Range Rover Sport Tdv6

Published: 11-May-2011
Engine - TDV6 2.7L Diesel -

Sealers
Description Land Rover Part No.
Camshaft caps 8510302
‘T’ joints - ladder frame to engine block STC 50550
Coolant plug - threaded STC 50552
Oil pump upper middle retaining bolt STC 50552
Lubricants
Description Specification
Engine oil, SAE 5W-30 Use 5W/30 oil to specification WSS-M2C-913B meeting ACEA B1/B3
Note: WSS is a Ford prefix to the oil specification
Capacities
Engine Oil Capacity Specification
Dry fill including filter for factory fitted engine 6.55 litres (11·5 pints) (6.9 US quarts)
Dry fill including filter for all new engines fitted in service 7.05 litres (12.4 pints) (7.4 US quarts)
Oil and filter change 5·54 litres (9·6 pints) (5.8 US quarts)
Amount of oil required to bring level from 'MIN' to 'MAX' mark on oil level indicator 1·5 litres (2·6 pints) (1.6 US quarts)
Dimensions
Item Specification
Length 523 mm (20·59 in)
Width 717 mm (28·25 in)
Height 771 mm (30·35 in)
General Specifications
Item Specification
Type 2.7 litre, 60 degree 'V', common rail direct injection, turbocharged and intercooled diesel, twin
overhead camshafts, 4 valves per cylinder
Cylinder arrangement V6, numbers 1 and 4 cylinders at front of engine when engine is viewed from rear
Cylinder numbering Number 1 cylinder - right hand bank; Number 4 cylinder - left hand bank
Bore - nominal 81·0 mm (3·188 in)
Stroke 88·0 mm (3·464 in)
Capacity 2720 cm³ (165·9 in³)
Firing order 1-4-2-5-3-6
Compression ratio 17.3:1
Direction of rotation Anti-clockwise viewed from rear of engine
Maximum power 147 kW (200 PS) (197 bhp) @ 4000 rev/min
Maximum torque 440 Nm (324 lb-ft) @ 1900 rev/min
Engine oil pressure:
At idle 0.7 bar (70 kPa) (10 lb/in²)
At 3500 rev/min 1.9 bar (190kPa) (27.5 lb/ft²)
Maximum permissible cylinder head warp
Total flame face 0.1 mm
150 mm x 150 mm square on 0.05 mm
flame face
25 mm x 25 mm square on 0.025 mm
flame face
Torque Specifications
Description Nm lb-ft
Accessory drive belt idler retaining bolt 47 35
Accessory drive belt tensioner M8 retaining bolts 47 35
Accessory drive belt tensioner M10 retaining bolts 25 18
Air conditioning (A/C) compressor retaining bolts 23 17
A/C compressor mounting bracket retaining bolts 23 17
A/C compressor low pressure pipe fixing 9 7
A/C manifold retaining bolt 20 15
Battery positive cable mounting bolts 10 7
* Camshaft inner bearing cap retaining bolts
Stage 1: tighten bolts 1 to 14 1 1
* Camshaft outer bearing cap retaining bolts
Camshaft position sensor retaining bolt 10 7
+¹ Camshaft hub retaining bolts
Stage 1 80 59
Stage 2 Further 90° Further 90°
Camshaft pulley retaining bolts 23 17
Camshaft timing belt cover securing bolts 10 7
+² Crankshaft pulley retaining bolt
Stage 1 100 74
Crankshaft damper bolts 14 10
Crankshaft position sensor retaining bolt 5 4
Crankshaft rear seal retainer plate 10 7
Coolant outlet elbow 10 7
*+² Cylinder head retaining bolts
Stage 1 20 15
Stage 2 40 30
Stage 3 80 59
Differential front mounting bracket heat shield 10 7
EGR valve inlet tube 10 7
EGR valve mounting bolts 10 7
EGR valve support bracket fixing 10 7
Engine breather tube securing bolt 10 7
Engine mount retaining nuts to cross member 62 46
Engine mount bracket to engine mount retaining bolts 62 46
Engine mount bracket to engine block retaining bolts 115 85
Exhaust cross over pipe retaining nuts 24 18
Exhaust manifold heat shield retaining bolts 10 7
Exhaust manifold retaining nuts 23 17
Exhaust manifold retaining studs 13 10
*+ Flexplate retaining bolts
Stage 1 50 37
Fuel injection pump 23 17
Fuel injection pump pulley retaining nut 50 37
Fuel injection supply manifold 23 17
Fuel injection supply manifold securing bracket 23 17
Fuel injection supply line unions
Stage 1 - High pressure fuel supply line union at the fuel injection diverter rail 15 11
Stage 2 - High pressure fuel supply line union at the fuel injection supply manifold 15 11
Stage 3 - High pressure fuel supply line union at the fuel injection diverter rail 30 22
Stage 4 - High pressure fuel supply line union at the fuel injection supply manifold 30 22
Fuel injection high pressure supply line mounting bolt 10 7
Fuel injector retaining bolts 10 7
Fuel filter mounting bolts 10 7
Generator retaining bolts 23 17
Generator mount bracket retaining bolts 23 17
Glow plugs 11 8
Intake air shut off throttle elbow support bracket bolts 10 7
Knock sensor retaining bolts 20 15
Oil cooler to cylinder block retaining bolts 10 7
Oil level indicator tube upper retaining bolt 10 7
Oil pan retaining bolts 10 7
Oil pump screen and pick-up tube 10 7
Oil pump to engine block retaining bolts 10 7
Oil pan drain plug 23 17
Oil separator retaining bolts 10 7
Oil temperature sensor 10 7
Oil filter 25 18
Piston cooling jet retaining bolt 10 7
Power steering bracket retaining bolts 23 17
Power steering pump retaining bolts 23 17
Power steering high pressure pipe fixing 25 18
Primary timing chain tensioner retaining bolts 10 7
Secondary timing chain tensioner bolts 10 7
Starter motor retaining bolts 45 33
Timing belt tensioner retaining bolt 24 18
Timing belt idler pulley retaining bolt 45 33
Transmission fluid cooler pipe securing bracket 10 7
Transmission retaining bolts 45 33
Turbo heat shield 10 7
Turbo support bracket 22 16
Coolant pump retaining bolts 10 7
Coolant pump pulley retaining bolts 23 17
Coolant pump outlet pipe retaining bolts 10 7
Valve cover retaining bolts 10 7
Vacuum pump retaining bolts 23 17
Vacuum pump retaining nuts 13 10
* Bolts must be tightened in sequence
+ New bolts must be installed
¹ Lightly oil bolt threads
² Do not apply lubricant to bolt threads

Engine - TDV6 2.7L Diesel - Engine
Description and Operation
External View
GENERAL
The TdV6 engine is a 2.7 liter, direct injection, six-cylinder diesel engine having two banks of three cylinders, arranged at 60
degrees to each other. There are 4 valves per cylinder, which are operated by two overhead camshafts per cylinder bank. The
engine emissions comply with ECD3 (European Commission Directive) legislative requirements and employs two catalytic
converters, electronic engine management control, positive crankcase ventilation and exhaust gas recirculation to limit the
emission of pollutants. The unit is water cooled and turbo-charged. The fuel injection system features common rail technology.
The cylinder block is manufactured in Compacted Graphite Iron (CGI) and is coupled with a separate aluminium ladder frame to
provide a lightweight, compact and very stiff bottom end of the engine. The cylinder heads are cast aluminium with a moulded
plastic camshaft cover. The single-piece oil sump is formed from stamped steel. The cast iron exhaust manifolds are unique for
each cylinder bank and a moulded plastic acoustic cover is fitted over the upper engine to reduce engine-generated noise.
TECHNICAL FEATURES
The technical features include:
60 degree 'vee' 6 cylinder engine with a CGI cylinder block

Plastic cylinder head cover
Two light, high strength, aluminium cylinder heads
4-valve technology with centrally arranged fuel injectors
Steel roller rockers with hydraulic lash adjusters
Twin plenum intake system integrated with the camshaft cover
Variable Geometry Turbocharger
Common rail direct fuel injection system
High pressure fuel pump
Gallery cooled pistons with a central crown bowl
Two electronically controlled Exhaust Gas Recirculation (EGR) valves
Two EGR coolers
Exhaust re-treatment by means of a diesel specific oxidation catalytic converter and primary catalytic converter
Cooling fan with electro-viscous clutch drive.
ENGINE DATA
The technical data is detailed below:
DESCRIPTION TYPE
Configuration 60 degree V6
Maximum power 147 kW at 4000 rpm
Maximum torque 440 Nm at 1900 rpm
Displacement 2720cc
Stroke/bore 81mm/88mm
Compression ratio 17.3:1
Firing order 142536
Oil capacity 6.55 litres (initial fill)
5.45 litres (service fill, includes oil filter)
Engine weight (with oil) 235kg (Automatic)
260kg (Manual, inc. clutch plate and cover)
CYLINDER BLOCK COMPONENTS

Item Part Number Description
1 - Oil filter cap
2 - Oil filter element
3 - Scavenge pipe
4 - Diaphragm
5 - Spring
6 - Scavenge pipe
7 - Crankcase ventilation oil separator assembly
8 - Turbocharger feed filter
9 - Bolt
10 - Crankcase ventilation drain reservoir assembly
11 - Bolt
12 - Crankcase ventilation oil return tube
13 - Bracket
14 - Bolt
15 - Crankcase ventilation oil return assembly
16 - Bolt
17 - Bolt
18 - Oil level gauge
19 - Bolt
20 - Crankcase ventilation return hose
21 - Cylinder head locating dowels
22 - Core plug
23 - Seal
24 - Transmission locating dowel
25 - Bolt, 2 of
26 - Water inlet connector assembly
27 - O ring
28 - Bolt
29 - Crankshaft position (CKP) sensor
30 - Cylinder block aperture cover
31 - Bolt
32 - Blanking plug
33 - O ring
34 - Crankshaft timing plug
35 - Bolt
36 - Bolt, 3 of
37 - Piston cooling jets
38 - O ring
39 - Water pump
40 - Bolt, 3 of
41 - Bolt, 3 of
42 - Water pump pulley
43 - Core plug
44 - Stud bolts, 3 of
45 - Coolant drain plug
46 - Cylinder head locating dowels
47 - Lower oil filter and cooler assembly
48 - Seal
49 - Upper oil filter and cooler assembly
50 - Bolt, 8 of
51 - Fuel cooler
Cylinder Block
The cylinders and crankcase are contained in the cylinder block, which is of single cast CGI construction with a hollow beam
structure. With this type of construction less material is required than for a conventional cast iron block, therefore, reducing
engine weight and length.
Piston Cooling Jets

1 - Bolt
2 - Piston 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 two internal wave shaped channels to help cool each piston crown.
Lubrication oil is distributed through the cylinder block, via the main oil gallery and channels bored in the block, to all critical
moving parts. These channels divert oil to the main and big-end bearings via holes machined into the crankshaft.
A tapping at the rear RH side of the cylinder block, below the RH cylinder head, connects a pipe to the turbocharger by means of a
banjo connection. Oil is supplied, under pressure via this tapping, from the oil pump to provide lubrication for the turbocharger
bearings.
Cylinder cooling is achieved by coolant circulating through chambers in the cylinder block casting.
Two hollow metal 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 rear LH side of the ladder frame, below the turbocharger, to connect the turbocharger oil return pipe to
the sump.
A plug sealing the lubrication cross-drilling gallery is located at the front RH side of the cylinder block. Plugs for the main
lubrication gallery are included at the front and rear of the cylinder block.
Engine Data Locations

1 - Engine data locations
Engine data is marked at two locations at the back of the cylinder block. Component diameters are represented by alphabetical
and numerical codes; keys to the codes are in the Service Repair Procedures (SRP) Manual.
Connecting Rods and Pistons

The connecting rods are manufactured from sinter-forged steel and have fracture-split bearing caps. The bearing caps are
produced by fracturing the opposing sides of the connecting rod at the bearing horizontal centre-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 selective connecting rod bearings are
aluminium/tin split plain bearings. The connecting rod bearing is 'sputter coated', 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.
Connecting Rod Installation

1 - Piston and connecting rod assembly, cylinders 4-6
2 - Piston and connecting rod assembly, cylinders 1-3
3 - Bolts
4 - Connecting rod bearing cap
5 - Connecting rod lower bearing
When installing a connecting rod, ensure the back of the connecting rod faces the centre of the 'vee'.
The pistons are made from aluminium alloy and 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 wrist pin located in a aluminium/tin bushing in the connecting rod.
Piston Installation
When installing pistons ensure the arrows on the piston crowns all point to the front of the engine and the pistons are located in
the correct cylinder banks, i.e. cylinders 1, 2, 3 or cylinders 4, 5, 6.
• NOTE: 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 bevelled
oil control ring must be opposite the spiral control joint.
Crankshaft Position Sensor
The Crankshaft Position (CKP) sensor is located at the rear of the crankshaft, behind the flywheel in the LH side of the rear oil seal
retainer. The sensor provides an input of engine crankshaft speed and position. The sensor works on the principle of the Hall
effect and scans a trigger wheel (magnetic disc) on the crankshaft. An air gap of 0.4 to 1.5mm, between the trigger wheel and
the CKP sensor, is achieved by the positional mounting of the sensor.
For additional information, refer to: Electronic Engine Controls (303-14C Electronic Engine Controls - TDV6 2.7L Diesel,
Description and Operation).
Starter Motor
The engine starter motor is installed at the rear RH side of the ladder frame, at the cylinder block to ladder frame split line.
For additional information, refer to: Starting System (303-06C Starting System - TDV6 2.7L Diesel, Description and Operation).
Coolant Drain Plug
Two coolant drain plugs are installed in the cylinder block, one is fitted in the rear RH side, and the other is fitted in the middle of
the cylinder block on the LH side.
Cylinder Block Heater
On vehicles destined for cold climates, a cylinder block heater replaces a core plug in the middle of the cylinder block on the LH
side.
Coolant Pump

