Engine And Ancillaries: Removal: 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	QUANTITY
Step 4	Differential case front bolt(s)	4
Step 5	Front differential case to engine oil pan O-ring seal	1
Step 14	Thermostat to cylinder block gasket	1
Step 30	Oil supply pipe sealing washers	1
Step 33	Oil return pipe O-ring seal	2
Step 39	Turbocharger to exhaust manifold gasket	1
Step 39	EGR cooler to EGR valve gasket	1
Step 40	EGR valve to turbocharger O-ring seal	1
Step 41	Low pressure exhaust gas recirculation cooler O-ring seal	1
Step 43	Oil level gauge O-ring seal	1
Step 45	EGR pipe to intake manifold O-ring seal	1
Step 45	EGR pipe to exhaust manifold gasket	1
Step 48	Fuel rail supply pipe(s)	1
Step 49	Fuel injector high pressure pipe(s)	4
Step 57	Engine number label	1
Step 58	Intake manifold gaskets	8
Step 61	Exhaust manifold bolts and spacers	1
Step 61	Exhaust manifold gasket	1
Step 62	Fuel injector clamp bolts	4
Step 64	Fuel injector seals	4
Step 70	Engine vent oil separator to valve cover gasket	1

CAUTION: Before disconnecting or removing components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

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.

Raise and support the vehicle on a suitable 2 post lift.
Refer to: LIFTING
Disconnect the battery ground cable.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT
Remove the engine.
Refer to: ENGINE ASSEMBLY REMOVE FOR ACCESS - VEHICLES WITH: AUTOMATIC TRANSMISSION
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- Remove and discard the 4 bolts.
  Renew Part: Differential case front bolt(s) Quantity: 4 .
- Remove the differential.
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Remove and discard the O-ring seal.

Renew Part: Front differential case to engine oil pan O-ring seal Quantity: 1 .
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- Release the hose clip.
- Disconnect the electrical connector.
- Remove the 4 bolts.
- Remove the charge air cooler assembly.
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- Release the 2 electrical wiring harness clips.
- Remove the 2 nuts.
- Remove the 2 bolts.
- Remove the charge air cooler mounting bracket.
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Remove the Noise, Vibration and Harshness (NVH) insulation.
CAUTION:
- Be prepared to collect escaping oil.
- Allow at least 10 minutes for the engine oil to drain.
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Drain the engine oil.
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- Install the oil pan plug removed in the previous step.
- Torque : 23Nm
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Release the 2 coolant hoses.
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Remove the coolant hose.
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LH side: Release the wiring harness.
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- Remove the thermostat.
- Remove and discard the gasket.
Renew Part: Thermostat to cylinder block gasket Quantity: 1 .
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Release the electrical harness.
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Release the glow plug wiring harness.
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Release the harness.
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Release the harness.
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Release the harness.
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Release the harness.
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Release the harness.
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Release the harness.
CAUTION: Make sure the wiring harness and electrical connectors are not damaged during this operation.

NOTE: Note the position of the wiring harnesses to aid installation.

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Remove the engine wiring harness.
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Remove the coolant hose assembly.
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Remove the coolant pump pulley.
NOTE:
- This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.
- Inspect the coolant pump seal for damage. If any damage is visible, a new coolant pump must be installed.
- If no seal damage is visible, the coolant pump is to be fitted to the new engine.
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Remove the coolant pump.
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Remove the accessory drive component bracket.
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Remove the accessory drive belt idler.
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Release the hose.
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- Remove the banjo bolt.
- Remove and discard the sealing washers.
Renew Part: Oil supply pipe sealing washers Quantity: 1 .
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Remove the bolt.
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Remove the turbocharger outlet pipe.
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- Remove the bolt.
- Push the oil drain tube into the engine and release it from the turbocharger.
- Rotate the oil drain tube and remove it from the engine.
- Remove and discard the 2 O-ring seals.
Renew Part: Oil return pipe O-ring seal Quantity: 2 .
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Remove the exhaust gas temperature sensor.
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Remove the turbocharger heat shield.
NOTE: This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

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Remove the breather tube.
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Remove the 2 bolts.
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Remove the nut.
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- Remove the turbocharger.
- Discard the gasket.
Renew Part: Turbocharger to exhaust manifold gasket Quantity: 1 .

Renew Part: EGR cooler to EGR valve gasket Quantity: 1 .
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- Remove the Exhaust Gas Recirculation (EGR) valve.
- Discard the O-ring seal.
Renew Part: EGR valve to turbocharger O-ring seal Quantity: 1 .
NOTE: This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

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- Release the coolant hose.
- Remove the 4 bolts.
- Remove the EGR assembly.
- Discard the O-ring seal.
Renew Part: Low pressure exhaust gas recirculation cooler O-ring seal Quantity: 1 .
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- Remove the 2 bolts.
- Remove the bracket.
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- Release the 3 clips.
- Remove the bolt.
- Remove the oil level indicator and tube.
- Discard the O-ring seal.
Renew Part: Oil level gauge O-ring seal Quantity: 1 .
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- Remove the 2 bolts.
- Release the EGR valve inlet tube.
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- Remove the 4 bolts.
- Remove the EGR pipe.
- Discard the O-ring seal.
  Renew Part: EGR pipe to intake manifold O-ring seal Quantity: 1 .
- Discard the gasket.
Renew Part: EGR pipe to exhaust manifold gasket Quantity: 1 .
NOTE: This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

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- Remove the 5 bolts.
- Remove the EGR valve.
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- Remove the 2 bolts.
- Disconnect and release the fuel return lines.
CAUTION:
- Be prepared to collect escaping fuel.
- Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
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Remove and discard the high pressure fuel line.

