Land Rover Lesson 2 Auto Trans Coolingine Rover Manual
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EGR Cooler and Modulator EGR modulator1EGR cooler2 Electric Throttle Body Inlet air temperature sensor1 Electric throttle body2 Electric throttle flap3 Electric throttle control motor4 Gas inlet port5 The EGR modulator and cooler are a combined unit.The combined EGR modulator and cooler is located under each cylinder bank, between the exhaust manifold and the cylinder head. The cooler side of the EGR is Engine Emission ControlLesson 2 – Powertrain 173Technical Training (G421135)
connected to the vehicle cooling system, via hoses. The inlet exhaust side is connected directly into the exhaust manifolds on each side. The exhaust gas passes through the cooler and is expelled via the actuator and a metal pipe into the throttle housing. The EGR modulator is a solenoid operated valve which is controlled by the ECM. The ECM uses the EGR modulator to control the amount of exhaust gas being recirculated in order to reduce exhaust emissions and combustion noise. The EGR is enabled when the engine is at normal operating temperature and under cruising conditions. The EGR modulator receives a 12V supply from the main relay. The ground for the solenoid is via the ECM and is controlled using a PWM signal. The PWM duty signal of the solenoid ground is varied to determine the precise amount of exhaust gas delivered to the cylinders. The modulators are operated through their full range at each engine start-up, to clear any carbon deposits that may have built up whilst the engine was running In the event of a failure of the EGR modulator, the EGR function will become inoperative. The ECM can monitor the EGR modulator solenoid for short circuits and store fault codes in the event of failure. The modulator can also be activated for testing using T4. (G421135) Technical Training174 Lesson 2 – PowertrainEngine Emission Control
CRANKCASE VENTILATION Breather tube1 Oil separator2 Breather tube3 Crankcase oil return connection4 Oil return tube5 Crankcase oil return valve6 Breather flow7 Engine Emission ControlLesson 2 – Powertrain 175Technical Training (G421135)
The crankcase ventilation system on the TdV6 ensures that all gasses emitted from the crankcase during engine running are separated from any oil particles. Crankcase gasses are drawn into the oil separator unit from the crankcase and the cylinder head covers (both banks) where the gas and oil are separated. The gas is returned to the inlet side of the air induction system prior to the turbo charger. The oil is drained down to the sump via an oil return valve locate at the rear of the cylinder block. (G421135) Technical Training176 Lesson 2 – PowertrainEngine Emission Control
External View NOTE: Variant without oil cooler shown. GENERAL The V6 petrol engine is a 4.0 litre, 6 cylinder, 60 degrees V unit, with 2 valves per cylinder, operated by a single overhead camshaft. The engine emissions comply with ECD4 (European Commission Directive) and USA Tier 2 Bin 8 legislative requirements and employs catalytic converters, electronic engine management control, positive crankcase ventilation and exhaust gas recirculation to limit the emission of pollutants. The cooling system is a low volume, high velocity system. The fuel injection system is controlled by the Engine Control Module (ECM). (G421093) Technical Training16 Lesson 2 – PowertrainEngine
The cylinder block is of cast iron construction with a cast aluminium ladder frame and balance shaft assembly bolted to the bottom of the block. The cylinder heads are cast aluminium with vinyl ester composite camshaft covers. The single-piece oil sump is formed from pressed steel. The intake manifold is manufactured from cast aluminium and incorporates a central chamber with six inlet port tracts . The dual wall stainless steel 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: •A six cylinder, 60 degree V configuration liquid cooled cast iron cylinder block •Pistons comprise two compression rings and a three piece oil control ring •Two aluminium cylinder heads, each incorporating a single hollow camshaft •Rocker valve arms with hydraulic lash