1 - Bolts
2 - Water pump
3 - 'O' ring seal
The coolant pump is installed on the LH side of the cylinder block front face and is secured and sealed via three bolts and an 'O'
ring. The coolant pump is driven by a poly-vee belt via the crankshaft.
High-Pressure Fuel Pump

1 - Fuel pipe
2 - Diverter rail assembly
3 - Rear cover
4 - Belt
5 - Fuel pump pulley
6 - Front cover
7 - Nut
8 - Bolt
9 - Bolt
10 - Tensioner
11 - LH exhaust camshaft pulley
12 - High pressure fuel pump
13 - Bolt
14 - Stud bolts
The high-pressure fuel pump supplies the common rail with fuel and is fixed to the rear of the cylinder block in the centre of the
'vee'. The pump is a 3 radial piston type controlled by the Engine Management System (EMS) and belt driven from the exhaust
camshaft of the LH cylinder head. For additional information, refer to:
Electronic Engine Controls (303-14C Electronic Engine Controls - TDV6 2.7L Diesel, Description and Operation),
Fuel Charging and Controls (303-04C Fuel Charging and Controls - TDV6 2.7L Diesel, Description and Operation).
CRANKSHAFT AND SUMP COMPONENTS

1 - Bolts, 3 of
2 - Fan driver bracket
3 - Oil pump
4 - Seal
5 - Cylinder block
6 - Rear oil seal retainer
7 - Bolts, 10 of
8 - Crankshaft position sensor trigger wheel
9 - Bolts, 8 of
10 - Main thrust bearing, upper
11 - Piston and connecting rod assembly
12 - Flywheel
13 - Lower main thrust bearing
14 - Main bearing caps, 4 of
15 - Cross bolts, 4 of
16 - Main bearing cap bolts, 16 of
17 - Gasket
18 - Seal
19 - Bracket
20 - Bolts, 2 of
21 - Bolts, 6 of
22 - Gasket
23 - Oil pick-up
24 - Bolt
25 - Oil temperature sensor
26 - Seal
27 - Drain plug
28 - Bolts, 14 of
29 - Oil pan assembly
30 - Bolts, 12 of
31 - Ladder frame
32 - Dowel
33 - Bolts, 2 of
34 - Connecting rod cap
35 - Connecting rod cap bearing
36 - Connecting rod bearing
37 - Connecting rod
38 - Piston
39 - Piston pin retainer
40 - Piston pin
41 - Cross bolts, 4 of
42 - Lower main bearings
43 - Bolts, 5 of
44 - Crankshaft damper pulley
45 - Bolt
46 - Crankshaft drive pulley
47 - Crankshaft front oil seal
48 - Upper main bearings
49 - Bolts, 10 of
50 - Seal
Crankshaft
The crankshaft is forged steel and fillet rolled with induction hardened journals, which run in four bearings with clamped two layer
bearing shells.
The main bearing caps are double and cross-bolted, this adds to the strength and rigidity of the engine block.
The crankshaft drive pulley is not keyed onto the crankshaft; it is secured to the crankshaft by a single bolt.
• NOTE: Under no circumstances must the crankshaft pulley be tightened or loosened with the timing belt fitted.
• NOTE: Do not attempt to remove the crankshaft drive pulley unless you have the correct special crankshaft-locking tool.
1 - Housing
2 - Seal
3 - Crankshaft
4 - Rear oil seal retainer
5 - Bolt, 10 of
The crankshaft rear oil seal is a press fit in the rear oil seal retainer. The rear oil seal retainer also houses the CKP sensor.

1 - CKP sensor trigger wheel
The trigger wheel is located on the rear of the crankshaft. It is pressed onto the crankshaft using a special tool, which also
precisely aligns the trigger wheel for crankshaft position and timing. The trigger wheel consists of 60 magnets, minus 2 for ECM
crankshaft position reference and synchronisation. The magnets cannot be seen on the trigger-wheel; therefore, it can only be
positioned using the special tool.
The CKP sensor air gap is 0.4mm to 0.5mm with no adjustment available. The sensor bolts into the rear oil seal retainer and the
tolerance on the retainer and sensor give an air gap within the specified range.
• NOTE: If the trigger wheel is removed for any reason, a new trigger wheel must be fitted. Do not reuse the old trigger wheel.
Main Bearings
The main bearings are aluminium/tin split plain selective bearings. An oil groove in the top half of each bearing transfers oil into
the crankshaft for lubrication of the connecting rod bearings. The upper and lower shells of bearing number four contain integral
thrust washers, which limits the end float of the crankshaft.
Ladder Frame

1 - Ladder frame
The ladder frame is fitted to the lower cylinder block to stiffen the base structure of the engine thus helping to reduce Noise,
Vibration and Harshness (NVH). The frame is made of high-pressure die cast aluminium and also incorporates an oil baffle plate to
reduce oil foaming and splash.
The ladder frame is secured to the cylinder block with 2 dowels, 2 locator pins for the gasket and 18 retaining bolts; three
different lengths of bolts are used:
M6 x 20, 6 of
M8 x 75, 4 of
M6 x 105, 8 of
Iron inserts, cast into the main bearing supports of the ladder frame, minimise main bearing clearance changes due to heat
expansion.
A gasket seals the joint between the ladder frame and the cylinder block.
A port for the oil level gage tube is included in the casting on the LH side of the ladder frame.
An oil pick-up pipe with integral strainer locates in the front of the ladder frame to provide oil to the crankshaft driven oil pump.
Sump
The sump consists of a pressed steel oil pan bolted to the aluminium alloy ladder frame with 14 M6 x 16 bolts. The engine oil
drain plug and the oil temperature sensor are located at the rear left corner of the sump.
A reusable gasket seals the joint between the oil pan and the ladder frame; a bead of sealant seals the joint between the sump
and the ladder frame.
Oil Temperature Sensor
The engine oil temperature sensor is located at the rear left corner of the sump. The sensor provides the ECM and the instrument
cluster with the engine oil temperature status.
The sensor circuit consists of an internal voltage divider circuit which, incorporates a Negative Temperature Coefficient (NTC)
thermistor. As the engine oil temperature rises the resistance through the sensor decreases and visa versa. The output from the
sensor is the change in voltage, as the thermistor allows more current to pass to ground relative to the temperature of the oil.
Rear Oil Seal Retainer
The crankshaft rear oil seal retainer is attached to the rear of the cylinder block by ten bolts and is sealed with a rubber seal. The
retainer also houses the crankshaft position sensor.
CAMSHAFT TIMING COMPONENTS

1 - Rear Engine Accessory Drive (READ) rear cover
2 - READ tensioner
3 - Bolt
4 - Fuel pump pulley
5 - Nut
6 - READ camshaft pulley
7 - READ belt
8 - Bolt
9 - READ front cover
10 - RH chain tensioner
11 - RH timing chain
12 - RH inlet camshaft
13 - RH exhaust camshaft
14 - LH inlet camshaft
15 - LH exhaust camshaft
16 - LH chain tensioner
17 - LH timing chain
18 - Timing belt
19 - Front cover bridge
20 - Primary drive cover
21 - Idler
22 - Bolt
23 - Bolt
24 - Tensioner
25 - Bolt
26 - Idler
27 - Camshaft hub
28 - LH camshaft timing pulley
29 - Bolt, 3 of
30 - Bolt, 1 of
31 - Idler
32 - Bolt, 1 of
33 - Bolt, 3 of
34 - Bolt, 1 of
35 - RH camshaft timing pulley
36 - Camshaft hub
Primary Drive
Primary drive is provided by a single toothed 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 an eccentric type tensioner mounted on the RH front face of the cylinder block.
Secondary Drive
1 - Timing chain
2 - Bolts
3 - Inlet camshaft
4 - Exhaust camshaft
5 - Tensioner firing pin
Secondary drive is provided by two short crossover chains, which transfer drive from the exhaust camshaft gears to the inlet
camshaft gears. The crossover drives are located at the rear of the RH cylinder bank and the front of the LH cylinder bank. This
allows for a much shorter and simpler run for the main camshaft drive belt at the front of the engine.
Each crossover 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 inlet 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.
Timing Cover
A - Bolt (M6 x 32), 13 of
B - Bolt (M6 x 36), 2 of
C - Bolt (M6 x 30), 2 of
The plastic timing cover is bolted to the front of the cylinder block and cylinder heads with sixteen bolts and sealed with a rubber
seal.
CYLINDER HEAD COMPONENTS

1 - Hydraulic lash adjusters
2 - Valve spring retainers
3 - Roller rockers
4 - Valve stem seals
5 - Valve guides
6 - Exhaust valves
7 - Intake valve seats
8 - Exhaust valve seats
9 - Intake valves
10 - Valve springs
11 - Bolt
12 - Bracket
13 - Cover
14 - Lifting eye
15 - Washer
16 - Bolt
17 - Bracket
18 - Bolt
19 - Seal
20 - Cap
21 - Inlet manifold cover assembly
22 - Washer
23 - Bolt
24 - Lifting eye
25 - Seal
26 - Camshaft bearing caps
27 - Bolts
28 - Gasket
29 - Camshaft bearing cap and seal housing
30 - Camshaft bearing cap and seal housing
31 - Inlet camshaft
32 - Exhaust camshaft
33 - LH cylinder head
34 - Cylinder head bolts
35 - Exhaust manifold studs
36 - LH cylinder head gasket
37 - Core plug
38 - Plug
39 - Seal
40 - Oil filler tube
41 - Oil filler cap
42 - Cover
43 - Injectors
44 - Bolts
45 - Bolt
46 - Vacuum pump
47 - Water outlet assembly
48 - Bolts
Cylinder Heads
1 - Studs
2 - Bolts
3 - Blanking plugs
The aluminium gravity die cast 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
inlet camshaft and four under the exhaust camshaft. Two hollow dowels align each cylinder head with the cylinder block.
• NOTE: The cylinder head bolts are not accessible with the camshafts fitted.
• NOTE: The cylinder head cannot be reworked.
The cylinder head has four ports machined at each cylinder location, two exhaust ports and two inlet ports. One of the inlet 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 six fuel injection nozzles are centrally mounted; one above each cylinder and each is fixed to the cylinder head by means of a
clamp and two M6 x 35 bolts. For additional information, refer to:
Glowplugs

1 - Harness connector
2 - Glow plugs
The glow plugs are arranged centrally on the inlet side of the cylinder head, between the two inlet ports of each cylinder.
Camshaft Position Sensor

1 - Camshaft Position (CMP) sensor
2 - Bolt
The CMP sensor locates through a hole in a flange on the front LH side of the LH cylinder head. The exhaust camshaft gear of the
LH cylinder head incorporates a trigger wheel, which is used in conjunction with the sensor to measure engine position.
The engine lifting eyes are bolted to the cylinder head, one at the front and two at the rear, one per cylinder head.
Camshaft Covers

1 - Stud bolt M6 x 40, 6 of
2 - Bolt M6 x 40, 7 of
3 - Oil filler aperture
4 - RH camshaft cover assembly
The camshaft covers are manufactured from vinyl ester composite. The RH bank camshaft cover incorporates an outlet for the full
load engine breather and the engine oil filler cap. The LH bank camshaft cover incorporates an outlet for the part load engine
breather.
Silicon rubber in-groove gaskets seal the joints between the camshaft covers and the cylinder heads. Together with spacers and
seals on the camshaft cover fasteners, they also isolate the covers from direct contact with the cylinder heads, to reduce noise.
Cylinder Head Gasket
The cylinder head gasket is a three-layer, laminated steel type and is available in five different thickness. 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.
Gasket Selection Table

Piston Protrusion (mm) Gasket Thickness (mm) Identification
0.541 - 0.590 1.12 1
0.591 - 0.640 1.17 2
0.641 - 0.690 1.22 3
0.691 - 0.740 1.27 4
0.741 - 0.790 1.32 5
To calculate the correct cylinder head gasket thickness, each piston must be measured at two points, with an average of the two
measurements taken to determine the piston protrusion. The highest of the three measurements will determine the gasket
required for that particular cylinder head.
• NOTE: The difference between the maximum and minimum protrusion measurement in any one bank should not be greater than
0.1mm. It is permissible to have a different grade of gaskets between the LH and RH banks.
Camshafts
The camshafts are of a hollow steel tube construction, with pressed on sintered lobes. Each camshaft is retained by aluminium
alloy caps, five for the exhaust camshafts and four for the inlet 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.
The LH cylinder bank exhaust camshaft is machined to accept a rear camshaft gear. The rear camshaft gear provides drive for
High Pressure (HP) fuel pump, located centrally at the rear of the 'vee', via a short-toothed belt and tensioner pulley.
The RH cylinder head exhaust camshaft is machined at the rear end to provide a drive connection for the vacuum pump.
• NOTE: The camshaft drive sprockets also form the thrust faces for the camshaft endfloat. In production the endfloat is 0.065mm
to 0.185mm. In service, if the endfloat is out of specification, the camshaft(s) or cylinder head(s) may have to be replaced.
Camshaft Timing
Valve Position
Inlet valve opens 8.5° BTDC
Inlet valve closes 35.5° ABDC
Exhaust valve opens 64° BBDC
Exhaust valve closes 12° ATDC
Key:
BTDC = Before Top Dead Center

