Short Engine Assembly Renew (G2443972): Part(s)

Fig 1: Windage Tray Bolts Tightening Sequence

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• Install the windage tray.
• Install and tighten the 4 bolts in the illustrated sequence.

  Torque  : 25 Nm 

• Install and tighten the remaining 7 bolts.

  Torque  : 25 Nm 

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• Install 2 new O-ring seals.

  Renew Part: Oil pump outlet tube O-ring seal(s)  Quantity: 2  .

• Connect the oil pump outlet pipe to the oil pump.

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• Install the oil pump.
• Install and tighten the 3 oil pump mounting bolts.

  Torque  : 25 Nm 

• Install and tighten the 3 oil pump outlet pipe bolts.

  Torque  : 11.5 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 pump inlet pipe.
• Install and tighten the 2 bolts.

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• Install a new crankshaft pulley bolt.

  Renew Part: Crankshaft pulley bolts  Quantity: 1  .

• Rotate the crankshaft in a clockwise direction until TDC on cylinder 1 as illustrated.
• Rotate the crankshaft in a clockwise direction by 45°.

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• Install a new friction washer.

  Renew Part: Crankshaft sprocket friction washer  Quantity: 1  .

• Install the crankshaft sprocket.
• Install a new friction washer.

  Renew Part: Crankshaft sprocket friction washer  Quantity: 1  .

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• Install the oil pump drive sprocket.
• Install, but do not fully tighten a new bolt.

  Renew Part: Oil pump gear bolt  Quantity: 1  .

• Use a suitable tool to hold the oil pump drive sprocket.
• Tighten the bolt.

  Torque  : 21 Nm 

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• Install a new lower timing chain tensioner.

  Renew Part: Lower timing chain tensioner  Quantity: 1  .

• Install and tighten the bolt.

  Torque  : 21 Nm 

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• Reposition the lower timing chain tensioner as illustrated.
• Install a suitable tool to hold the lower timing chain tensioner.

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• Install a new lower timing chain.

  Renew Part: Lower timing chain  Quantity: 1  .

• Make sure the orange link (2) aligns with the timing mark on the High Pressure (HP) fuel pump camshaft.
• Make sure the blue link (1) aligns with the timing mark on the crankshaft sprocket.
• Make sure the blue link (3) is in the middle point of the blue link (1) and the orange link (2).

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• Install a new lower timing chain guide.

  Renew Part: Lower timing chain guide  Quantity: 1  .

• Install and tighten the bolt.

  Torque  : 11.5 Nm 

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• Remove the holding tool.
• Slowly release the lower timing chain tensioner.

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• Install the crankshaft sprocket.
• Install a new friction washer.

  Renew Part: Crankshaft sprocket friction washer  Quantity: 1  .

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• Install the 2 timing chain lubrication pipes.
• Install and tighten the 2 bolts.

  Torque  : 11 Nm 

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Apply RTV sealant WSE-M4G323-A6 (Loctite 5901G or Loctite 59000) to the areas shown.

Fig 2: Oil Pan Bolts Tightening Sequence

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• Install the oil pan.
• Install and tighten 16 new bolts in the illustrated sequence.

  Renew Part: Oil pan bolts M8 x 35  Quantity: 11  .

  Renew Part: Oil pan bolts M8 x 80  Quantity: 5  .

  Torque  : 25 Nm 

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Apply RTV sealant (Loctite 5901G) to the areas shown.

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• Install the special tool.

  Special Tool(s): 303-1442 

• Install and tighten the 2 bolts.

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Install a new engine rear cover with a space of 8 mm between the engine rear cover and the mating face.

Renew Part: Crankshaft rear cover  Quantity: 1  .

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• Install, but do not fully tighten the 4 bolts.
• Make sure there is a space of 8 mm between the engine rear cover and the mating face.

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

  Special Tool(s): 303-1442 

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• Apply pressure to the engine rear cover and install the special tool.

  Special Tool(s): JLR-303-1622 

• Make sure there is a space of 8 mm between the engine rear cover and the mating face.

Fig 3: Engine Rear Cover Tightening Sequence

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• Use the special tool to fully install the engine rear cover.

  Special Tool(s): JLR-303-1622 

• Tighten the 4 bolts in the illustrated sequence.

  Torque  : 11.5 Nm 

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Remove the special tool.

Special Tool(s): JLR-303-1622 

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Install and tighten the 8 bolts.

Torque  : 11.5 Nm 

Refer to: CYLINDER HEAD DISTORTION - INGENIUM I4 2.0L PETROL/TDV6 3.0L DIESEL/TDV8 4.4L DIESEL/V6 S/C 3.0L PETROL/V8 S/C 5.0L PETROL

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Make sure that the mating faces are clean and free of foreign material.

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Install a new right cylinder head gasket.

Renew Part: Cylinder head gasket  Quantity: 1  .

