General Equipment

Equipment name
Engine stand

WARNING:

This procedure involves fuel handling, be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
Be prepared to collect escaping fuel.

CAUTION:

Be prepared to collect escaping coolant.
Make sure the coolant is inspected for signs of contamination, or overheating. If found a thorough strip and cleaning of the engine cooling system is required.
Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.
Make sure that coolant system components are cleaned and checked carefully for damage, contamination or deterioration before installing to the new engine.
Coolant passages in the old engine should be inspected for contamination before commencing assembly of the new engine.

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.

Always refer to the Petrol-Ethanol fuel systems health and safety precautions before any repairs to the fuel system are done.
Refer to: PETROL AND PETROL-ETHANOL FUEL SYSTEMS HEALTH AND SAFETY PRECAUTIONS
Raise and support the vehicle on a suitable 2 post lift.
Refer to: JACKING AND LIFTING
Disconnect the startup battery ground cable.
Refer to: SPECIFICATIONS
Remove the engine.
Refer to: ENGINE
Mount the engine to an engine stand.
General Equipment: Engine stand
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- Disconnect the breather pipe.
- Release the clip.
- Remove the breather pipe.
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- Remove the 2 bolts.
- Reposition the engine wiring harness.
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- Disconnect the vacuum pipe.
- Release the 2 clips.
- Remove the vacuum pipe.
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- Disconnect the breather pipe.
- Release the 2 clips.
- Remove the breather pipe.
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- Disconnect the purge valve assembly.
- Remove the purge valve assembly.
CAUTION:
- Make sure the components are cleaned and checked carefully for damage, contamination or deterioration before installing to the new engine.
- Be prepared to collect escaping coolant.
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- Release the 2 clips and reposition the wiring harness away from the thermostat housing.
- Release the 2 clamps.
- Disconnect the 2 coolant hoses.
- Remove and discard the 2 upper screws.
- Remove the lower screw.
- Remove the thermostat housing assembly.
CAUTION: Make sure that the water pipe and o-ring seal is discarded. Failure to follow this instruction might result in damage to the engine.

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- Release the clamp.
- Remove and discard the water pipe and o-ring seal assembly.
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- Remove the oil filter element cap.
- Remove and discard the oil filter element.
- Remove and discard the O-ring seal.
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- Remove the 4 bolts.
- Remove the oil filter housing.
- Remove and discard the oil filter housing gasket.
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- Remove and discard the 4 bolts.
- Remove the right side exhaust manifold heatshield.
NOTE: Note the installed position of the bolts.

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- Remove and discard the 4 bolts.
- Remove the left side exhaust manifold heatshield.
NOTE: If equipped.

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- Disconnect the electrical connector.
- Release the clip.
- Remove the 2 nuts.
- Release the clamp.
- Disconnect the hose.
- Remove the right differential pressure sensor assembly.
NOTE: If equipped.

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- Disconnect the electrical connector.
- Release the clip.
- Remove the 2 nuts.
- Release the clamp.
- Disconnect the hose.
- Remove the left differential pressure sensor assembly.
NOTE: Note the installed position and orientation of the spacers.

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- Remove and discard the 8 bolts.
- Remove the 8 spacers.
- Remove the right exhaust manifold.
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Remove and discard the right exhaust manifold gasket.
NOTE: Note the installed position and orientation of the spacers.

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- Remove and discard the 8 bolts.
- Remove the 8 spacers.
- Remove the left exhaust manifold.
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Remove and discard the left exhaust manifold gasket.
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- Remove the 3 bolts.
- Remove the idler pulley.
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- Disconnect the electrical connector.
- Remove the 3 bolts.
- Remove the generator.
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- Remove the 2 bolts.
- Remove the starter motor cover.
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- Remove the 2 bolts.
- Remove the starter motor.
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- Disconnect the 2 electrical connectors.
- Release the clip.
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- Remove the 2 bolts.
- Remove the cover.
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- Remove the nut.
- Remove the 2 bolts.
- Disconnect the 4 fuel line unions.
- Remove and discard the High Pressure (HP) fuel pump outlet pipe assembly.
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- Remove the bolt.
- Disconnect the 2 fuel line unions.
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- Remove the 2 bolts.
- Release the 2 clips.
- Release the HP fuel pump inlet pipe from the 2 clips.
- Remove the HP fuel pump inlet pipe.
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Remove the 2 HP fuel pump covers.
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- Remove the 4 bolts.
- Remove the 2 HP fuel pumps.
- Remove and discard the 2 O-ring seals.
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Remove the 2 HP fuel pump tappets.
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- Disconnect the 3 electrical connectors.
- Release the clip.
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- Remove the 4 bolts.
- Disconnect the fuel line union.
- Remove the fuel rail crossover pipe.
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- Disconnect the 4 electrical connectors.
- Release the 2 clips.
- Remove the bolt.
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- Disconnect the 4 electrical connectors.
- Release the clip.
- Remove the bolt.
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- Remove the nut.
- Disconnect the 9 electrical connectors.
- Release the 5 clips.
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- Disconnect the 8 electrical connectors.
- Release the 4 clips.
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- Release the 5 clips.
- Disconnect the 2 electrical connectors.
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- Release the clip.
- Disconnect the 3 electrical connectors.
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Remove the engine wiring harness.
CAUTION: Make sure the coolant passages are cleaned and checked carefully for damage, contamination or deterioration before installing to the new engine.

