Thread: TDV6 fan cover keeps popping out

I've broken two of them trying to get them off for maintenance. I have carefully drilled holes and ziptied it in 4 places

Yep, even my indie breaks them everytime, they use a clear drying plastic glue to re fit them. Zip ties is a good idea. I wouldn't remove it altogether for the reasons you mentioned.

Once the fan shroud is removed, the fan loses its efficiency.

Thanks guys, I'll follow your advice.

Update on how this ended up:
Of course I was too lazy to actually do something with the fan cover, convincing myself that if properly seated it will stay in place.
A month or two later it disappeared!
This was around the time my indy replaced the coolant expansion tank (yes due to 'Low coolant level ' false alarm), so I naturally assumed he was the culprit.
As luck may have it, a few hundred kilometers later I helped someone with a flat battery start his car. While hooking the cables with a running engine I could not help noticing an odd sound from the fan.
Peering inside I was startled to see the infamous fan cover jammed between the fan and the radiator - yes the entire thing was devoured by the fan and sucked inside, and apparently lightly touched the fan creating that odd noise.
So with some effort I pulled the thing outside, half amazed to realize no evident damage was sustained by the fan nor the radiator and not even by the cover itself (!).
Bottom line I threw the damn thing in the shed - indy says absolutely no issue having it removed, and I decided to trust him on that.
Kudus for Landrover choosing an extremely robust fan assembly for the D4..

It has a purpose. Will you notice the slight reduction in performance? Probably not until you push the car to the envelope it was designed for.