Fig 4: Cylinder Head Bolts Tightening Sequence

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• Install the right cylinder head.
• Use the special tool to install and tighten 10 new cylinder head bolts in the illustrated sequence.

  Special Tool(s): JLR-303-1653 

  Renew Part: Cylinder head bolts  Quantity: 10  .

  Torque 

  Stage 1: 20 Nm 

  Stage 2: 35 Nm 

• Loosen each bolt and then tighten each bolt in the illustrated sequence.

  Torque  : 35 Nm 

• Tighten the 10 bolts in the illustrated sequence.

  Torque  : 90° 

• Tighten the 10 bolts in the illustrated sequence.

  Torque  : 120° 

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Install and tighten a new bolt.

Renew Part: Cylinder head bolts  Quantity: 1  .

Torque  : 25 Nm 

Fig 5: Cylinder Head Bolts Tightening Sequence

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Install and tighten 2 new cylinder head bolts in the illustrated sequence.

Renew Part: Cylinder head bolts  Quantity: 2  .

Torque  : 11.5 Nm 

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Install a new left cylinder head gasket.

Renew Part: Cylinder head gasket  Quantity: 1  .

Fig 6: Left Cylinder Head Bolts Tightening Sequence

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• Install the left cylinder head.
• Use the special tool to install and tighten 10 new cylinder head bolts in the illustrated sequence.

  Special Tool(s): JLR-303-1653 

  Renew Part: Cylinder head bolts  Quantity: 10  .

  Torque 

  Stage 1: 20 Nm 

  Stage 2: 35 Nm 

• Loosen each bolt and then tighten each bolt in the illustrated sequence.

  Torque  : 35 Nm 

• Tighten the 10 bolts in the illustrated sequence.

  Torque  : 90° 

• Tighten the 10 bolts in the illustrated sequence.

  Torque  : 120° 

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Install and tighten a new bolt.

Renew Part: Cylinder head bolts  Quantity: 1  .

Torque  : 25 Nm 

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Install and tighten 2 new cylinder head bolts in the illustrated sequence.

Renew Part: Cylinder head bolts  Quantity: 2  .

Torque  : 11.5 Nm 

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Lubricate each of the areas shown with a drop of clean engine oil.

Refer to: SPECIFICATIONS 

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Lubricate each of the areas shown with a drop of clean engine oil.

Refer to: SPECIFICATIONS 

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Install the 32 valve tappets to their noted removal position.

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Lubricate each of the areas shown with a drop of clean engine oil.

Refer to: SPECIFICATIONS 

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Lubricate each of the areas shown with a drop of clean engine oil.

Refer to: SPECIFICATIONS 

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• Make sure a filter is installed in each camshaft prior to installing the camshafts.
• Lubricate each of the areas shown with a drop of clean engine oil.

  Refer to: SPECIFICATIONS 

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Install the 2 right camshafts to their noted removal position.

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Install the 2 left camshafts to their noted removal position.

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Lubricate each of the areas shown with a drop of clean engine oil.

Refer to: SPECIFICATIONS 

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Lubricate each of the areas shown with a drop of clean engine oil.

Refer to: SPECIFICATIONS 

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• Install the 10 camshaft bearing caps to their noted removal position.
• Working from the front of the engine to the rear, install and tighten the 20 bolts.

  Torque  : 11 Nm 

• Make sure each camshaft can rotate freely.

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• Install the 10 camshaft bearing caps to their noted removal position.
• Working from the front of the engine to the rear, install and tighten the 20 bolts.

  Torque  : 11 Nm 

• Make sure each camshaft can rotate freely.

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Install and tighten the 2 bolts.

Torque  : 11.5 Nm 

Fig 7: Drive Plate Bolt Tightening Sequence

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• Install the drive plate.
• Install, but do not fully tighten 10 new bolts.

  Renew Part: Drive plate bolts  Quantity: 10  .

• Install the special tools as illustrated.

  Special Tool(s): JLR-303-1303  , JLR-303-1304 

• Tighten the 10 bolts in the illustrated sequence.

  Torque 

  Stage 1: 45 Nm 

  Stage 2: 90° 

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• Install a new upper right upper timing chain guide.

  Renew Part: Upper timing chain guide  Quantity: 1  .

• Install and tighten the 3 bolts.

  Torque  : 11.5 Nm 

• Install a new lower left upper timing chain guide.

  Renew Part: Upper timing chain guide  Quantity: 1  .

• Install and tighten the 3 bolts.

  Torque  : 11.5 Nm 

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• Install a new lower right upper timing chain guide.

  Renew Part: Upper timing chain guide  Quantity: 1  .

• Install and tighten the bolt.

  Torque  : 25 Nm 

• Install a new upper left upper timing chain guide.

  Renew Part: Upper timing chain guide  Quantity: 1  .

• Install and tighten the bolt.

  Torque  : 25 Nm 

• Install a new right upper timing chain tensioner.