ABDC = After Bottom Dead Center
BBDC = Before Bottom Dead Center
ATDC = After Top Dead Center.
Inlet and Exhaust Valves

1 - Valve spring collets
2 - Valve spring retainer
3 - Valve spring
4 - Valve stem seal
5 - Inlet valve
6 - Exhaust valve
Each cylinder head incorporates two overhead camshafts operating four valves per cylinder via steel roller rockers with hydraulic
lash adjusters.
1 - Roller rocker
2 - Hydraulic lash adjuster
The lightweight valve gear provides good economy and noise levels. Valve head diameters are 31mm (1.220 in) for the exhaust
and 35mm (1.378 in) for the intake. All valves have 5mm (0.197 in) diameter stems supported in sintered metal seats and guide
inserts. Collets, valve collars and spring seats locate single valve springs on both intake and exhaust valves. Valve stem seals are
integrated into the spring seats.
Vacuum Pump

1 - Location dowels
2 - Bracket
3 - Vacuum pump
4 - Bolt
5 - Bolts
6 - Nut
7 - Bracket (transmission breather hose)
8 - Stud
The vacuum pump is located at the rear of the RH side cylinder head and is driven from the exhaust camshaft.
Fuel Injectors

1 - Bolt, 2 per injector
2 - Clamp
3 - Injectors
The fuel injectors inject the quantity of fuel required for all the engine operating conditions into the combustion chambers. The
quantity of fuel injected during each working cycle is composed of a noise-reducing pilot injection phase and a main injection
phase.
The six, side fed, piezo electrically controlled fuel injectors are installed in the fuel rails. The start of fuel injection and the quantity
of fuel injected is controlled directly by the ECM. Two O-rings seal each injector to the manifold interface. For additional
information, refer to:
Water Outlet Assembly

1 - Bolt, 4 of
2 - Water outlet assembly
3 - Seals
A - Water outlet housing assembly, EGR outlet
B - Water outlet housing assembly, radiator outlet
C - Water outlet housing assembly, bleed valve
The water outlet assembly connects the cooling channels of the cylinder block to the cooling channels of the LH and RH cylinder
heads and provides the coolant outlet for the EGR and coolant return.
LUBRICATION SYSTEM
General
Oil is drawn from the reservoir in the oil pan and pressurised 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. Pressurised oil is also provided for operation of the hydraulic adjusters
and the timing gear chain tensioners.
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
and fuel cooler, 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. This eliminates the need for an additional engine oil cooler remotely mounted.
The fuel cooler, which forms part of the oil filter body, is also cooled by engine coolant. In addition there is a further fuel cooler in
the return line to the fuel tank.
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 RH camshaft cover.
With the exception of the pump and level gauge, all oil system components are installed on the sump.
Oil Pick-up
The moulded composite oil pick-up is immersed in the oil reservoir to provide a supply to the oil pump during all normal vehicle
attitudes. The castellated inlet allows the supply to be maintained even if the sump pan is deformed (e.g. by 'grounding'). A mesh
screen in the inlet prevents debris from entering the oil system.
Oil Pump

1 - Oil pump
2 - Bolt
The oil pump is a gear type pump and is bolted and dowelled to the front of the engine block. It is sealed by means of a rubber
gasket, which is recessed into the oil pump housing. The pump inlet and outlet ports align with oil passages in the ladder frame.
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 Psi).
The front crankshaft oil seal is housed in the oil pump casing and is fitted such that its front face is 1mm underflush 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 Filter
The oil filter is a replaceable cartridge installed on an adapter in the centre of the 'vee'. An internal bypass facility permits full flow
bypass if the filter is blocked.
• NOTE: In service care must be taken when removing the oil filter to minimise oil drips and spillage into the engine 'vee' and cam
covers:
Do not use air/power tools

Unscrew oil filter cap 4-5 turns
Leave for a minimum of 1 minute to allow to drain
Remove cap, ensuring minimal oil spillage
Replace oil filter element into the cap (can only be fitted in one direction)
Replace cap and torque to specification.
Oil Pressure Switch

1 - Oil pressure switch
The oil pressure switch, located in the 'vee' at the front of the LH cylinder head, connects a ground input to the instrument cluster
when oil pressure is present. The switch operates at a pressure of 0.15 to 0.41 Bar (2.2 to 5.9 Psi).
Oil Level Gage
The oil level gage locates midway along the LH side of the oil pan, supported in a tube installed in the ladder frame. Two holes in
the end of the gage indicate the minimum and maximum oil levels. There is a difference of approximately 1 litre (1 US quart)
between the two levels.
EXHAUST MANIFOLD

1 - LH exhaust manifold
2 - RH exhaust manifold
The exhaust manifolds are cast from steel alloy and are unique for each cylinder bank. 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.
Each manifold has a connection for the EGR transfer pipe.

The engine is fitted with a Variable Geometry Turbocharger (VGT), which is fixed to the exhaust manifold by a three-hole flange
with a steel gasket.
Crossover Pipe
A crossover pipe carries the exhaust gasses from the RH exhaust manifold to the turbocharger on the LH exhaust manifold. The
crossover pipe is located at the rear of the engine and is routed across the top of the transmissions bell housing.
Diagnosis and Testing
For additional information,

REFER to: Engine - TDV8 3.6L Diesel (303-00 Engine System - General Information, Diagnosis and Testing).
Engine - TDV6 2.7L Diesel - Engine Oil Draining and Filling
General Procedures
Special Tool(s)
Oil filter element remover
303-1128
1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00 Battery
and Charging System - General Information, Specifications).
2. 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.

3. Remove the engine cover.
For additional information, refer to: Engine Cover - TDV6 2.7L
Diesel (501-05 Interior Trim and Ornamentation, Removal and
Installation).
4. CAUTION: When removing the oil filter assembly, make sure

the fuel temperature sensor is not 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.
Remove and discard the O-ring seal.
5. Remove the engine undershield.

For additional information, refer to: Engine Undershield (501-02
Front End Body Panels, Removal and Installation).
6. Remove the lubricant drain plug.
Position a container to collect the fluid.
Discard the oil pan drain plug seal.
7. Install the lubricant drain plug.
Clean the component mating faces.
Install a new sealing washer.
Tighten the drain plug to 25 Nm (18 lb.ft).
8. Install the oil filter element.
Clean the components.
Make sure the oil filter element spigot aligns with the hole in
the filter housing.
Install a new O-ring seal.
Tighten the element cover to 25 Nm (18 lb.ft).
9. Fill the engine with oil.

10. Install the engine undershield.
For additional information, refer to: Engine Undershield (501-02
Front End Body Panels, Removal and Installation).
11. Install the engine cover.
Installation).
12. Connect the battery ground cable.
13. Check and top-up the engine oil.
Engine - TDV6 2.7L Diesel - Camshafts LH
In-vehicle Repair
Special Tool(s)
Camshaft pulley holding tool
303-1145/1
Camshaft pulley bolt remover
303-1145/2
Camshaft pulley bolt socket
303-1145/3
Installer - Camshaft Oil Seal
303-1119
Materials
Name Specification
Loctite 242 ESK-M4G247-A1
Removal
For additional information, refer to: Specifications (414-00 Battery and
Charging System - General Information, Specifications).
2. Remove the camshaft front seal.
For additional information, refer to: Camshaft Front Seal (303-01C Engine
- TDV6 2.7L Diesel, In-vehicle Repair).
3. Remove the LH valve cover.
For additional information, refer to: Valve Cover LH (303-01C Engine -
TDV6 2.7L Diesel, In-vehicle Repair).
4. Remove the fuel injection pump belt.
For additional information, refer to: Fuel Injection Pump Belt (303-05C
Accessory Drive - TDV6 2.7L Diesel, Removal and Installation).
5. Install the special tool to the camshaft rear pulley.
Rotate the crankshaft to align the special tool to the engine lifting
bracket.
Install the special tool retaining bolt.
6. Install the special tool to the camshaft rear pulley retaining bolt.
7. Using the special tools, remove and discard the camshaft rear pulley
retaining bolt.
Rotate the crankshaft clockwise to retain the camshaft rear pulley.
8. Remove the special tools.

9. Remove the camshaft rear pulley.
10. Remove the fuel injection pump belt rear cover.
Remove the fuel injection pump belt rear cover retaining bolt.
11. Retain the secondary timing chain tensioner piston.
Reposition the secondary timing chain tensioner.
Install a 1.5 mm (0.060 in.) diameter pin into the secondary timing
chain tensioner piston.
12. CAUTION: Evenly and progressively, release the camshaft bearing

caps.
Remove the camshaft bearing caps.
Remove the 18 retaining bolts.
13. Remove the camshafts and secondary timing chain tensioner assembly.
Remove the two retaining bolts.
Release the LH secondary timing chain tensioner.

14. Remove the secondary timing chain tensioner.
15. Remove the LH camshafts.
Release the secondary timing chain from the LH camshafts.
Remove and discard the LH camshaft rear seal.
Installation
1. Install the secondary timing chain onto the camshafts.
2. CAUTION: Do not release the secondary timing chain tensioner

locking pin until all of the camshaft bearing caps have been installed.
Install the secondary timing chain tensioner.
Align the marks on the camshafts with the marks on the secondary
timing chain.
3. Install the camshafts and secondary timing chain tensioner assembly.
Lubricate the journals and camshaft lobes.
4. Attach the LH secondary timing chain tensioner.
Tighten the two retaining bolts to 10 Nm (7 lb.ft).

5. Install the camshaft bearing caps.
Do not install the two exhaust camshaft end bearing caps at this
stage.
Tighten the bolts evenly in three stages in the sequence shown.
Stage one: Tighten to 1 Nm (1 lb.ft).
Stage two: Tighten to 5 Nm (4 lb.ft).
Stage three: Tighten to 10 Nm (7 lb.ft).

6. Apply sealant
to the two
exhaust
camshaft end
bearing caps
at the
positions
shown.
For additional
information,
refer to:
Specifications
(303-01C
Engine - TDV6
2.7L Diesel,
Specifications).
7. Install the exhaust camshaft end bearing caps.
Tighten the bolts evenly in three stages in the sequence shown.
8. Release the secondary timing chain tensioner piston.
Remove the locking pin.
9. Install the fuel injection pump belt rear cover.
Install the fuel injection pump belt rear cover retaining bolt.
10. Using the special tool, install the new camshaft rear seal.
11. Install the camshaft rear pulley.
Apply loctite 242 to the new camshaft pulley bolt.
Install a new camshaft pulley retaining bolt.

14. CAUTION: Make sure the torque wrench setting procedure is

followed correctly. Failure to follow this instruction may result in damage to
the vehicle.
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.

the vehicle.
Using the special tools, tighten the camshaft rear pulley retaining bolt to
40 Nm (30 lb.ft).

the vehicle.
Using the special tools, tighten the camshaft rear pulley bolt a further 75
Nm (56 lb.ft).
Rotate the crankshaft counter-clockwise to retain the camshaft rear

pulley.

18. Install the fuel injection pump belt.
For additional information, refer to: Fuel Injection Pump Belt (303-05C
19. Install the LH valve cover.
For additional information, refer to: Valve Cover LH (303-01C Engine -
20. Install the camshaft front seal.
For additional information, refer to: Camshaft Front Seal (303-01C Engine
- TDV6 2.7L Diesel, In-vehicle Repair).
For additional information, refer to: Specifications (414-00 Battery and
Charging System - General Information, Specifications).
Engine - TDV6 2.7L Diesel - Camshaft RH
In-vehicle Repair
Removal
2. Remove the camshaft front seal.
For additional information, refer to: Camshaft Front Seal (303-01C
Engine - TDV6 2.7L Diesel, In-vehicle Repair).
3. Remove the brake vacuum pump.
For additional information, refer to: Brake Vacuum Pump - TDV6
2.7L Diesel (206-07 Power Brake Actuation, Removal and
Installation).
4. Remove the RH valve cover.
For additional information, refer to: Valve Cover RH (303-01C
5. Retain the secondary timing chain tensioner piston.
Install a 1.5 mm (0.060 in.) diameter pin into the secondary

timing chain tensioner piston.
6. CAUTION: Evenly and progressively, release the camshaft

bearing caps.
Remove the camshaft bearing caps.
Remove the 18 retaining bolts.

