Engine And Ancillaries (G2464048): Part(S)

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

STEP	PART NAME	QUANTITY
Step 95	Gasoline Particulate Filter (GPF) to exhaust manifold pipe	1
Step 24	Brake vacuum pump gasket	1
Step 28	Camshaft position sensor O-ring seal	2
Step 29	Camshaft position sensor O-ring seal	2
Step 43	Charge air cooler gasket	1
Step 12	Crankshaft pulley bolts	1
Step 3	Crankshaft pulley friction washer	1
Step 66	Cylinder block coolant outlet O-ring seals	2
Step 2	Drive plate bolts	10
Step 64	Engine block heater manifold seal(s)	1
Step 26	Engine coolant pump gasket	2
Step 21	Engine mount bolt(s)	4
Step 22	Engine mount bolt(s)	4
Step 88	Exhaust manifold bolts	8
Step 90	Exhaust manifold bolts	8
Step 87	Exhaust manifold gasket	1
Step 89	Exhaust manifold gasket	1
Step 51	Fuel injector refit kit	8
Step 76	Fuel pump O-ring seal	2
Step 79	Fuel rail supply pipe(s)	1
Step 93	Heatshield Screw - M6.3X13	3
Step 94	Heatshield Screw - M6.3X13	4
Step 93	Heatshield screw - M8x30	1
Step 39	Intake manifold gasket	2
Step 20	Oil cooler bolts	18
Step 19	Oil cooler gasket	1
Step 26	Oil cooler to coolant pump pipe	1
Step 26	Oil cooler to water pump O-ring seals	1
Step 97	Oil filter	1
Step 96	Oil filter housing gasket	1
Step 98	Thermostat to top coolant hose tube	1
Step 30	Variable Camshaft Timing (VCT) solenoid O-ring seals	2
Step 31	Variable Camshaft Timing (VCT) solenoid O-ring seals	2
Step 35	Water outlet to cylinder block tube	1

CAUTION:

Make sure that the components removed from the old engine are cleaned and inspected before installing to the replacement engine, any worn or damaged components or clips must be replaced.
Before installing any components make sure that the area is clean and free of any foreign material.
Make sure that all blanking caps are removed before installing components to the replacement engine. Failure to follow the above instructions might result in premature failure of the replacement engine.

NOTE:

Note the orientation of the components prior to removal.
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.

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- Install the special tool.
  Special Tool(s): JLR-303-1304
- Install and tighten the 2 bolts.
  Torque : 10 Nm
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- Install the drive plate.
- Install and tighten 10 new bolts in the illustrated sequence.
  Renew Part: Drive plate bolts Quantity: 10 .
  
  Torque
  
  Stage 1: 45 Nm
  
  Stage 2: 90°
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Install a new friction washer.

Renew Part: Crankshaft pulley friction washer Quantity: 1 .
CAUTION:
- Make sure that the components have been thoroughly cleaned and inspected before installing to the new engine. Failure to follow this instruction might result in premature engine failure.
- Make sure that all the required tools are present to fully seat the crankshaft damper in 7 minutes from the application of the RTV sealant. Failure to follow this instruction might result in excessive oil leaks.
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Apply RTV sealant to the crankshaft pulley keyway.

Material: Silicone Sealant LB (WSE-M4G323-A4/2U7J-M4G323-AA)

Material: Silicone Sealant LB (WSS-M4G320-A3/6G9N-M4G320-AA)
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Install the crankshaft pulley.
NOTE: The thread is left handed.

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Install the special tool.

Special Tool(s): 303-1440
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- Install the special tool.
  Special Tool(s): 303-1439
- Install and tighten the 4 bolts.
  Torque : 25 Nm
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- Install the special tool.
  Special Tool(s): 303-1441
- Rotate the crankshaft pulley installation tool until the pulley is fully located, do not over tighten. Failure to do this may result in damage to the components.
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Remove the special tools.

Special Tool(s): 303-1440 , 303-1441
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- Remove the 4 bolts.
- Remove the special tool.
  Special Tool(s): 303-1439
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Install and tighten the 2 bolts.

Torque : 65 Nm
NOTE:
- The thread is left handed.
- Make sure to use thread locking material.
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Install and tighten the bolt.

