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Home >> Jaguar >> 2017 >> F-Pace First Edition >> Repair and Diagnosis >> External Pages >> Different car >> Section 229 (Engine - INGENIUM I4 2.0L Petrol -- XE (X760)) >> Engine - INGENIUM I4 2.0L Petrol >> Engine And Ancillaries >> Removal And Installation >> Installation

Removal And Installation: Installation

WARNING: This page is about a different car, the 2018 Jaguar XE. However, it is still accessible from the selected car via links, so may be relevant.

Special Tool(s) 

G11419143
 303-1450 
Spark Plug Remover/Installer
G11308987
 JLR-303-1630 
Locking Tool, Crankshaft Pulley
G11307911
 JLR-310-255 
Guide pins threaded
G11307912
 JLR-310-256 
Guide pins unthreaded
G11587655
 310-198 
Installer, Teflon Seal
G11327692
 JLR-310-257 
Teflon Seal Resize Tool

General Equipment 

EQUIPMENT NAME
Hydraulic jib crane
Two-post lift

Part(s) 

STEP PART NAME QUANTITY
Installation Step 3 Oil filter housing inlet / outlet O-ring seals 1
Installation Step 5 Oil filter 1
nstallation Step 8 Oil cooler gasket 1
nstallation Step 9 Valve cover vent oil separator to cylinder head seal 1
nstallation Step 14 High pressure fuel pump retaining bolts 2
Installation Step 15 Fuel Injector replacement kits 4
Installation Step 35 Crankshaft pulley bolts 4
Installation Step 42 Coolant pump inlet O-ring seal 1
Installation Step 43 Exhaust manifold to turbocharger studs 4
Installation Step 44 Turbocharger to exhaust manifold gasket 1
Installation Step 45 Exhaust manifold to turbocharger nuts 2
Installation Step 46 Exhaust manifold to turbocharger nuts 2
Installation Step 47 Turbocharger oil return pipe seals 2
Installation Step 52 Turbocharger oil feed pipe banjo bolt washers 2
Installation Step 53 Turbocharger oil feed pipe banjo bolt washers 2
Installation Step 56 Thermostat to cylinder block gasket 1
Installation Step 58 Intake manifold seals 1
Installation Step 71 Oil level gauge O-ring seal 1
Installation Step 81 Flexplate bolts 8

Procedure 

CAUTION:
  • All the components removed from the old engine must be cleaned and inspected before installing to the new engine. Any worn or damaged components or retaining clips must be replaced.
  • New engines may be supplied with untapped bolt holes for some of the components. Reuse bolts from the original engine, as these are self tapping and will cut threads where required.
  • Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.
NOTE:
  • This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
  • This procedure contains illustration showing certain components removed to provide extra clarity.
  1. Always follow the fuel system health and safety precautions, when preforming any repairs to the fuel system.

    Refer to: Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions .

  2. Support the engine on a suitable stand.
  3. Renew the oil filter housing O-ring seals.
    G00569411

    Renew Part: Oil filter housing inlet/outlet O-ring seals Quantity: 1. 

  4. Install the oil filter housing.
    G00565489

    Torque Specification: 12 Nm 

  5. Renew the oil filter element and O-ring seal.

    Renew Part: Oil filter Quantity: 1. 

    Torque Specification: 27 Nm 

  6. Install the piston cooling jet solenoid.
    G00565487

    Torque Specification: 11.5 Nm 

  7. Install the block heater.
    NOTE: If equipped.
    G00565486

    Torque Specification: 55 Nm 

  8. Install the oil cooler. Renew the gasket.
    CAUTION: Bolts must be tightened in the sequence illustrated.
    Fig 1: Engine Oil Cooler Bolts Tightening Sequence
    G00565490Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    Renew Part: Oil cooler gasket Quantity: 1. 

    Torque Specifications: 

    Stage 1: 10 Nm 

    Stage 2: 25 Nm 

  9. Install the valve cover vent oil separator. Renew the gasket.
    G00565488

    Renew Part: Valve cover vent oil separator to cylinder head seal Quantity: 1. 