7. Remove the camshafts and secondary timing chain tensioner
assembly.
Release the RH secondary timing chain tensioner.
8. Remove the secondary timing chain tensioner.
9. Remove the RH camshafts.
Release the secondary timing chain from the RH camshafts.
Installation
1. Install the secondary timing chain onto the camshafts.
2. CAUTION: Do not release the secondary timing chain
tensioner locking pin until all of the camshaft bearing caps have
been installed.
Install the secondary timing chain tensioner.
Align the marks on the camshafts with the marks on the

secondary timing chain.
3. Install the camshafts and secondary timing chain tensioner

assembly.
4. Attach the RH secondary timing chain tensioner.
Do not install the two exhaust camshaft end bearing caps at

this stage.
Tighten the bolts evenly in three stages in the sequence

shown.

6. Apply sealant to the two exhaust camshaft end bearing caps at
the positions shown.
For additional information, refer to: Specifications (303-01C
Engine - TDV6 2.7L Diesel, Specifications).
Tighten the bolts evenly in three stages in the sequence

shown.
8. Release the secondary timing chain tensioner piston.
9. Install the RH valve cover.

For additional information, refer to: Valve Cover RH (303-01C
10. Install the brake vacuum pump.
For additional information, refer to: Brake Vacuum Pump - TDV6
2.7L Diesel (206-07 Power Brake Actuation, Removal and
Installation).
11. Install the camshaft front seal.
For additional information, refer to: Camshaft Front Seal (303-01C
Published: 13-Jul-2011
Engine - TDV6 2.7L Diesel - Camshaft Rear Seal
In-vehicle Repair
Special Tool(s)
Camshaft Seal Remover
303-1118
Camshaft Seal Installer
303-1119
303-1145/1
Camshaft pulley bolt remover
303-1145/2
Camshaft pulley bolt socket
303-1145/3
Removal
2. Remove the fuel injection pump belt.
For additional information, refer to: Fuel Injection Pump Belt
(303-05C Accessory Drive - TDV6 2.7L Diesel, Removal and
Installation).
Rotate the crankshaft to align the special tool to the engine

lifting bracket.
5. Using the special tools, remove and discard the camshaft rear
pulley retaining bolt.
Rotate the crankshaft clockwise to retain the camshaft rear

pulley.

8. Install the special tool to the camshaft.
9. 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.
Install the special tool into the camshaft rear seal.

Install the special tool into the camshaft rear seal.
11. Using the special tool, remove and discard the camshaft rear
seal.
Installation
1. Using the special tool, install the new camshaft rear seal.
Install a new camshaft pulley retaining bolt.
followed correctly. Failure to follow this instruction may result in
damage to the vehicle.
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.

Using the special tools, tighten the camshaft rear pulley retaining
bolt to 40 Nm (30 lb.ft).

Rotate the crankshaft counter-clockwise to retain the

camshaft rear pulley.
Stage two: Tighten a further 80 degrees.
9. CAUTION: Install a new fuel injection pump belt. Failure to

follow this instruction may result in damage to the vehicle.
Install the fuel injection pump belt.

For additional information, refer to: Fuel Injection Pump Belt
(303-05C Accessory Drive - TDV6 2.7L Diesel, Removal and
Installation).
Published: 13-Jul-2011
Engine - TDV6 2.7L Diesel - Camshaft Front Seal
In-vehicle Repair
Special Tool(s)
Holder - Camshaft Pulleys Front
303-1124
Installer - Camshaft Oil Seal
303-1119
Remover - Camshaft Oil Seal
303-1118
Timing Pin - Camshaft Pulleys
303-1126
Removal
2. Raise and support the vehicle.
3. Remove and discard the timing belt.
For additional information, refer to: Timing Belt (303-01C Engine -
4. Remove the special tool.
Stage one: Retain the camshaft pulley.
Stage two: Remove the special tool.
5. Remove the camshaft pulley.
Remove the three retaining bolts.
6. Using the special tool, remove the camshaft pulley hub.
Remove and discard the retaining bolt.
7. Install the special tool to the camshaft.

Install the special tool into the camshaft front seal.
9. Install the special tool extracting bolt.
10. Install the special tool into the camshaft front seal.
11. Using the special tool, remove the camshaft front seal.
Installation
1. CAUTIONS:
Make sure the seal is installed correctly.
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.
Using the special tool, install the camshaft front seal.
Use the discarded camshaft pulley hub retaining bolt with the
special tool.
2. Using the special tool, install the camshaft pulley hub.
Install a new retaining bolt.
Tighten the retaining bolt in two stages:
3. Install the camshaft pulley.
Install the bolts, but do not tighten fully at this stage.
4. Install the special tool.
Stage one: Retain the camshaft pulley.
Stage two: Install the special tool.
5. Install the new timing belt.

Engine - TDV6 2.7L Diesel - Crankshaft Front Seal
In-vehicle Repair
Special Tool(s)
Locking Tool - Flywheel
303-1123
Timing Pin - Manual Transmission
303-1116
Timing Pin - Automatic Transmission
303-1117
Crankshaft Front Seal Remover
303-1120
Crankshaft Front Seal Sleeve
303-1122
Crankshaft Front Seal Installer
303-1121
Removal
All vehicles

Vehicles with automatic transmission

Vehicles with manual transmission

All vehicles
7. Loosen the crankshaft pulley retaining bolt.
8. Using a suitable tool, release the crankshaft pulley.
9. Remove the crankshaft pulley.
Remove the crankshaft pulley retaining bolt.
Discard the bolt.
10. Install the special tool to the crankshaft.
11. Using the special tool, remove the crankshaft front seal.
Remove the special tool.
Remove and discard the seal from the special tool.
Installation
All vehicles
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.
Install a new crankshaft front seal to the special tool.
2. Reposition the crankshaft front seal along the special tool.
Remove the sleeve from the special tool.

5. CAUTION: Make sure the seal is installed correctly.
Using the special tool, install the crankshaft front seal.
Use the discarded crankshaft bolt with the service tool.
6. CAUTION: Make sure the seal is installed correctly.
Remove and discard the crankshaft pulley retaining bolt.
7. Install the crankshaft pulley.
Install a new crankshaft pulley retaining bolt.
Tighten the retaining bolt in two stages:


All vehicles
11. Install the new timing belt.
Engine - TDV6 2.7L Diesel - Cylinder Head LH
In-vehicle Repair
Removal
2. Remove the LH bank camshafts.
3. Remove the LH exhaust manifold.
For additional information, refer to: Exhaust Manifold LH (303-01C
4. Disconnect the LH glow plug wiring harness electrical connector.
5. Remove the cylinder head coolant outlet connector.
6. Remove the hydraulic adjuster and rocker assemblies.

7. CAUTIONS:
Only use a plastic scraper to clean off the old gasket.
The cylinder head must not be placed mating face down.

Failure to follow this instruction may result in damage to the vehicle.
Remove the LH cylinder head assembly.
Remove and discard the eight cylinder head bolts.
Remove and discard the cylinder head gasket.
Installation
1. Clean the component mating faces.
2. Check cylinder head face for distortion, across the center and from
corner to corner.
3. NOTE: The cylinder head gasket must be installed over the
cylinder head to cylinder block dowels.
Install a new cylinder head gasket.
4. CAUTION: Use care when installing the cylinder head.

Damage to the cylinder block, cylinder head or cylinder head gasket
may result.
• NOTE: Install a new cylinder head gasket.
• NOTE: The cylinder head gasket must be installed over the

cylinder head to cylinder block dowels.
• NOTE: Make sure the cylinder head is installed in its original

position.
• NOTE: Tighten the retaining bolts in the indicated sequence in four

stages.
Install the LH cylinder head assembly and install new cylinder

head retaining bolts.
Stage four: Tighten a further 180 degrees.
5. Install the hydraulic adjuster and rocker assemblies.

6. Connect the LH glow plug wiring harness electrical connector.
7. NOTE: Install new O-ring seals.
Install the cylinder head coolant outlet connector.
Install the four retaining bolts and tighten to 10 Nm (7 lb.ft).
8. Install the LH exhaust manifold.

For additional information, refer to: Exhaust Manifold LH (303-01C
9. Install the LH bank camshafts.
Engine - TDV6 2.7L Diesel - Cylinder Head RH
In-vehicle Repair
Removal
2. Remove the RH exhaust manifold.
For additional information, refer to: Exhaust Manifold RH (303-01C
3. Remove the RH camshafts.


5. Release the engine breather tube.
Remove the retaining bolt.
6. Release the coolant bleed hose.
Release the retaining clip.

7. 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.
8. Remove the hydraulic adjuster and rocker assemblies.
9. CAUTIONS:

Remove the RH cylinder head assembly.
Remove and discard the eight cylinder head bolts.
Remove and discard the cylinder head gasket.
Installation
1. Clean the component mating faces.
2. Check cylinder head face for distortion, across the center and from
corner to corner.
For additional information, refer to: Specifications (303-01C
Engine - TDV6 2.7L Diesel, Specifications).
3. CAUTION: The head gasket must be installed over the

cylinder block dowels.
Install a new cylinder head gasket.

4. NOTE: Tighten the retaining bolts in the indicated sequence in
four stages.
Install the RH cylinder head assembly
Install new cylinder head retaining bolts.
Tighten the bolts evenly in four stages to the sequence

shown.
Stage four: Tighten a further 180 degrees.
5. Install the hydraulic adjuster and rocker assemblies.

6. Install the cylinder head coolant outlet elbow.
Install new O-ring seals.
Connect the hoses and secure with the clips.
7. Secure the coolant bleed hose.

8. Secure the engine breather tube.
Tighten the bolt to 10 Nm (7 lb.ft).
9. Install the RH camshafts.

10. Install the RH exhaust manifold.
For additional information, refer to: Exhaust Manifold RH (303-01C
Engine - TDV6 2.7L Diesel - Valve Cover LH
In-vehicle Repair
Removal
• WARNINGS:
Wait at least 30 seconds after the engine stops before commencing any repair to the high-pressure fuel injection system.
Failure to follow this instruction may result in personal injury.
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 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.
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.
• CAUTIONS:
Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign
matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in
later malfunction.
Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to
follow this instruction may result in foreign matter ingress to the fuel injection system.
Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that
absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines.
Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

2. Remove the intake air shutoff throttle.
For additional information, refer to: Intake Air Shutoff Throttle
(303-04C Fuel Charging and Controls - TDV6 2.7L Diesel, Removal
and Installation).
3. Remove the accessory drive belt.
For additional information, refer to: Accessory Drive Belt (303-05C
4. Remove the accessory drive belt idler pulley.

5. Release the knock sensor (KS) harness from the valve cover.
6. Disconnect the KS electrical connector.
7. Release the glow plug harness from the valve cover.
8. Disconnect the engine oil pressure (EOP) sensor electrical

connector.
9. Disconnect the valve cover breather hose.
10. Remove the fuel injector.

For additional information, refer to: Fuel Injector (303-04C Fuel
Charging and Controls - TDV6 2.7L Diesel, Removal and
Installation).
11. Remove the 2 remaining fuel injectors.
12. Release the high-pressure fuel supply line.
13. CAUTION: Make sure that the high-pressure fuel supply

line remains in contact with the fuel injection supply manifold and
the 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.
Remove and discard the high-pressure fuel supply line.
Install blanking caps to the exposed ports.
14. Remove the fuel injection supply manifold.

15. Remove the fuel injection supply manifold securing bracket.
Release the dipstick tube.
16. Remove the engine cover locating studs.
17. Release the timing belt cover.
Reposition the timing cover to access the two front valve

cover retaining bolts.
Fully loosen the seven timing belt cover retaining bolts

shown.
Loosen the 13 valve cover retaining bolts.

Installation
1. Install the LH valve cover.
Tighten the 13 retaining bolts to 10 Nm (7 lb.ft).
2. Attach the timing belt cover.
Tighten the seven retaining bolts to 10 Nm (7 lb.ft).
3. Install the engine cover locating studs.

4. Install the fuel injection supply manifold securing bracket.
Install the two retaining bolts.
Tighten the bolts to 23 Nm (17 lb.ft).
Secure the dipstick tube.
5. Install the fuel injection supply manifold.
Install the two bolts, but do not fully tighten at this stage.
6. Install a 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.
Tighten the fuel injection supply manifold retaining bolts to

23 Nm (17 lb.ft).
Tighten the fuel injection supply line unions in the sequence

shown in four stages:
Stage 1: Tighten the high-pressure fuel supply line union at

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

the fuel injection supply manifold to 15 Nm (11 lb.ft).


7. Secure the high-pressure fuel supply line.
Tighten the retaining bolt to 10 Nm (7 lb.ft).
8. Install the fuel injector.

Installation).
9. Install the 2 remaining fuel injectors.
10. Connect the valve cover breather hose.
11. Connect the EOP sensor electrical connector.
12. Connect the KS electrical connector.
13. Attach the glow plug harness and KS harness to the valve cover.
14. Install the accessory drive belt idler pulley.
Install the retaining bolt and tighten to 47 Nm (35 lb.ft).
15. Install the accessory drive belt.

For additional information, refer to: Accessory Drive Belt (303-05C
16. Install the intake air shutoff throttle.
and Installation).
Engine - TDV6 2.7L Diesel - Valve Cover RH
In-vehicle Repair
Removal
• WARNINGS:
• CAUTIONS:
later malfunction.
Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to
follow this instruction may result in foreign matter ingress to the fuel injection system.

and Installation).
3. Release the glow plug harness from the valve cover.
4. Release the knock sensor (KS) harness from the valve cover.
5. Disconnect the KS electrical connector.
6. Disconnect the valve cover breather hose.

