Special Tool(S)

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

G15618166

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100-012
Slide Hammer

G15618167

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100-012-01
Slide Hammer Adapter

G15618168

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JLR-303-1630
Locking Tool, Crankshaft Pulley

G15618169

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JLR-310-254
Injector Remover

WARNING:

Be prepared to collect escaping fuel.
Be prepared to collect escaping oil.
Be prepared to collect escaping coolant.

CAUTION:

All the components removed from the old engine must be cleaned and inspected before installing to the new engine. Any worn or damaged components or retaining clips must be replaced.
Note the orientation of the components prior to removal.
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.
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.

Always follow the fuel system health and safety precautions, when preforming any repairs to the fuel system.
Refer to: PETROL AND PETROL-ETHANOL FUEL SYSTEMS HEALTH AND SAFETY PRECAUTIONS .
Raise and support the vehicle on a suitable 2 post lift.
Refer to: LIFTING .
Disconnect the 12 V system.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT .
Remove the engine assembly.
Refer to: REMOVAL .
Support the engine on a suitable stand.
Remove the accessory drive belt.
Refer to: ACCESSORY DRIVE BELT (G1998262) .
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Install the special tool.

Special Tool(s): JLR-303-1630
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Remove the drive plate. Discard the bolts.
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Remove the engine mounting brackets.
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Remove and discard the crankshaft pulley bolts.
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Remove the special tool.

Special Tool(s): JLR-303-1630
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Remove the crankshaft pulley.
CAUTION: Lubricate the O-ring seal with clean engine oil.

NOTE: If equipped.

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Install the halfshaft support bracket.
NOTE: If equipped.

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Remove the front differential case.
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Remove the drain plug and allow engine oil to drain into a suitable container.
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Remove the Noise, Vibration and Harshness (NVH) material.
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Remove the breather.
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Remove the coolant hose.
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Remove the generator.
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Remove the Air Conditioning (A/C) compressor.
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Remove the vacuum pipe assembly.
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Remove the oil level gauge assembly. Discard the O-ring seal.
CAUTION: Do not use excessive force to remove the bolt covers.

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Remove the accessory drive belt idler pulleys.
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Remove the accessory drive belt tensioner.
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Disconnect and release the coolant hose.
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Remove the coolant hose.
CAUTION: Take care when disconnecting and releasing the wiring harness.

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Disconnect and release the wiring harness.
CAUTION: Take care when disconnecting and releasing the wiring harness.

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Disconnect and release the wiring harness.
CAUTION: Take care when disconnecting and releasing the wiring harness.

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Disconnect and release the wiring harness.
CAUTION: Take care when disconnecting and releasing the wiring harness.

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Disconnect and release the wiring harness.
CAUTION: Note the original routing of the wiring harness prior the removal.

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Remove the wiring harness.
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Remove both fuel supply pipes.
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Remove the purge valve.
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- Release the knock sensor wiring harness.
- Remove the intake manifold. Discard the seals.
CAUTION: Note the orientation of the knock sensors prior to removal.

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Remove the knock sensors.
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Remove the thermostat housing. Discard the gasket.
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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.
NOTE: Note the orientation of the oil supply hose prior to removal.

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Disconnect the turbocharger oil supply hose. Discard the sealing washers.
NOTE: Note the orientation of the oil supply hose prior to removal.

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Remove the turbocharger oil supply hose. Discard the sealing washers.
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Disconnect the turbocharger coolant supply and return hoses. Inspect the O-ring seals, discard the components if damaged or worn.
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Remove the coolant degas separator. Discard the O-ring seal.
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Remove the turbocharger lower heatshield.
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Remove the turbocharger heatshield.
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Remove the turbocharger oil return pipe. Discard the 2 O-ring seals.
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Remove the turbocharger. Discard the nuts and gasket.
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Remove the coolant pump inlet pipe. Discard the O-ring seal.
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Remove the crankshaft position sensor. Discard the O-ring seal
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Remove the camshaft position sensors. Discard the 2 O-ring seals.
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Remove the Variable Camshaft Timing (VCT) solenoids. Discard the 2 O-ring seals.
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Remove the oil filler neck.
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Remove the engine lifting eye.
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Remove the ignition coil-on-plugs.
CAUTION: Take care when disconnecting and removing the wiring harness.

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Release the fuel injector wiring harness.
CAUTION: Loosen each of the bolts 1 turn at a time until the spring tension is fully released.

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Remove the fuel rail.
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Remove the fuel injector wiring harness.
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Remove and discard the 4 fuel injector spring clamps.
CAUTION: Make sure that the special tool is correctly installed.

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Install the special tool to the fuel injector.

Special Tool(s): JLR-310-254
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Using the special tools, remove the injector.

Special Tool(s): 100-012 , 100-012-01 , JLR-310-254
CAUTION: Do not use any sharp tools to remove the O-ring seal as damage could occur to the fuel injector.

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Remove and discard the O-ring seals.
CAUTION:
- Do not use a knife to remove the Teflon seal as damage could occur to the fuel injector.
- Pinch the Teflon seal to allow the tool to cut the Teflon seal without damaging the fuel injector.
- Do not cut the Teflon seal too deep as damage could occur to the fuel injector.
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Remove and discard the Teflon seal.
Repeat steps 57 to 60 for the remaining injectors.
CAUTION: Loosen each of the bolts 1 turn at a time until the spring tension is fully released.

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Remove the high pressure fuel pump. Discard the bolts.
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Remove the purge valve mounting bracket.
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Install the drain plug.
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Remove the NVH material.
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Remove the NVH material.
NOTE: If equipped.

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Remove the block heater.
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Remove the engine vent oil separator. Discard the gasket.