adjusters •Engine front cover manufactured from aluminium which accommodates the coolant pump assembly •Each camshaft is driven by a separate single row chain •Electronically controlled vacuum operated Exhaust Gas Recirculation (EGR) valve •Exhaust re-treatment by means of catalytic converters •Cast aluminium engine ladder frame assembly •A fully counter balanced cast iron crankshaft •An advanced engine management system incorporating electronic throttle control •Electronic Intake Manifold Tuning Valve (IMTV) with ECM control •Emissions comply with ECD4 (European Commission Directive) and USA Tier 2 Bin 8 legislative requirements. Engine Data The technical data is detailed below. TYPEDESCRIPTION 60 degree V6Configuration 156 kW at 4750 rpmMaximum power 346 Nm at 3000 rpmMaximum torque 4009ccDisplacement 84.4mm/100.4mmStroke/bore 9.7:1Compression ratio 1 4 2 5 3 6Firing order 6.2 litresOil capacity EngineLesson 2 – Powertrain 17Technical Training (G421093)
CYLINDER BLOCK COMPONENTS NOTE: Variant with oil cooler shown. (G421093) Technical Training18 Lesson 2 – PowertrainEngine
Piston Rings1 Piston2 Piston pin3 Connecting rod4 Connecting rod bearing - upper5 Connecting rod bearing - lower6 Connecting rod cap7 Oil filter8 Oil cooler (if fitted)9 Oil filter adapter mounting bolt10 O ring11 O ring12 Oil filter adapter13 O ring14 Knock sensor15 Cylinder block16 Locating dowel17 Knock sensor18 Oil pressure switch19 Starter motor20 Gasket21 Front cover22 Seal23 Gasket24 Water pump25 Crankshaft pulley26 Jackshaft shaft chain27 Jackshaft shaft sprocket28 Chain tensioner29 Jackshaft shaft30 Jackshaft thrust plate31 Chain guide32 Chain guide33 Oil gallery plug34 Plug35 Spacer36 Oil gallery plug37 Cylinder Block The cylinder block is a V design, which provides an inherently rigid structure with good vibration levels. A low volume coolant jacket improves warm-up times and piston noise levels; the longitudinal flow design of the jacket, with a single cylinder head coolant transfer port in each bank, improves rigidity and head gasket sealing. EngineLesson 2 – Powertrain 19Technical Training (G421093)
Engine Data Locations Engine data1 Engine data2 Vehicle Identification Number (primary location)3 Vehicle Identification Number(secondary location) 4 Engine data is marked at three locations. (G421093) Technical Training20 Lesson 2 – PowertrainEngine
Pistons and Connecting Rod Assembly Piston ring, upper compression1 Piston ring, lower compression2 Piston rings, oil control3 Piston4 Piston pin5 Connecting rod6 Oil squirt hole7 Connecting rod bearing, upper8 Connecting rod bearing, lower9 Connecting rod cap10 Nut11 Bolt12 The aluminium alloy, thermal expansion, lightweight pistons, with semi-floating piston pins, are offset to the thrust side and are carried on forged steel connecting rods. Pistons are supplied in four grades, 1, 2, 3 and 4. The pistons are marked to ensure they are correctly oriented in the cylinder bore; the arrow mark should be toward the front of the engine. The V6 petrol engine utilises forged steel H-sectioned connecting rods, with the piston pin being an interference fit in the small end of the connecting rod. The big ends are horizontally split. Selective bearing shells with two grades of thickness; standard and 0.25 mm undersize, control big end bearing diametric clearance. The big-end upper and lower bearing shells are plain with locating tags. Each piston is fitted with two compression rings and an oil control ring. The top compression ring has a nitrided surface, a process that involves the diffusion of nitrogen into the surface layers of a low carbon steel. The formation of nitrides provides an increased hardness. The 2nd compression ring is chrome-plated. The oil control rings have stainless steel top and bottom rails and integral expander rings. Jackshaft Assembly Jackshaft1 Thrust plate2 The jackshaft assembly is located centrally in the upper part of the cylinder block. The assembly is used to supply drive to each camshaft, via a chain. The LH camshaft is driven from the front of the jackshaft and the RH camshaft is driven from the rear. The Jackshaft EngineLesson 2 – Powertrain 21Technical Training (G421093)