the vanes becomes disconnected.
  • Local Interconnect Network (LIN) Bus communication fault and Node detection fault – A fault with the motor, its signal wire or its supply that causes a breakdown in signals to the PCM. If the motor is still operational and only the signal wire has a short circuit/open circuit, then the motor will fail safe fully open after 10 seconds of not receiving a signal.
 
CONTROL DIAGRAM
E189629
 

A = HARDWIRED; AL = PULSE WIDTH MODULATION (PWM); AM = HIGH SPEED (HS) CONTROLLER AREA NETWORK (CAN) CHASSIS SYSTEMS BUS; AX = FLEXRAY BUS; AY = HIGH SPEED (HS) CONTROLLER AREA NETWORK (CAN) POWER MODE ZERO BUS; O = LOCAL INTERCONNECT NETWORK LIN) BUS.

ITEM DESCRIPTION
1 Powertrain Control Module (PCM)
2 Instrument Cluster (IC)
3 Body Control Module/Gateway Module (BCM/GWM) Assembly
4 Terrain Response (TR) switchpack
5 Anti-lock Brake System (ABS) control module
6 HVAC Control Module
7 Variable coolant pump
8 Electric cooling fan - main
9 Charge air coolant pump
10 Electric cooling fan - auxiliary
11 Active grille air shutter motor - If equipped
12 Ground
13 Power supply
14 Cylinder head temperature sensor
15 Fuel temperature sensor
16 Engine Coolant Temperature (ECT) sensor
17 Ambient Air Temperature (AAT) sensor
18 Coolant level sensor

 

Diagnosis and Testing

ENGINE COOLING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 (G1551114)

DIAGNOSIS AND TESTING
 
 
PRINCIPLE OF OPERATION

For a detailed description of the engine cooling system and operation, refer to the relevant Description and Operation section of the workshop manual. 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).

 
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
  • Coolant leaks
  • Coolant hoses
  • Coolant expansion tank
  • Radiator
  • Heater core
  • Active grill air shutter
  • Accessory drive belt
  • Cooling fan
  • Fuses
  • Harnesses
  • Loose or corroded connector(s)
  • Engine coolant temperature sensor
  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 (Diagnostic Trouble Code(s) (DTC)s) and refer to the DTC Index.
 
SYMPTOM CHART
SYMPTOM POSSIBLE CAUSES ACTION
Coolant loss
  • Hoses
  • Hose connections
  • Radiator
  • Coolant pump
  • Heater core
  • Gaskets
  • Engine casting cracks
  • Cylinder block core plugs
  • Complete out a visual inspection. If there are no obvious leaks, complete a cooling system pressure test. Rectify any leaks as necessary. Refer to the relevant section of the workshop manual
Overheating
  • Low/contaminated coolant
  • Thermostat
  • Cooling fan
  • Engine coolant temperature sensor
  • Restricted air flow over the radiator
  • Active grill air shutter
  • Check the coolant level and condition. Complete a cooling system pressure test. Rectify any leaks as necessary. Check the thermostat and rectify as necessary. Check the cooling fan operation, make sure the cooling fan rotates freely. Check for obstructions to the air flow over the radiator. Check the active grill air shutter operation using the manufacturer approved service tool
Engine not reaching normal temperature
  • Thermostat
  • Cooling fan
  • Check the thermostat operation. Check the cooling fan operation, make sure the cooling fan is not seized
Message centre displays "Coolant Level Low" warning message
  • Coolant loss
  • Engine coolant level sensor fault
  • Engine coolant level sensor circuit fault
  • GO to Pinpoint TestA.
 
PINPOINT TESTS

 

PINPOINT TEST A : COOLANT LEVEL SENSOR TESTS
NOTE:

The coolant expansion tank float is designed to be positioned near the bottom of the tank, significantly (more than 15mm) below the MIN cold fill level. A float in this position does NOT signify float failure (e.g. ‘sinking’ or ‘sticking’). Continue to follow the procedure as stated below.
A1: COOLANT LEVEL SENSOR TEST 1 - COOLANT LEVEL CHECK
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
WARNINGS:

  • DO NOT remove the coolant expansion tank cap when the engine is hot. Failure to follow this instruction may result in personal injury.