Renew Part: Fuel rail supply pipe(s) Quantity: 1 .
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

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Remove and discard the 4 high-pressure fuel supply lines.

Renew Part: Fuel injector high pressure pipe(s) Quantity: 4 .
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- Remove the 2 bolts.
- Remove the bracket.
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- Remove the 2 bolts.
- Remove the fuel rail.
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Remove the vacuum pipe assembly.
NOTE: If equipped.

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Remove the block heater.
CAUTION: If accidentally dropped or knocked install a new glow plug.

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Remove the glow plugs.
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- Remove the 2 bolts.
- Remove the mounting bracket.
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- Remove the 2 bolts.
- Remove the bracket.
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Remove and discard the engine number label.

Renew Part: Engine number label Quantity: 1 .
NOTE: This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

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- Remove the 9 bolts.
- Remove the inlet manifold complete with throttle body.
- Remove and discard the intake manifold gaskets.
Renew Part: Intake manifold gaskets Quantity: 8 .
NOTE: This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

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- Remove the bolt.
- Remove the Crankshaft Position Sensor (CKP) sensor.
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- Remove the 2 bolts.
- Remove the exhaust manifold heat shield.
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- Remove the 8 bolts.
- Discard the spacers and the bolts.
  Renew Part: Exhaust manifold bolts and spacers Quantity: 1 .
- Remove the exhaust manifold.
- Remove and discard the gasket.
Renew Part: Exhaust manifold gasket Quantity: 1 .
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- Remove and discard the 4 bolts.
  Renew Part: Fuel injector clamp bolts Quantity: 4 .
- Remove the fuel injector retaining clamps.
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- Special Tool(s): 100-012
- Special Tool(s): JLR-310-253
- Using the special tool, remove the fuel injectors.
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Remove and discard the fuel injector seal.

Renew Part: Fuel injector seals Quantity: 4 .
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- Remove the 4 bolts.
- Remove the engine mounting bracket.
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- Remove the bolt.
- Remove the bracket.
NOTE: This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

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- Remove the bolt.
- Remove the engine oil filler pipe.
NOTE: This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

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- Remove the bolt.
- Remove the Camshaft Position Sensor (CMP) sensor.
NOTE: This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

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Remove the Variable Camshaft Timing (VCT) solenoid.
NOTE: This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

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- Remove the 8 bolts.
- Remove the engine vent oil separator.
- Remove and discard the gasket.
Renew Part: Engine vent oil separator to valve cover gasket Quantity: 1 .
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- Install the special tool.
- Special Tool(s): JLR-303-1630
NOTE: Vehicles with automatic transmission.

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- Remove and discard the 8 bolts.
- Remove the drive plate.
NOTE: Vehicles with manual transmission.

Fig 1: Clutch Pressure Plate Bolts Loosening Sequence
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- Slacken the bolts of the clutch pressure plate each two turns at a time in the sequence shown.
- Remove and discard the 6 bolts.
NOTE:
- Vehicles with manual transmission.
- This step requires the aid of another technician.
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- Remove the drive plate.
- Remove and discard the 8 bolts.
NOTE: This step is only required if a re-manufactured engine is being installed.

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- Remove the 2 bolts.
- Remove the fuel pump cover.
- Remove and discard the O-ring seal.
NOTE: This step is only required if a re-manufactured engine is being installed.

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- Install the special tool.
  Special Tool(s): JLR-303-1627
- Install, but do not fully tighten the 2 bolts.
NOTE: This step is only required if a re-manufactured engine is being installed.

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Install, but do not fully tighten the 4 bolts.
NOTE: This step is only required if a re-manufactured engine is being installed.

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Tighten the 6 bolts in the illustrated sequence.

Torque : 5Nm
NOTE: This step is only required if a re-manufactured engine is being installed.

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

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Release the 3 bolts.

Torque : Loosen 4 turn(s)
NOTE: This step is only required if a re-manufactured engine is being installed.

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Install and tighten the special tool bolt to break the taper on the fuel pump shaft.
NOTE: This step is only required if a re-manufactured engine is being installed.

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The fuel pump will release from the cylinder block.
NOTE: This step is only required if a re-manufactured engine is being installed.

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

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- Remove the 6 bolts.
- Remove the special tool.
Special Tool(s): JLR-303-1627
NOTE: This step is only required if a re-manufactured engine is being installed.

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- Remove and discard the 3 bolts.
- Remove the fuel pump.
- Remove and discard the O-ring seal.
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Remove and discard the 4 bolts.
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- Remove the special tool.
  Special Tool(s): JLR-303-1630
- Remove the crankshaft pulley.
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Remove the NVH pad.