Renew Part: Crankshaft pulley bolts Quantity: 1 .

Torque : 200 Nm
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- Install the special tools.
  Special Tool(s): 303-1437 , 303-1438
- Install and tighten the 2 bolts.
  Torque : 25 Nm
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- Remove the 2 bolts.
- Remove the special tool.
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Mark up the socket at 9 o'clock and the special tool at 12 o'clock to aid the tightening of the bolt.
CAUTION: Make sure that the markings made in the previous step are followed accurately during the tightening of the bolt.

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- Use a suitable stand to support the special tool.
- Use the special tool to tighten the bolt.
  Special Tool(s): 303-1191
  
  Torque
  
  Stage 1: 200 Nm
  
  Stage 2: 270°
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- Remove the 2 bolts.
- Remove the special tools.
  Special Tool(s): 303-1437 , 303-1438
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Install and tighten the 2 bolts.

Torque : 65 Nm
CAUTION: Make sure that the mating faces are clean and free of any foreign material.

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Install a new oil cooler gasket.

Renew Part: Oil cooler gasket Quantity: 1 .
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- Install the oil cooler.
- Install and tighten 18 new bolts in the illustrated sequence.
  Renew Part: Oil cooler bolts Quantity: 18 .
  
  Torque : 11.5 Nm
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- Install the right engine mount.
- Install and tighten the 4 new bolts.
  Renew Part: Engine mount bolt(s) Quantity: 4 .
  
  Torque
  
  Stage 1: 45 Nm
  
  Stage 2: 60°
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- Install the left engine mount.
- Install and tighten the 4 new bolts.
  Renew Part: Engine mount bolt(s) Quantity: 4 .
  
  Torque
  
  Stage 1: 45 Nm
  
  Stage 2: 60°
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- Install the generator bracket.
- Install and tighten the 2 bolts.
  Torque : 47.5 Nm
CAUTION: Make sure that the components have been thoroughly cleaned and inspected before installing to the new engine. Failure to follow this instruction might result in premature engine failure.

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- Install a new gasket.
  Renew Part: Brake vacuum pump gasket Quantity: 1 .
- Install the brake vacuum pump.
- Install and tighten the 2 bolts.
  Torque : 11.5 Nm
CAUTION: Observe correct installation of the coolant pump to oil cooler tube o-ring seals. Failure to do so may result in coolant loss.

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Make sure that the coolant pump to oil cooler tube o-ring seals are correctly installed.
CAUTION:
- Coolant system components should be cleaned and checked carefully for damage, contamination or deterioration before installing to the new engine.
- If any contamination or damage is visible to the coolant pump, or the engine has been overheated make sure to replace the component.
- Make sure that no twisting or excessive force is used to install the coolant pump to the coolant inlet pipe. Failure to follow this instruction might result in premature failure of the engine.
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- Install 2 new O-ring seals.
  Renew Part: Oil cooler to water pump O-ring seals Quantity: 1 .
- Install the new coolant pump inlet pipe.
  Renew Part: Oil cooler to coolant pump pipe Quantity: 1 .
- Install 2 new gaskets.
  Renew Part: Engine coolant pump gasket Quantity: 2 .
- Install the coolant pump.
- Install, but do not fully tighten the 4 bolts.
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Tighten the 4 bolts in the sequence illustrated.