  • Never, under any circumstances, remove the coolant expansion tank pressure cap while the engine is operating. To avoid having scalding hot water or steam blow out of the cooling system, use extreme care when removing the coolant expansion tank pressure cap from a hot cooling system. Wait until the engine has cooled, then wrap a thick cloth around the coolant expansion tank pressure cap and turn it slowly until the pressure begins to release, step back while the pressure is released from the system. When certain all the pressure has been released (still with a cloth) turn and remove the coolant expansion tank pressure cap. Failure to follow these instructions may result in damage to the cooling system, engine and/or cause personal injury.
 
1
Check the coolant level

 
Is the coolant level within specification?
Yes
GO toA2.
No
Refer to the relevant section of the workshop manual and fill and bleed the cooling system as necessary. Check for coolant loss
A2: COOLANT LEVEL SENSOR TEST 2 - SENSOR CIRCUIT CONTINUITY CHECK
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 
1
Check harness connector is firmly attached to the level sensor. Rectify as required
 
2
Uncouple the engine coolant level sensor/switch assembly harness connector. Confirm that the “Coolant Level Low” warning message appears on the instrument cluster when the harness has been disconnected from the engine coolant level sensor/switch assembly
E256557
3
Create a circuit short across the pins of the level sensor harness connector. It is recommended to connect a MICRO blade fuse (of any amp rating, as illustrated) to the pins level sensor harness connector. Alternatively, a suitable jumper wire may be used. Shorting the circuit should make the “Coolant Level Low” warning message disappear
 
4
If the “Coolant Level Low” warning message does not disappear, using the Jaguar Land Rover approved diagnostic equipment, check the engine coolant level sensor/switch circuit between the coolant expansion tank and the body control module/central junction box for open circuit faults and rectify as required

 
Is the “Coolant Level Low” message displayed on the instrument cluster when the level sensor harness terminals is short circuited (e.g. with a jumper wire or a blade fuse)?
Yes
Repair the harness and repeat Pinpoint Test E2
No
If this is the first reported instance of the fault, GO toA3. . If this same fault has been previously reported on the vehicle GO toA4.
A3: COOLANT LEVEL SENSOR TEST 3 - SENSOR CIRCUIT CONTINUITY CHECK
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 
1
1. Replace the level sensor REFER to:Engine Coolant Level Switch (303-03A Engine Cooling - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
 
2
Reconnect the engine coolant level sensor/switch assembly harness connector

 
Is the "Coolant Level Low" warning message displayed?
Yes
GO toA4.
No
No further action required
A4: COOLANT LEVEL SENSOR TEST 4 - COOLANT EXPANSION TANK REPLACEMENT
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
 
1
Replace the coolant expansion tank
 
2
Refill the coolant expansion tank and visually confirm that the coolant level is between the maximum and minimum marks that are moulded on the coolant expansion tank body

 
Is the "Coolant Level Low" warning message displayed?
Yes
Check the integrity and security of the wiring harness and circuit connectors. Rectify as required and retest
No
No further action required
 
DTC INDEX

For a list of Diagnostic Trouble Codes (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).

 

COOLING SYSTEM DRAINING AND VACUUM FILLING (G1509365)

GENERAL PROCEDURES
 
  • 26.10.05
  • COOLING SYSTEM DRAINING AND VACUUM FILLING
  • 3000 CC, TDV6
  • 1.80
  • USED WITHINS
 
DRAINING
CAUTION:

Since injury such as scalding could be caused by escaping steam or coolant, make sure the vehicle cooling system is cool prior to carrying out this procedure.

 
    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:Engine Undershield (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. E142386
 
    1. WARNING:

      When releasing the cooling system pressure, cover the coolant expansion tank cap with a thick cloth.

      E142385
 
    1. CAUTION:

      Be prepared to collect escaping coolant.

      E142381
NOTE:

Steps 7-10 and 12-13 are only required if the vehicle is equipped with auxiliary climate control.

 
    1. Remove the front right wheel arch liner.
      Refer to:Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
 
    1. CAUTION:

      Be prepared to collect escaping coolant.

      E143105
 
    1. Remove the rear left wheel arch liner.
      Refer to:Rear Fender Splash Shield (501-08 Exterior Trim and Ornamentation, Removal and Installation).
 
    1. CAUTION:

      Be prepared to collect escaping coolant.

