High Pressure Turbocharger - INGENIUM I4 2.0L Diesel - High Power (G1914798): Installation

WARNING: This page is about a different variant/trim than selected.

Install a new exhaust manifold gasket.
Renew Part: Exhaust manifold gasket Quantity: 1.
CAUTION: This step only applies if the original cylinder head is installed.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC
- Install the special tool as illustrated.
  Special Tool(s): 303-1444-01
- Install the exhaust manifold.
CAUTION: This step only applies if a new cylinder head is installed.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC
- Install the special tool as illustrated.
  Special Tool(s): 303-1444-02
- Install the exhaust manifold.
Fig 1: Exhaust Manifold Tightening Sequence
Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC
- Use the special tool to install and tighten the 3 bolts in the illustrated sequence.
  Special Tool(s): JLR-303-1652
  
  Renew Part: Exhaust manifold bolts and spacers Quantity: 8.
  
  Torque: 15 Nm
- Remove the special tools.
  Special Tool(s): 303-1444-01, 303-1444-02
Fig 2: Exhaust Manifold Tightening Sequence
Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Use the special tool to install and tighten the 8 bolts in the illustrated sequence.

Special Tool(s): JLR-303-1652

Torque

Stage 1: 15 Nm

Stage 2: 28 Nm
- Secure the EGR pipe to the exhaust manifold.
- Install a new gasket.
  Renew Part: Exhaust gas recirculation pipe gasket Quantity: 1.
- Torque: 12 Nm
- Install the turbocharger support bracket.
  Torque
  
  M8: 25 Nm
  
  M6: 10 Nm
- Install the turbocharger oil return tube.
- Install new O-ring seals.
  Renew Part: Upper oil return pipe O-ring seal Quantity: 1.
  
  Renew Part: Lower oil return pipe O-ring seal(s) Quantity: 1.
- Torque: 11 Nm
- Install the exhaust manifold heat shields.
- Torque: 9 Nm
- Install new O-ring seals.
  Renew Part: Turbocharger outlet pipe O-ring kit Quantity: 1.
- Install the turbocharger outlet pipe.
- Install and tighten the 4 bolts.
  Torque: 9 Nm
- Install the turbocharger oil feed pipe.
- Install new sealing washers and bolt.
  Renew Part: Turbocharger oil supply pipe banjo bolt Quantity: 1.
  
  Renew Part: Turbocharger oil feed pipe banjo bolt washers Quantity: 2.
- Install and tighten the banjo bolt.
  Torque: 18 Nm
Connect the turbocharger electrical connector.
Install the low pressure turbocharger.
Refer to: LOW PRESSURE TURBOCHARGER - INGENIUM I4 2.0L DIESEL - HIGH POWER
Connect the battery ground cable.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT
If a new turbocharger is installed, the powertrain air path learn process must be done with the use of the Jaguar Land Rover (JLR) approved diagnostic equipment.
General Equipment: Jaguar Land Rover approved diagnostic equipment