    Torque Specification: 12 Nm 

  10. Install the Noise, Vibration and Harshness (NVH) material.
    G00565484
  11. Install the NVH material.
    G00565483

    Torque Specification: 11.5 Nm 

  12. Install the purge valve mounting bracket.
    G00565482

    Torque Specification: 11.5 Nm 

  13. Install the high pressure fuel pump tappet in the correct orientation.
    CAUTION: Lubricate the component with clean engine oil.
    G11307951
  14. CAUTION:
    • Tighten the bolts half a turn at a time until the pump is fully seated.
    • Lubricate the O-ring seal with clean engine oil.
    G11307949

    Install the high pressure fuel pump. Renew the bolts.

    Renew Part: High pressure fuel pump retaining bolts Quantity: 2. 

    Torque Specification: 11.5 Nm 

  15. Installation steps 9 to 14 must be completed for each of the fuel injectors.
    CAUTION: New fuel injector replacement kits must be installed.

    Renew Part: Fuel Injector replacement kits Quantity: 4. 

  16. Install the new fuel injector O-ring seal and washer.
    G00565480
  17. Install the special tool to the injector with 'T' symbol towards the top of the injector as shown.
    G11307930

    Special Tool(s):  JLR-310-257

    Renew Part: Fuel Injector replacement kits Quantity: 4. 

    Torque Specification: 11.5 Nm 

  18. Using the special tool, install the new Teflon seal to the injector.
    G11307931

    Special Tool(s):  310-198

  19. Wait 2 minutes to allow the Teflon seal to recover its shape.
  20. G11307932

    Remove the special tool.

    Check for correct installment of the Teflon seal.

  21. Install the injector spring clamp.
    G11307933
  22. Carefully install all the injectors into the fuel rail.
    CAUTION: Lubricate the fuel injector O-ring seals with clean engine oil.
  23. Make sure the injectors are correctly aligned.
    G11307935
  24. Make sure the injectors are correctly aligned.
    G11307936
  25. Install the injector wiring harness.
    G11307937
  26. Install the appropriate special tools. If a new cylinder head has not been installed then the special tool JLR- 310-255 with the threaded section must be used.

    If a new cylinder head has been installed then the special tool JLR-310-256 without the threaded section must be used.

    G11307938

    Special Tool(s):  JLR-310-255, JLR-310-256

  27. Install the fuel rail and injector assembly allowing the guide pins to control position.
    G11307939

    Tighten the bolts 1 turn at a time.

    Torque Specification: 20 Nm 

  28. Remove the special tools.
  29. Install the remaining 2 fuel rail bolts.

    Torque Specification: 20 Nm 

  30. Tighten the bolts in the sequence illustrated.
    Fig 2: Fuel Rail And Fuel Injector Assembly Bolts Tightening Sequence
    G11307940Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC
  31. Using special tool, Install the spark plugs
    G11327964

    Install the special tool to the fuel injector

    Special Tool(s):  303-1450

    Torque Specification: 23 Nm 

  32. Install the ignition coil-on-plugs.
    G00569412

    Torque Specification: 8 Nm 

  33. Install the engine lifting eye.
    G00565476

    Torque Specification: 

    M8 Bolts: 25 Nm 

    M10 Bolts: 48 Nm 

  34. CAUTION: Lubricate the O-ring seal with clean engine oil.
    G00565475

    Install the oil filler neck.

    Torque Specification: 11.5 Nm 

  35. Before installing the new crankshaft damper bolts check the length of the thread as shown in the illustration. The new bolts must be 48mm in length.
    G11308997

    Renew Part: Crankshaft pulley bolts Quantity: 4. 

  36. Install the crankshaft pulley.
    G00565437
  37. Install the special tool.
    G11306806

    Special Tool(s):  JLR-303-1630

  38. Install the new crankshaft pulley bolts.
    G00565435

    Torque Specification: 

    Stage 1: 40 Nm 

    Stage 2: 90° 

  39. CAUTION: Lubricate the O-ring seals with clean engine oil.
    G00565474

    Install the variable valve timing solenoids.

    Torque Specification: 9 Nm 

  40. Camshaft position sensors.
    CAUTION: Lubricate the O-ring seal with clean engine oil.
    G00565473

    Install the camshaft position sensors.

    Torque Specification: 9 Nm 

  41. Crankshaft position sensor.
    CAUTION: Lubricate the O-ring seal with clean engine oil.
    G00565472

    Install the crankshaft position sensor.

    Torque Specification: 8 Nm 

  42. Install the coolant pump inlet pipe. Renew the O-ring seal.
    CAUTION: Lubricate the O-ring seal with clean engine oil.
    G00565471

    Renew Part: Coolant pump inlet O-ring seal Quantity: 1. 