      E143104
 
    1. E142381
      Torque: 3.5Nm
 
    1. E143105
 
    1. E143104
 
  1. Complete the fill procedure up to step 10 in the filling section 3 times. Fill the cooling system with clean water at the first 2 drains, At the final refill use a suitable measuring tool to make sure that the cooling system maintains the specified concentration mix.
 
FILLING
 
    1. CAUTIONS:

      • Engine coolant concentration must be maintained at 50%.

      • Vehicles with block heater coolant concentration must be maintained at 60%.

      • Install the cooling system vacuum refill adapter to the expansion tank.
      • Install the vacuum filler gauge to the cooling system vacuum refill adapter.
      • Install the venturi tube assembly to the vacuum filler gauge.
 
    1. NOTES:

      • Make sure the coolant supply valve is in the closed position on the vacuum filler gauge assembly.

      • The coolant vacuum fill tool needs an air pressure of 6 to 8 bar (87 to 116 psi) to operate correctly.

      • Small diameter or long airlines may restrict airflow to the coolant vacuum fill tool.

      • Connect a regulated compressed air supply to the venturi tube assembly.
 
    1. Position the evacuated air hose into a container.
 
    1. Open the air supply valve.
 
    1. NOTE:

      Make sure the coolant supply hose is positioned into a container of 50% mixture of Land Rover Premium Cooling System Fluid or equivalent, meeting Land Rover specification Halvoline XLC and fifty percent water. Make sure no air can enter the coolant supply hose.

      Open the coolant supply valve for 2 seconds to prime the coolant supply hose.
 
    1. Apply air pressure progressively until the arrow on the vacuum filler gauge reaches the green segment.
 
    1. Disconnect the compressed air supply line.
 
    1. NOTE:

      Close the coolant supply valve when the coolant expansion tank MAX mark is reached or coolant movement has ceased.

      Open the coolant supply valve and allow the coolant to be drawn into the system.
 
    1. Remove the vacuum filler gauge and cooling system vacuum refill adapter assembly.
 
    1. Continue to fill the coolant expansion tank to the rim until the coolant level stops dropping.
 
    1. E142385
 
    1. Start and run the engine.
 
    1. Set the heater controls to maximum.
 
    1. Increase the engine speed from idle to 3500 Revolutions Per Minute (RPM) until hot air is emitted from the front and rear face vents.
 
    1. Run the engine until the thermostat opens and hot air is emitted from the front and rear face vents.
 
    1. Switch the engine off and allow to cool.
 
    1. Visually check the engine and cooling system for signs of coolant leakage.
 
  1. WARNING:

    When releasing the cooling system pressure, cover the coolant expansion tank cap with a thick cloth.

    CAUTIONS:

    • Since injury such as scalding could be caused by escaping steam or coolant, make sure the vehicle cooling system is cool prior to carrying out this procedure.

    • Make sure the coolant level remains above the "COLD FILL RANGE" lower level mark.

    NOTE:

    When the cooling system is warm, the coolant will be approximately 10mm above the upper level mark on the expansion tank with the cap removed.

    Check and top-up the coolant if required.

COOLING SYSTEM PARTIAL DRAINING AND VACUUM FILLING (G1798818)

GENERAL PROCEDURES
 
  • 26.10.09
  • COOLING SYSTEM PARTIAL DRAINING AND VACUUM FILLING
  • ALL DERIVATIVES
  • 0.70
  • USED WITHINS

SPECIAL TOOL(S)

E169995
 

HU-919

Coolant System Vacuum Refill Kit

 
E166365
 

JLR-303-1634

Adaptor, Cooling System Vacuum Refill Kit

 
DRAINING
WARNING:

Since injury such as scalding could be caused by escaping steam or coolant, do not remove the filler cap from the coolant expansion tank while the system is hot.

CAUTIONS:

  • The engine cooling system must be maintained with the correct concentration and type of engine coolant to prevent corrosion and frost damage. Failure to follow this instruction may result in damage to the engine.

  • Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the area with water.

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. WARNING:

      When releasing the cooling system pressure, cover the coolant expansion tank cap with a thick cloth.

      CAUTION:

      Since injury such as scalding could be caused by escaping steam or coolant, make sure the vehicle cooling system is cool prior to carrying out this procedure.

