Intake Manifold - INGENIUM I4 2.0L Diesel - High Power (G1915173): Removal

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

CAUTION: 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.

Raise and support the vehicle on a suitable 2 post lift.
Refer to: LIFTING
Always follow the Diesel fuel system health and safety precautions, when carrying out any repairs to the fuel system.
Refer to: DIESEL FUEL SYSTEM HEALTH AND SAFETY PRECAUTIONS
Disconnect the startup battery ground cable.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT
Remove the engine cover.
Refer to: ENGINE COVER - INGENIUM I4 2.0L DIESEL
Remove the left side secondary bulkhead panel.
Refer to: SECONDARY BULKHEAD LEFT PANEL - INGENIUM I4 2.0L DIESEL
NOTE: Vehicles fitted with high pressure Exhaust Gas Recirculation (EGR) cooler.

Drain the cooling system.

Refer to: COOLING SYSTEM PARTIAL DRAINING AND VACUUM FILLING
NOTE: If equipped.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Remove the rear cover protecting the high pressure fuel rail.
CAUTION: Be prepared to collect escaping fuel.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Disconnect the fuel lines and reposition them away from the intake manifold.
Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Release the fuel lines from the 4 retaining clips and reposition away from the intake manifold.
Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC
- Disconnect the 5 electrical connectors from the intake manifold assembly.
- Release the wiring loom from the 7 retaining clips.
- Reposition the wiring loom away from the intake manifold.
Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Release the dipstick tube and reposition away from the intake manifold assembly.
NOTE: Vehicles fitted with high pressure EGR cooler.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Disconnect the 3 electrical connectors from the front of the intake manifold.
CAUTION: Be prepared to collect escaping coolant.

NOTE: Vehicles fitted with high pressure EGR cooler.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Release the high pressure EGR cooler coolant pipes.
NOTE: Vehicles fitted with high pressure EGR cooler.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Release the high pressure EGR cooler pipes.
NOTE: Vehicles fitted with high pressure EGR cooler.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Release the 3 securing bolts and remove the high pressure EGR cooler and discard both EGR gaskets.
NOTE:
- If equipped.
- Discard the gasket.
- Discard the O ring seal.
Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Release the 4 bolts and remove the EGR pipe between the intake manifold and the EGR valve.
NOTE: Discard the exhaust gas crossover pipe gasket.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Release the 2 bolts and reposition the exhaust gas crossover pipe away from the intake manifold.
NOTE: Discard the EGR valve gasket.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Release the 3 retaining bolts and reposition the EGR valve away from the intake manifold.
Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Release the retaining bolt securing the coolant pipe that is connected to the lower thermostat outlet.
Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC
- Disconnect the 4 electrical connectors for the glow plugs.
- Release the 3 wiring loom clips and reposition the wiring harness away from the intake manifold.
Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC
- Release the clamp securing the air pipe between the throttle body assembly and the charge air radiator.
- Reposition the air pipe away from the throttle body assembly.
Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Remove the intake manifold support bracket.
Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC
- Release the wiring harness clip and reposition the wiring harness away from the intake manifold.
- Remove the fuel pipe support bracket.
NOTE: Discard the air intake manifold gasket.

Fig 1: Intake Manifold Bolts Tightening Sequence
Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Release the bolts in the sequence illustrated and then remove the intake manifold.
NOTE:
- Do not disassemble further if the component is removed for access only.
- Discard the O ring seal.
Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Remove the throttle body assembly.
Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Remove the actuator flap motor.
Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Remove the 3 wiring harness brackets from the intake manifold assembly.
Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Remove the Manifold Absolute Pressure (MAP) sensor. Inspect the O-ring seal and replace the component if damaged.