General Equipment

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

EQUIPMENT NAME
Engine stand
Feeler gauge
Hydraulic jib crane

CAUTION: When installing new seals, make sure that the mating faces are clean and free from foreign material.

NOTE:

This procedure contains illustrations showing certain components removed to provide extra clarity.
This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.

Disconnect the startup battery ground cable.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT
Raise and support the vehicle on a suitable 2 post lift.
Refer to: LIFTING
Disassemble the engine.
Refer to: ENGINE AND ANCILLARIES
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- Remove the 3 bolts.
- Remove and discard the oil filter housing assembly.
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- Remove the 10 bolts.
- Remove the upper timing cover.
- Remove and discard the gasket.
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- Remove the 2 bolts.
- Remove the fuel pump cover.
- Inspect the O-ring seal. Remove and discard the O-ring seal if damaged or worn.
NOTE: Special tool JLR-303-1686 is required for Mild Hybrid Electric Vehicle (MHEV) vehicles only.

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Install the special tool to the position illustrated.

Special Tool(s): JLR-303-1686 , JLR-303-1630
CAUTION: Only rotate the engine clockwise.

NOTE: Special tool JLR-303-1686 is required for MHEV vehicles only.

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- Install the crankshaft pulley.
- Install and hand tighten the 4 crankshaft pulley bolts.
- Use the special tool to rotate the engine.
  Special Tool(s): JLR-303-1630
- Rotate the engine until the timing marks align to the positions illustrated.
- Install the 2 bolts of the special tool.
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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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Remove the nut.
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Release the 3 bolts.
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Install and tighten the special tool bolt to break the taper on the fuel pump shaft.
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The fuel pump will release from the cylinder block.
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Remove the bolt.
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Install, but do not fully tighten the nut.
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- Remove the 6 bolts.
- Remove the special tool.
  Special Tool(s): JLR-303-1627
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- Install the special tool.
  Special Tool(s): JLR-303-1625
- Install and tighten the bolt.
  Torque : 10 Nm
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The upper timing chain will not be under any tension in the positions highlighted in the illustration.
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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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Loosen, but do not fully remove the bolt.
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- Remove the 2 bolts.
- Remove the special tool.
  Special Tool(s): JLR-303-1631
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Remove and discard the upper timing chain tensioner.
CAUTION: Inspect the timing sprocket. Discard the sprocket if damaged or worn.

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- Remove and discard the bolt.
- Remove the variable valve timing unit.
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- Remove the bolt.
- Remove and discard the upper timing chain left guide.
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Remove and discard the upper timing chain right guide.
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Remove the upper timing chain.
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Inspect the timing sprocket. If the sprocket is damaged or worn, contact Technical Assistance (TA).
CAUTION: Note the position of the bolts, prior to removal.

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Remove the 16 bolts.
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Remove the camshaft carrier.
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Remove and discard the gasket.
NOTE: Note the installed position of the components before removal.

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Remove the 16 cam follower roller fingers.
Fig 1: Cylinder Head Bolts Tightening Sequence
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- Remove the 14 bolts in the illustrated sequence.
- Discard the 10 cylinder head M10 bolts.
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- Remove the cylinder head.
- Place the cylinder head on a suitable workbench.
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Remove and discard the cylinder head gasket.
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Inspect the cylinder head and if required, use a suitable tool and cleaning solution to clean the mating face.
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- Use a suitable metallic straight edge and feeler gauge to measure the cylinder head face longitudinally in the areas illustrated.
  General Equipment: Feeler gauge
- Note the maximum value.
NOTE: The measurements must be taken at the section of the cylinder head bolt holes.

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- Use a suitable metallic straight edge and feeler gauge to measure the cylinder head face transversely in the areas illustrated.
- Note the maximum value.
- Refer to the specifications.
  Refer to: SPECIFICATIONS
- If the cylinder head distortion exceeds the maximum value, the cylinder head must not be reused.
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Remove the bolt.
CAUTION: Note the position of the bolts, prior to removal.

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- Remove the 14 bolts.
- Remove the lower timing chain cover.
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Remove and discard the crankshaft rear oil seal.
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The lower timing chain will not be under any tension in the positions highlighted in the illustration.
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- Use a suitable tool to counter the spring force from the tensioner.
- Remove the 2 bolts.
- Remove and discard the lower timing chain tensioner.
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- Remove the nut.
- Remove and discard the lower timing chain tensioner guide.
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- Remove the 2 bolts.
- Remove and discard the lower timing chain left guide.
CAUTION: Inspect the timing sprocket. Discard the sprocket if damaged or worn.

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Remove the lower timing chain idler sprocket.
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Remove and discard the lower timing chain upper guide.
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Remove the lower timing chain.
CAUTION: Inspect the timing sprocket. Discard the sprocket if damaged or worn.

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- Remove and discard the nut.
- Remove the fuel pump drive sprocket.
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- Remove and discard the 3 bolts.
- Remove the fuel pump.
- Remove and discard the O-ring seal.
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- Remove the 4 bolts.
- Remove the special tool.
  Special Tool(s): JLR-303-1630
- Remove the crankshaft pulley.
NOTE: MHEV only.

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Remove the 2 bolts.
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- Remove the 12 bolts.
- Remove the engine front cover.
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Use the special tool to remove and discard the crankshaft front oil seal.

Special Tool(s): JLR-303-1628
CAUTION: Note the position of the bolts, prior to removal.

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Remove the 16 bolts.
CAUTION: Make sure the oil pan is suitably supported.

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Use a suitable tool to release the oil pan from the cylinder block at the positions illustrated.
NOTE: If equipped.

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Use a suitable tool to lock the oil pump chain tensioner.
CAUTION: Inspect the oil pump chain and sprockets. Discard the oil pump chain and sprockets if damaged or worn.

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- Use the special tool to counter the force and remove the bolt from the oil pump sprocket.
  Special Tool(s): 205-053
- Remove the 2 sprockets and the oil pump drive chain.
- Discard the bolt.
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- Remove the 2 bolts.
- Remove the oil pickup pipe.
- Remove and discard the O-ring seal.
CAUTION: The oil pickup pipe must be completely clean and free from foreign material.

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Use a suitable cleaning solution to clean the oil pickup pipe.
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- Remove the bolt.
- Remove the vacuum pipe connector.
- Remove and discard the O-ring seal.
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- Remove the bolt.
- Remove the coolant pipe.
- Remove and discard the 2 seals.
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Remove the bolt.
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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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- Install the special tool.
  Special Tool(s): JLR-303-1633
- Support the engine using suitable lifting equipment.
  General Equipment: Hydraulic jib crane
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Tighten the 3 bolts of the lifting brackets.

Torque : 47.5 Nm
WARNING: Make sure the cylinder block is suitably supported at all times.

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Remove the cylinder block from the engine stand.

General Equipment: Engine stand
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- Support the cylinder block on suitable wooden blocks.
- Disconnect the special tool from the lifting brackets.
  Special Tool(s): JLR-303-1633
- Remove the engine crane.
  General Equipment: Hydraulic jib crane
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Remove the special tools.

Special Tool(s): JLR-303-1591
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Remove the special tool.

Special Tool(s): JLR-303-1673