      E142385
 
    1. Remove engine undershield
      Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).
 
    1. Position a container to collect the fluid.
 
    1. CAUTION:

      Be prepared to collect escaping coolant.

      E188580
      Remove the radiator drain plug and allow the coolant to drain into a suitable container.
 
  1. E188581
    Install the radiator drain plug.
    Torque: 3.5Nm
 
FILLING
 
    1. Install the engine undershield.
      Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).
 
    1. Prepare a sufficient amount of coolant to the specified concentration.
      Refer to:Specifications (303-03B Engine Cooling - V6 S/C 3.0L Petrol, Specifications).
 
    1. CAUTION:

      Make sure the air ejecting from the vac fill tool is pointed away from the vehicle.

      NOTES:

      • Make sure the coolant volume in the container is greater than the amount of coolant the vehicle requires.

      • Make sure the coolant supply valve is in the closed position on the special tool.

      • The special tool needs an air pressure of 6 to 8 bar (87 to 116 psi) to operate correctly.

      • Small diameter or long airlines may restrict airflow to the coolant vacuum fill tool.

      E170526
      • Connect the hose from the vacuum refill adapter into a container of clean coolant, making sure the hose is submerged in coolant at all times during the fill operation.
      • Connect a regulated compressed air supply to the venturi tube assembly.
      • Install the cooling system vacuum refill adapter to the expansion tank.
 
    1. NOTE:
      • Make sure the coolant supply valve is in the closed position on the vacuum filler gauge assembly.
      • The coolant vacuum fill tool needs an air pressure of 6 to 8 bar (87 to 116 psi) to operate correctly.
      • Small diameter or long airlines may restrict airflow to the coolant vacuum fill tool.
      E170527
      Open the air supply valve until -0.8 (-12 psi) Bar is shown on the gauge.
 
    1. E170525
      • Close the air supply valve.
      • Allow 1 minute to check the vacuum is held.
 
    1. E170528
      Open the coolant supply valve and allow the coolant to be drawn into the system until the header tank is at least half full and no further fluid is entering the tank. If the fill process appears to stop and the header tank is not yet half full then stop the fill process, remove the tool and restart the cooling system draining and vacuum filling procedure.
 
    1. Remove the special tools.
 
    1. Check and top-up the coolant to MAX.
 
    1. CAUTIONS:

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

      • Do not exceed 1.0 bar (15 psi) when pressurizing the cooling system.

      NOTE:

      If the pressure continues to drop after the initial tolerance, there is a coolant leak.

      E182460
      • Using the correct adapter connect the cooling system pressure test kit to the vehicle expansion tank.
      • Slowly pressurize the cooling system until the pressure gauge reads 1.0 bar (15 psi).
      • Make sure the cooling system holds pressure, and continue to the next step to bleed coolant from the bleed points.
 
    1. E191867
      Remove the front trim panel.
 
    1. E143102
      Open the bleed screw, when coolant is visible from the outlet close the bleeding point.
      Torque: 2Nm
 
    1. NOTE:

      Where installed.

      E143099
      Open the bleed screw, when coolant is visible from the outlet close the bleeding point.
      Torque: 2Nm
 
    1. E143110
      Open the bleed screw, when coolant is visible from the outlet close the bleeding point.
      Torque: 2Nm
 
    1. E191867
      Install the front trim panel.
 
    1. E182462
      • Depressurize and remove the cooling system pressure tester.
      • Check and top-up the coolant to MAX.
 
    1. CAUTION:

      Correct installation of the coolant expansion tank cap can be obtained by tightening the cap until 3 audible clicks are heard.

      Install the coolant expansion tank cap.
 
    1. Connect exhaust extraction hoses to the tail pipes.
 
      • Select sand driving/dynamic mode if available.
      • Make sure the interior heater is switched off.
 
    1. Start and run the engine and allow to idle for 30 seconds.
 
    1. CAUTION:

      Make sure to observe the coolant level at all times and top up to the MAX mark as required.

      Hold the engine speed at 3500 rpm until the cooling fan starts to run and the thermostat opens, this will be evident as the radiator side coolant temperature will rise as coolant starts to flow around the radiator.
 
    1. Switch the engine off and allow the engine to cool.
 
    1. WARNING:

      Release the cooling system pressure by slowly turning the coolant expansion tank cap a quarter of a turn. Cover the expansion tank cap with a thick cloth to prevent the possibility of scalding. Failure to follow this instruction may result in personal injury.