Installation).
8. Remove the remaining fuel injectors.
9. Release the high-pressure fuel supply line.
10. CAUTION: Make sure that the high-pressure fuel supply

line remains in contact with the fuel injection supply manifold and
the 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.
Remove and discard the high-pressure fuel supply line.
Install blanking caps to the exposed ports.
11. Remove the fuel injection supply manifold.
12. Detach the fuel lines.

13. Remove the fuel line securing bracket.
14. Remove the fuel injection supply manifold securing bracket.
15. Remove the engine cover locating studs.
Fully loosen the 14 valve cover retaining bolts.

Installation
1. Install the RH valve cover.
Tighten the 14 retaining bolts to 10 Nm (7 lb.ft).
2. Install the engine cover locating studs.

3. Install the fuel injection supply manifold securing bracket.
4. Install the fuel line retaining bracket.
Tighten to 10 Nm (7 lb.ft).
5. Attach the fuel lines to the retaining bracket.

6. Install the fuel injection supply manifold.
Install the two bolts, but do not fully tighten at this stage.
7. Install a new high-pressure fuel supply line.
Remove the blanking caps from the ports.
Loosely install the new high-pressure fuel supply line.
Tighten the fuel injection supply manifold retaining bolts to

23 Nm (17 lb.ft).
Tighten the fuel injection supply line unions in the sequence

shown in four stages:




8. Secure the high-pressure fuel supply line.

Installation).
10. Install the remaining fuel injectors.
11. Connect the valve cover breather hose.
12. Connect the KS electrical connector.
13. Attach the glow plug harness and KS harness to the valve cover.
14. Install the intake air shutoff throttle.
and Installation).
Engine - TDV6 2.7L Diesel - Engine Mount LH
In-vehicle Repair
Removal


3. Remove the turbocharger.
For additional information, refer to: Turbocharger (303-04E Fuel
Charging and Controls - Turbocharger - TDV6 2.7L Diesel,
Removal and Installation).
4. CAUTION: Protect the engine during this operation.
Support the engine.
Raise the engine clear of its LH mount.
5. Remove the engine mount.
Remove the retaining nut.
Raise the engine clear of its LH mount.
Remove and discard the two retaining bolts.
Installation
1. Install the engine mount.
Install new retaining bolts.
Tighten the bolts to 45 Nm (33 lb.ft), then a further 60

degrees.
Lower the engine onto the mount.

3. Install the engine mount retaining nut.
Tighten the nut to 90 Nm (66 lb.ft).
4. Install the turbocharger.

Engine - TDV6 2.7L Diesel - Engine Mount RH
In-vehicle Repair
Removal


3. Remove the generator.
For additional information, refer to: Generator (414-02, Removal
and Installation).
4. Disconnect the ground cable.
Remove the ground cable retaining bolt.
5. Remove the engine mount bracket.
Remove the nut.
Detach the engine mounting bracket.
Support the engine.

7. Remove the engine mount.
Remove and discard the two retaining bolts.
Installation
1. Install the engine mount.
Install new retaining bolts.
Tighten the two new bolts to 45 Nm (33 lb.ft), then a further

60 degrees.
2. Install the engine mount bracket.
Tighten the four retaining bolts to 80 Nm (59 lb.ft).
3. Attach the engine mounting bracket.
Lower the engine onto its mount.
4. Connect the ground cable.
Install the retaining bolt.
5. Install the generator.

and Installation).
Engine - TDV6 2.7L Diesel - Flexplate
In-vehicle Repair
Special Tool(s)
Flex plate locking tool (LRT-12-145)
303-947
Removal


3. Remove the transmission.
For additional information, refer to: Transmission (307-01C
Automatic Transmission/Transaxle - TDV6 2.7L Diesel, Removal
and Installation).
4. Remove the torque converter flexplate.
Using the special tool, lock the flexplate.
Remove the 8 Torx bolts.
Installation
1. CAUTION: Tighten the bolts in a diagonal sequence.
Install the torque converter flexplate.
Tighten the Torx bolts progressively in 3 stages.
Tighten the Torx bolts to 50 Nm (37 lb.ft).
Tighten the Torx bolts by 45 degrees.
Tighten the Torx bolts by a further 45 degrees.
2. Install the transmission.

For additional information, refer to: Transmission (307-01C
Automatic Transmission/Transaxle - TDV6 2.7L Diesel, Removal
and Installation).
Engine - TDV6 2.7L Diesel - Oil Pump
In-vehicle Repair
Removal
and Installation).
3. Remove the accessory drive belt tensioner.
Remove the LH retaining bolt.
4. Remove the oil pan extension.

5. Remove the crankshaft front oil seal.
For additional information, refer to: Crankshaft Front Seal
(303-01C Engine - TDV6 2.7L Diesel, In-vehicle Repair).
6. Remove the generator mounting bracket.
Remove the five retaining bolts.
7. Remove the timing belt idler pulley.
Remove the LH retaining bolt.


9. Release the battery positive cable.
10. Remove the oil pump lower retaining bolts.
11. Remove the oil pump.
Remove the ten retaining bolts.
Remove the timing belt cover sealing strips.
Remove and discard the gasket.
Installation
1. Prime the oil pump.
Fill the orifice shown with 20 ml of engine oil.
Rotate the oil pump drive 2 complete turns.

2. CAUTIONS:
Make sure that the mating faces are clean and free of foreign
material.
Make sure the gasket is installed correctly.
Install the oil pump.
Install a new gasket.
Lightly tighten the bolts in the position shown.
3. CAUTION: Make sure the base of the oil pump is aligned

within 0.2 mm of the base of the engine block. Failure to follow this
instruction may result in damage to the vehicle.
• NOTE: Vehicles fitted with oil pumps without dowels.
Check the oil pump to engine block alignment.

4. Secure the oil pump.
Tighten the bolts in the sequence shown to 10 Nm .
5. Install the oil pump lower retaining bolts.
Tighten the 4 bolts to 10 Nm (7 lb.ft).
6. Install the battery positive cable.
7. Install the timing belt idler pulley.
8. Install the crankshaft front oil seal.

For additional information, refer to: Crankshaft Front Seal
(303-01C Engine - TDV6 2.7L Diesel, In-vehicle Repair).
9. Install the oil pan extension.
10. Install the generator mounting bracket.
11. Install the accessory drive belt tensioner.
12. Install the generator.

and Installation).
Engine - TDV6 2.7L Diesel - Oil Pressure Switch
In-vehicle Repair
1. Refer to Engine Oil Pressure (EOP) Sensor.

For additional information, refer to: Engine Oil Pressure (EOP)
Sensor (303-14C Electronic Engine Controls - TDV6 2.7L Diesel,
Engine - TDV6 2.7L Diesel - Oil Cooler
In-vehicle Repair
Removal
• WARNINGS:
• CAUTIONS:
Before disconnecting or removing components, ensure the area around the joint faces and connections are clean. Plug open
connections to prevent contamination.
later malfunction.

2. Drain the cooling system.
For additional information, refer to: Cooling System Draining,
Filling and Bleeding (303-03C Engine Cooling - TDV6 2.7L Diesel,
General Procedures).
3. Remove the crankcase vent oil separator.
For additional information, refer to: Crankcase Vent Oil Separator
(303-08C Engine Emission Control - TDV6 2.7L Diesel, Removal
and Installation).
4. Release the coolant bleed hose from the LH exhaust gas
recirculation (EGR) coolant inlet hose.
5. Remove the cylinder head coolant elbow.
Release the two retaining clips and disconnect the hoses.
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.

8. NOTE: Some fluid spillage is inevitable during this operation.
Remove the oil cooler.
Remove the eight retaining bolts.
Installation
1. CAUTION: Make sure the gasket is installed correctly.
• NOTE: Make sure all component mating faces are clean.
Install the oil cooler.
Install the eight retaining bolts and tighten to 10 Nm (7 lb.ft).
2. Install the LH KS.
Connect the knock sensor electrical connector.
Attach the KS harness to the valve cover.
3. Install the cylinder head coolant outlet elbow.
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
(303-08C Engine Emission Control - TDV6 2.7L Diesel, Removal
and Installation).
7. Refill and bleed the cooling system.
Engine - TDV6 2.7L Diesel - Timing Belt Cover
In-vehicle Repair
Removal
Installation).
3. Release the intake air shutoff throttle elbow.
4. Release the intake air shutoff throttle elbow.
Disconnect the electrical connector.
5. Remove the intake air shutoff throttle elbow support bracket.
6. Remove the fan cowl.

For additional information, refer to: Cooling Fan Shroud (303-03C
Engine Cooling - TDV6 2.7L Diesel, Removal and Installation).
7. Remove the crankshaft damper.
Remove the six retaining bolts.


10. Disconnect the coolant hose from the cylinder head coolant
outlet elbow.
Release the coolant hose retaining clip.
Reposition the coolant top hose.
11. Remove the accessory drive belt idler.

12. NOTE: Right-hand shown, left-hand similar.
Release the exhaust gas recirculation (EGR) valve outlet tube

clamps from the timing cover.
13. Disconnect the right-hand EGR coolant inlet hose from the EGR
cooler.
Release the coolant hose retaining clip.
14. Position the EGR coolant hose aside for access.

15. Remove the coolant pump and accessory drive belt idler pulleys.
Remove the six retaining bolts.
16. Remove the timing belt cover.
Fully loosen the 16 timing belt cover retaining bolts.
Release the 2 wiring harness clips.

Installation
1. Install the timing belt cover.
Attach the 2 wiring harness clips.
Tighten the 16 timing belt cover retaining bolts to 10 Nm (7

lb.ft).
2. Install the coolant pump and accessory drive belt idler pulleys.
Tighten the six retaining bolts to 23 Nm (17 lb.ft).
3. Connect the right-hand EGR coolant inlet hose to the EGR cooler.
Install the coolant hose retaining clip.
4. Secure the EGR valve outlet tube clamps to the timing cover.
5. Connect the coolant hose to the cylinder head coolant outlet

elbow.
Install the retaining clip.
6. Install the accessory drive belt idler.
7. Install the crankshaft damper.
Tighten the six retaining bolts to 23 Nm (17 lb.ft).
8. Install the fan cowl.

9. Install the intake air shutoff throttle elbow support bracket.
Install the three retaining bolts and tighten to 10 Nm (7

lb.ft).
10. Secure the intake air shutoff throttle elbow.
Install the retaining clip.
Install the retaining bolt.
Connect the electrical connector.

Installation).
Engine - TDV6 2.7L Diesel - Timing Belt
In-vehicle Repair
Special Tool(s)
Check Pin - Camshaft Pulleys
303-1132
303-1126
303-1117
Timing Pin - Manual Transmission
303-1116
Removal
All vehicles
For additional information, refer to: Timing Belt Cover (303-01C


4. Remove the starter motor.
For additional information, refer to: Starter Motor (303-06C
Starting System - TDV6 2.7L Diesel, Removal and Installation).
5. Remove the crankshaft timing alignment grommet from the
engine block.
6. Rotate the crankshaft clockwise to align the crankshaft alignment
hole in the flywheel or flexplate with the block aperture.
7. Check the camshaft pulley alignment holes are correctly
aligned. If the alignment holes are not aligned, rotate the
crankshaft one full turn clockwise.

8. Using the special tool, lock the flexplate.
Install a starter motor bolt to retain the special tool.

9. Using the special tool, lock the flywheel.

10. Install the special tools to the exhaust camshaft pulleys.
11. 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.
Loosen the six exhaust camshaft pulley damper retaining bolts.
Using a suitable tool, counterhold the camshaft pulley center

retaining bolts.
12. Remove and discard the timing belt tensioner.
Remove and discard the bolt.

Installation
All vehicles
1. Rotate both camshaft pulleys clockwise.
2. Install a new timing belt tensioner.
Install a new bolt, but do not fully tighten at this stage.
3. CAUTION: Make sure the camshaft pulleys remain in the

clockwise position.
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.
4. CAUTION: Make sure the timing belt tensioner window is

aligned with the groove.
Tension the timing belt.
Rotate the tensioner assembly counterclockwise.
Tighten to 24 Nm (18 lb.ft).

Using a suitable tool, counterhold the camshaft pulley center

retaining bolts.
Tighten the six exhaust camshaft pulley damper retaining

bolts.
6. Remove the special tools from the camshaft pulleys.

7. Remove the special tool from the flywheel.

8. Remove the special tool from the flexplate.
All vehicles
9. Rotate the engine two complete turns clockwise.

10. Using the special tool, lock the flywheel.

If the special tool does not fit correctly, repeat the timing
belt installation procedure.
Remove the special tools from the camshaft pulleys.

13. Remove the special tool from the flywheel.
Install the grommet.

Install the grommet.
All vehicles
15. Install the starter motor.
For additional information, refer to: Starter Motor (303-06C
Starting System - TDV6 2.7L Diesel, Removal and Installation).
For additional information, refer to: Timing Belt Cover (303-01C
Engine - TDV6 2.7L Diesel - Exhaust Manifold LH
In-vehicle Repair
Removal
2. Remove the turbocharger.
4. Remove the battery tray.
For additional information, refer to: Battery Tray (414-01 Battery,
Mounting and Cables, Removal and Installation).
5. Remove the LH EGR valve outlet tube.
For additional information, refer to: Exhaust Gas Recirculation
(EGR) Valve Outlet Tube (303-08C Engine Emission Control - TDV6
2.7L Diesel, Removal and Installation).
6. Disconnect the coolant outlet hose from the LH EGR valve.
Release the clip.
7. Release the LH EGR valve inlet tube.
Remove the two support bracket retaining bolts.
Remove the support bracket.
Remove and discard the retaining clip.

