Engine And Ancillaries: Installation
WARNING: This page is about a different car, the 2018 Jaguar XE and 2017 Jaguar XE. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)
| JLR-303-1630 Locking Tool, Crankshaft Pulley |
PART(S)
| STEP | PART NAME | QUANTITY |
|---|---|---|
| Step 2 | Engine NVH pad | 1 |
| Step 4 | Engine vent oil separator to valve cover gasket | 1 |
| Step 8 | Oil filter housing drain port O-ring seal | 1 |
| Step 8 | Oil filter housing inlet / outlet O-ring seals | 4 |
| Step 13 | Fuel injector O-ring seals | 4 |
| Step 15 | Fuel injector clamp bolts | 4 |
| Step 16 | Exhaust manifold gasket | 1 |
| Step 16 | Exhaust manifold bolts and spacers | 8 |
| Step 19 | Intake manifold gaskets | 1 |
| Step 24 | Fuel injector high pressure pipe(s) | 4 |
| Step 28 | Fuel rail supply pipe(s) | 1 |
| Step 32 | EGR outlet pipe to throttle body gasket | 1 |
| Step 32 | Exhaust gas recirculation outlet pipe to exhaust gas recirculation valve gasket | 1 |
| Step 33 | EGR inlet pipe to EGR valve gasket | 1 |
| Step 34 | Oil level gauge O-ring seal | 1 |
| Step 36 | Oil cooler gasket | 1 |
| Step 37 | EGR cooler to cylinder block gasket | 1 |
| Step 38 | Low pressure exhaust gas recirculation valve to turbocharger seal | 1 |
| Step 39 | Turbocharger to exhaust manifold gasket | 1 |
| Step 45 | Oil return pipe O-ring seal | 2 |
| Step 48 | Turbocharger oil supply tube to turbocharger sealing washers | 1 |
| Step 54 | Crankshaft pulley bolts | 4 |
| Step 67 | Thermostat to cylinder block gasket | 1 |
CAUTION:
Before disconnecting any components, make sure the area is clean and free from foreign material. ?When ?disconnected all openings must be sealed.
NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.
- For the list of part numbers required for this job please refer to the specifications.
Refer to: Specifications .
- Install a new NVH pad.
Replace Part: Engine NVH pad.
- Install the NVH pad.
-
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.
Replace Part: Engine vent oil separator to valve cover gasket.
- Install the engine vent oil separator.
- Torque Specification: 12 Nm
- Install a new gasket.
- Install the Variable Camshaft Timing (VCT) solenoidNOTE: 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.
- Torque Specification: 9 Nm
- Install the camshaft position (CMP) sensor.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.
- Torque Specification: 8 Nm
- Install the engine oil filler pipe.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.
- Torque Specification: 12 Nm
- Install new O-ring seals.
Replace Part: Oil filter housing drain port O-ring seal.
Replace Part: Oil filter housing inlet/outlet O-ring seals.
- Install the oil filter housing.
-
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.
- Torque Specification: 12 Nm
-
- Install the engine oil filter.
Refer to: Oil Filter Element .
- Install the bracket.
- Torque Specification: 12 Nm
- Install the engine mounting bracket.
- Torque Specification: 60 Nm
- Install new fuel injector seals.
Replace Part: Fuel injector O-ring seals.
- Install the fuel injectors.
- Install new bolts.
Replace Part: Fuel injector clamp bolts.
Torque Specification:
- Stage 1: 11 Nm
- Stage 2: 162°
- Install the new gasket.
Replace Part: Exhaust manifold gasket.
- Install new bolts and spacers.
Replace Part: Exhaust manifold bolts and spacers.
- Install the exhaust manifold.
Torque Specification:
Stage 1: 15 Nm
Stage 2: 28 Nm
- Install the new gasket.
- Install the exhaust manifold heat shield.
- Torque Specification: 8 Nm
- Install the Crankshaft Position (CKP) sensor.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.
- Torque Specification: 8 Nm
- Install the new gaskets.
-
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.
Replace Part: Intake manifold gaskets.
- Install the inlet manifold complete with throttle body.
Torque Specification: 12 Nm
-
- Install the new engine number label.
- Install the bracket.
- Torque Specification: 12 Nm
- Install the fuel rail.
- Torque Specification: 25 Nm
- Install the bracket.
- Torque Specification: 12 Nm
- Install the new high-pressure fuel supply lines.
Replace Part: Fuel injector high pressure pipes.
Torque Specification:
Stage 1: 15 Nm
Stage 2: 60°
- Install the bracket.
- Torque Specification: 12 Nm
- Install the glow plugs.CAUTION: If accidentally dropped or knocked install a new glow plug.
- Torque Specification: 12 Nm
- Install the bock heater.NOTE: If equipped.
- Torque Specification: 55 Nm
- Install a new high-pressure fuel supply line.
- Replace Part: Fuel rail supply pipe.
