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DISCO3.CO.UK > Maintenance & Mods (D4)

2.7 TDV6 EGR coolant system delete

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twr7cx

Member Since: 03 Mar 2019
Location: Tasmania
Posts: 181

2012 Discovery 4 TDV6 Base 5 Seat Auto Nara Bronze

2.7 TDV6 EGR coolant system delete

One of our MY12 D4's with the 2.7 TDV6 (same as D3) has a coolant leak. Looks like this top hose has dropped down and rubbed on the pulley below:

I believe that this hose is LR004537 / LR006638 Hose Inlet Cooled EGR.

The vehicle has the EGR blanking kit <https> and BAS EGR deactivation patch <https> fitted.
I'd assume therefore that the EGR coolers are no longer required and no longer required to have a coolant flow going through them.

Is there a method of deleting/bypassing the coolant system from the EGR coolers and making this hose redundant? The benefit would be to simplify the coolant piping (you'd remove the cooling hose loop that runs entirely around the engine) and reduce areas for failure. One issue may be that there is a bleed point on the rear metal pipe for this loop. Another consideration may be if the coolant flow through the coolers prolongs there life before the exhaust gas leak through.
It looks to me like it'd be a matter of joining these two hoses here on the opposite (drivers) side of the engine:

Or, given that there is a mini thermostat (3) in the EGR coolers, am I better off capping the outlets for these?

Mine - MY09 L319 D3 HSE Lion 2.7 TDV6 and modified MY03 LT L318 Discovery 2a HSE Td5 15P
Hers - MY12 L319 D4 Lion 2.7L TDV6
Dads - MY12 L319 D4 Lion 2.7L TDV6

20th Sep 2021 2:54 am

twr7cx

Member Since: 03 Mar 2019
Location: Tasmania
Posts: 181

After some disassembly I found the actual cause of why the hose had managed to contact and rub on the serpentine belt pulley below it.

This Norma RSGU 27 pipe retaining clip has a larger internal diameter than the external diameter of the hose it secures in place. This allows the hose to drop lower than ideal if it's not all assembled exactly right (which it clearly wasn't after I did the timing belt - well done me...).
Changing this to a smaller pipe retaining clip resolves this and ensures the hose is held in place high enough. I had a spare size 25 on hand which proved this theory, but the internal diameter was smaller than ideal for the hoses external diameter. Size 26 <https> would be the sweet spot.

The Engine Cooling - TDV6 2.7L Diesel - Cooling System Draining, Filling and Bleeding procedure in the Land Rover workshop manual doesn't refer to the bleed screw point on the EGR cooler circuit at all in the bleeding process which added to my suspicion that this coolant circuit is solely for the EGR cooler purpose making me more comfortable to eliminate it.

Followed the two hoses from the EGR cooling circuit, down to where they connect to two seperate black plastic t-pieces near the thermostat of the bottom radiator hose assembly. The two hoses and barbs are different sizes to each other.

I found a 19mm (or 3/4") blanking cap (left over spare that I keep on hand for my D2a TD5's behind the turbocharger water outlet) was the correct fitment for the smaller and a 25mm (or 1") for the larger. Tried all the industrial and hose specialists locally and only one had a 25mm blanking cap in stock - it's fairly thin rubber and I'm not very comfortable with it's quality (it looks like a door stopper to me!). I've ordered some better quality replacements online - Samco Sport silicone units:
25mm - https://www.williamsraceservices.com.au/bl...30mm-black
19mm - https://www.williamsraceservices.com.au/bl...30mm-black

Alternatively you could possibly purchase a new right angle joiner for the smaller and a straight joiner for the larger one. For the larger t-piece the two inline connection barbs are definitely larger than the 25mm of the t-off connection barb. Not sure about the smaller unit but looks like the three barbs are all the same size for that one.

For now I've left the bulk of the piping in place incase I need to revert back.

So next up is to now stop the exhaust gas flowing into the EGR coolers - as eventually these will corrode through and fail.

Spoke to Pete Bell at Bell Auto Service who provided the EGR Deactivation Patch and he's not sure if issues will be caused by the entire removal of the EGR cooler units as they leave them in place to assist with their MOT inspection compliance. Reading some threads on here I found:

[QUOTE=discorevy;2900611]The plates from a td5 egr delete kit will fit on the tdv6 manifolds when approx 2mm is taken out from the outside edge of the bolt holes.[/QUOTE]
https://www.aulro.com/afvb/l319-discovery-...ost2900611

So it's likely I can just get some of the Td5 EGR delete blanking plates with suitably longer bolts, and slip them in between the exhaust manifold outlet and EGR cooler stopping the exhaust flow into the EGR cooler but retaining the units in place to avoid upset to the electronics (discorevy also suggested leaving them in place as they form a bit of a heatshield for the exhaust system). Mine - MY09 L319 D3 HSE Lion 2.7 TDV6 and modified MY03 LT L318 Discovery 2a HSE Td5 15P
Hers - MY12 L319 D4 Lion 2.7L TDV6
Dads - MY12 L319 D4 Lion 2.7L TDV6

20th Sep 2021 1:37 pm

lynalldiscovery

Member Since: 22 Dec 2009
Location: Maidstone
Posts: 7274

2006 Discovery 3 TDV6 Metropolis LE Auto Bonatti Grey

Iirc the later 2.7s have thermostats in or near the egr valves, not sure if or how this could effect things?

20th Sep 2021 4:46 pm

twr7cx

Member Since: 03 Mar 2019
Location: Tasmania
Posts: 181

Yes it does. The mini thermostat is to control/limit/prevent the flow of cold coolant around the EGR cooling circuit when the engine is warming up as otherwise the engine would take longer to warm up. This is why the blanking cap method is used rather than my initial though of joining the circuits inlet and outlet which would result in cold coolant by passing the main thermostat. Mine - MY09 L319 D3 HSE Lion 2.7 TDV6 and modified MY03 LT L318 Discovery 2a HSE Td5 15P
Hers - MY12 L319 D4 Lion 2.7L TDV6
Dads - MY12 L319 D4 Lion 2.7L TDV6

20th Sep 2021 9:41 pm

twr7cx

Member Since: 03 Mar 2019
Location: Tasmania
Posts: 181

Two weeks later and no issues with deleting this circuit.
New step is fitting plates to stop exhaust gases entering the coolers completely preventing later failure issues. Mine - MY09 L319 D3 HSE Lion 2.7 TDV6 and modified MY03 LT L318 Discovery 2a HSE Td5 15P
Hers - MY12 L319 D4 Lion 2.7L TDV6
Dads - MY12 L319 D4 Lion 2.7L TDV6

5th Oct 2021 12:11 am

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