Engine And Ancillaries: Installation: Part(S)

WARNING: This page is about a different car, the 2019 Jaguar XE. However, it is still accessible from the selected car via links, so may be relevant.

STEP	PART NAME	PART NUMBER	QUANTITY
Step 3	Engine NVH pad		1
Step 8	Fuel pump O-ring seal		1
Step 8	Fuel Injection Pump retaining bolts		3
Step 10	Fuel pump drive sprocket nut		1
Step 12	Fuel pump cover O-ring seal		1
Step 14	Drive plate/flywheel bolts - Ingenium Diesel	LR074135/T2R15200	8
Step 15	Clutch pressure plate bolts (manual transmission only) - Ingenium Diesel	LR072974/T2R15201	1
Step 16	Flexplate bolts		8
Step 18	Engine vent oil separator to valve cover gasket		1
Step 19	Variable Valve Timing Solenoid O-ring seal(s)		1
Step 24	Fuel injector O-ring seals		4
Step 27	Fuel injector clamp bolts		4
Step 28	Exhaust manifold gasket		1
Step 28	Exhaust manifold bolts and spacers		8
Step 31	Intake manifold gaskets		1
Step 36	Fuel injector high pressure pipe(s)		4
Step 40	Fuel rail supply pipe(s)		1
Step 44	EGR outlet pipe to throttle body gasket		1
Step 44	Exhaust gas recirculation outlet pipe to exhaust gas recirculation valve gasket		1
Step 45	EGR inlet pipe to EGR valve gasket		1
Step 46	Oil level gauge O-ring seal		1
Step 48	EGR cooler to cylinder block gasket		1
Step 49	Low pressure exhaust gas recirculation valve to turbocharger seal		1
Step 50	Turbocharger to exhaust manifold gasket		1
Step 52	Low pressure exhaust gas recirculation (EGR) valve to low pressure EGR cooler gasket		1
Step 56	Oil return pipe O-ring seal		2
Step 59	Turbocharger oil supply tube to turbocharger sealing washers		1
Step 75	Thermostat to cylinder block gasket		1
Step 82	Front differential case to engine oil pan O-ring seal		1
Step 83	Differential case front bolt(s)		4

CAUTION: 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 illustrations showing certain components removed to provide extra clarity.

NOTE: The engine number label is in yy/mm/dd format, represented by the first 6 digits. For example, the first 6 digits in the illustration shows 200110. This represents 10th January 2020.

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- Check the engine number of the new engine.
- If the engine number is after 200110W000001**** (10th January 2020) proceed to step 2.
- If the engine number is before 200110W000001**** (10th January 2020) complete the replacement engine - balance shaft assembly procedure and continue to step 2.
  Refer to: REPLACEMENT ENGINE - BALANCE SHAFT ASSEMBLY
For the list of part numbers required for this job please refer to the specifications.
Refer to: SPECIFICATIONS
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Install a new Noise, Vibration and Harshness (NVH) pad.

Renew Part: Engine NVH pad Quantity: 1 .
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Install the NVH pad.
CAUTION: During the installation, make sure that all components are clean and free from foreign material.

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- Install the crankshaft pulley.
- Install the special tool.
Special Tool(s): JLR-303-1630
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Before installing the new crankshaft damper bolts check the length of the thread as shown in the illustration. The new bolts must be 48 mm in length.
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Install and tighten the 4 bolts.

Torque

Stage 1: 37Nm

Stage 2: 90°
NOTE: This step is only required if a re-manufactured engine is being installed.

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- Install a new O-ring seal.
  Renew Part: Fuel pump O-ring seal Quantity: 1 .
- Lubricate the O-ring seal with new engine oil.
  Refer to: SPECIFICATIONS
- Install the fuel pump.
- Install and tighten the 3 bolts.
Renew Part: Fuel Injection Pump retaining bolts Quantity: 3 .

Torque: 25Nm
NOTE: This step is only required if a re-manufactured engine is being installed.

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Loosen the 4 bolts by 4 mm.
NOTE: This step is only required if a re-manufactured engine is being installed.

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Install and tighten the nut.

Renew Part: Fuel pump drive sprocket nut Quantity: 1 .

Torque : 80Nm
NOTE: This step is only required if a re-manufactured engine is being installed.

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- Remove the 6 bolts.
- Remove the bracket.
NOTE: This step is only required if a re-manufactured engine is being installed.

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- Install a new O-ring seal.
  Renew Part: Fuel pump cover O-ring seal Quantity: 1 .
- Lubricate the O-ring seal with new engine oil.
  Refer to: SPECIFICATIONS
- Install the fuel pump cover.
- Install and tighten the 2 bolts.
  Torque : 11Nm
NOTE: 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.