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- Release the clamp.
- Disconnect the coolant hose.
- Remove the 4 bolts.
- Remove the coolant pipe.
- Remove and discard the 2 gaskets.
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- Release the 2 clips.
- Remove the 3 bolts.
- Remove the wiring harness bracket.
NOTE: If equipped.

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- Remove the block heater.
- Remove and discard the gasket.
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- Remove the 4 bolts.
- Remove the 4 left ignition coils.
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- Remove the 4 bolts.
- Remove the 4 right ignition coils.
NOTE: Repeat this step for the other side.

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Use the special tool to remove the 4 spark plugs.

Special Tool(s): 303-1450
CAUTION: Make a note of the fuel injector clamp alignment to the fuel rail prior to removal.

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- Remove the 4 bolts.
- Remove the right fuel rail.
CAUTION: Make a note of the fuel injector clamp alignment to the fuel rail prior to removal.

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- Remove the 4 bolts.
- Remove the left fuel rail.
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Use the special tool to remove the 4 right fuel injectors.

Special Tool(s): 310-197
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Use the special tool to remove the 4 left fuel injectors.

Special Tool(s): 310-197
NOTE: Repeat this step for the remaining 7 fuel injectors.

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- Remove and discard the fuel injector clamp.
- Remove and discard the fuel injector O-ring seal and washer.
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- Remove the 2 bolts.
- Remove the bracket.
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- Remove the 25 bolts.
- Remove the charge air cooler assembly.
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Remove and discard the gasket.
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- Remove the 8 bolts.
- Remove the supercharger assembly.
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Remove and discard the 2 intake manifold gaskets.
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- Note the installed position of the 4 knock sensors.
- Remove the 4 bolts.
- Remove the 4 knock sensors and wiring harness assembly.
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Remove the 2 Noise, Vibration and Harshness (NVH) components.
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- Remove the 2 bolts.
- Remove and discard the coolant pipe and 2 o-ring seals.
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- Remove the bolt.
- Remove the accessory drive belt tensioner.
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- Remove the 3 bolts.
- Remove the idler pulley.
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- Remove the 4 bolts.
- Remove the accessory drive belt tensioner bracket.
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- Remove the 4 bolts.
- Remove the 2 Variable Camshaft Timing (VCT) solenoids.
- Remove and discard the 2 O-ring seals.
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- Remove the 4 bolts.
- Remove the 2 VCT solenoids.
- Remove and discard the 2 O-ring seals.
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- Remove the 2 bolts.
- Remove the 2 Camshaft Position Sensor (CMP) sensors.
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- Remove the 2 bolts.
- Remove and discard the 2 O-ring seals.
- Remove the 2 CMP sensors.
CAUTION: Make sure that the o-ring is removed from the coolant pump.

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- Remove the 4 bolts.
- Remove the coolant pump.
- Remove and discard the pipe from the coolant pump.
- Remove and discard the 2 O-ring seals.
- Remove and discard the 2 gaskets.
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- Remove the 2 bolts.
- Remove the brake vacuum pump.
- Remove and discard the gasket.
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- Remove and discard the 18 bolts.
- Remove the oil cooler.
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Remove and discard the gasket.
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- Install the special tool.
  Special Tool(s): JLR-303-1304
- Install and tighten the 2 bolts.
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- Remove and discard the 10 bolts.
- Remove the drive plate.
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- Remove the 2 bolts.
- Remove the generator bracket.
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- Remove and discard the 4 bolts.
- Remove the left engine mount.
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- Remove and discard the 4 bolts.
- Remove the right engine mount.
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Remove the 2 bolts.
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Install the special tools.

Special Tool(s): 303-1437 , 303-1438

Torque : 25 Nm
NOTE: The thread is left handed.

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- Use a suitable stand to support the special tool.
- Use the special tool to remove the bolt.
- Discard the bolt.
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Remove the 2 bolts.
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Install the special tool.

Special Tool(s): 303-1440
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Install the special tool.

Special Tool(s): 303-1441
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- Install the special tool.
  Special Tool(s): 303-1439
- Install and tighten the 4 bolts.
  Torque : 10 Nm
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Use the special tools to remove the crankshaft pulley.
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- Remove the 4 bolts.
- Remove the special tool.
  Special Tool(s): 303-1439
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Remove the special tools.

Special Tool(s): 303-1440 , 303-1441
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- Remove the 2 bolts.
- Remove the special tool.
  Special Tool(s): JLR-303-1304