Published: 11-May-2011

Engine - TDV6 2.7L Diesel - Oil Cooler

In-vehicle Repair

Removal
• WARNINGS:

Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable
vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

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

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

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

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

• CAUTIONS:

Before disconnecting or removing components, ensure the area around the joint faces and connections are clean.
Plug open connections to prevent contamination.

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

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

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and Charging System - General Information,
Specifications).
2. Drain the cooling system.
For additional information, refer to: Cooling System Draining,
Filling and Bleeding (303-03A Engine Cooling - TDV6 2.7L
Diesel, General Procedures).
3. Remove the crankcase vent oil separator.
For additional information, refer to: Crankcase Vent Oil
Separator (303-08, Removal and Installation).
4. Release the coolant bleed hose from the LH exhaust gas
recirculation (EGR) coolant inlet hose.

Release the retaining clip.

 5. Remove the cylinder head coolant elbow.

Release the two retaining clips and disconnect the

hoses.

Remove the four retaining bolts.

Remove and discard the O-ring seals.

6. Disconnect the knock sensors (KS) electrical connector.

Release the KS harness from the valve cover.

7. Remove the LH KS.

Remove the retaining bolt.

8. NOTE: Some fluid spillage is inevitable during this

operation.

Remove the oil cooler.

Remove the eight retaining bolts.

Remove and discard the gasket.

Remove and discard the O-ring seal.

Installation

1. CAUTION: Make sure the gasket is installed correctly.

• NOTE: Make sure all component mating faces are clean.

Install the oil cooler.

Install a new gasket.

Install a new O-ring seal.

Install the eight retaining bolts and tighten to 10 Nm (7

lb.ft).

2. Install the LH KS.

Install the retaining bolt and tighten to 20 Nm (15 lb.ft).

Connect the knock sensor electrical connector.

Attach the KS harness to the valve cover.

3. Install the cylinder head coolant outlet elbow.

Install new O-ring seals.

Install the four retaining bolts and tighten to 10 Nm (7

lb.ft).

Connect the hoses and secure with the clips.

4. Secure the coolant bleed hose to the EGR coolant inlet hose.
5. Install the crankcase vent oil separator.
For additional information, refer to: Crankcase Vent Oil
Separator (303-08, Removal and Installation).
6. Connect the battery ground cable.
For additional information, refer to: Specifications (414-00
Battery and Charging System - General Information,
Specifications).
7. Refill and bleed the cooling system.
For additional information, refer to: Cooling System Draining,
Filling and Bleeding (303-03A Engine Cooling - TDV6 2.7L
Diesel, General Procedures).
8. Check and top-up the engine oil.
 Published: 11-May-2011
Engine Cooling - TDV6 2.7L Diesel - Cooling System Draining, Filling and
Bleeding
General Procedures

All vehicles
1. Position the vehicle on a lift.
2. Set the heater controls to maximum.
3. Disconnect the battery ground cable.
For additional information, refer to: Specifications (414-00
Battery and Charging System - General Information,
Specifications).
4. Remove the engine cover.
For additional information, refer to: Engine Cover - 2.7L V6 -
TdV6 (501-05 Interior Trim and Ornamentation, Removal and
Installation).

5. 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.

Remove the coolant expansion tank cap.

6. Remove the radiator access panel.

Remove the 4 bolts.

7. Position a container to collect the fluid.

8. CAUTION: Engine coolant will damage the paint

finished surfaces. If spilt, immediately remove the coolant and
clean the area with water.

Release the clip and disconnect the radiator lower hose,

allow the coolant to drain.

9. Remove the container.

Vehicles with auxiliary climate control

10. Remove the spare wheel and tire.

Remove the tool kit.

Access the winch.

11. Position a container to collect the fluid.

 12. Disconnect the rear heater coolant hoses.

Release the 2 clips.

Allow the coolant to drain.

13. Remove the container.

14. Connect the rear heater coolant hoses.

Secure the two clips.

15. Install the spare wheel and tire.

Stow the tool kit.

All vehicles
16. Connect and secure the radiator lower hose.

Secure with the clip.

17. Connect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and Charging System - General Information,
Specifications).
18. Connect exhaust extraction hoses to the tail pipes.
19. Loosen the coolant expansion tank bleed screw.