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- Use a suitable M10 x 1.0 mm tap to clean out the threads illustrated.
- Use a suitable cleaning solution to remove any foreign material from the threads.
NOTE:
- Vehicles with manual transmission.
- This step requires the aid of another technician.
Fig 1: Drive Plate Tightening Sequence
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- Install the drive plate.
- Tighten the new bolts in the sequence indicated.
Renew Part: Drive plate/flywheel bolts - Ingenium Diesel Quantity: 8 . Part Number: LR074135/T2R15200

Torque

Stage 1: 30Nm

Stage 2: 120°
NOTE: Vehicles with manual transmission.

Fig 2: Clutch Pressure Plate Tightening Sequence
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- Install the clutch pressure plate.
- Tighten the new bolts in the sequence indicated.
  Renew Part: Clutch pressure plate bolts (manual transmission only) - Ingenium Diesel Quantity: 1 .
  
  Part Number: LR072974/T2R15201
  
  Torque : 29Nm
- Make sure the clutch assembly is installed in its released state. Refer to operating instructions supplied with the kit for the correct installation procedure.
General Equipment: Clutch alignment kit JLR-308-943
NOTE:
- Vehicles with automatic transmission.
- The drive plate will only locate in one position.
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- Install the drive plate.
- Tighten the new bolts in the sequence indicated.
Renew Part: Flexplate bolts Quantity: 8 .

Torque

Stage 1: 30Nm

Stage 2: 120°
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- Remove the special tool.
- Special Tool(s): JLR-303-1630
NOTE: 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.

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- Install a new gasket.
  Renew Part: Engine vent oil separator to valve cover gasket Quantity: 1 .
- Install the engine vent oil separator.
- Torque : 12Nm
NOTE: 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.

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- Install the Variable Camshaft Timing (VCT) solenoid
  Renew Part: Variable Valve Timing Solenoid O-ring seal(s) Quantity: 1 .
- Torque : 9Nm
NOTE: 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.

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- Install the Camshaft Position Sensor (CMP) sensor.
- Torque : 8Nm
NOTE: 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.

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- Install the engine oil filler pipe.
- Torque : 12Nm
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- Install the bracket.
- Torque : 12Nm
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- Install the engine mounting bracket.
- Torque : 60Nm
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Install new fuel injector seals.

Renew Part: Fuel injector O-ring seals Quantity: 4 .
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- Make sure the fuel injectors are not installed into the same cylinder number they were removed from.
- Swap the fuel injectors with the adjacent cylinder as illustrated.
- Note the fuel injector correction factor number.
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Install the fuel injectors.
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Install new bolts.

Renew Part: Fuel injector clamp bolts Quantity: 4 .

Torque

Stage 1: 11Nm

Stage 2: 162°
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- Install the new gasket.
  Renew Part: Exhaust manifold gasket Quantity: 1 .
- Install new bolts and spacers.
  Renew Part: Exhaust manifold bolts and spacers Quantity: 8 .
- Install the exhaust manifold.
Torque

Stage 1: 15Nm

Stage 2: 28Nm
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- Install the exhaust manifold heat shield.
- Torque : 8Nm
NOTE: 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.

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- Install the Crankshaft Position Sensor (CKP) sensor.
- Torque : 8Nm
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- Install the new gaskets.
  Renew Part: Intake manifold gaskets Quantity: 1 .
- Install the inlet manifold complete with throttle body.
  Torque : 12Nm
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- Install the new engine number label.
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- Install the bracket.
- Torque : 12Nm
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- Install the fuel rail.
- Torque : 25Nm
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- Install the bracket.
- Torque : 12Nm
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- Install the new high-pressure fuel supply lines.
Renew Part: Fuel injector high pressure pipe(s) Quantity: 4 .

Torque

Stage 1: 15Nm

Stage 2: 60°
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- Install the bracket.
- Torque : 12Nm
CAUTION: If accidentally dropped or knocked install a new glow plug.

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- Install the glow plugs.
- Torque : 12Nm
NOTE: If equipped.

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- Install the bock heater.
- Torque : 55Nm
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- Install a new high-pressure fuel supply line.
  Renew Part: Fuel rail supply pipe(s) Quantity: 1 .
  
  Torque
  
  Fuel line connection.
  
  Stage 1: 15Nm
  
  Stage 2: 60°
- Torque
Bolt: 10Nm
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Install the vacuum pipe assembly.
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- Install the fuel return lines.
- Install and tighten the 2 bolts.
  Torque : 8Nm
NOTE: 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.