      • Remove the coolant expansion tank pressure cap.
      • Maintain the coolant level in the coolant expansion tank at the MAX mark.
 
  1. CAUTION:

    Correct installation of the coolant expansion tank cap can be obtained by tightening the cap until 3 audible clicks are heard.

    Install the coolant expansion tank cap.

 

ENGINE COOLING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

COOLING SYSTEM CONCENTRATION CHECK (G2154751)

GENERAL PROCEDURES
 

GENERAL EQUIPMENT

EQUIPMENT NAME
Refractometer / Hydrometer
 
CHECK
CAUTIONS:

  • The engine cooling system must be maintained with the correct concentration and type of coolant solution to prevent corrosion and frost damage.

  • Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the area with water.

  • Never remove the coolant expansion tank cap under any circumstances while the engine is operating.

NOTES:

  • 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. E207352
      Raise the cover plate.
      General Equipment: Refractometer / Hydrometer
 
    1. E207353
      Clean the prism surface with a soft cloth.
 
    1. E207386
      Put 2 drops of pure distilled water on the prism surface.
 
    1. E207354
      Lower the cover plate.
 
    1. E207356
      Observe the shadow line on the scale.
 
    1. E207357
      If required, use the adjustment screw to align the shadow line as shown.
 
    1. E207352
      Raise the cover plate.
 
    1. E207353
      Clean the prism surface with a soft cloth.
 
    1. WARNING:

      Release the cooling system pressure by slowly turning the coolant expansion tank cap a quarter of a turn. Cover the expansion tank cap with a thick cloth to prevent the possibility of scalding.

      CAUTIONS:

      • Be prepared to collect escaping coolant.

      • Since injury such as scalding could be caused by escaping steam or coolant, make sure the vehicle cooling system is cool prior to carrying out this procedure.

      E207350
      Remove the coolant expansion tank cap.
 
    1. E207351
      Use the pipette to extract a coolant sample.
 
    1. E207352
      Raise the cover plate.
 
    1. E207355
      Put 2 drops of coolant on the prism surface.
 
    1. E207354
      Lower the cover plate.
 
    1. NOTE:

      50% coolant concentration mix provides a freeze point of -37°C.

      E207385
      Observe the shadow line on the scale.
 
    1. E207352
      Raise the cover plate.
 
    1. E207353
      Clean the prism surface with a soft cloth.
 
    1. E207515
      • If the coolant concentration mix is at 50%, proceed to Step 20.
      • If the coolant concentration mix is below 50%, proceed to Step 18.
      • If the coolant concentration mix is above 50%, proceed to Step 19.
 
    1. NOTE:

      Coolant concentration mix % must divided by 100. 50% would be calculated as 0.5

      • If the coolant concentration mix is below 50%, the following calculation steps must be followed.
      • Step 1. Multiply the required coolant concentration mix % by the cooling system capacity.
      • Step 2. Multiply the current coolant concentration mix % by the cooling system capacity.
      • Step 3. Subtract the total of step 1 by total of step 2.
      • Step 4. Subtract the current coolant concentration mix % from 1.
      • Step 5. Divide the total of step 3 by the total of step 4.
      • Drain the coolant quantity given by the calculations and replace with concentrated antifreeze.
      • Proceed to Step 20.
 
    1. NOTE:

      Coolant concentration mix % must divided by 100. 50% would be calculated as 0.5

      • If the coolant concentration mix is above 50%, the following calculation steps must be followed.
      • Step 1. Multiply the current coolant concentration mix % by the cooling system capacity.
      • Step 2. Multiply the required coolant concentration mix % by the cooling system capacity.
      • Step 3. Subtract the total of step 1 by total of step 2.
      • Step 5. Divide the total of step 3 by the current coolant concentration mix %.
      • Drain the coolant quantity given by the calculations and replace with distilled water.
 
  1. CAUTION:

    Correct installation of the coolant expansion tank cap can be obtained by tightening the cap until 3 audible clicks are heard.