Torque : 11.5 Nm
CAUTION:
- Make sure that all the mating faces are clean and free of any foreign material.
- Make sure that the components have been thoroughly cleaned and inspected before installing to the new engine. Failure to follow this instruction might result in premature engine failure.
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- Install 2 new o-ring seals to the 2 Camshaft Position Sensor (CMP).
  Renew Part: Camshaft position sensor O-ring seal Quantity: 2 .
- Lubricate the o-ring seals.
- Install the 2 CMP sensors.
- Install and tighten the 2 bolts.
  Torque : 9 Nm
CAUTION:
- Make sure that all the mating faces are clean and free of any foreign material.
- Make sure that the components have been thoroughly cleaned and inspected before installing to the new engine. Failure to follow this instruction might result in premature engine failure.
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- Install 2 new o-ring seals to the 2 CMP.
  Renew Part: Camshaft position sensor O-ring seal Quantity: 2 .
- Lubricate the o-ring seals.
- Install the 2 CMP sensors.
- Install and tighten the 2 bolts.
  Torque : 9 Nm
CAUTION:
- Make sure that all the mating faces are clean and free of any foreign material.
- Make sure that the components have been thoroughly cleaned and inspected before installing to the new engine. Failure to follow this instruction might result in premature engine failure.
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- Install 2 new O-ring seals.
  Renew Part: Variable Camshaft Timing (VCT) solenoid O-ring seals Quantity: 2 .
- Install the 2 Variable Camshaft Timing (VCT) solenoids.
- Install and tighten the 4 bolts.
  Torque : 9 Nm
CAUTION:
- Make sure that all the mating faces are clean and free of any foreign material.
- Make sure that the components have been thoroughly cleaned and inspected before installing to the new engine. Failure to follow this instruction might result in premature engine failure.
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- Install 2 new O-ring seals.
  Renew Part: Variable Camshaft Timing (VCT) solenoid O-ring seals Quantity: 2 .
- Install the 2 VCT solenoids.
- Install and tighten the 4 bolts.
  Torque : 9 Nm
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- Install the accessory drive belt tensioner bracket.
- Install and tighten the 4 bolts.
  Torque : 25 Nm
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- Install the viscous fan pulley.
- Install and tighten the 3 bolts.
  Torque : 25 Nm
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- Install the accessory drive belt tensioner.
- Install and tighten the bolt.
  Torque : 47.5 Nm
CAUTION: Make sure that a new component is installed. Failure to follow this instruction might result in damage to the vehicle.

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- Install the 2 new O-ring seals.
- Use clean distilled water to lubricate the cylinder block coolant port bore.
- Install the new coolant outlet to cylinder block tube.
  Renew Part: Water outlet to cylinder block tube Quantity: 1 .
- Install and tighten the 2 bolts.
  Torque : 11.5 Nm
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Install the 2 Noise, Vibration and Harshness (NVH) components.
CAUTION: Take extra care when working near open inlet ports, any foreign material must be cleaned or removed immediately.

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- Install the knock sensor harness to its noted position on removal.
- Install and tighten the 4 bolts.
  Torque : 20 Nm
CAUTION:
- If a new cylinder head has been installed then the special tool 303-1449-02 without the thread must be used to install the supercharger.
- Take extra care when working near open inlet ports, any foreign material in the ports must be cleaned or removed immediately.
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Install the special tools.

Special Tool(s): 303-1449-01 , 303-1449-02
CAUTION: Take extra care when working near open inlet ports, any foreign material in the ports must be cleaned or removed immediately.

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Install 2 new intake manifold gaskets.

Renew Part: Intake manifold gasket Quantity: 2 .
CAUTION: Take extra care when working near open inlet ports, any foreign material in the ports must be cleaned or removed immediately.

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- Install the supercharger assembly.
- Install and tighten the 4 bolts in the illustrated sequence.
  Torque : 25 Nm
- Loosen but do not fully remove bolts 1 and 2.
- Tighten the 2 bolts.
  Torque : 25 Nm
CAUTION: Take extra care when working near open inlet ports, any foreign material in the ports must be cleaned or removed immediately.

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Remove the special tools.

Special Tool(s): 303-1449-01 , 303-1449-02
CAUTION: Take extra care when working near open inlet ports, any foreign material in the ports must be cleaned or removed immediately.

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Install and tighten the 4 bolts in the illustrated sequence.

Torque : 25 Nm
CAUTION: Take extra care when working near open inlet ports, any foreign material in the ports must be cleaned or removed immediately.

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- Install the special tools.
  Special Tool(s): JLR-303-1677
- Install a new gasket.
  Renew Part: Charge air cooler gasket Quantity: 1 .
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- Install the charge air cooler assembly.
- Install and tighten the 4 bolts in the illustrated sequence.
  Torque : 25 Nm
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- Remove the special tools.
  Special Tool(s): JLR-303-1677
- Install and tighten the 5 bolts in the illustrated sequence.
  Torque : 25 Nm
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Install and tighten the 7 bolts in the illustrated sequence.