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- Install the Exhaust Gas Recirculation (EGR) valve.
- Torque : 10Nm
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- Install a new O-ring seal.
  Renew Part: EGR outlet pipe to throttle body gasket Quantity: 1 .
- Install a new gasket.
  Renew Part: Exhaust gas recirculation outlet pipe to exhaust gas recirculation valve gasket Quantity: 1 .
- Install the EGR pipe.
- Torque
Inlet Manifold: 8Nm

Exhaust Valve: 10Nm
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- Install a new gasket.
  Renew Part: EGR inlet pipe to EGR valve gasket Quantity: 1 .
- Torque : 10Nm
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- Install a new O-ring seal.
  Renew Part: Oil level gauge O-ring seal Quantity: 1 .
- Install the oil level indicator and tube.
- Secure the 3 clips.
- Torque : 7Nm
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- Install the bracket.
- Torque : 25Nm
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- Install a new O-ring seal.
  Renew Part: EGR cooler to cylinder block gasket Quantity: 1 .
- Torque : 25Nm
- Connect and secure the coolant hose.
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- Install a new O-ring seal.
  Renew Part: Low pressure exhaust gas recirculation valve to turbocharger seal Quantity: 1 .
- Install the EGR valve.
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- Install the new gasket.
  Renew Part: Turbocharger to exhaust manifold gasket Quantity: 1 .
- Install the turbocharger.
- Torque : 28Nm
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Torque : 28Nm
NOTE: 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.

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Renew Part: Low pressure exhaust gas recirculation (EGR) valve to low pressure EGR cooler gasket Quantity: 1 .

Torque : 25Nm
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- Connect the breather pipe.
- Torque : 10Nm
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- Install the turbocharger heat shield.
- Torque : 8Nm
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- Install the exhaust gas temperature sensor.
- Torque : 44Nm
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- Install the new O-ring seals.
  Renew Part: Oil return pipe O-ring seal Quantity: 2 .
- Push the oil drain tube into the engine and rotate it into position.
- Lift the oil drain tube into the turbocharger and secure it into position.
- Torque : 10Nm
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Install the turbocharger outlet pipe.
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Torque : 10Nm
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- Install new sealing washers.
  Renew Part: Turbocharger oil supply tube to turbocharger sealing washers Quantity: 1 .
- Torque : 18Nm
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Install the hose.
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- Install the accessory drive belt idler.
- Torque : 48Nm
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- Install the accessory drive component bracket.
- Torque : 48Nm
NOTE:
- 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.
- The coolant pump from the previous engine is to be installed.
- Inspect the coolant pump seal. If any damage is visible, a new coolant pump must be installed.
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Install the coolant pump.
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- Install the coolant pump pulley.
- Torque : 26Nm
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- Install the coolant hose assembly.
- Torque : 12Nm
CAUTION: Make sure the wiring harness and electrical connectors are not damaged during this operation.

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Install the engine wiring harness.
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Secure the wiring harness.
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Secure the wiring harness.
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Secure the wiring harness.
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Secure the wiring harness.
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Secure the wiring harness.
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Secure the wiring harness.
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Secure the glow plug wiring harness.
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Secure the wiring harness.
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- Install a new gasket.
  Renew Part: Thermostat to cylinder block gasket Quantity: 1 .
- Install the thermostat.
- Secure the coolant hose.
- Torque : 12Nm
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- Secure the wiring harness.
- Torque : 12Nm
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Install the coolant hose.
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Install the coolant hoses.
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- Install the NVH insulation.
- Torque : 10Nm
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- Install the charge air cooler mounting bracket.
- Install and tighten the 2 bolts.
  Torque : 47Nm
- Install and tighten the 2 nuts.
  Torque : 10Nm
- Install the 2 electrical wiring harness clips.
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- Install the charge air cooler assembly.
- Install and tighten the 4 bolts.
  Torque : 7Nm
- Tighten the hose clip.
- Connect the electrical connector.
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Install a new O-ring seal.

Renew Part: Front differential case to engine oil pan O-ring seal Quantity: 1 .
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- Install the differential.
- Install and tighten 4 new bolts.
Renew Part: Differential case front bolt(s) Quantity: 4 .

Torque

Stage 1: 80Nm

Stage 2: 180°
Install the engine assembly.
Refer to: ENGINE ASSEMBLY REMOVE FOR ACCESS - VEHICLES WITH: AUTOMATIC TRANSMISSION
Install the battery ground cable.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT
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Remove the engine oil level indicator.
Fill the engine with oil.
Refer to: SPECIFICATIONS
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Clean any residual engine oil from the oil filler cap area.
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Using the engine oil level indicator check the engine oil level.
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- Start the engine and allow to run for 10 minutes, stop the engine.
- Check for leaks.
- Check the engine oil level.
NOTE: SRO(s) to be claimed separately.
- Connect the Jaguar Land Rover approved diagnostic equipment and run the following service functions.
  General Equipment: Jaguar Land Rover approved diagnostic equipment
- Fuel injector replacement.
- Air path setup routine.
- Engine Control Module (ECM) Low Pressure (LP) EGR adaption clear.