Engine And Ancillaries (G1867846): Installation: Part(S)

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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

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.

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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: 37 Nm 

Stage 2: 90° 

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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: 25 Nm 

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Loosen the 4 bolts by 4 mm.

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: 80 Nm 

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• Remove the 6 bolts.
• Remove the bracket.

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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: 11 Nm 

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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.

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: 30 Nm 

  Stage 2: 120° 

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: 29 Nm 

• 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 

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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: 30 Nm 

  Stage 2: 120° 

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• Remove the special tool.
• Special Tool(s): JLR-303-1630 

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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: 12 Nm 

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• Install the Variable Camshaft Timing (VCT) solenoid

  Renew Part: Variable Valve Timing Solenoid O-ring seal(s) Quantity: 1  .

• Torque: 9 Nm 

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

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• Install the engine oil filler pipe.
• Torque: 12 Nm 

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• Install the bracket.
• Torque: 12 Nm 

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• Install the engine mounting bracket.
• Torque: 60 Nm 

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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: 11 Nm 

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: 15 Nm 

  Stage 2: 28 Nm 

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• Install the exhaust manifold heat shield.
• Torque: 8 Nm 

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• Install the Crankshaft Position Sensor (CKP) sensor.
• Torque: 8 Nm 

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• 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.

  Install the new gaskets.

  Renew Part: Intake manifold gaskets Quantity: 1  .

• Install the inlet manifold complete with throttle body.

  Torque: 12 Nm 

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• Install the new engine number label.

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• Install the bracket.
• Torque: 12 Nm 

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• Install the fuel rail.
• Torque: 25 Nm 

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• Install the bracket.
• Torque: 12 Nm 

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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: 15 Nm 

  Stage 2: 60° 

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• Install the bracket.
• Torque: 12 Nm 

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• Install the glow plugs.
• Torque: 12 Nm 

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• Install the bock heater.
• Torque: 55 Nm 

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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: 1 5 Nm 

  Stage 2: 60° 

• Torque 

  Bolt: 10 Nm 

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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: 8 Nm 

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• Install the Exhaust Gas Recirculation (EGR) valve.
• Torque: 10 Nm 

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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: 8 Nm 

  Exhaust Valve: 10 Nm 

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• 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.

  Install a new gasket.

  Renew Part: EGR inlet pipe to EGR valve gasket Quantity: 1  .

• Torque: 10 Nm 

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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: 7 Nm 

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• Install the bracket.
• Torque: 25 Nm 

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• 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.

  Install a new O-ring seal.

  Renew Part: EGR cooler to cylinder block gasket Quantity: 1  .

• Torque: 25 Nm 
• Connect and secure the coolant hose.

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• CAUTION: Take care not to damage the O-ring seals during installation.

  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: 28 Nm 

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Torque: 28 Nm 

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

Torque: 25 Nm 

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• 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.

  Connect the breather pipe.

• Torque: 10 Nm 

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• Install the turbocharger heat shield.
• Torque: 8 Nm 

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• Install the exhaust gas temperature sensor.
• Torque: 44 Nm 

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• 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.

  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: 10 Nm 

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Install the turbocharger outlet pipe.

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Torque: 10 Nm 

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• Install new sealing washers.

  Renew Part: Turbocharger oil supply tube to turbocharger sealing washers Quantity: 1  .

• Torque: 18 Nm 

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Install the hose.

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• Install the accessory drive belt idler.
• Torque: 48 Nm 

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• Install the accessory drive component bracket.
• Torque: 48 Nm 

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Install the coolant pump.

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• CAUTION: During the installation, make sure that all components are clean and free from foreign material.

  Install the coolant pump pulley.

• Torque: 26 Nm 

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• Install the coolant hose assembly.
• Torque: 12 Nm 

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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: 12 Nm 

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• Secure the wiring harness.
• Torque: 12 Nm 

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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: 10 Nm 

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• Install the charge air cooler mounting bracket.
• Install and tighten the 2 bolts.

  Torque: 47 Nm 

• Install and tighten the 2 nuts.

  Torque: 10 Nm 

• Install the 2 electrical wiring harness clips.

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• Install the charge air cooler assembly.
• Install and tighten the 4 bolts.

  Torque: 7 Nm 

• 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: 80 Nm 

  Stage 2: 1 80° 

Refer to: ENGINE ASSEMBLY REMOVE FOR ACCESS - VEHICLES WITH: AUTOMATIC TRANSMISSION 

Refer to: ENGINE ASSEMBLY REMOVE FOR ACCESS - VEHICLES WITH: AUTOMATIC TRANSMISSION 

Refer to: STARTUP BATTERY DISCONNECT AND CONNECT

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Remove the engine oil level indicator.

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.

• Start the engine and allow to run for 10 minutes, stop the engine.
• Check for leaks.
• Check the engine oil level.

• 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.