Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Engine Emission Control - Ingenium i4 2.0l Diesel High Pressure Exhaust Gas Recirculation Cooler (G2162458) / Removal and Installation

Land Rover Discovery (2009–2016) Service Manual / Powertrain / Engine / Engine Emission Control - Ingenium i4 2.0l Diesel High Pressure Exhaust Gas Recirculation Cooler (G2162458) / Removal and Installation

PART(S)

PART(S)

REMOVAL

NOTE:

  • This procedure contains some variation in the illustration depending on the vehicle specification, but essential information is always correct.
  • This procedure contains illustrations showing certain components removed to provide extra clarity.

Disconnect the startup battery ground cable.

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

Raise and support the vehicle on a suitable 2 post lift.

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

Remove the battery tray.

Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).

Remove the air cleaner assembly.

Refer to: Air Cleaner (303-12B Intake Air Distribution and Filtering - INGENIUM I4 2.0L Diesel, Removal and Installation).

Partially drain the coolant.

Refer to: Cooling System Partial Draining and Vacuum Filling (303- 03A Engine Cooling - TD4 2.2L Diesel, General Procedures).

Engine Emission Control - Ingenium i4 2.0l Diesel High Pressure Exhaust Gas Recirculation Cooler (G2162458) / Removal and Installation

Remove the air intake pipe.

Engine Emission Control - Ingenium i4 2.0l Diesel High Pressure Exhaust Gas Recirculation Cooler (G2162458) / Removal and Installation

Disconnect the breather and reposition away from the high pressure Exhaust Gas Recirculation (EGR) cooler.

Engine Emission Control - Ingenium i4 2.0l Diesel High Pressure Exhaust Gas Recirculation Cooler (G2162458) / Removal and Installation

Disconnect the 3 high pressure EGR cooler electrical connectors.

CAUTION:

Be prepared to collect escaping coolant.

Engine Emission Control - Ingenium i4 2.0l Diesel High Pressure Exhaust Gas Recirculation Cooler (G2162458) / Removal and Installation

Release the upper coolant hose and reposition away from the high pressure EGR cooler.

CAUTION:

Be prepared to collect escaping coolant.

Engine Emission Control - Ingenium i4 2.0l Diesel High Pressure Exhaust Gas Recirculation Cooler (G2162458) / Removal and Installation

Remove the lower high pressure EGR cooler coolant hose.

Engine Emission Control - Ingenium i4 2.0l Diesel High Pressure Exhaust Gas Recirculation Cooler (G2162458) / Removal and Installation

Remove the 2 bolts securing the high pressure EGR cooler to the throttle body assembly.

NOTE:

Remove and discard the O-ring seal.

Engine Emission Control - Ingenium i4 2.0l Diesel High Pressure Exhaust Gas Recirculation Cooler (G2162458) / Removal and Installation

Release and remove the high pressure EGR cooler clamp.

CAUTION:

Be prepared to collect escaping coolant.

NOTE:

Remove and discard the gasket.

Engine Emission Control - Ingenium i4 2.0l Diesel High Pressure Exhaust Gas Recirculation Cooler (G2162458) / Removal and Installation

Remove the 2 bolts securing the high pressure EGR cooler to the EGR valve assembly.

CAUTION:

Be prepared to collect escaping coolant.

Engine Emission Control - Ingenium i4 2.0l Diesel High Pressure Exhaust Gas Recirculation Cooler (G2162458) / Removal and Installation

Release the 3 bolts and remove the high pressure EGR cooler.

Engine Emission Control - Ingenium i4 2.0l Diesel High Pressure Exhaust Gas Recirculation Cooler (G2162458) / Removal and Installation

Remove the high pressure EGR cooler temperature sensor.

INSTALLATION

  1. Install the high pressure Exhaust Gas Recirculation (EGR) sensor.

Torque: 3.6 Nm

  1. Install the high pressure EGR cooler and tighten the 3 bolts to the correct torque.

Torque:

M6 x 80 12 Nm

M6 x 25 7 Nm

NOTE:

Make sure that a new gasket is installed.

Install a new gasket between the high pressure EGR cooler and the EGR valve and tighten the 2 bolts.

Renew Part: EGR cooler to EGR valve gasket.

Torque: 12 Nm

NOTE:

Make sure that a new O-ring seal is installed.

Install the high pressure EGR cooler clamp and tighten to the correct torque.

Renew Part: Exhaust gas recirculation O-ring seal.

Torque: 4 Nm

Install and tighten the 2 bolts securing the high pressure EGR cooler to the throttle body assembly.

Torque: 8 Nm

Install the lower high pressure EGR cooler coolant hose.

Install the upper coolant hose.

Connect the 3 high pressure EGR cooler electrical connectors.

Install the breather into the correct position.

Install the air intake pipe and tighten the 3 nuts.

Torque: 8 Nm

Install the air cleaner assembly.

Refer to: Air Cleaner (303-12B Intake Air Distribution and Filtering - INGENIUM I4 2.0L Diesel, Removal and Installation).

Install the battery tray.

Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).

Connect the startup battery ground cable.

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

Fill and bleed the cooling system.

Refer to: Cooling System Partial Draining and Vacuum Filling (303- 03A Engine Cooling - TD4 2.2L Diesel, General Procedures).

Engine Emission Control - Ingenium i4 2.0l Diesel High Pressure Exhaust Gas Recirculation Temperature Sensor (G1875916) / Removal and Installation

REMOVAL

NOTES:

  • Some variation in the illustrations may occur, but the essential information is always correct.
  • To install, reverse the removal sequence.

Refer to: Engine Cover - INGENIUM I4 2.0L Diesel (501-05 Interior Trim and Ornamentation, Removal and Installation).

Engine Emission Control - Ingenium i4 2.0l Diesel High Pressure Exhaust Gas Recirculation Cooler (G2162458) / Removal and Installation

Torque: 3.6 Nm

INSTALLATION

CAUTION:

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

To install, reverse the removal procedure.

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