20. Loosen the cylinder head bleed hose bleed screw.

21. Refill the cooling system.

22. Tighten the bleed screws to 14 Nm (10 lb.ft).
23. 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.
24. NOTE: When the coolant bleed is complete and prior to
installing the expansion tank cap, top up the expansion tank to
30mm above the maximum level.

Install the coolant expansion tank cap.

25. WARNING: Release the cooling system pressure by

slowly turning the 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.

Start and run the engine.

Hold the engine speed at 3,000 RPM for one minute.

Return the engine to idle for five minutes.

Hold the engine speed at 3,000 RPM for one minute.

Run the engine until the thermostat opens.

Remove coolant expansion tank cap, allow float to settle

and top-up coolant if required. Install cap.

26. Switch the engine off and allow to cool.

27. Install the engine cover.
For additional information, refer to: Engine Cover - 2.7L V6 -
TdV6 (501-05 Interior Trim and Ornamentation, Removal and
Installation).
28. Clean any remaining coolant from the chassis and
surrounding area.
29. Install the radiator access panel.

Tighten the 4 bolts to 10 Nm (7 lb.ft).

30. Check and top-up the coolant if required.

 Published: 11-May-2011
Engine Emission Control - TDV6 2.7L Diesel - Engine Emission Control
Description and Operation

Item Part Number Description

1 - EGR modulator/ cooler assembly
2 - Electric throttle
3 - EGR thermostat (from 2007MY)
4 - EGR to electric throttle tube
5 - EGR cooler
6 - EGR modulator valve
7 - EGR modulator solenoid valve
8 - EGR coolant hoses

EGR SYSTEM
The EGR system comprises:

EGR modulator x 2
EGR cooler x 2
Associated connecting pipes

EGR Cooler and Modulator

 Item Part Number Description
1 - EGR modulator
2 - EGR cooler
3 - EGR thermostat (from 2007MY)
Electric Throttle Body

Item Part Number Description

1 - Inlet air temperature sensor
2 - Electric throttle body
3 - Electric throttle flap
4 - Electric throttle control motor
5 - Gas inlet port
The EGR modulator and cooler are a combined unit.

The combined EGR modulator and cooler is located under each cylinder bank, between the exhaust manifold and the
cylinder head. The cooler side of the EGR is connected to the vehicle cooling system, via hoses. The inlet exhaust side is
connected directly into the exhaust manifolds on each side. The exhaust gas passes through the cooler and is expelled via
the actuator and a metal pipe into the throttle housing. The EGR modulator is a solenoid operated valve which is
controlled by the ECM. The ECM uses the EGR modulator to control the amount of exhaust gas being recirculated in order
to reduce exhaust emissions and combustion noise. The EGR is enabled when the engine is at normal operating
temperature and under cruising conditions.

On vehicles from 2007MY, a flow regulating, wax thermostat is fitted to the coolant outlet of the EGR cooler. The purpose
of the thermostat is to promote faster engine warm-up, improve cabin heater performance and assist the emissions to
comply with the requirements of EU4 regulations. The thermostat is closed when cold, starts to open at 75°C (167°F) and
is fully open at normal operating temperatures. The thermostat has a small bleed hole which allows a small amount of
leakage when cold.

The EGR modulator receives a 12V supply from the main relay. The ground for the solenoid is via the ECM and is controlled
using a PWM signal. The PWM duty signal of the solenoid ground is varied to determine the precise amount of exhaust gas
delivered to the cylinders.
The modulators are operated through their full range at each engine start-up, to clear any carbon deposits that may have
built up whilst the engine was running

In the event of a failure of the EGR modulator, the EGR function will become inoperative. The ECM can monitor the EGR
modulator solenoid for short circuits and store fault codes in the event of failure. The modulator can also be activated for
testing using a Land Rover approved diagnostic system.

CRANKCASE VENTILATION

Item Part Number Description

1 - Breather tube
2 - Oil separator
3 - Breather tube
4 - Crankcase oil return connection
5 - Oil return tube
6 - Crankcase oil return valve
7 - Breather flow
The crankcase ventilation system on the TdV6 ensures that all gasses emitted from the crankcase during engine running
are separated from any oil particles.

Crankcase gasses are drawn into the oil separator unit from the crankcase and the cylinder head covers (both banks) where
the gas and oil are separated. The gas is returned to the inlet side of the air induction system prior to the turbo charger.
The oil is drained down to the sump via an oil return valve locate at the rear of the cylinder block.
 Published: 11-May-2011
Engine Emission Control - TDV6 2.7L Diesel - Crankcase Vent Oil Separator
Removal and Installation

Removal
1. Disconnect the battery ground cable.
For additional information, refer to: Specifications (414-00
Battery and Charging System - General Information,
Specifications).
2. Disconnect the low-pressure fuel lines.

