Long/Stripped Engine Assembly Renew - INGENIUM I4 2.0L Petrol - PHEV (G2876751): Assembly: Part(S)

STEP	PART NAME	QUANTITY
Step 33	Camshaft position sensor O-ring seal	2
Step 35	Coolant pump inlet O-ring seal	1
Step 34	Crankshaft position (CKP) Sensor O-ring seal	1
Step 28	Crankshaft pulley bolts	4
Step 38	Exhaust manifold to turbocharger nuts	2
Step 39	Exhaust manifold to turbocharger nuts	2
Step 36	Exhaust manifold to turbocharger studs	4
Step 70	Flexplate bolts	8
Step 9	Fuel Injector replacement kits	4
Step 8	High pressure fuel pump retaining bolts	2
Step 51	Intake manifold seals	1
Step 62	Oil level gauge O-ring seal	1
Step 49	Thermostat to cylinder block gasket	1
Step 45	Turbocharger oil feed pipe banjo bolt washers	2
Step 46	Turbocharger oil feed pipe banjo bolt washers	2
Step 40	Turbocharger oil return pipe seals	2
Step 37	Turbocharger to exhaust manifold gasket	1
Step 4	Valve cover vent oil separator to cylinder head seal	1
Step 32	Variable Camshaft Timing (VCT) solenoid O-ring seals	2

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.
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 .
Support the engine on a suitable stand.
NOTE: If equipped.

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Install the block heater.

Torque : 55 Nm
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Install the engine vent oil separator. Renew the gasket.

Renew Part: Valve cover vent oil separator to cylinder head seal Quantity: 1 .

Torque : 12 Nm
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Install the Noise, Vibration and Harshness (NVH) material.
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Install the NVH material.

Torque : 11.5 Nm
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Install the purge valve mounting bracket.

Torque : 11.5 Nm
CAUTION:
- Tighten the bolts half a turn at a time until the pump is fully seated.
- Lubricate the O-ring seal with clean engine oil.
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Install the high pressure fuel pump. Renew the bolts.

Renew Part: High pressure fuel pump retaining bolts Quantity: 2 .

Torque : 11.5 Nm
CAUTION: New fuel injector replacement kits must be installed.

Installation steps 11 to 16 must be completed for each of the fuel injectors.

Renew Part: Fuel Injector replacement kits Quantity: 4 .
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Install the new fuel injector O-ring seal and washer.
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Install the special tool to the injector with 'T' symbol towards the top of the injector as shown.

Special Tool(s): JLR-310-257
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Using the special tool, install the new Teflon seal to the injector.

Special Tool(s): 310-198
Wait 2 minutes to allow the Teflon seal to recover its shape.
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- Remove the special tool.
- Check for correct installment of the Teflon seal.
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Install the injector spring clamp.
CAUTION: Lubricate the fuel injector O-ring seals with clean engine oil.

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Carefully install all the injectors into the fuel rail.
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Make sure the injectors are correctly aligned.
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Make sure the injectors are correctly aligned.
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Install the injector wiring harness.
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Install the appropriate special tools. If a new cylinder head has not been installed then the special tool JLR-310-255 with the threaded section must be used. If a new cylinder head has been installed then the special tool JLR-310-256 without the threaded section must be used.

Special Tool(s): JLR-310-255 , JLR-310-256
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- Install the fuel rail and injector assembly allowing guide pins to control position.
- Tighten the bolts 1 turn at a time.
  Torque : 20 Nm
Remove the special tools.
Install the remaining 2 fuel rail bolts.
Torque : 20 Nm
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Tighten the bolts in the sequence illustrated.

Torque : 30 Nm
WARNING: Make sure that the ignition coil rubber boot is pushed down fully over the spark plug insulator ceramic. Double check by installing the ignition coil as usual and then pushing on the ignition coil head gently for a second time to make sure that the ignition coil rubber boot has seated correctly over the spark plug insulator.

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Install the ignition coil-on-plugs.

Torque : 8 Nm
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Install the engine lifting eye.

Torque
1. M8 Bolts: 25 Nm
2. M10 Bolt: 48 Nm
CAUTION: Lubricate the O-ring seal with clean engine oil.

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Install the oil filler neck. Renew the O-ring seal.