Torque : 25 Nm
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Install and tighten the 7 bolts in the illustrated sequence.

Torque : 25 Nm
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Install and tighten the 2 bolts in the illustrated sequence.

Torque : 25 Nm
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- Install the bracket.
- Install and tighten the 2 bolts.
  Torque : 10 Nm
NOTE: Repeat this step for the remaining 4 injectors.

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Cut and remove the 4 seals.
CAUTION: Make sure that the mating surfaces are clean and free from debris and foreign material.

NOTE: Repeat this step for the remaining 7 fuel injectors.

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- Install the special tool.
  Special Tool(s): 310-198
- Use the special tool to install the new Teflon™ seal to the fuel injector.
- Make sure the Teflon™ seal is correctly installed.
  Renew Part: Fuel injector refit kit Quantity: 8 .
- Remove the special tool.
  Special Tool(s): 310-198
NOTE: Repeat this step for the remaining 7 fuel injectors.

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Use the special tool to fully install the Teflon™ seal.

Special Tool(s): 310-199
NOTE: Repeat this step for the remaining 7 fuel injectors.

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- Install the new fuel injector O-ring seal and washer supplied in the fuel injector installation kit.
- Install the new fuel injector clamp supplied in the fuel injector installation kit.
CAUTION: If a new cylinder head has been installed then the special tool 310-200-02 without the thread must be used to install the fuel rail.

NOTE: Repeat this step for the other side.

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Install the special tools.

Special Tool(s): 310-200-01 , 310-200-02
NOTE: Repeat this step for the other side.

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Install the 4 fuel injectors.
CAUTION: Make sure that the fuel injectors are aligned and installed into the fuel rail correctly, as noted in the removal step.

NOTE: Repeat this step for the other side.

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- Install the fuel rail.
- Install and tighten the 2 bolts a half turn at a time until the correct torque is achieved.
  Torque : 20 Nm
NOTE: Repeat this step for the other side.

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Remove the special tools.

Special Tool(s): 310-200-01 , 310-200-02
NOTE: Repeat this step for the other side.

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Install and tighten the 2 bolts in the illustrated sequence.

Torque : 20 Nm
NOTE: Repeat this step for the other side.

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Install and tighten the 2 bolts in the illustrated sequence.

Torque : 30 Nm
NOTE: Repeat this step for the other side.

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Install and tighten the 2 bolts in the illustrated sequence.

Torque : 30 Nm
NOTE: Repeat this step for the other side.

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Use the special tool to install and tighten the 4 spark plugs.

Special Tool(s): 303-1450

Torque : 20 Nm
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- Install the 4 ignition coils.
- Install and tighten the 4 bolts.
  Torque : 8 Nm
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- Install the 4 ignition coils.
- Install and tighten the 4 bolts.
  Torque : 8 Nm
CAUTION: Coolant system components should be cleaned and checked carefully for damage, contamination or deterioration before installing to the new engine.

NOTE: If equipped.