    Install the coolant expansion tank pressure cap
 

Removal and Installation

ENGINE COOLING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

COOLANT EXPANSION TANK (G1509367)

REMOVAL AND INSTALLATION
 
  • 26.15.01
  • COOLANT EXPANSION TANK - RENEW
  • ALL DERIVATIVES
  • 0.30
  • USED WITHINS
 
 
REMOVAL
WARNING:

Since injury such as scalding could be caused by escaping steam or coolant, make sure the vehicle cooling system is cool prior to carrying out this procedure.

 
    1. E142386
 
    1. WARNING:

      When releasing the cooling system pressure, cover the coolant expansion tank cap with a thick cloth.

      E142385
 
    1. Using a syringe, remove the cooling fluid from the expansion tank.
 
    1. CAUTION:

      Clamp the hoses to minimize coolant loss.

      E143869
 
    1. CAUTION:

      Be prepared to collect escaping coolant.

      E142438
 
    1. E142439
 
  1. CAUTION:

    Be prepared to collect escaping coolant.

    E142440
 
INSTALLATION
 
    1. E142440
 
    1. E143869
 
    1. NOTE:

      Keep the coolant expansion tank vertically.

      E143101
      Raise the coolant expansion tank minimum 110mm from its original position.
 
    1. Fill the cooling system, keeping coolant to the upper level mark of the expansion tank, until a steady stream of coolant is seen returning to the tank.
 
    1. E144702
 
    1. E142438
      Torque: 2.8Nm
 
    1. CAUTION:

      Make sure the coolant level remains above the "COLD FILL RANGE" lower level mark.

      Check and top up the cooling system as required.
 
  1. E148864
     

    ENGINE COOLING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

    COOLANT PUMP - TDV6 3.0L DIESEL - GEN 2 (G1780455)

    REMOVAL AND INSTALLATION
     
    • 26.50.01
    • COOLANT PUMP - RENEW
    • 3000 CC, TDV6
    • 1.10
    • USED WITHINS
    • 26.50.01
    • COOLANT PUMP - RENEW
    • 3000 CC, TDV6, DIESEL, IC
    • 0.80
    • 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:Cooling System Partial 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. NOTES:

        • Note the fitted position of the accessory drive belt.

        • Engine shown removed for clarity.

        E142466
     
      1. E142943
        • Using a suitable 6mm bar, retain the coolant pump pulley.
        • Torque: 25Nm
     
      1. E167283
        Torque: 10Nm
     
    1. CAUTIONS:

      • A new O-ring seal is to be installed.

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

      E167284
     
    INSTALLATION
     
    1. To install, reverse the removal procedure.

     

     

    ENGINE COOLING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

    COOLING FAN (G1509369)

    REMOVAL AND INSTALLATION
     
    • 26.25.39
    • ELECTRIC COOLING FAN AND SHROUD - RENEW
    • 3000 CC, TDV6, DIESEL, IC
    • 1.30
    • 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.

    • Some components shown removed for clarity.


     

     

    The following step(s) applies to:
    All vehicles

     

     
      1. Refer to:Specifications (501-03 Body Closures, Specifications).
     
      1. Refer to:Engine Undershield (501-02 Front End Body Panels, Removal and Installation).
     
      1. Refer to:Cooling System Partial Draining and Vacuum Filling (303-03A, General Procedures).
     
    1. Refer to:Coolant Expansion Tank (303-03 Engine Cooling - SDV6 3.0L Diesel - Hybrid Electric Vehicle, Removal and Installation).

     

     

    The following step(s) applies to:
    Cold climate vehicles

     

     
    1. E142859

     

     

    The following step(s) applies to:
    Cold climate vehicles

     

     
    1. E146022
      Torque: 7Nm

     

     

    The following step(s) applies to:
    All vehicles

     

     
      1. E147485
        Torque: 8Nm
     
      1. E147484
     
      1. E147487
     
      1. E147478
        Torque: 7Nm
     
      1. E147489
     
      1. E147479
     
      1. E147480
     
      1. E147482
        Torque: 5Nm
     
      1. E147483
     
      1. E147490
        Torque: 7Nm
     
      1. E144210
        Torque: 10Nm
     
      1. E144208
     
      1. E147481
        Torque: 7Nm
     
    1. CAUTION:

      Protect the radiator during this operation.

      NOTE:

      With assistance remove the component.

      E144212
      • Release both locking tangs.
     
