Short Engine Assembly Renew (G2688930): Part(S)

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• Install the special tool.

  Special Tool(s): JLR-303-1673 

• Install and tighten the 4 bolts.

  Torque  : 40 Nm 

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• Install the 3 lifting brackets.

  Special Tool(s): JLR-303-1591 

• Install and tighten the 3 bolts.

  Torque  : 5 Nm 

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Use a suitable engine crane and the special tool to support the cylinder block.

Special Tool(s): JLR-303-1633 

General Equipment: Hydraulic jib crane 

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Tighten the 3 bolts of the lifting brackets.

Torque  : 47.5 Nm 

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Install the cylinder block to a suitable engine stand.

General Equipment: Engine stand 

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Disconnect the special tool and remove the engine crane.

Special Tool(s): JLR-303-1633-01 

General Equipment: Hydraulic jib crane 

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Remove the special tools.

Special Tool(s): JLR-303-1591 

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Install and tighten the bolt.

Torque  : 25 Nm 

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• Install 2 new seals.

  Renew Part: Turbocharger coolant pipe to cylinder block O-ring seal Quantity: 2 . 

• Install the coolant pipe.
• Install and tighten the bolt.

  Torque  : 25 Nm 

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• Install a new O-ring seal.

  Renew Part: Vacuum pipe O-ring seal Quantity: 1 . 

• Lubricate the O-ring seal with new engine oil.
• Install the vacuum pipe connector.
• Install and tighten the bolt.

  Torque  : 5 Nm 

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• Install a new O-ring seal.

  Renew Part: Oil pump inlet tube O-ring seal(s) Quantity: 1 . 

• Install the oil pickup pipe.
• Install and tighten the 2 bolts.

  Torque  : 12 Nm 

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• Install the 2 sprockets and the oil pump drive chain.
• Use the special tool to counter the force and install and tighten the bolt.

  Renew Part: Oil pump gear bolt Quantity: 1 . 

  Torque 

  Stage 1: 60 Nm 

  Stage 2: 90° 

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Release the oil pump chain tensioner.

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Inspect the oil pan and if required, use a suitable tool and cleaning solution to clean the mating face.

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Apply a continuous 3 mm diameter bead of sealant to the area illustrated.

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• Install the oil pan.
• Install, but do not fully tighten the 2 shoulder bolts to the positions illustrated.

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• Install and tighten the 16 bolts in the illustrated sequence.
• Bolts 1 - 13, 15 and 16;

  Torque  : 25 Nm 

• Bolt 14;

  Torque  : 35 Nm 

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Use the special tool to install a new crankshaft front oil seal.

Special Tool(s): JLR-303-1628 

Renew Part: Crankshaft front oil seal Quantity: 1 . 

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Apply a continuous 3 mm diameter bead of sealant to the area illustrated.

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Use the special tool to install and align the engine front cover.

Special Tool(s): JLR-303-1672 

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• Install and tighten bolts 1 - 4 in the illustrated sequence.

  Torque  : 11.5 Nm 

• Install and tighten the remaining 8 bolts.

  Torque  : 11.5 Nm 

• Remove the special tool.

  Special Tool(s): JLR-303-1672 

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Install and tighten the 2 bolts.

Torque  : 25 Nm 

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Install the special tool to the position illustrated.

Special Tool(s): JLR-303-1686  , JLR-303-1630 

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• Install the crankshaft pulley.
• Install the 4 bolts finger tight.
• Rotate the crankshaft until the dowel is in the position illustrated.
• Install the special tool.

  Special Tool(s): JLR-303-1630 

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• Install a new O-ring seal.

  Renew Part: Fuel pump O-ring seal Quantity: 1 . 

• Lubricate the O-ring seal with clean engine oil.
• Install the fuel pump.
• Install and tighten the 3 bolts.

  Renew Part: Fuel Injection Pump retaining bolts Quantity: 3 . 

  Torque  : 25 Nm 

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• Install the fuel pump drive sprocket.
• Install, but do not fully tighten the nut.

  Renew Part: Fuel pump drive sprocket nut Quantity: 1 . 

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Make sure the fuel pump drive sprocket is in the position illustrated.

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Install the lower timing chain.

Renew Part: Lower timing chain Quantity: 1 . 

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• Install the lower timing chain idler sprocket.

  Torque  : 35 Nm 

• Make sure that the timing marks align as illustrated.

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• Install the left lower timing chain guide.

  Renew Part: Lower timing chain guide Quantity: 1 . 

• Install and tighten the 2 bolts.

  Torque  : 25 Nm 

• Make sure that the timing marks align as illustrated.

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• Install the lower timing chain tensioner guide.

  Renew Part: Lower timing chain tensioner guide Quantity: 1 . 

• Install and tighten the nut.

  Torque  : 11.5 Nm 

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Make sure that the timing marks align as illustrated.

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• Install the lower timing chain tensioner.

  Renew Part: Lower timing chain tensioner Quantity: 1 . 