    Torque Specification: 12 Nm 

  43. Renew the turbocharger studs.
    G00569413

    Renew Part: Exhaust manifold to turbocharger studs Quantity: 4. 

    Torque Specification: 18 Nm 

  44. Renew the turbocharger gasket.
    G00569414

    Renew Part: Turbocharger to exhaust manifold gasket Quantity: 1. 

  45. Install the turbocharger. Renew the nuts.
    CAUTION: Make sure that the mating faces are clean and free of foreign material.
    G00569415

    Renew Part: Exhaust manifold to turbocharger nuts Quantity: 2. 

    Torque Specification: 10 Nm 

  46. Fully tighten the turbocharger retaining nuts in the sequence illustrated.
    G00569416

    Renew Part: Exhaust manifold to turbocharger nuts Quantity: 2. 

    Torque Specification: 25 Nm 

  47. Install the turbocharger oil return pipe. Renew the 2 O-ring seals.
    CAUTION: Lubricate the O-ring seal with clean engine oil.
    G00565469

    Renew Part: Turbocharger oil return pipe seals Quantity: 2. 

    Torque Specification: 11 Nm 

  48. Install the turbocharger heatshield.
    G00565468

    Torque Specifications: 

    Bolt M6 x 14 mm: 9 Nm 

    Bolt M6 x 25 mm: 12 Nm 

  49. Install the turbocharger lower heatshield.
    G00565467

    Torque Specification: 9 Nm 

  50. Install the coolant degas separator.
    CAUTION: Lubricate the O-ring seal with clean engine oil.
    G00565465

    Torque Specification: 12 Nm 

  51. Connect the turbocharger coolant supply and return hoses. Inspect the O-ring seals, discard the components if damaged or worn.
    CAUTION: Lubricate the O-ring seal with clean engine oil.
    G00565464

    Torque Specification: 12 Nm 

  52. Install the turbocharger oil supply hose. Renew the sealing washers.
    NOTE: Make sure the oil supply hose is installed in the same orientation as noted in the removal procedure.
    G00565463

    Remove the turbocharger oil supply hose. Discard the sealing washers.

    Renew Part: Turbocharger oil feed pipe banjo bolt washers Quantity: 2. 

    Torque Specification: 18 Nm 

  53. Connect the turbocharger oil supply hose. Renew the sealing washers.
    NOTE: Make sure the oil supply hose is installed in the same orientation as noted in the removal procedure.
    G00565462

    Renew Part: Turbocharger oil feed pipe banjo bolt washers Quantity: 2. 

    Torque Specification: 18 Nm 

  54. Install coolant pump
    NOTE: The coolant pump from the previous engine is to be reused.
    CAUTION: Bolts must be tightened in the sequence illustrated.
    Fig 3: Coolant Pump Bolts Tightening Sequence
    G00569417Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    Torque Specification: 

    Stage 1: 5 Nm 

    Stage 2: 12 Nm 

  55. Install the coolant pump pulley.
    G00565460

    Torque Specification: 25 Nm 

  56. Install the thermostat housing. Renew the gasket.
    G00565459

    Renew Part: Thermostat to cylinder block gasket Quantity: 1. 

    Torque Specification: 12 Nm 

  57. Install the knock sensors.
    CAUTION: Make sure the knock sensors are installed in the same orientation as noted in the removal procedure.
    G00565458

    Torque Specification: 20 Nm 

  58. Install the intake manifold. Renew the seals.
    CAUTION: Tighten the bolts in a diagonal sequence starting from the center and working outwards.
    G00565457

    Renew Part: Intake manifold seals Quantity: 1. 

    Torque Specification: 12 Nm 

    • Secure the knock sensor wiring harness.
  59. Install the wiring harness.
    CAUTION: Make sure the wiring harness is installed to the original routing.
    G00565454
  60. Install the purge valve.
    G00565456

    Torque Specification: 11.5 Nm 

  61. Fuel supply pipes.
    CAUTION: Fuel pipes may be used a maximum of 4 times, paint mark fuel tube after each full tightening sequence.
    G00565455
    1. Install the high pressure fuel pump to fuel rail pipe hand tight until the 2 unions are fully seated.
    2. Fully tighten the high pressure fuel pump union.

      Torque Specification: 21 Nm 

    3. Fully tighten the fuel rail union.

      Torque Specification: 21 Nm 

    4. Wait for 30 seconds
    5. Check the high pressure fuel pump union.

      Torque Specification: 21 Nm 

    6. Check the fuel rail union torque.

      Torque Specification: 21 Nm 

    7. Install the high pressure fuel pump supply pipe hand tight until the union is fully seated.
    8. Install the high pressure fuel pump supply pipe mounting bracket bolts hand tight, then loosen by 90 degrees.
    9. Fully tighten the high pressure fuel pump supply tube union.

      Torque Specification: 21 Nm 

    10. Fully tighten the high pressure fuel pump supply pipe mounting bracket bolts.

      Torque Specification: 11.5 Nm 

    11. Wait for 30 seconds.
    12. Check the high pressure fuel pump supply tube union torque.

      Torque Specification: 21 Nm 

  62. Connect and secure the wiring harness.
    CAUTION: Make sure the wiring harness is not twisted and all the clips and connectors are fully secured.
    G00565453
  63. Connect and secure the wiring harness.
    CAUTION: Make sure the wiring harness is not twisted and all the clips and connectors are fully secured.
    G00565452
  64. Connect and secure the wiring harness.
    CAUTION: Make sure the wiring harness is not twisted and all the clips and connectors are fully secured.
    G00565451

    Torque Specification: 8.5 Nm 

  65. Connect and secure the wiring harness.
    CAUTION: Make sure the wiring harness is not twisted and all the clips and connectors are fully secured.
    G00565450

    Torque Specification: 8.5 Nm 

  66. Install the coolant hose.
    G00565449

    Torque Specification: 25 Nm 

  67. Connect and secure the coolant hose.
    G00565448

    Torque Specification: 7 Nm 

  68. Install the generator.
    G00565447

    Torque Specification: 47.5 Nm 

  69. Install the accessory drive belt tensioner.
    G00565446

    Torque Specification: 47.5 Nm 

  70. Install the accessory drive belt idler pulleys.
    CAUTION: Do not use excessive force to install the bolt covers.
    G00565445

    Torque Specifications: 

    M6 Bolt: 25 Nm 

    M10 Bolt: 47.7 Nm 

  71. Install the oil level gauge assembly. Renew the O-ring seal.
    CAUTION: Lubricate the O-ring seal with clean engine oil.
    G00565444

    Renew Part: Oil level gauge O-ring seal Quantity: 1. 

    Torque Specification: 7 Nm 

  72. Install the vacuum pipe assembly.
    G00565443
  73. Install the coolant hose.
    G00565442

    Torque Specification: 11.5 Nm 

  74. Install the breather.
    G00565441
  75. Install the NVH material.
    G00565440
  76. Install the halfshaft support bracket.
    NOTE: If equipped.
    CAUTION: Lubricate the O-ring seal with clean engine oil.
    G00565438
  77. Install the front differential case.
    NOTE: If equipped.
    CAUTION: Lubricate the O-ring seal with clean engine oil.
    G11305851
  78. Install the engine mounting brackets.
    G00565434

    Torque Specification: 60 Nm 

  79. Remove the engine from the stand.
  80. Crankshaft flange bolt thread cleaning.
    CAUTION:
    • Under no circumstances should the drive plate retaining bolts be inserted into the crankshaft with the drive plate removed. Failure to follow this instruction will result in damage to the engine.
    • Do not insert the bottoming tap more than the depth of the threaded holes (16mm).
    • Apply tape to the bottoming tap 16mm from the end as a visual guide.
    G11309144
    • Using a suitable bottoming tap, clean out the threads.
    • Using suitable brake cleaner, remove any foreign material from the threads.
    • Dry the threads.
  81. Install the drive plate. Renew the bolts.
    CAUTION: Tighten the bolts in a diagonal sequence.
    Fig 4: Drive Plate Bolts Tightening Sequence
    G11309145Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    Torque Specification: 

    Stage 1: 30 Nm 

    Stage 2: 120° 

  82. Remove the special tool.
    G00565436

    Special Tool(s):  JLR-303-1630

  83. Remove and discard the old engine number label.
    G00569418
  84. Clean and dry the valve cover vent oil separator.
  85. Install the new engine number label supplied with the new engine.
    G00569419
  86. Install the engine assembly.

    Refer to engine - Installation .

  87. Fill engine with the correct specification and amount of oil and engine coolant.

    Refer to SPECIFICATIONS .

  88. Run the engine and check for fluid leaks.
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