    INSTALLATION
     
    1. To install, reverse the removal procedure.

    ENGINE COOLING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

    RADIATOR (G1509371)

    REMOVAL AND INSTALLATION
     
    • 26.40.01
    • RADIATOR ASSEMBLY - RENEW
    • 3000 CC, TDV6, DIESEL, IC
    • 2.70
    • USED WITHINS
     

    PART(S)

    STEP PART NAME QUANTITY
    Installation Step 13 Air conditioning pipes to condenser O-ring seals 2
    Installation Step 15 Air conditioning pipes to condenser O-ring seals 2
     
    REMOVAL
    CAUTION:

    Make sure that all openings are sealed.

    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. Recover the Air Conditioning (A/C) system.
        Refer to:Air Conditioning System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures).
     
      1. Remove the cooling fan.
        Refer to:Cooling Fan (303-03A Engine Cooling - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
     
      1. E143881
        • Release the 2 clips.
        • Remove the 2 radiator support pegs.
     
      1. E147486
        • Remove the nut.
        • Release the A/C pipe.
        • Remove and discard the 2 O-ring seals.
     
      1. E147339
        • Remove the 4 bolts.
        • Remove the 2 screws.
        • Reposition the lower part of the bumper.
     
      1. E143875
        • Remove the nut.
        • Release the A/C pipe.
        • Remove and discard the 2 O-ring seals.
     
      1. E147340
        Remove the hose clip.
     
      1. E143877
        • Remove the 2 lower radiator bolts.
        • Remove the 2 lower rubber mounts.
     
      1. NOTE:

        If equipped.

        E143863
        • Remove the bolt.
        • Remove the nut.
     
      1. E147338
        Disconnect the 2 lower coolant hoses.
     
      1. CAUTION:

        Always protect the cooling pack elements to prevent accidental damage.

        E143874
        • Release the radiator from the 2 upper clips.
        • Release the radiator from the shroud.
     
      1. NOTE:

        If equipped.

        E245092
        • Remove the 2 clips.
        • Remove the lower hose from the cooler.
     
      1. CAUTION:

        Always protect the cooling pack elements to prevent accidental damage.

        E147492
        Remove the cooling pack.
     
      1. NOTE:

        If equipped.

        E147491
        Disconnect and remove the 2 pipes.
     
      1. NOTE:

        If equipped.

        E147343
        • Release the cooler from the 4 clips.
        • Remove the cooler.
     
      1. E147344
        • Remove the 3 bolts.
        • Remove the 2 brackets.
     
      1. NOTE:

        If equipped.

        E245093
        • Release the hose clamp.
        • Release the hose from the radiator.
     
    1. E147345
      Remove the A/C condenser assembly from the radiator.
     
    INSTALLATION
     
      1. Install the Air Conditioning (A/C) condenser to radiator.
     
      1. NOTE:

        If equipped.

        • Install the upper cooler hose to the radiator.
        • Install the hose clamp.
     
        • Install the 2 brackets.
        • Install and tighten the 3 bolts.
          Torque: 4.5Nm
     
      1. NOTE:

        If equipped.

        Install the cooler into the 4 clips.
     
      1. NOTE:

        If equipped.

        Install the 2 pipes to the cooler.
     
      1. CAUTION:

        Always protect the cooling pack elements to prevent accidental damage.

        Install the cooling pack.
     
      1. NOTE:

        If equipped.

        • Install the lower hose to the cooler.
        • Install the 2 clips.
     
        • Install the radiator to the shroud.
        • Secure the radiator to the 2 upper clips.
     
      1. Install the 2 lower coolant hoses.
     
      1. NOTE:

        If equipped.

        Install and tighten the nut and bolt.
        Torque: 7Nm
     
        • Install the 2 lower rubber mounts.
        • Install and tighten the 2 lower radiator bolts.
          Torque: 15Nm
     
      1. Install the hose clip.
     
        • Install the A/C pipe.
        • Install and tighten the nut.
          Torque: 8Nm
     
        • Reposition the lower part of the bumper to the correct position.
        • Install the 4 bolts.
        • Install the 2 screws.
     
        • Install the A/C pipe.
        • Install and tighten the nut.
          Torque: 8Nm
     
        • Install the 2 radiator support pegs.
        • Secure the 2 clips.
     
      1. Install the cooling fan.
        Refer to:Cooling Fan (303-03A Engine Cooling - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
     
    1. Recharge the Air Conditioning (A/C) system.
      Refer to:Air Conditioning System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures).