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- Install a new gasket.
  Renew Part: Engine block heater manifold seal(s) Quantity: 1 .
- Install and tighten the block heater.
  Torque : 50 Nm
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- Install the bracket.
- Install and tighten the 3 bolts.
  Torque : 11.5 Nm
- Install the 2 clips.
CAUTION:
- Coolant system components should be cleaned and checked carefully for damage, contamination or deterioration before installing to the new engine.
- If any contamination or damage is visible to the coolant pipe, or the engine has been overheated make sure to replace the component.
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- Install 2 new O-ring seals.
  Renew Part: Cylinder block coolant outlet O-ring seals Quantity: 2 .
- Install the coolant pipe.
- Install and tighten the 2 bolts.
  Torque : 9 Nm
- Connect the coolant hose.
- Install the clamp.
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Install the engine wiring harness.
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- Connect the 3 electrical connectors.
- Install the clip.
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- Reposition the engine wiring harness in the correct location.
- Connect the 2 electrical connectors.
- Install the 5 clips.
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- Reposition the engine wiring harness in the correct location.
- Install the 4 clips.
- Connect the 8 electrical connectors.
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- Reposition the engine wiring harness in the correct location.
- Install the 5 clips.
- Connect the 9 electrical connectors.
- Install and tighten the nut.
  Torque : 6.2 Nm
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- Reposition the engine wiring harness in the correct location.
- Connect the 4 electrical connectors.
- Install the clip.
- Install and tighten the bolt.
  Torque : 9 Nm
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- Reposition the engine wiring harness in the correct location.
- Connect the 4 electrical connectors.
- Install the 2 clips.
- Install and tighten the bolt.
  Torque : 9 Nm
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- Connect the 3 electrical connectors.
- Install the clip.
CAUTION:
- Make sure that all the mating faces are clean and free of any foreign material.
- Make sure that the components have been thoroughly cleaned and inspected before installing to the new engine. Failure to follow this instruction might result in premature engine failure.
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- Lubricate the High Pressure (HP) fuel pump tappet bores.
- Install the 2 HP fuel pump tappets.
CAUTION:
- Install the rear HP fuel pump first.
- Make sure that all the mating faces are clean and free of any foreign material.
- Make sure that the components have been thoroughly cleaned and inspected before installing to the new engine. Failure to follow this instruction might result in premature engine failure.
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- Install and lubricate the 2 new O-ring seals.
  Renew Part: Fuel pump O-ring seal Quantity: 2 .
- Install the rear HP fuel pump.
- Install, but do not fully tighten the 2 bolts.
- Tighten each bolt one turn at a time until the correct torque is achieved.
  Torque : 11.5 Nm
- Install the front HP fuel pump.
- Install, but do not fully tighten the 2 bolts.
- Tighten each bolt one turn at a time until the correct torque is achieved.
  Torque : 11.5 Nm
CAUTION: Make sure that the components have been thoroughly cleaned and inspected before installing to the new engine. Failure to follow this instruction might result in premature engine failure.

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Install the 2 HP fuel pump covers.
CAUTION:
- Make sure that all the mating faces are clean and free of any foreign material.
- Make sure that the components have been thoroughly cleaned and inspected before installing to the new engine. Failure to follow this instruction might result in premature engine failure.
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- Install the HP fuel pump inlet pipe.
- Install the HP fuel pump inlet pipe to the 2 clips.
- Install the 2 clips.
- Tighten the 2 fuel line unions.
  Torque : 20 Nm
- Install and tighten the 3 bolts.
  Torque : 11.5 Nm
CAUTION: Make sure that all the mating faces are clean and free of any foreign material.

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- Install a new HP fuel pump outlet pipe assembly to the stud on the valve cover.
  Renew Part: Fuel rail supply pipe(s) Quantity: 1 .
- Connect the 3 fuel line unions.
- Tighten the 3 fuel line unions.
  Torque : 20 Nm
- Install and tighten the M6 bolt.
  Torque : 11.5 Nm
- Install and tighten the M8 bolt.
  Torque : 26 Nm
- Install and tighten the nut.
  Torque : 6 Nm
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- Connect but do not fully tighten the 2 fuel line unions.
- Install and tighten the 4 bolts.
  Torque : 11.5 Nm
- Tighten the 2 fuel line unions and 2 bolts in the illustrated sequence.
  Torque : 20 Nm
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- Install the starter motor.
- Install and tighten the rear bolt.
  Torque : 47 Nm
- Install and tighten the front bolt.
  Torque : 25 Nm
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- Install the cover.
- Install and tighten the 2 bolts.
  Torque : 6 Nm
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- Install the cover.
- Install and tighten the M10 bolt.
  Torque : 29 Nm
- Install and tighten the M6 bolt.
  Torque : 11.5 Nm
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- Reposition the engine wiring harness in the correct location.
- Connect the 2 electrical connectors.
- Install the clip.
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- Install the generator.
- Install and tighten the 3 bolts.
  Torque : 47.5 Nm
- Connect the electrical connector.
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- Install the idler pulley.
- Install and tighten the 3 bolts.
  Torque : 25 Nm
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Install a new left exhaust manifold gasket.

Renew Part: Exhaust manifold gasket Quantity: 1 .
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- Install the left exhaust manifold.
- Install the 8 bolts and spacers.
  Renew Part: Exhaust manifold bolts Quantity: 8 .
- Tighten the 8 bolts in the illustrated sequence.
  Torque : 18 Nm
NOTE: LH illustration shown, RH is similar.

