Engine And Ancillaries (G1867846): Part(S)

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Check the engine number of the new engine.
• If the engine number is after  200110W000001 (10th January 2020) proceed to step 2.
• If the engine number is before  200110W000001 (10th January 2020) complete the replacement engine - balance shaft assembly procedure and continue to step 2.

  Refer to: REPLACEMENT ENGINE - BALANCE SHAFT ASSEMBLY

Refer to: SPECIFICATIONS

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Install a new Noise, Vibration and Harshness (NVH) pad.

Renew Part: Engine NVH pad Quantity: 1 . 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Install the NVH  pad.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the crankshaft pulley.
• Install the special tool.

  Special Tool(s): JLR-303-1630 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

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.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Install and tighten the 4 bolts.

Torque 

Stage 1: 37 Nm 

Stage 2: 90° 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install a new O-ring seal.

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

• Lubricate the O-ring seal with new engine oil.

  Refer to: SPECIFICATIONS

• Install the fuel pump.
• Install and tighten the 3 bolts.

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

  Torque  : 25 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Loosen the 4 bolts by 4 mm.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Install and tighten the nut.

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

Torque  : 80 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Remove the 6 bolts.
• Remove the bracket.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install a new O-ring seal.

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

• Lubricate the O-ring seal with new engine oil.

  Refer to: SPECIFICATIONS

• Install the fuel pump cover.
• Install and tighten the 2 bolts.

  Torque  : 11 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Use a suitable M10 x 1.0 mm tap to clean out the threads illustrated.
• Use a suitable cleaning solution to remove any foreign material from the threads.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the drive plate.
• Tighten the new bolts in the sequence indicated.

  Renew Part: Drive plate/flywheel bolts - Ingenium Diesel Quantity: 8 .  Part Number: LR074135/T2R15200

  Torque 

  Stage 1: 30 Nm 

  Stage 2: 120° 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the clutch pressure plate.
• Tighten the new bolts in the sequence indicated.

  Renew Part: Clutch pressure plate bolts (manual transmission only) - Ingenium Diesel Quantity: 1 .  Part Number: LR072974/T2R15201

  Torque  : 29 Nm 

• Make sure the clutch assembly is installed in its released state. Refer to operating instructions supplied with the kit for the correct installation procedure.

  General Equipment: Clutch alignment kit JLR-308-943 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the drive plate.
• Tighten the new bolts in the sequence indicated.

  Renew Part: Flexplate bolts Quantity: 8 . 

  Torque 

  Stage 1: 30 Nm 

  Stage 2: 120° 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Remove the special tool.
• Special Tool(s): JLR-303-1630 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install a new gasket.

  Renew Part: Engine vent oil separator to valve cover gasket Quantity: 1 . 

• Install the engine vent oil separator.
• Torque  : 12 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the Variable Camshaft Timing (VCT) solenoid

  Renew Part: Variable Valve Timing Solenoid O-ring seal(s) Quantity: 1 . 

• Torque  : 9 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the Camshaft Position Sensor (CMP) sensor.
• Torque  : 8 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the engine oil filler pipe.
• Torque  : 12 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the bracket.
• Torque  : 12 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the engine mounting bracket.
• Torque  : 60 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Install new fuel injector seals.

Renew Part: Fuel injector O-ring seals Quantity: 4 . 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Make sure the fuel injectors are not  installed into the same cylinder number they were removed from.
• Swap the fuel injectors with the adjacent cylinder as illustrated.
• Note the fuel injector correction factor number.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Install the fuel injectors.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Install new bolts.

Renew Part: Fuel injector clamp bolts Quantity: 4 . 

Torque 

Stage 1: 11 Nm 

Stage 2: 162° 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the new gasket.

  Renew Part: Exhaust manifold gasket Quantity: 1 . 

• Install new bolts and spacers.

  Renew Part: Exhaust manifold bolts and spacers Quantity: 8 . 

• Install the exhaust manifold.

  Torque 

  Stage 1: 15 Nm 

  Stage 2: 28 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the exhaust manifold heat shield.
• Torque  : 8 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the Crankshaft Position Sensor (CKP) sensor.
• Torque  : 8 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• 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 gaskets.

  Renew Part: Intake manifold gaskets Quantity: 8 . 

• Install the inlet manifold complete with throttle body.

  Torque  : 12 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the new engine number label.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the bracket.
• Torque  : 12 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the fuel rail.
• Torque  : 25 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the bracket.
• Torque  : 12 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the new high-pressure fuel supply lines.

  Renew Part: Fuel injector high pressure pipe(s) Quantity: 4 . 