Torque Specification:
- Fuel pipe connection.
Stage 1: 15 Nm
Stage 2: 60°
- Fuel pipe connection.
- Torque Specification:
Bolt 10 Nm
- Replace Part: Fuel rail supply pipe.
- Install the vacuum pipe assembly.
- Install the fuel return pipes.
- Torque Specification: 8 Nm
- Install the EGR valve.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.
- Torque Specification: 10 Nm
- Install a new O-ring seal.
Replace Part: EGR outlet pipe to throttle body gasket.
- Install a new gasket.
Replace Part: Exhaust gas recirculation outlet pipe to exhaust gas recirculation valve gasket.
- Install the EGR pipe.
- Torque Specification:
Inlet Manifold 8 Nm
EGR Valve 10 Nm
- Install a new O-ring seal.
- Install a new gasket.
-
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.
Replace Part: EGR inlet pipe to EGR valve gasket.
- Torque Specification: 10 Nm
-
- Install a new O-ring seal.
Replace Part: Oil level gauge O-ring seal.
- Install the oil level indicator and tube.
Secure the 3 clips.
- Torque Specification: 7 Nm
- Install a new O-ring seal.
- Install the bracket.
- Torque Specification: 25 Nm
-
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.
Replace Part: Oil cooler gasket.
- Install the oil cooler.
- Torque Specification: 12 Nm
- Install a new gasket.
- Install a new O-ring seal.
-
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.
Replace Part: EGR cooler to cylinder block gasket.
- Torque Specification: 25 Nm
- Connect and secure the coolant hose.
-
-
CAUTION: Take care not to damage the O-ring seals during installation.
Install a new O-ring seal.
Replace Part: Low pressure exhaust gas recirculation valve to turbocharger seal.
- Install the EGR valve.
-
- Install the new gasket.
Replace Part: Turbocharger to exhaust manifold gasket.
- Install the turbocharger.
- Torque Specification: 28 Nm
- Install the new gasket.
Torque Specification: 28 Nm
-
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.
Torque Specification: 25 Nm
-
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 Specification: 10 Nm
-
- Install the turbocharger heat shield.
- Torque Specification: 8 Nm
- Install the exhaust gas temperature sensor.
- Torque Specification: 44 Nm
-
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.
Replace Part: Oil return pipe O-ring seal.
- 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 Specification: 10 Nm
-
- Install the turbocharger outlet pipe.
Torque Specification: 10 Nm
- Install new sealing washers.
- Replace Part: Turbocharger oil supply tube to turbocharger sealing washers.
- Torque Specification: 18 Nm
- Install the hose.
- Install the accessory drive belt idler.
- Torque Specification: 48 Nm
- Install the accessory drive component bracket.
- Torque Specification: 48 Nm
- Install the crankshaft pulley.CAUTION: During the installation, make sure that all components are clean and free from foreign material.
- Install the special tool.
- Special Tool(s): JLR-303-1630
- Before installing the new crankshaft damper bolts check the length of the thread as shown in the illustration. The new bolts must be 48mm in length.
- Install the new bolts.
- Torque Specification:
Stage 1: 40 Nm
Stage 2: 90°
Renew Part: Crankshaft pulley bolts.
- Torque Specification:
- Install the coolant pump.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.
- The coolant pump from the previous engine is to be re-used.
- Install the water pump pulley.
-
CAUTION: During the installation, make sure that all components are clean and free from foreign material.
- Torque Specification: 26 Nm
-
- Install the coolant hose assembly.
- Torque Specification: 12 Nm
- Install the engine wiring harness.CAUTION: Make sure the wiring harness and electrical connectors are not damaged during this operation.
- Secure the wiring harness.
- Secure the wiring harness.
- Secure the wiring harness.
- Secure the wiring harness.
- Secure the wiring harness.
- Secure the wiring harness.
- Secure the glow plug wiring harness.
- Secure the wiring harness.
- Install a new gasket.
Replace Part: Thermostat to cylinder block gasket.
- Install the thermostat.
- Secure the coolant hose.
- Torque Specification: 12 Nm
- Install a new gasket.
- Secure the wiring harness.
- Torque Specification: 12 Nm
- Install the coolant hose.
- Install the coolant hoses.
- Install the NVH insulation.
- Torque Specification: 10 Nm
- Remove the engine from the engine stand.
- Remove the special tool.
- Special Tool(s): JLR-303-1630
- Install the engine assembly.
Refer to: Engine - Vehicles With: 8HP45 8-Speed Automatic Transmission RWD .
Refer to: Engine - Vehicles With: 6S45 6-Speed Manual Transmission RWD .
- Install the battery ground cable.
Refer to: Battery Disconnect and Connect .
- Remove the engine oil level indicator.
- Fill the engine with oil.
Refer to: Specifications .
- Clean any residual engine oil from the oil filler cap area.
- 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.