Engine Assembly Remove For Access - Vehicles With: Manual Transmission (G2Z19824): Part(S)

Refer to: DIESEL FUEL SYSTEM HEALTH AND SAFETY PRECAUTIONS

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Using the hydraulic jib crane, remove the engine assembly from the engine stand.

Special Tool(s): JLR-303-1673  , JLR-303-1633 

General Equipment: Hydraulic jib crane 

General Equipment: Engine stand 

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Remove the special service tool.

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Install the engine mount bracket and tighten the bolts to the correct torque.

Torque: 63 Nm 

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• Install the vacuum reservoir and tighten the retaining nuts to the correct torque.

  Torque: 10 Nm 

• Install the vacuum hose.

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Install the engine into the vehicle. Make sure care is taken when aligning the transmission dowels and engine mounting studs.

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Install the right side engine mount nut and tighten to the correct torque.

Torque: 50 Nm 

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Install the left side engine mount nut and tighten to the correct torque.

Torque: 50 Nm 

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Install the bolts and tighten to the correct torque.

Torque: 48 Nm 

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Connect the electrical connector.

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Connect the vacuum hose.

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• Install the solenoid and the bracket retaining bolt and tighten to the correct torque.

  Torque: 10 Nm 

• Connect the electrical connector.

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Connect the expansion tank coolant hose.

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Connect the coolant hoses.

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Install new O-ring seals and connect the air conditioning pipe.

Renew Part: Air conditioning pipe O-ring seal(s) Quantity: 2  .

Torque: 8 Nm 

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Connect the fuel pipes and secure in the correct position.

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Install the ground cable.

Torque: 25 Nm 

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Install the electrical connectors and secure in the correct position.

Torque: 8 Nm 

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Install the 4 bolts and tighten to the correct torque.

Torque: 48 Nm 

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Install the 3 bolts and tighten to the correct torque.

Torque: 48 Nm 

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Install the starter motor and tighten to the correct torque.

Torque: 48 Nm 

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Install the starter motor electrical connector.

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• Connect the starter motor cable.

  Torque: 12 Nm 

• Secure the cover.

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• Install the cable mounting nut.

  Torque: 8 Nm 

• Secure the plastic fixing.
• Connect the cable.

  Torque: 12 Nm 

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Reposition the junction box cover.

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• position the left side front fender splash shield.
• Install the 5 fixings.

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• Install the Diesel Particulate Filter (DPF).
• Only tighten the upper DPF bracket nuts finger tight at this stage.

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Install the diesel particulate filter to turbocharger clamp. Install a new gasket.

Renew Part: Catalytic converter to turbocharger gasket Quantity: 1  .

Torque: 11 Nm 

Tighten the upper DPF bracket fixing nuts to the correct torque.

Torque: 25 Nm 

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• Install the DPF differential pressure sensor hoses.
• Install the High pressure hose clamp.
• Install the DPF diesel particulate filter retaining bracket bolt and tighten to the correct torque.

  Torque: 9 Nm 

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Connect electrical connectors.

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• Install the heatshield fixing bolts and tighten to the correct torque.

  Torque: 8 Nm 

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Tighten bolts to the correct torque.

Renew Part: Exhaust gas recirculation pipe gasket Quantity: 1  .

Torque: 10 Nm 

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Install the lower DPF bolts and tighten to the correct torque.

Torque: 25 Nm 

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Connect the exhaust system to the (DPF) and tighten the nuts to the correct torque.

Renew Part: Right exhaust downpipe to DPF gasket Quantity: 1  .

Renew Part: Right exhaust downpipe to Diesel Particulate Filter (DPF) nut(s) Quantity: 2  .

Torque: 40 Nm 

Refer to: COOLING MODULE

Refer to: SECONDARY BULKHEAD LEFT PANEL - INGENIUM I4 2.0L DIESEL

Refer to: COWL PANEL

Refer to: HOOD

Refer to: STARTUP BATTERY DISCONNECT AND CONNECT