Torque : 11.5 Nm
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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.

Renew Part: Crankshaft pulley bolts Quantity: 4 .
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Install the crankshaft pulley.
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Install the special tool.

Special Tool(s): JLR-303-1630
CAUTION: Tighten the bolts in a diagonal sequence.

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Install the new crankshaft pulley bolts.

Torque
1. Stage 1: 40 Nm
2. Stage 2: 90°
CAUTION: Lubricate the O-ring seals with clean engine oil.

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Install the variable valve timing solenoids. Renew the 2 O-ring seals.

Renew Part: Variable Camshaft Timing (VCT) solenoid O-ring seals Quantity: 2 .

Torque : 9 Nm
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- Renew the 2 O-ring seals.
  Renew Part: Camshaft position sensor O-ring seal Quantity: 2 .
- Install the 2 camshaft position sensors.
- Install and tighten the 2 bolts.
  Torque : 9 Nm
CAUTION: Lubricate the O-ring seal with clean engine oil.

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- Renew the O-ring seal.
  Renew Part: Crankshaft position (CKP) Sensor O-ring seal Quantity: 1 .
- Install the crankshaft position sensor.
- Install and tighten the bolt.
  Torque : 8 Nm
CAUTION: Lubricate the O-ring seal with clean engine oil.

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Install the coolant pump inlet pipe. Renew the O-ring seal.

Renew Part: Coolant pump inlet O-ring seal Quantity: 1 .

Torque : 12 Nm
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Renew the turbocharger studs.

Renew Part: Exhaust manifold to turbocharger studs Quantity: 4 .

Torque : 18 Nm
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Renew the turbocharger gasket.

Renew Part: Turbocharger to exhaust manifold gasket Quantity: 1 .
CAUTION: Make sure that the mating faces are clean and free of foreign material.

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Install the turbocharger. Renew the nuts.

Renew Part: Exhaust manifold to turbocharger nuts Quantity: 2 .

Torque : 10 Nm
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Fully tighten the turbocharger retaining nuts in the sequence illustrated.

Renew Part: Exhaust manifold to turbocharger nuts Quantity: 2 .

Torque : 25 Nm
CAUTION: Lubricate the O-ring seal with clean engine oil.

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Install the turbocharger oil return pipe. Renew the 2 O-ring seals.

Renew Part: Turbocharger oil return pipe seals Quantity: 2 .

Torque : 11 Nm
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Install the turbocharger heatshield.

Torque
1. Bolt M6 x 14 mm: 9 Nm
2. Bolt M6 x 25 mm: 12 Nm
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Install the turbocharger lower heatshield.

Torque : 9 Nm
CAUTION: Lubricate the O-ring seal with clean engine oil.

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Install the coolant degas separator.

Torque : 12 Nm
CAUTION: Lubricate the O-ring seal with clean engine oil.

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Connect the turbocharger coolant supply and return hoses. Inspect the O-ring seals, renew the components if damaged or worn.

Torque : 12 Nm
CAUTION: Make sure the oil supply hose is installed in the same orientation as noted in the removal procedure.

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Install the turbocharger oil supply hose. Renew the sealing washers.

Renew Part: Turbocharger oil feed pipe banjo bolt washers Quantity: 2 .

Torque : 18 Nm
CAUTION: Make sure the oil supply hose is installed in the same orientation as noted in the removal procedure.

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Connect the turbocharger oil supply hose. Renew the sealing washers.

Renew Part: Turbocharger oil feed pipe banjo bolt washers Quantity: 2 .

Torque : 18 Nm
CAUTION: Bolts must be tightened in the sequence illustrated.
NOTE:
- New engines may be supplied with untapped bolt holes for some of the components. Use the 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 installed.
- Inspect the coolant pump seal. If any damage is visible, a new coolant pump must be installed.
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Install the coolant pump.

Torque
1. Stage 1: 5 Nm
2. Stage 2: 12 Nm
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Install the coolant pump pulley.

Torque : 25 Nm
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Install the thermostat housing. Renew the gasket.

Renew Part: Thermostat to cylinder block gasket Quantity: 1 .

Torque : 12 Nm
CAUTION: Make sure the knock sensors are installed in the same orientation as noted in the removal procedure.

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Install the knock sensors.