  Renew Part: Upper timing chain tensioner  Quantity: 1  .

• Install and tighten the 2 bolts.

  Torque  : 11.5 Nm 

• Install a new left upper timing chain tensioner.

  Renew Part: Upper timing chain tensioner  Quantity: 1  .

• Install and tighten the 2 bolts.

  Torque  : 11.5 Nm 

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• Install the special tools as illustrated.

  Special Tool(s): 303-1452 

• Install and tighten the 6 bolts.

  Torque  : 10 Nm 

• Repeat this step for the other side.

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Make sure all the camshafts are oriented as illustrated.

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• Install the special tool as illustrated.

  Special Tool(s): 303-1445 

• Use a suitable tool to carefully rock the camshaft clockwise then counter clockwise. Turn the special tool locking nuts until there is no movement left in the camshaft.
• Repeat this step for the other camshafts.

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• Remove the 6 bolts.
• Remove the special tools.

  Special Tool(s): 303-1452 

• Repeat this step for the other side.

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• Install a new left upper timing chain to the left exhaust Variable Camshaft Timing (VCT) actuator.

  Renew Part: Upper timing chain  Quantity: 1  .

• Make sure the yellow left upper timing chain link (1) aligns with the notch on the VCT  actuator.
• Install the left upper timing chain and the left exhaust VCT  actuator.
• Make sure the white left upper timing chain link (2) aligns with the timing mark on the lower left upper timing chain guide.
• Install, but do not fully tighten the 3 bolts.

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• Install the left intake VCT  actuator.
• Make sure the yellow left upper timing chain link (3) aligns with the timing mark on the left intake VCT  actuator.
• Install, but do not fully tighten the 3 bolts.

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• Install a new right upper timing chain to the right intake VCT  actuator.

  Renew Part: Upper timing chain  Quantity: 1  .

• Make sure the yellow right upper timing chain link (4) aligns with the timing mark on the VCT  actuator.
• Install the right upper timing chain and the right intake VCT  actuator.
• Install, but do not fully tighten the 3 bolts.
• Make sure the white right upper timing chain link (5) aligns with the timing mark on the upper right upper timing chain guide.

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• Install the right exhaust VCT  actuator.
• Make sure the yellow right upper timing chain link (6) aligns with the notch on the VCT  actuator.
• Install, but do not fully tighten the 3 bolts.

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• Tighten the 12 bolts in the illustrated sequence.

  Torque  : 10 Nm 

• Loosen the 12 bolts.

  Torque  : 2 turn(s) 

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• Remove and discard the 2 locking pins.
• Slowly release the 2 upper timing chain guides.

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Tighten the 12 bolts in the illustrated sequence.

Torque  : 10 Nm 

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Tighten the 12 bolts in the illustrated sequence.

Torque  : 32 Nm 

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

  Special Tool(s): 303-1445 

• Repeat this step for the other side.

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Apply RTV sealant (Loctite 5901G) in a 3 mm diameter to the areas shown.

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Remove and discard the bolt.

Fig 8: Engine Front Cover Tightening Sequence

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

  Special Tool(s): 303-1433 

• Install, but do not fully tighten the 4 bolts.
• Tighten the 4 bolts in the illustrated sequence.

  Torque 

  M6: 11.5 Nm 

  M8: 20 Nm 

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• Install and tighten the 9 bolts.

  Torque  : 11 Nm 

• Remove the special tool.

  Special Tool(s): 303-1433 

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Apply RTV sealant (Loctite 5901G) in a 3 mm diameter to the areas shown.

Fig 9: Upper Timing Cover Tightening Sequence

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• Install the upper timing cover.
• Install and tighten the 5 bolts in the illustrated sequence.

  Torque  : 11.5 Nm 

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Apply RTV sealant (Loctite 5901G) in a 3 mm diameter to the areas shown.

Fig 10: Upper Timing Cover Tightening Sequence

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• Install the upper timing cover.
• Install and tighten the 5 bolts in the illustrated sequence.

  Torque  : 11.5 Nm 

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• Install a new right valve cover gasket.

  Renew Part: Valve cover gasket  Quantity: 1  .

• Install 4 new spark plug boss seals.

  Renew Part: Spark plug boss seals  Quantity: 1  .

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• Install a new left valve cover gasket.

  Renew Part: Valve cover gasket  Quantity: 1  .

• Install 4 new spark plug boss seals.

  Renew Part: Spark plug boss seals  Quantity: 1  .

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• Install the right valve cover.
• Tighten the 18 bolts.

  Torque  : 13 Nm 

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• Install the left valve cover.
• Tighten the 18 bolts.

  Torque  : 13 Nm 

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Install the oil filler cap.

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• Remove the bolt.
• Remove the special tool.

  Special Tool(s): JLR-303-1303 

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

  Special Tool(s): JLR-303-1304