8. Remove the LH EGR valve inlet tube.
9. Disconnect the LH EGR valve electrical connector.
10. Disconnect the coolant inlet hose from the LH EGR valve.
Release the clip.
11. Remove the LH EGR valve.

12. Remove the LH exhaust manifold heat shield.
13. Remove the three exhaust cross-over pipe retaining nuts.
14. Remove the LH exhaust manifold.
Remove the six retaining nuts.
15. Remove and discard the LH exhaust manifold gasket.
Remove and discard the studs.

Installation
1. Tighten the LH exhaust manifold retaining studs to 13 Nm (10
lb.ft).
2. NOTE: Tighten the retaining nuts in the sequence shown.
Install the LH exhaust manifold.
Tighten the nuts to 24 Nm (18 lb.ft).
3. Install the three exhaust cross-over pipe retaining nuts.
4. Install the LH exhaust manifold heat shield.
Install the two retaining bolts and tighten to 10 Nm (7 lb.ft).
5. Install the LH EGR valve.
Install the three EGR valve retaining bolts, but do not fully
tighten at this stage.
6. NOTE: Do not fully close the retaining clip at this stage.
Install the LH EGR valve inlet tube.
Install a new retaining clip.
Loosely install the two EGR valve inlet tube retaining bolts.
7. Fully close the retaining clip.

8. Tighten the two EGR valve inlet tube retaining bolts to 10 Nm (7
lb.ft).
9. Tighten the three EGR valve retaining bolts to 10 Nm (7 lb.ft).
10. Install the support bracket.
11. Connect the coolant inlet hose to the LH EGR valve.

12. Connect the LH EGR valve electrical connector.
13. Connect the coolant outlet hose to the LH EGR valve.
14. Install the LH EGR valve outlet tube.
15. Install the battery tray.
For additional information, refer to: Battery Tray (414-01 Battery,
Mounting and Cables, Removal and Installation).
16. Install the turbocharger.
Engine - TDV6 2.7L Diesel - Exhaust Manifold RH
In-vehicle Repair
Removal


4. Remove the auxiliary battery tray.
For additional information, refer to: Auxiliary Battery Tray (414-01
Battery, Mounting and Cables, Removal and Installation).
5. Remove the RH exhaust gas recirculation (EGR) valve outlet tube.
6. Remove the fuel line bracket.
Release the fuel lines.
Remove the bolt.
7. Disconnect the EGR valve electrical connector.

8. Disconnect the coolant inlet hose from the EGR valve.
Release the clip.
9. Disconnect the coolant outlet hose from the EGR valve.
Remove the bolt.
Release the clip.
10. Remove the EGR valve inlet tube.
Release the clip.
Remove the 2 bolts.
Remove and discard the clip.
11. Remove the RH front wheel and tire.

12. Remove the upper suspension arm and brake line heat shields
for access.
13. Remove the RH EGR valve and cooler assembly.
Remove the 3 bolts.
14. Remove the RH exhaust manifold heat shield.
Remove the 3 bolts.
15. Remove the 2 exhaust cross-over pipe nuts.
16. Remove the remaining exhaust cross-over pipe nut.

17. Remove the RH exhaust manifold.
Remove the 6 nuts.
Remove and discard the studs.
Installation
1. Tighten the exhaust manifold studs to 13 Nm (10 lb.ft).
2. NOTE: Tighten the retaining nuts in the sequence shown.
Install the RH exhaust manifold.
3. Tighten the exhaust cross-over pipe nut to 24 Nm (18 lb.ft).

4. Tighten the 2 exhaust cross-over pipe nuts to 24 Nm (18 lb.ft).
5. Install the RH exhaust manifold heat shield.
Install the bolts and tighten to 10 Nm (7 lb.ft).
6. Install the RH EGR valve and cooler assembly.
Install the EGR valve bolts, but do not fully tighten at this
stage.
7. NOTE: Do not fully close the retaining clip at this stage.
Install the EGR valve inlet tube.
Install a new clip.
Loosely install the 2 EGR valve inlet tube bolts.
8. Fully close the clip.

9. Tighten the two EGR valve inlet tube bolts to 10 Nm (7 lb.ft).
10. Tighten the three EGR valve bolts to 10 Nm (7 lb.ft).
11. Install the upper suspension arm and brake line heat shields.
12. Install the wheel and tire.
13. Tighten the EGR valve bolt to 10 Nm (7 lb.ft).
14. Connect the coolant outlet hose to the EGR valve.
15. Connect the coolant inlet hose to the EGR valve.
16. Connect the EGR valve electrical connector.
17. Install the fuel line bracket.
Install the fuel line retaining bracket bolt and tighten to 10

Nm (7 lb.ft).
Secure the fuel lines.
18. Install the RH EGR valve outlet tube.

19. Install the auxiliary battery tray.
For additional information, refer to: Auxiliary Battery Tray (414-01
Battery, Mounting and Cables, Removal and Installation).
21. Fill and bleed the cooling system.
Engine - TDV6 2.7L Diesel - Oil Pan
In-vehicle Repair
Removal
Installation).


4. Drain the engine oil.
For additional information, refer to: Engine Oil Draining and Filling
(303-01C Engine - TDV6 2.7L Diesel, General Procedures).
5. Remove the oil temperature sensor.
Disconnect the engine oil temperature sensor electrical

connector.
6. Disconnect the engine wiring harness.
Release the engine wiring harness from the retaining bracket.
7. Remove the oil pan.
Remove the 14 oil pan bolts.
Installation
1. Install the oil pan.

Evenly and progressively tighten the bolts to 10 Nm (7 lb.ft).
2. Connect the engine wiring harness.
Attach the engine wiring harness to the retaining bracket.
3. Install the oil temperature sensor.
Tighten the sensor to 10 Nm (7 lb.ft).
4. Fill the engine with oil.

Installation).
Engine - TDV6 2.7L Diesel - Oil Pump Screen and Pickup Tube
In-vehicle Repair
Removal


For additional information, refer to: Oil Pan (303-01C Engine -
4. Remove the oil pump screen and pickup tube.
Remove the bolt.
Remove and discard both O-ring seals.
Clean the seal contact area.
Installation
1. NOTE: Lubricate new seals with clean engine oil.
Install the oil pump screen and pickup tube.
2. Install the oil pan.

For additional information, refer to: Oil Pan (303-01C Engine -
Engine - TDV6 2.7L Diesel - Oil Filter Housing
In-vehicle Repair
1. Refer to oil cooler.

For additional information, refer to: Oil Cooler (303-01C Engine -
Engine - TDV6 2.7L Diesel - Crankshaft Rear Seal with Retainer Plate
In-vehicle Repair
Removal
• NOTE: The crankshaft rear seal and retainer plate are supplied as an assembly and cannot be serviced separately.



3. Remove the CKP sensor ring.
For additional information, refer to: Crankshaft Position (CKP)
Sensor Ring (303-14C Electronic Engine Controls - TDV6 2.7L
Diesel, Removal and Installation).
4. Remove the crankshaft seal retainer plate.
Remove the 14 bolts.
Installation
1. CAUTIONS:
Oil seals must be fitted dry.
Tighten the bolts securing the seal retainer to the cylinder

block first.
Install the crankshaft seal retainer plate.
Install the seal retainer with its protection sleeve onto the
crankshaft.
Locate the seal retainer onto the sump flange.
Engage the seal retainer dowels with the cylinder block and
lightly tighten 2 bolts on opposite sides of the retainer.
Remove the seal protection sleeve.
Install the 8 remaining bolts and tighten all bolts evenly to

10 Nm (7 lb.ft).
2. Install the CKP sensor ring to the crankshaft.

For additional information, refer to: Crankshaft Position (CKP)
Sensor Ring (303-14C Electronic Engine Controls - TDV6 2.7L
Diesel, Removal and Installation).
Removal
Special Tool(s)
Engine lifting cradle
303-1141
Removal


3. Remove the wheels and tires.
4. Remove the body.
For additional information, refer to: Body - TDV6 2.7L Diesel
(502-02 Full Frame and Body Mounting, Removal and Installation).
5. Remove the cooling fan shroud.
and Installation).
7. Remove the intake air shutoff throttle elbow support bracket.
Remove the 3 bolts.

8. Disconnect the upper coolant hose from the coolant distribution
manifold.
Remove the clip.
9. Disconnect the RH exhaust gas recirculation (EGR) coolant hose.
Release the clip.
10. Remove the accessory drive belt.
Rotate the accessory drive belt tensioner counter-clockwise.
11. Remove the 2 LH upper suspension arm and brake line heat
shields.
Remove the 2 nuts.
Remove the 3 bolts.

12. Disconnect the breather hose.
Release the clip.
13. Release the charge air cooler inlet pipe.
Remove the 2 nuts.
Remove the bolt.
14. CAUTION: Make sure that all openings are sealed. Use new
blanking caps.
Disconnect the air conditioning (A/C) compressor low-pressure

line.
Remove the bolt.
15. Disconnect the charge air cooler inlet hose.
Loosen the clip.

16. Disconnect the charge air cooler inlet hose.
Loosen the clip.
17. Disconnect the coolant lower hose.
Release the clip.
18. Remove the power steering pump rear bolt.

19. Reposition the power steering pump.
Remove the 3 bolts.
20. Remove the charge air cooler inlet pipe.
21. CAUTIONS:
Immediately cap all refrigerant lines to prevent ingress of dirt

and moisture.
Care must be taken to avoid damage to the mating surfaces.
Disconnect the A/C compressor high-pressure pipe.
Remove the bolt.
22. Reposition the lower coolant hose.

23. Remove the turbocharger intake tube.
Loosen the clip.

24. Release the transmission fluid lines.
Remove the nut.
25. Release the battery positive cable.
Release the clip.
26. Release the exhaust from the turbocharger.
Remove and discard the 3 nuts.
27. Remove the turbocharger support bracket.
Remove the 2 bolts.
Remove the nut.

28. Release the exhaust cross-over pipe bracket.
Remove the 6 bolts.
blanking caps.
Disconnect the 2 fuel lines.
30. Release the 2 fuel lines.
Remove the bolt.
Release from the 2 clips.

31. Release the transmission breather lines.
Remove the bolt.
32. Release and reposition the fuel cooler.
Remove the bolt.
33. Release the engine ground cable.
Remove the bolt.
34. Remove the starter motor support bracket.
Remove the 4 bolts.

35. Disconnect the 2 starter motor wiring harness connectors from
the starter motor solenoid.
Remove the rubber insulator.
Remove the 2 nuts.
36. Remove the starter motor.
Remove the 2 bolts.
37. Release the flexplate.
Remove the access plug.
Remove and discard the 4 bolts.

38. Remove the LH engine mount nut.
39. Remove the RH engine mount nut.
Install and tighten the bolts.

41. Release the transmission from the engine.
42. NOTE: Note the routing of the battery positive cable.
• NOTE: Note the routing of the transmission wiring harness.
With assistance, carefully remove the engine.
Using a suitable hydraulic jack, support the transmission.
Carefully guide the transmission wiring harness out as the

engine is being removed.
Carefully guide the battery positive cable out as the engine is

being removed.
Installation
Special Tool(s)
Engine lifting Cradle
303-1141
Installation
1. CAUTIONS:
Apply grease of the correct specification to the torque

converter spigot.
Make sure the torque converter is fully located into the oil
pump drive.
With assistance, carefully install the engine.
2. CAUTION: Make sure the torque converter remains

connected to the transmission.
Secure the engine to the transmission.
Remove the jack supporting the transmission.
Remove the bolts.
4. Secure both the LH and the RH engine mounts.
Lower the engine onto its mounts.
5. NOTE: Make sure that new bolts are installed.
Secure the flexplate to the torque converter.

Install the access plug.
6. Install the starter motor.
7. Connect the 2 starter motor wiring harness connectors to the

starter motor solenoid.
Tighten the solenoid terminal integral connector nut to 8 Nm

(6 lb.ft).
Tighten the battery positive cable nut to 11 Nm (8 lb.ft).
Install the rubber insulator.
8. Install the starter motor support bracket.
9. Secure the engine ground cable.
10. Secure the fuel cooler.
11. NOTE: Remove and discard the blanking caps.
Connect the low-pressure fuel lines.

12. Secure the fuel lines.
Secure in the clips.
13. Secure the transmission breather lines.
14. Install the turbocharger support bracket.
15. WARNING: Make sure that new nuts are installed.
• NOTE: Make sure that all the component mating faces are clean.
Secure the exhaust to the turbocharger.
16. Install the exhaust manifold crossover pipe center support

bracket.
Loosely install the 2 bolts.
17. Install the exhaust manifold crossover pipe RH support bracket.
18. Install the exhaust manifold crossover pipe LH support bracket.