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Install a new right exhaust manifold gasket.

Renew Part: Exhaust manifold gasket Quantity: 1 .
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- Install the right exhaust manifold.
- Install the 8 bolts and spacers.
  Renew Part: Exhaust manifold bolts Quantity: 8 .
- Tighten the 8 bolts in the illustrated sequence.
  Torque : 18 Nm
NOTE: If equipped.

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- Install the right differential pressure sensor assembly.
- Install and tighten the 2 nuts.
  Torque : 9 Nm
- Connect the hose.
- Install the clamp.
- Connect the electrical connector.
- Install the clip.
NOTE: If equipped.

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- Install the left differential pressure sensor assembly.
- Install and tighten the 2 nuts.
  Torque : 9 Nm
- Connect the hose.
- Install the clamp.
- Connect the electrical connector.
- Install the clip.
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- Install the left exhaust manifold heatshield.
- Install and tighten the 4 new bolts.
  Renew Part: Heatshield Screw - M6.3X13 Quantity: 3 .
  
  Renew Part: Heatshield screw - M8x30 Quantity: 1 .
  
  Torque : 2.5 Nm
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- Install the right exhaust manifold heatshield.
- Install and tighten the 4 new bolts.
  Renew Part: Heatshield Screw - M6.3X13 Quantity: 4 .
  
  Torque : 2.5 Nm
NOTE:
- If equipped.
- Perform on both sides.
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- Install a new Gasoline Particulate Filter (GPF) pipe.
  Renew Part: Gasoline Particulate Filter (GPF) to exhaust manifold pipe Quantity: 1 .
- Secure the hose clamp.
- Install and tighten the bolt.
  Torque : 48 Nm
CAUTION:
- Make sure that the mating faces are clean and free of any foreign material.
- Take extra care when working near to the open oil filter housing, any foreign materials must be cleaned or removed immediately.
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- Install a new gasket.
  Renew Part: Oil filter housing gasket Quantity: 1 .
- Install the oil filter housing.
- Install and tighten the 4 bolts.
  Torque : 11.5 Nm
CAUTION: Make sure that the mating faces are clean and free of any foreign material.

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- Install a new oil filter element.
  Renew Part: Oil filter Quantity: 1 .
- Install the O-ring seal provided with the oil filter to the oil filter cap.
- Check all 3 o-ring seals are in place and seated correctly.
- Install and tighten the oil filter cap.
  Torque : 27.5 Nm
CAUTION: Make sure that the mating faces are clean and free of any foreign material.

NOTE: The new coolant tube is sold as a kit with the new o-ring seal and retaining screws.

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- Install the new thermostat to top coolant hose tube to the thermostat housing assembly.
  Renew Part: Thermostat to top coolant hose tube Quantity: 1 .
- Secure the clamp.
- Install the new o-ring seal to the coolant pipe.
CAUTION:
- Coolant system components should be cleaned and checked carefully for damage, contamination or deterioration before installing to the new engine. Damaged components must be replaced.
- Make sure that the mating faces are clean and free of any foreign material.
NOTE: The new coolant tube is sold as a kit with the new o-ring seal and retaining screws.

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- Install the thermostat housing assembly.
- Install and tighten the 2 new upper screws.
  Torque : 9 Nm
- Install and tighten the lower bolt.
  Torque : 9 Nm
- Connect the 2 coolant hoses.
- Install the 2 clamps.
- Install the 2 clips.
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Install the purge valve assembly.
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- Install the breather pipe.
- Install the 2 clips.
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- Install the vacuum pipe.
- Install the 2 clips.
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- Reposition the engine wiring harness in the correct location.
- Install and tighten the 2 bolts.
  Torque : 9 Nm
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- Install the breather pipe.
- Install the clip.
Use a suitable hydraulic jib crane to remove the engine from the stand.
General Equipment: Hydraulic jib crane
Install the engine.
Refer to: ENGINE - AWD - V8 S/C 5.0L PETROL (G2260898) .
Connect the startup battery ground cable.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT