Removal And Installation: Removal

Special Tool(s) 

	100-012  Slide Hammer
	JLR-303-1630  Locking Tool, Crankshaft Pulley
	303-1450  Spark Plug Remover/Installer
	JLR-310-254A  Injector Remover

General Equipment 

Procedure 

1. Before working on the fuel system make sure to study the fuel system health and safety section of this manual.

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

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

   Refer to: Lifting .

   General Equipment:  Two-post lift

3. Disconnect the startup battery ground cable.

   Refer to: Battery Disconnect and Connect .

4. Remove the engine assembly from wehicle.

   Refer to: ENGINE .

5. Install the special tool.

   Special Tool(s):  JLR-303-1630

6. Remove the drive plate. Discard the bolts.
7. Support the engine on a suitable engine stand.
8. Remove the engine mounting brackets.
9. Remove and discard the crankshaft pulley bolts.
10. Remove the special tool.

    Special Tool(s):  JLR-303-1630

11. Remove the crankshaft pulley.
12. NOTE: If equipped.

    Remove the front differential case.

13. NOTE: If equipped.

    Remove the halfshaft support bracket.

14. Remove the drain plug and allow engine oil to drain into a suitable container.
15. Remove the Noise, Vibration and Harshness (NVH) material.
16. Remove the breather.
17. Remove the coolant hose.
18. Remove the vacuum pipe assembly.
19. Remove the oil level gauge assembly. Discard the O-ring seal.
20. CAUTION: Do not use excessive force to remove the bolt covers.

    Remove the accessory drive belt idler pulleys.

21. Remove the accessory drive belt tensioner.
22. Remove the generator.
23. Disconnect and release the coolant hose.
24. Remove the coolant hose.

    Disconnect the engine management wiring harness from the main engine compartment harness.

25. Disconnect and release the wiring harness.
    CAUTION: Take care when disconnecting and releasing the wiring harness.
26. Disconnect and release the wiring harness.
    CAUTION: Take care when disconnecting and releasing the wiring harness.
27. CAUTION: Take care when disconnecting and releasing the wiring harness.

    Disconnect and release the wiring harness.

28. Disconnect and release the wiring harness.
    CAUTION: Take care when disconnecting and releasing the wiring harness.
29. Remove the wiring harness.
    CAUTION: Note the original routing of the wiring harness prior the removal.
30. Remove both fuel supply pipes.
31. Remove the purge valve.
32. Remove the intake manifold.
    • Release the knock sensor wiring harness.
    • Remove the intake manifold. Discard the seals.
33. Remove the knock sensors.
    CAUTION: Note the orientation of the knock sensors prior to removal.
34. Remove the thermostat housing. Discard the gasket.
35. Remove the coolant pump pulley.
36. Remove the coolant pump.
37. Disconnect the turbocharger oil supply hose. Discard the sealing washers.
    NOTE: Note the orientation of the oil supply hose prior to removal.
38. Remove the turbocharger oil supply hose. Discard the sealing washers.
    NOTE: Note the orientation of the oil supply hose prior to removal.
39. Disconnect the turbocharger coolant supply and return hoses. Inspect the O-ring seals, discard the components if damaged or worn.
40. Remove the coolant degas separator.
41. Remove the turbocharger lower heatshield.
42. Remove the turbocharger heatshield.
43. Remove the turbocharger oil return pipe. Discard the 2 O-ring seals.
44. Remove the turbocharger. Discard the nuts and gasket.
45. Remove the coolant pump inlet pipe. Discard the O-ring seal.
46. Remove the crankshaft position sensor.
47. Remove the camshaft position sensors.
48. Remove the variable valve timing solenoids.
49. Remove the oil filler neck.
50. Remove the engine lifting eye.
51. Remove the ignition coil-on-plugs.
52. Using special tool, remove the spark plugs.

    Special Tool(s):  303-1450

53. Release the fuel injector wiring harness.
    CAUTION: Take care when disconnecting and removing the wiring harness.
54. Remove the fuel rail.
    CAUTION: Loosen each of the bolts 1 turn at a time until the spring tension is fully released.
55. Remove the fuel injector wiring harness.
56. Remove and discard the 4 fuel injector spring clamps.
57. Install the special tool to the fuel injector.
    CAUTION: Make sure that the special tool is correctly installed.

    Special Tool(s): JLR-310-254A

58. Using the special tools, remove the injector.

    Special Tool(s): JLR-310-254A

59. Remove and discard the O-ring seals
    CAUTION: Do not use any sharp tools to remove the O-ring seal as damage could occur to the fuel injector.
60. CAUTION:

    • Do not use a knife to remove the Teflon seal as damage could occur to the fuel injector.
    • Pinch the Teflon seal to allow the tool to cut the Teflon seal without damaging the fuel injector.
    • Do not cut the Teflon seal too deep as damage could occur to the fuel injector.

    Remove and discard the Teflon seal.

61. Repeat steps  57 to 60 for the remaining injectors.
62. Remove the high pressure fuel pump. Discard the bolts.
    CAUTION: Loosen each of the bolts 1 turn at a time until the spring tension is fully released.
63. Remove the high pressure fuel pump. Discard the bolts.
64. Remove the purge valve mounting bracket.
65. Install the drain plug.
66. Remove the NVH material.
67. Remove the NVH material.
68. Remove the oil cooler. Discard the gasket.
69. Remove the block heater.
    NOTE: If equipped.
70. Remove the piston cooling jet solenoid.
71. Remove the valve cover vent oil separator. Discard the gasket.
72. Remove and discard the oil filter element and O-ring seal.
73. Remove the oil filter housing.
74. Discard the oil filter housing O-ring seals.