19. Tighten the exhaust manifold crossover pipe mounting bracket

bolts in the following sequence.
Tighten the 2 bolts marked 1 to 10 Nm (7 lb.ft).
Loosen the 2 bolts by 90 degrees.
Tighten the 2 bolts marked 3 to 10 Nm (7lb.ft).
Loosen the 2 bolts by 90 degrees.
Tighten the 4 bolts maked 2 to 25 Nm (18 lb. ft).
Attach the wiring harness.
20. Secure the battery positive cable.
Secure with the clip.
21. Secure the transmission fluid lines.
22. Install the turbocharger intake tube.
Tighten the clip.
23. Reposition the lower coolant hose.

Connect the A/C compressor high-pressure line.
25. Install the charge air cooler inlet pipe.

26. Position the power steering pump to the power steering pump
bracket.
Loosely install the rear bolt.
27. Secure the power steering pump.
Tighten the 3 front bolts to 22 Nm (16 lb.ft).
Loosen the 3 front bolts by a quarter of a turn.
Tighten the rear bolt to 22 Nm (16 lb.ft).
Tighten the 3 front bolts to 22 Nm (16 lb.ft).
28. Connect the coolant lower hose.
29. Connect the charge air cooler inlet hoses.
Tighten the clips.
Connect the A/C compressor low-pressure pipe.

31. Secure the charge air cooler inlet pipe.
Tighten the bolt to 10 Nm (7 Lb.ft).
32. Connect the breather hose.
33. Install the 2 LH upper suspension arm and brake line heat
shields.
Tighten the bolts to 10 Nm (7 Lb.ft).
34. Install the accessory drive belt.
Rotate the accessory drive belt tensioner counter-clockwise.
35. Connect the RH EGR coolant hose.
36. Connect the upper coolant hose to the coolant distribution

manifold.
Install the clip.
37. Install the intake air shutoff throttle elbow support bracket.
Tighten the bolts to 10 Nm (7 Lb.ft).
38. Install the intake air shut off valve.

and Installation).
39. Install the cooling fan shroud.
40. Install the body.
For additional information, refer to: Body - TDV6 2.7L Diesel
(502-02 Full Frame and Body Mounting, Removal and Installation).
41. Install the wheels and tires.
Tighten the wheel nuts to 140 Nm (103 lb.ft).

Disassembly
Special Tool(s)
303-1117
303-1145/1
303-1124
Flex plate locking tool
303-947
303-1123
Disassembly
All vehicles
For additional information, refer to: Specifications (414-02A
Generator and Regulator - V8 S/C 4.2L Petrol, Specifications).


3. Drain the engine oil.
4. Remove the engine.
For additional information, refer to: Engine (303-01C Engine -
TDV6 2.7L Diesel, Removal).
5. Install the engine to a suitable engine stand.
6. Remove the power steering pump bracket.
Remove the 3 bolts.
7. Remove the air conditioning (A/C) compressor.
Remove the 3 bolts.
8. Remove the A/C compressor bracket.
Remove the 2 bolts.

9. Remove the LH engine mount bracket.
Remove the 4 bolts.
blanking caps.
Remove the oil level indicator and tube.
Release the wiring harness clip.
Remove the bolt.
11. Remove the LH exhaust gas recirculation (EGR) valve and cooler
assembly.
Release the clip and disconnect the coolant hose.
Remove the 5 bolts.
Collect the bracket.

12. Remove the LH exhaust manifold heat shield.
Remove the 2 bolts.
13. Remove the turbocharger heat shield.
Remove the 2 bolts.
blanking caps.
Remove the turbocharger oil return tube.
Remove the 3 bolts.
15. Release the turbocharger support bracket.
Remove the 4 bolts.

blanking caps.
Disconnect the turbocharger oil supply tube.
Remove the banjo bolt.
Remove and discard the 2 sealing washers.
17. Release the exhaust cross-over pipe from the LH exhaust

manifold.
18. Remove the LH exhaust manifold and turbocharger assembly.
19. Remove the cylinder block coolant inlet pipe.
Remove the 2 bolts.

20. Remove the crankshaft position (CKP) sensor.
Reposition the access cover.
Remove the bolt.
21. Remove the RH EGR valve and cooler assembly.
Release the clip and disconnect the coolant hose.
Remove the 4 bolts.
22. Disconnect the generator electrical connectors.
Reposition the rubber insulator.
Remove the nut.
Remove the 3 bolts.

24. Remove the RH exhaust manifold heat shield.
Remove the 3 bolts.
25. Remove the RH engine mount bracket.
Remove the 4 bolts.
26. Remove the generator bracket.
Remove the 5 bolts.
27. Remove the RH exhaust manifold and exhaust cross-over pipe

assembly.

28. Remove the EGR valve coolant pipe.
Remove the bolt.
Release from the 2 clips.
Release the clip.
29. Remove the coolant pump.
Remove the 3 bolts.
30. Remove the accessory drive belt idler pulley.
Remove the bolt.
31. Remove the cooling fan pulley.
Remove the 3 bolts.

32. Remove the crankshaft pulley.
Remove the 6 bolts.
Fully loosen the 16 bolts.
34. NOTE: Note the fitted position.
Remove the 2 low pressure fuel pipes.
Disconnect the 2 quick release connectors.
35. Disconnect the engine oil pressure (EOP) sensor electrical

connector.

36. NOTE: LH shown, RH is similar
Disconnect the 6 fuel injector electrical connectors.
Release the 4 wiring harness clips.
37. Disconnect the camshaft position (CMP) sensor electrical

connector.
38. Disconnect the engine oil temperature sensor electrical

connector.
39. NOTE: LH shown, RH similar.
Disconnect the 2 knock sensor (KS) electrical connectors.

40. Disconnect the fuel temperature sensor electrical connector.
41. Remove the crankcase vent oil separator.
Disconnect and release the 2 breather hoses.
42. Disconnect the fuel rail pressure (FRP) sensor electrical

connector.
43. Disconnect the 2 fuel injection pump electrical connectors.

44. Remove the engine wiring harness.
Remove the nut.
Release the 2 clips.
Vehicles built up to 12/2006
blanking caps.
• NOTE: RH shown, LH is similar
Remove and discard the 2 high-pressure fuel rail supply lines.
blanking caps.
Remove and discard the high-pressure fuel diverter rail supply

line.
Vehicles built 01/2007 onwards

blanking caps.
• NOTE: LH shown, RH is similar
Remove and discard the 2 high-pressure fuel rail supply lines.
Release the clip.
All vehicles
48. CAUTIONS:
Make sure the high-pressure fuel supply line remains in

contact with both the fuel injector and the fuel injection supply
manifold until both unions have been detached and cleaned. Failure
to follow this instruction may result in foreign matter ingress to the
fuel injection system.
Make sure that the fuel injector adaptor union does not move
when loosening the high-pressure fuel supply lines. Failure to follow
this instruction may result in damage to the fuel injector or the fuel
injector adaptor union.
Make sure that all openings are sealed. Use new blanking
caps.
Remove and discard the 6 high-pressure fuel supply lines.
49. Disconnect the fuel return line from the fuel injectors.
Remove and discard the 6 clips.

50. Remove the two fuel injector bolts.
51. Install the special tool studs.
52. CAUTION: Make sure the fuel injector remover legs are
correctly engaged to the fuel injector. Failure to follow this
instruction may result in damage to the component.
Install the special tool remover legs to the studs.
Rotate the special tool bolts evenly, in a clockwise direction.
Remove and discard the fuel injector clamp.
Remove and discard the sealing washer.

54. Remove the remaining fuel injectors.
55. NOTE: LH shown, RH is similar.
Remove the 2 fuel rails.
Remove the 4 bolts.
56. NOTE: RH shown, LH is similar
Remove the 2 fuel rail brackets.
Remove the 4 bolts.
57. Remove the fuel injection pump belt cover.
58. Remove and discard the fuel injection pump belt tensioner.
Remove the bolt.

59. Remove and discard the fuel injection pump belt.
Rotate the crankshaft to align the special tool to the engine

lifting bracket.
Install and tighten the bolt.
61. NOTE: Discard the bolt.
Using the special tool, remove the camshaft rear pulley bolt.
Remove the bolt.

64. Remove the fuel injection pump belt rear cover.
65. Remove the LH engine cover locating studs.
Release the KS electrical connector from the valve cover.
Remove the fuel line support bracket.

67. Remove the RH engine cover locating studs.
Remove the nut.
Remove the bolt.
Remove the bracket.
Release the glow plug electrical connector from the valve

cover.
Release the KS electrical connector from the valve cover.
69. Remove the brake vacuum pump.
Remove the 3 bolts.
Remove the bracket.
70. Remove the breather line.
Remove the bolt.
Release the clip.

71. Remove the turbocharger oil supply line.
Remove the bolt.
Remove and discard the 2 O-ring seals.
72. Remove the cylinder head coolant outlet assembly.
Remove the 4 bolts.
blanking caps.
Disconnect the fuel pipe from the fuel cooler.
blanking caps.
Remove and discard the fuel injector return line.

75. Rotate the crankshaft clockwise to align the crankshaft
alignment hole in the flywheel or flexplate with the cylinder
block aperture.
76. Check the camshaft pulley alignment holes are correctly aligned.
If the alignment holes are not aligned, rotate the crankshaft one
full turn clockwise.

Loosen the 6 exhaust camshaft pulley bolts.

79. Remove and discard the timing belt tensioner.
Remove the bolt.
80. Remove the 2 timing belt idler pulley's.
Remove the 2 bolts.
Collect the plastic shield from behind the upper idler pulley.

Remove the 2 camshaft pulleys.
Remove the 6 bolts.
83. Using the special tool, remove the 2 camshaft pulley hubs.

84. Remove the cooling fan drive hub bearing.
Remove the 3 bolts.
85. Retain the RH secondary timing chain tensioner piston.


bearing caps.
Remove the RH bank camshaft bearing caps.
87. Remove the RH bank camshafts and secondary timing chain

tensioner assembly.
Remove the 2 bolts.
Release the RH secondary timing chain tensioner.

88. Remove the RH bank secondary timing chain tensioner.
89. Remove the RH bank camshafts.
Release the secondary timing chain from the RH camshafts.
Remove and discard the seal.
90. CAUTIONS:

Remove the RH cylinder head assembly.
91. Retain the LH secondary timing chain tensioner piston.

bearing caps.
Remove the LH bank camshaft bearing caps.
93. Remove the LH bank camshafts and secondary timing chain

tensioner assembly.
Release the LH secondary timing chain tensioner.
Remove the 2 bolts.
94. Remove the LH bank secondary timing chain tensioner.
95. Remove the LH bank camshafts.
Release the secondary timing chain from the LH camshafts.
Remove and discard the 2 seals.

96. CAUTIONS:

Remove the LH cylinder head assembly.
98. Remove the flexplate.
Remove the 8 bolts.
99. Remove the oil cooler assembly.
Remove the 8 bolts.

100. Remove the fuel injection pump.
Remove the 4 bolts.
102. Remove the oil pump screen and pickup tube.
Remove the bolt.
Remove and discard the 2 O-ring seals.

103. Remove the oil pan extension.

Assembly
Special Tool(s)
303-1117
303-1145/1
303-1124
Flex plate locking tool
303-947
303-1123
303-1126
Assembly
All vehicles
1. NOTE: Clean the component mating faces.
• NOTE: It is important that the oil pan extension is bolted to the

crankshaft main bearing carrier within twenty minutes of applying the
sealant.
Apply an 8 mm bead of sealant to the cylinder block in the areas

shown.
Use WSS-M4G323-A4-RTV sealant.
Install the oil pan extension.
Loosely install the bolts.

3. CAUTION: Tighten the bolts in the indicated sequence in 2
stages.
Secure the oil pan extension.
1. Tighten bolts A to 10 Nm (7 lb.ft). Tighten bolts B to 4 Nm

(2 lb.ft).
2. Tighten bolts A to 24 Nm (18 lb.ft). Tighten bolts B to 10 Nm

(7 lb.ft).
4. NOTE: Lubricate the new seals with clean engine oil.
• NOTE: Clean the components.
Install the oil pump screen and pickup tube.
Install the oil pan.
Evenly and progressively tighten the bolts to 10 Nm (7 lb.ft).

6. Install the fuel injection pump.
7. CAUTION: Make sure the gasket is installed correctly.
• NOTE: Clean the component mating faces.
Install the oil cooler assembly.
8. Install the crankshaft position (CKP) sensor.
Reposition the access cover.
9. CAUTIONS:
Tighten the bolts in a diagonal sequence.
Tighten the bolts in the stages shown.
Install the flexplate.
Stage 1: Tighten the bolts to 50 Nm (37 lb.ft).
Stage 2:Tighten the bolts 45 degrees.
Stage 3:Tighten the bolts a further 45 degrees.

Rotate the crankshaft clockwise to align the crankshaft alignment

hole in the flywheel or flexplate with the cylinder block aperture.
11. Check the LH cylinder head face for distortion, across the center and
from corner to corner.
12. NOTE: The cylinder head gasket must be installed over the cylinder
head to cylinder block dowels.
Install a new LH cylinder head gasket.
13. CAUTIONS:
Use care when installing the cylinder head. Damage to the cylinder
block, cylinder head or cylinder head gasket may result.
Make sure that new bolts are installed.
• NOTE: The cylinder head gasket must be installed over the cylinder
• NOTE: Make sure the cylinder head is installed in its original position.
• NOTE: Tighten the bolts in the indicated sequence in 4 stages.
• NOTE: Clean the component mating face.
Install the LH cylinder head assembly.
Stage 4: Tighten the bolts a further 180 degrees.
14. Check the RH cylinder head face for distortion, across the center and
from corner to corner.
15. NOTE: The cylinder head gasket must be installed over the cylinder
Install a new RH cylinder head gasket.