    ENGINE COOLING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

    THERMOSTAT (G1509372)

    REMOVAL AND INSTALLATION
     
    • 26.45.01
    • THERMOSTAT - RENEW
    • 3000 CC, TDV6
    • 0.90
    • USED WITHINS
     
     
    REMOVAL
    NOTE:

    Removal steps in this procedure may contain installation details.


     
      1. Disconnect the battery ground cable.
        Refer to:Specifications (501-03 Body Closures, Specifications).
     
      1. Refer to:Cooling System Partial 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. E142810
        Torque: 5Nm
     
      1. CAUTION:

        Be prepared to collect escaping coolant.

        E143981
     
      1. CAUTION:

        Be prepared to collect escaping coolant.

        E143982
     
    1. CAUTION:

      Be prepared to collect escaping coolant.

      E143983
      Torque: 5Nm
     
    INSTALLATION
     
    1. To install, reverse the removal procedure.

    ENGINE COOLING - TDV6 3.0L DIESEL /TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2

    ENGINE COOLANT LEVEL SWITCH (G1715431)

    REMOVAL AND INSTALLATION
     
    • 26.10.06
    • SENSOR - LOW COOLANT LEVEL - RENEW
    • ALL DERIVATIVES
    • 0.30
    • USED WITHINS
     
     
    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. E211367
        • Remove the 6 fasteners.
        • Remove the 3 engine compartment trim panels.
     
      1. E255194
        • Remove the bolt.
        • Reposition the coolant expansion tank to get access to the engine coolant level switch.
     
      1. E255195
        Disconnect the electrical connector.
     
    1. CAUTION:

      Do not use excessive force to remove the coolant level switch. Failure to follow this instruction may result in damage to vehicle.

      E255102
      • Release the engine coolant level switch from the coolant expansion tank.
      • Remove the engine coolant level switch.
     
    INSTALLATION
     
      1. Install the engine coolant level switch.
     
      1. Connect the electrical connector.
     
        • Reposition the coolant expansion tank into the correct location.
        • Install and tighten the bolt.
          Torque: 7Nm
     
      • Install the 3 engine compartment trim panels.
      • Install the 6 fasteners.

    CHARGE AIR RADIATOR - TDV6 3.0L DIESEL - GEN 2 (G1875611)

    REMOVAL AND INSTALLATION
     
    • 26.40.20
    • RADIATOR - CHARGE AIR - RENEW
    • 3000 CC, TDV6, GEN 2
    • 1.40
    • USED WITHINS
     

    PART(S)

    STEP PART NAME QUANTITY
    Removal Step 3 Retaining clip 1
    Removal Step 8 Retaining clip 1
     
    REMOVAL
     
      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:Front Bumper Cover (501-19 Bumpers, Removal and Installation).
     
      1. NOTE:

        Make sure that new components are installed.

        E178849
        Renew Part: Retaining clip Quantity: 1.
     
      1. E178850
     
      1. E178851
     
      1. E178870
        Torque: 7Nm
     
      1. E178852
        Torque: 4Nm
     
      1. NOTES:

        • Make sure that new components are installed.

        • Left side shown, right side similar.

        E178787
        Renew Part: Retaining clip Quantity: 1.
     
      1. NOTE:

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

        E178854
     
      1. E178855
        Torque: 9Nm
     
    1. E178856
      Inspect the components and renew if damaged or worn.
     
    INSTALLATION
     
    1. To install, reverse the removal procedure.

    COOLANT PUMP - CHARGE AIR COOLER - TDV6 3.0L DIESEL - GEN 2 (G1875618)

    REMOVAL AND INSTALLATION
     
    • 26.50.44
    • COOLANT PUMP - CHARGE AIR COOLER - RENEW
    • 3000 CC, TDV6, GEN 2
    • 0.80
    • USED WITHINS
     
     
    REMOVAL
     
      1. Refer to:Cooling System Partial 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:Left Air Cleaner (303-12A Intake Air Distribution and Filtering - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2, Removal and Installation).
     
      1. E178883
     
      1. E178884
     
      1. E178885
     
      1. E178886
        Torque: 7Nm
     
    1. E178887
     
    INSTALLATION
     
    1. To install, reverse the removal procedure.