• Install and tighten the 2 bolts.

  Torque  : 11.5 Nm 

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Install the lower timing chain guide.

Renew Part: Lower timing chain guide Quantity: 1 . 

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Remove the locking tool and release the lower timing chain tensioner.

Refer to: LOWER TIMING COVER SEALING

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Clean the cylinder block mating face.

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Install the new cylinder head gasket.

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Install the cylinder head.

Fig 1: Cylinder Head Bolts Tightening Sequence

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• Install and tighten bolts 1 -10 in the illustrated sequence.

  Renew Part: Cylinder head bolts Quantity: 10 . 

  Torque 

  Stage 1: 20 Nm 

  Stage 2: 53 Nm 

  Stage 3: Loosen 180° 

  Stage 4: 53 Nm 

  Stage 5: 90° 

  Stage 6: 120° 

• Install and tighten bolts 11 - 14 in the illustrated sequence.

  Torque  : 11.5 Nm 

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• Lubricate the 16 hydraulic valve tappets, roller finger cam followers and hydraulic valve tappet bores with clean engine oil.
• Install the 16 roller finger camshaft followers to their noted removal position.

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Install the camshaft carrier gasket.

Renew Part: Camshaft carrier gasket Quantity: 1 . 

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Install the camshaft carrier.

Fig 2: Camshaft Carrier Bolts Tightening Sequence

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• Install and tighten the 16 bolts in the illustrated sequence.

  Torque  : 7.5 Nm 

• Bolts 1, 4, 5, 10 and 11.

  Torque 

  Stage 1: 15 Nm 

  Stage 2: 42° 

• Bolts 2, 3, 6, 7, 8, 9 and 12 - 16.

  Torque  : 25 Nm 

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Remove and discard the cover.

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Install the upper timing chain.

Renew Part: Upper timing chain Quantity: 1 . 

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Install the upper timing chain right guide.

Renew Part: Right upper timing chain guide Quantity: 1 . 

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• Install the upper timing chain left guide.

  Renew Part: Upper timing chain guide Quantity: 1 . 

• Install and tighten the bolt.

  Torque  : 25 Nm 

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• Install the variable valve timing unit.
• Install and tighten the bolt.

  Renew Part: Variable valve timing unit retaining bolt Quantity: 1 . 

  Torque  : 10 Nm 

• Make sure that the timing marks align as illustrated.

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Make sure that the timing marks align as illustrated.

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Before installing the upper timing chain tensioner, make sure that the ratchet clip is in the first groove.

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Install and tighten the upper timing chain tensioner.

Renew Part: Upper timing chain tensioner Quantity: 1 . 

Torque  : 55 Nm 

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• Install the special tool.

  Special Tool(s): JLR-303-1631 

• Install and tighten the 2 bolts.

  Torque  : 10 Nm 

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Tighten the bolt.

Torque 

Stage 1: 25 Nm 

Stage 2: 40° 

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• Remove the 2 bolts.
• Remove the special tool.

  Special Tool(s): JLR-303-1631 

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To correctly deploy the upper timing chain tensioner, push the upper timing chain guide against the upper timing chain tensioner as shown in the illustration.

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Install the cover.

Renew Part: Lower timing cover blanking cap Quantity: 1 . 

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Remove the special tool.

Special Tool(s): JLR-303-1625 

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• Install the special tool.

  Special Tool(s): JLR-303-1627 

• Install, but do not fully tighten the 2 bolts.

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Install, but do not fully tighten the 4 bolts.

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Tighten the 6 bolts in the illustrated sequence.

Torque  : 5 Nm 

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Loosen the 4 bolts by 5 mm.

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Tighten the nut.

Torque  : 80 Nm 

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• Remove the 6 bolts.
• Remove the special tool.

  Special Tool(s): JLR-303-1627 

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• Lubricate the O-ring seal with clean engine oil.
• Install the fuel pump cover.
• Install and tighten the 2 bolts.

  Torque  : 11 Nm 

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Apply a continuous 3 mm diameter bead of sealant to the area illustrated.

Renew Part: Upper timing chain cover gasket Quantity: 1 . 

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Install the new upper timing cover gasket.

Fig 3: Upper Timing Cover Tightening Sequence

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• Install the upper timing cover.
• Install and tighten the 10 bolts in the illustrated sequence.

  Torque 

  Stage 1: 13.5 Nm 

  Stage 2: Loosen 180° 

  Stage 3: 13.5 Nm 

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• Lubricate the 3 O-ring seals with new engine oil.

  Renew Part: Oil Filter Housing Assembly Quantity: 1 . 

• Install the oil filter housing assembly.
• Install and tighten the 3 bolts.

  Torque  : 12 Nm 

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• Remove and discard the 4 bolts.
• Remove the special tool.

  Special Tool(s): JLR-303-1630 

• Remove the crankshaft pulley.

Refer to: ENGINE AND ANCILLARIES 

Refer to: STARTUP BATTERY DISCONNECT AND CONNECT