Torque : 20 Nm
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- CAUTION: Tighten the bolts in a diagonal sequence starting from the centre and working outwards.
  
  Install the intake manifold. Renew the seals.
  
  Renew Part: Intake manifold seals Quantity: 1 .
  
  Torque : 12 Nm
- Secure the knock sensor wiring harness.
CAUTION: Make sure the wiring harness is installed to the original routing.

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Install the wiring harness.
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Install the purge valve.

Torque : 11.5 Nm
CAUTION: Fuel pipes may be used a maximum of 4 times, paint mark fuel tube after each full tightening sequence.

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1. Install the high pressure fuel pump to fuel rail pipe hand tight until the 2 unions are fully seated.
2. Fully tighten the high pressure fuel pump union.
  Torque : 21 Nm
3. Fully tighten the fuel rail union.
  Torque : 21 Nm
4. Wait for 30 seconds.
5. Check the high pressure fuel pump union
  Torque : 21 Nm
6. Check the fuel rail union torque.
  Torque : 21 Nm
7. Install the high pressure fuel pump supply pipe hand tight until the union is fully seated.
8. Install the high pressure fuel pump supply pipe mounting bracket bolts hand tight, then loosen by 90 degrees.
9. Fully tighten the high pressure fuel pump supply tube union.
  Torque : 21 Nm
10. Fully tighten the high pressure fuel pump supply pipe mounting bracket bolts.
  Torque : 11.5 Nm
11. Wait for 30 seconds.
12. Check the high pressure fuel pump supply tube union torque.
  Torque : 21 Nm
CAUTION: Make sure the wiring harness is not twisted and all the clips and connectors are fully secured.

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Connect and secure the wiring harness.
CAUTION: Make sure the wiring harness is not twisted and all the clips and connectors are fully secured.

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Connect and secure the wiring harness.
CAUTION: Make sure the wiring harness is not twisted and all the clips and connectors are fully secured.

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Connect and secure the wiring harness.

Torque : 8.5 Nm
CAUTION: Make sure the wiring harness is not twisted and all the clips and connectors are fully secured.

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Connect and secure the wiring harness.

Torque : 8.5 Nm
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Install the coolant hose.

Torque : 25 Nm
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Connect and secure the coolant hose.

Torque : 7 Nm
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- Install and tighten the 2 bolts.
  Torque : 48 Nm
- Install the Belt Integrated Starter Generator (BISG).
CAUTION: Lubricate the O-ring seal with clean engine oil.

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Install the oil level gauge assembly. Renew the O-ring seal.

Renew Part: Oil level gauge O-ring seal Quantity: 1 .

Torque : 7 Nm
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Install the vacuum pipe assembly.
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Install the coolant hose.

Torque : 11.5 Nm
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Install the breather.
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Install the NVH material.
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Install the engine mounting brackets.

Torque : 60 Nm
Remove the engine from the stand.
CAUTION:
- Under no circumstances should the drive plate retaining bolts be inserted into the crankshaft with the drive plate removed. Failure to follow this instruction will result in damage to the engine.
- Do not insert the bottoming tap more than the depth of the threaded holes (16 mm). Apply tape to the bottoming tap 16 mm from the end as a visual guide.
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- Using a suitable bottoming tap, clean out the threads.
- Using suitable brake cleaner, remove any foreign material from the threads.
- Dry the threads.
CAUTION: Tighten the bolts in a diagonal sequence.

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Install the drive plate. Renew the bolts.

Renew Part: Flexplate bolts Quantity: 8 .

Torque
1. Stage 1: 30 Nm
2. Stage 2: 120°
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Remove the special tool.

Special Tool(s): JLR-303-1630
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Remove and discard the old engine number label.
Clean and dry the engine vent oil separator.
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Install the new engine number label supplied with the new engine.
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- Install the Air Conditioning (A/C) compressor.
- Install and tighten the 3 bolts.
  Torque : 24 Nm
Install the belt integrated starter generator belt.
Refer to: BELT INTEGRATED STARTER GENERATOR BELT - VEHICLES WITH: PHEV (G2743728) .
Install the engine assembly.
Refer to: INSTALLATION .
Fill engine with the correct specification and amount of oil.
Refer to: SPECIFICATIONS .
Run the engine and check for fluid leaks.