  Torque 

  Stage 1: 15 Nm 

  Stage 2: 60° 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the bracket.
• Torque  : 12 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the glow plugs.
• Torque  : 12 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the bock heater.
• Torque  : 55 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install a new high-pressure fuel supply line.

  Renew Part: Fuel rail supply pipe(s) Quantity: 1 . 

  Torque 

  Fuel line connection.

  Stage 1: 15 Nm 

  Stage 2: 60° 

• Torque 

  Bolt: 10 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Install the vacuum pipe assembly.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the fuel return lines.
• Install and tighten the 2 bolts.

  Torque  : 8 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the Exhaust Gas Recirculation (EGR) valve.
• Torque  : 10 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install a new O-ring seal.

  Renew Part: EGR outlet pipe to throttle body gasket Quantity: 1 . 

• Install a new gasket.

  Renew Part: Exhaust gas recirculation outlet pipe to exhaust gas recirculation valve gasket Quantity: 1 . 

• Install the EGR  pipe.
• Torque 

  Inlet Manifold: 8 Nm 

  Exhaust Valve: 10 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• 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.

  Renew Part: EGR inlet pipe to EGR valve gasket Quantity: 1 . 

• Torque  : 10 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install a new O-ring seal.

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

• Install the oil level indicator and tube.
• Secure the 3 clips.
• Torque  : 7 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the bracket.
• Torque  : 25 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• 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 O-ring seal.

  Renew Part: EGR cooler to cylinder block gasket Quantity: 1 . 

• Torque  : 25 Nm 
• Connect and secure the coolant hose.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install a new O-ring seal.

  Renew Part: Low pressure exhaust gas recirculation valve to turbocharger seal Quantity: 1 . 

  CAUTION: Take care not to damage the O-ring seals during installation.
• Install the EGR  valve.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the new gasket.

  Renew Part: Turbocharger to exhaust manifold gasket Quantity: 1 . 

• Install the turbocharger.
• Torque  : 28 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Torque  : 28 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Renew Part: Low pressure exhaust gas recirculation (EGR) valve to low pressure EGR cooler gasket Quantity: 1 . 

Torque  : 25 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• 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  : 10 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the turbocharger heat shield.
• Torque  : 8 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the exhaust gas temperature sensor.
• Torque  : 44 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• 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.

  Renew Part: Oil return pipe O-ring seal Quantity: 2 . 

• 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  : 10 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Install the turbocharger outlet pipe.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Torque  : 10 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install new sealing washers.

  Renew Part: Turbocharger oil supply tube to turbocharger sealing washers Quantity: 1 . 

• Torque  : 18 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Install the hose.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the accessory drive belt idler.
• Torque  : 48 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the accessory drive component bracket.
• Torque  : 48 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Install the coolant pump.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the coolant pump pulley.
  CAUTION: During the installation, make sure that all components are clean and free from foreign material.
• Torque  : 26 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the coolant hose assembly.
• Torque  : 12 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Install the engine wiring harness.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Secure the wiring harness.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Secure the wiring harness.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Secure the wiring harness.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Secure the wiring harness.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Secure the wiring harness.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Secure the wiring harness.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Secure the glow plug wiring harness.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Secure the wiring harness.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install a new gasket.

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

• Install the thermostat.
• Secure the coolant hose.
• Torque  : 12 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Secure the wiring harness.
• Torque  : 12 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Install the coolant hose.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Install the coolant hoses.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the NVH  insulation.
• Torque  : 10 Nm 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the charge air cooler mounting bracket.
• Install and tighten the 2 bolts.

  Torque  : 47 Nm 

• Install and tighten the 2 nuts.

  Torque  : 10 Nm 

• Install the 2 electrical wiring harness clips.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the charge air cooler assembly.
• Install and tighten the 4 bolts.

  Torque  : 7 Nm 

• Tighten the hose clip.
• Connect the electrical connector.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Install a new O-ring seal.

Renew Part: Front differential case to engine oil pan O-ring seal Quantity: 1 . 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

• Install the differential.
• Install and tighten 4 new bolts.

  Renew Part: Differential case front bolt(s) Quantity: 4 . 

  Torque 

  Stage 1: 80 Nm 

  Stage 2: 180° 

Refer to: ENGINE ASSEMBLY REMOVE FOR ACCESS 

Refer to: STARTUP BATTERY DISCONNECT AND CONNECT

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Remove the engine oil level indicator.

Refer to: SPECIFICATIONS

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Clean any residual engine oil from the oil filler cap area.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

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.

• Connect the Jaguar Land Rover approved diagnostic equipment and run the following service functions.

  General Equipment: Jaguar Land Rover approved diagnostic equipment 

• Fuel injector replacement.
• Air path setup routine.
• Engine Control Module (ECM) Low Pressure (LP) EGR  adaption clear.