16. CAUTIONS:
Use care when installing the cylinder head. Damage to the cylinder
block, cylinder head or cylinder head gasket may result.
Make sure that new bolts are installed.
• NOTE: The cylinder head gasket must be installed over the cylinder
• NOTE: Make sure the cylinder head is installed in its original position.
• NOTE: Tighten the bolts in the indicated sequence in four stages.
Install the RH cylinder head assembly.
Stage 1: Tighten to 20 Nm (15 lb.ft).
Stage 4: Tighten a further 180 degrees.
17. Install the secondary timing chain to the RH bank camshafts.

Install the RH bank secondary timing chain tensioner.

19. NOTE: Clean the components.
• NOTE: Install a new seal.
Install the RH bank camshafts and secondary timing chain tensioner

assembly.
20. Secure the RH bank secondary timing chain tensioner.

21. CAUTION: Tighten the bolts evenly in 3 stages in the sequence
shown.
• NOTE: Do not install the two exhaust camshaft end bearing caps at this
stage.
Install the RH bank camshaft bearing caps.

22. Apply
sealant
to the
RH
exhaust
camshaft
end
bearing
cap at
the
positions
shown.
23. CAUTION: Tighten the bolts in the sequence shown.
Install the RH bank exhaust camshaft end bearing caps.
24. Release the RH bank secondary timing chain tensioner piston.
25. Install the secondary timing chain to the LH bank camshafts.

Install the LH bank secondary timing chain tensioner.

27. NOTE: Clean the components.
• NOTE: Install new seals.
Install the LH bank camshafts and secondary timing chain tensioner

assembly.

28. Secure the LH bank secondary timing chain tensioner.
29. CAUTION: Tighten the bolts evenly in 3 stages in the sequence

shown.
• NOTE: Do not install the two exhaust camshaft end bearing caps at this
stage.
Install the LH bank camshaft bearing caps.

30. Apply
sealant
to the 2
LH
exhaust
camshaft
end
bearing
caps at
the
positions
shown.
Install the LH bank exhaust camshaft end bearing caps.
Stage 1: Tighten the bolt to 1 Nm (1 lb.ft).
32. Release the LH bank secondary timing chain tensioner piston.
33. Install the fuel injection pump belt rear cover.
Install a new camshaft pulley bolt.

Install and tighten the bolt.
36. CAUTION: Tighten the bolts in the stages shown.
Secure the camshaft rear pulley.
Remove the bolt.
38. CAUTION: Do not install the new fuel injection pump belt to
the pulleys with the fuel pump belt tensioner installed. Failure to follow
this instruction may result in damage to the fuel pump belt.
• NOTE: The fuel injection pump rotates in a counter-clockwise direction

when viewed from the rear of the engine.
Install the new fuel injection pump belt.
39. CAUTIONS:
Make sure that the fuel injection pump belt tensioner locking pin is
not removed until the fuel injection pump belt tensioner is fully installed.
Make sure that the fuel injection pump belt tensioner tang is
correctly located to the fuel injection pump belt rear cover. Failure to
follow this instruction may result in damage to the engine.
Install a new fuel injection pump belt tensioner.
Locate the tang on the new fuel injection pump belt tensioner
into the fuel injection pump rear cover.
Remove and discard the fuel injection pump belt tensioner

locking pin.
40. Install the fuel injection pump belt cover.
41. Install the cooling fan drive hub bearing.
42. CAUTION: Make sure that new bolts are installed.
• NOTE: LH is shown, RH is similar.
Using the special tool, install the 2 camshaft pulley hubs.
Stage 2: Tighten a further 90 degrees.
43. Install the 2 exhaust camshaft pulleys.
44. Install the special tools.
Rotate the camshafts.

45. Install the 2 timing belt idler pulleys.
Install the plastic shield behind the upper idler pulley.
46. Rotate both camshaft pulleys clockwise.
47. Install a new timing belt tensioner.
Install a new bolt, but do not fully tighten at this stage.
48. CAUTION: Make sure the camshaft pulleys remain in the

clockwise position.
Install the new timing belt.
Starting at the crankshaft pulley, install the timing belt in a

counter-clockwise direction, in the sequence shown.
Stage 1: Attach the timing belt to the crankshaft pulley.
Stage 2: Attach the timing belt to the idler pulley.
Stage 3: Attach the timing belt to the left-hand camshaft pulley.
Stage 4: Attach the timing belt to the idler pulley.
Stage 5: Attach the timing belt to the RH camshaft pulley.
Stage 6: Attach the timing belt to the timing belt tensioner.

49. CAUTION: Make sure the timing belt tensioner window is
aligned with the groove.
Tension the timing belt.
Rotate the tensioner assembly counter-clockwise.
50. 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.
Secure the camshaft pulleys.
Using a suitable tool, hold the camshaft pulley center bolts.
Remove the bolt.
53. Rotate the engine two complete turns clockwise.

If the special tool does not fit correctly, repeat the timing belt
installation procedure.
Remove the special tools from the camshaft pulleys.
Remove the bolt.
Install a new fuel injector return line.

Connect the fuel pipe to the fuel cooler.
• NOTE: Make sure that all the component mating faces are clean.
Install the cylinder head coolant outlet assembly.
Install the turbocharger oil supply line.
61. Install the breather line.
Secure the clip.

• NOTE: Install a new gasket.
Install the brake vacuum pump.
Install the bracket.
Install the RH valve cover.
Secure the glow plug electrical connector in the valve cover.
Secure the knock sensor (KS) electrical connector in the valve

cover.
64. Install the RH engine cover locating studs.
Install the bracket.
• NOTE: Install anew gasket.
Install the LH valve cover.
Secure the KS electrical connector in the valve cover.

66. Install the LH engine cover locating studs.
67. Install the fuel rail brackets.
68. Install the fuel rails.
Vehicles built up to 12/2006

Install the new RH fuel rail high-pressure supply line.
Tighten the fuel injection supply manifold retaining bolts to 23

Nm (17 lb.ft).
Stage 1: Tighten the high-pressure fuel supply line union at the

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

fuel rail to 15 Nm (11 lb.ft).


Secure the clip.

Install the new LH fuel rail high-pressure supply line.

Nm (17 lb.ft).




Secure the clip.
Install the new fuel diverter rail high-pressure supply line.

fuel injection pump to 15 Nm (11 lb.ft).



Vehicles built 01/2007 onwards

Install the new RH fuel rail high-pressure supply line.

Nm (17 lb.ft).




Secure the clip.
Install the new LH fuel rail high-pressure supply line.

Nm (17 lb.ft).




Secure the clip.
All vehicles
74. CAUTIONS:
Do not disassemble the fuel injectors or clean the nozzles, even

with an ultrasonic cleaner. Always install new fuel injectors when
required.
Do not use tools to install the new fuel return line retaining clip.
Failure to follow this instruction will result in damage to the retaining
clip.
Install a new fuel injector clamp.
1. Install the fuel injector retaining clamp spacer.
2. Install a new fuel return line retaining clip.
3. Install a new sealing washer.
76. Install the remaining fuel injectors.
77. CAUTIONS:
Do not allow the unions to hit the olive ends of the high-pressure
fuel supply line as this may damage the ends of the line and allow
foreign matter to enter the fuel injection system.
Maintain pressure on the high-pressure fuel supply line to keep the

olives in contact with the fuel injectors and the fuel rail cones while
installing unions.
Do not use any aggressive cleaning fluid or a wire brush to clean

the fluid injector nozzle.
• NOTE: Remove and discard the blanking caps.
Install the new high-pressure fuel injector supply lines.

injector to 15 Nm (11 lb.ft).


injector to 30 Nm (22 lb.ft).

78. CAUTION: Make sure the fuel return line retaining clip is
correctly installed to the fuel injector before installing the return line.
Connect the fuel return line to the fuel injectors.
Apply a light coating of petroleum jelly to the fuel return line

O-ring seals.
79. Install the engine wiring harness.
Secure the clips.
80. Connect the fuel injection pump electrical connectors.
81. Connect the fuel rail pressure (FRP) sensor electrical connector.
82. Install the crankcase vent oil separator.
Connect and secure the 2 breather hoses.
83. Connect the fuel temperature sensor electrical connector.
Connect the 2 KS electrical connectors.
85. Connect the engine oil temperature sensor electrical connector.
Secure the wiring harness clip.

86. Connect the camshaft position (CMP) sensor electrical connector.
87. NOTE: RH shown, LH is similar
Connect the 6 fuel injector electrical connectors.
Secure the 4 wiring harness clips.
88. Connect the engine oil pressure (EOP) sensor electrical connector.
89. Install the 2 low pressure fuel pipes.

91. Install the crankshaft pulley.
92. Install the cooling fan pulley.
93. Install the accessory drive belt idler.

• NOTE: Install a new O-ring seal.
Install the coolant pump.
95. Install the exhaust gas recirculation (EGR) valve coolant pipe.
Install the bolt.
Secure in the 2 clips.
Secure the clip.
96. CAUTION: Make sure that new nuts are installed.
• NOTE: Tighten the nuts in the sequence shown.
Install the RH exhaust manifold and exhaust cross-over pipe assembly.
97. Install the generator bracket.

98. Install the RH engine mount bracket.
99. Install the RH exhaust manifold heat shield.
Install the generator.

101. Connect the generator electrical connectors.
Reposition the rubber insulator.
102. Install the RH EGR valve and cooler assembly.
Connect the coolant hose and secure with the clip.
Install and secure the new clip.
103. NOTE: Install a new O-ring seal.
Install the cylinder block coolant inlet pipe.
• NOTE: Tighten the nuts in the sequence shown.
Install the LH exhaust manifold and turbocharger assembly.

Secure the exhaust cross-over pipe to the LH exhaust manifold.
• NOTE: Install new sealing washers.
Connect the turbocharger oil supply tube.
Tighten the banjo bolt to 30 Nm (22 lb.ft).
107. Secure the turbocharger support bracket.
Install the turbocharger oil return tube.

109. Install the turbocharger heat shield.
110. Install the LH exhaust manifold heat shield.
111. NOTE: Install a new clip.
Install the LH EGR valve and cooler assembly.
Install the support bracket.
Connect the coolant hose and secure with the clip.
Install and secure the clip.

Install the oil level indicator and tube.
Tighten the bolt to 10 Nm (7 Lb.ft).
113. Install the LH engine mount bracket.
114. Install the air conditioning (A/C) compressor bracket.

115. Install the A/C compressor.
116. Install the power steering pump bracket.
117. Remove the engine from the engine stand.

118. Install the engine.
For additional information, refer to: Engine (303-01C Engine - TDV6
2.7L Diesel, Installation).
119. Fill the engine with the recommended oil to the correct level.

Range Rover Sport Tdv6

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Range Rover Sport Tdv6

Uploaded by

Copyright:

Available Formats

Published: 11-May-2011

Engine - TDV6 2.7L Diesel -

+ New bolts must be installed

¹ Lightly oil bolt threads

² Do not apply lubricant to bolt threads

The technical features include:

60 degree 'vee' 6 cylinder engine with a CGI cylinder block

The technical data is detailed below:

CYLINDER BLOCK COMPONENTS

Piston Cooling Jets

Engine Data Locations

Connecting Rods and Pistons

• NOTE: The connecting rods are not selective.

Connecting Rod Installation

Crankshaft Position Sensor

Coolant Drain Plug

Cylinder Block Heater

Item Part Number Description

High-Pressure Fuel Pump

CRANKSHAFT AND SUMP COMPONENTS

Item Part Number Description

Item Part Number Description

Item Part Number Description

Rear Oil Seal Retainer

CAMSHAFT TIMING COMPONENTS

CYLINDER HEAD COMPONENTS

• NOTE: The cylinder head cannot be reworked.

Item Part Number Description

Camshaft Position Sensor

Item Part Number Description

Cylinder Head Gasket

Gasket Selection Table

BTDC = Before Top Dead Center

Inlet and Exhaust Valves

Item Part Number Description

Item Part Number Description

Water Outlet Assembly

Item Part Number Description

Do not use air/power tools

Oil Pressure Switch

Oil Level Gage

Item Part Number Description

Each manifold has a connection for the EGR transfer pipe.

For additional information,

1. Disconnect the battery ground cable.

2. WARNING: Do not work on or under a vehicle supported only

Raise and support the vehicle.

4. CAUTION: When removing the oil filter assembly, make sure

Using the special tool, remove the oil filter element.

Loosen the element cover 4 complete turns to allow engine

Remove element cover.

Remove and discard the O-ring seal.

5. Remove the engine undershield.

Position a container to collect the fluid.

Discard the oil pan drain plug seal.

7. Install the lubricant drain plug.

Clean the component mating faces.

Install a new sealing washer.

Tighten the drain plug to 25 Nm (18 lb.ft).

8. Install the oil filter element.

Clean the components.

Install a new O-ring seal.

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