Install blanking caps to the exposed ports.

3. Disconnect both exhaust gas recirculation (EGR) coolant

cross-over pipe hoses.

Clamp the EGR coolant hoses to minimize coolant loss.

4. Remove the EGR coolant cross-over pipe.

Remove the two retaining bolts.

5. Disconnect the engine oil pressure (EOP) sensor electrical
connector.

6. CAUTION: The O-ring seal is to be reused unless

damaged.

Using the special tool, remove the oil filter element.

Loosen the element cover 4 complete turns to allow

engine oil to drain from the filter cover.

Remove element cover.

Clean the immediate area.

7. NOTE: Left-hand shown, right-hand similar.

Remove the breather pipes.

8. Disconnect the glow plug electrical connectors.

 9. Disconnect the low-pressure fuel lines.

Install blanking caps to the exposed ports.

10. CAUTION: Make sure that the high-pressure fuel supply

line remains in contact with the fuel pump and fuel injection
diverter rail until both unions have been detached and cleaned.
Failure to follow this instruction may result in foreign matter
ingress to the fuel injection system.

• NOTE: Crankcase vent oil separator shown removed for clarity.

Remove and discard the high-pressure fuel supply line.

Install blanking caps to the exposed ports.

11. Remove the low-pressure fuel line.

Disconnect the low-pressure fuel line.

Release the low-pressure fuel line.

Install blanking caps to the exposed ports.

12. NOTE: Right-hand shown, left-hand similar.

Remove the glow plug wires.

 13. Reposition the crankcase vent oil separator.

14. Disconnect the fuel injection pump electrical connectors.

15. Disconnect the fuel rail pressure (FRP) sensor electrical

connector.

Release the fuel charging wiring harness.

16. CAUTION: The O-ring seals are to be reused unless

damaged.

• NOTE: Remove the crankcase vent oil separator drain tube

seal prior to the removal of the crankcase vent oil separator.

• NOTE: Using a suitable adhesive tape, protect the oil cooler.

Remove the crankcase vent oil separator.

Installation

1. CAUTION: The O-ring seals are to be reused unless

damaged.
 Position the crankcase vent oil seperator, but do not fully
install at this stage.

Clean the immediate area.

2. Connect the FRP sensor electrical connector.

Attach the fuel charging wiring harness.

3. Install the crankcase vent oil separator.

4. Connect the fuel injection pump electrical connectors.
5. Install the glow plug wires.
6. Install the low-pressure fuel line.

Remove the blanking caps from the ports.

Connect the low-pressure fuel line.

Attach the low-pressure fuel line.

7. Install the new high-pressure fuel supply line.

Remove the blanking caps from the ports.

Install the new high-pressure fuel supply line, but do not

tighten unions at this stage.

Stage 1: Tighten the high-pressure fuel supply line union

at the fuel pump to 15 Nm (11 lb.ft).

Stage 2: Tighten the high-pressure fuel supply line union

at the fuel injection diverter rail to 15 Nm (11 lb.ft).

Stage 3: Tighten the high-pressure fuel supply line union

at the fuel pump to 30 Nm (22 lb.ft).

Stage 4: Tighten the high-pressure fuel supply line union

at the fuel injection diverter rail to 30 Nm (22 lb.ft).

8. Connect the low-pressure fuel lines.

Remove the blanking caps from the ports.

9. Connect the glow plug electrical connectors.

10. Install the breather pipes.

11. CAUTION: The O-ring seal is to be reused unless

damaged.

Install the oil filter element.

Clean the components.

Tighten the oil filter element cover to 25 Nm (18 lb.ft).

12. Connect the EOP sensor electrical connector.

13. Install the EGR coolant cross-over pipe.

Install the two retaining bolts.

Tighten to 13 Nm (10 lb.ft).

14. Connect both EGR coolant cross-over pipe hoses.

Remove the EGR coolant hose clamps.

 15. Connect the low-pressure fuel lines.

Remove the blanking caps from the ports.

16. Connect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and Charging System - General Information,
Specifications).
17. Check and top-up the engine oil.
18. Check and top-up the coolant.
19. Bleed the fuel system.