Engine Assembly Remove For Access (G2340859): Part(S)

STEP	PART NAME	QUALIFICATION	QUANTITY
Step 52	Air conditioning pipe O-ring seal(s)	All vehicles	6
Step 70	Air conditioning pipe O-ring seal(s)	All vehicles	2
Step 16	Catalytic converter to turbocharger clamp	All vehicles	1
Step 14	Catalytic converter to turbocharger gasket	All vehicles	1
Step 8	Drive plate bolts	All vehicles	6
Step 82	Driveshaft flange bolts	All vehicles	6
Step 43	Engine mounting bracket to engine bolts	All vehicles	5
Step 44	Engine mounting bracket to engine bolts	All vehicles	3

WARNING:

Make sure the powertrain is suitably supported at all times.
Failure to support the engine and transmission may cause personal injury.
Be prepared to collect escaping fuel.
Be prepared to collect escaping coolant.
Be prepared to collect escaping oil.

CAUTION: Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all components must be sealed.

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.

The following step(s) applies to:

All vehicles

WARNING: This step requires the aid of another technician.

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- Install the engine lifting bracket.
  Special Tool(s): JLR-303-1569
- Support the powertrain assembly using a suitable hydraulic jib crane.
  General Equipment: Hydraulic jib crane
- Remove the 4 bolts and 4 nuts from the engine stand.
- With the aid of another technician, remove the engine assembly from the engine stand.
  General Equipment: Engine stand
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Remove the 4 bolts and remove the special tool.

Special Tool(s): JLR-303-1673
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- Connect the 2 electrical connectors.
- Install the wiring harness clip.
WARNING:
- Make sure the engine and transmission are suitably supported at all times.
- This step requires the aid of another technician.
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Install the transmission assembly.
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Install and tighten the transmission bolt.

Torque : 60 Nm
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Install and tighten the 2 lower transmission bolts.

Torque : 60 Nm
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Install and tighten the 4 upper transmission bolts.

Torque : 60 Nm
CAUTION: Only rotate the crankshaft in a clockwise direction.

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Install and tighten the 6 new drive plate bolts.

Renew Part: Drive plate bolts Quantity: 6 .

Torque : 62 Nm
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- Install the starter motor.
- Install and tighten the 2 bolts.
  Torque : 48 Nm
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- Reposition the wiring harness.
- Install and tighten the 2 nuts.
  Torque : 10 Nm
- Connect the breather hose.
- Install the wiring harness clip.
WARNING: This step requires the aid of another technician.

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- With the aid of another technician, install the Power Transfer Unit (PTU).
- Install and tighten the 4 bolts.
  Torque : 65 Nm
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Install and tighten the 2 bolts.

Torque : 65 Nm
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Connect the PTU breather hose.
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- Install a new gasket to the catalytic converter.
  Renew Part: Catalytic converter to turbocharger gasket Quantity: 1 .
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Install the catalytic converter.
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Install the new catalytic converter clamp finger tight at this stage.

Renew Part: Catalytic converter to turbocharger clamp Quantity: 1 .
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Install and tighten the 2 catalytic converter bracket bolts finger tight at this stage
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- Install the halfshaft support bracket.
- Install and tighten the 6 bolts.
  Torque : 70 Nm
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Install and tighten the 2 bolts.

Torque : 60 Nm
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- Install the bracket.
- Install and tighten the 3 bolts.
  Torque : 24 Nm
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Install and tighten the 2 bolts.

Torque : 24 Nm
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- Install the lower exhaust bracket.
- Install and tighten the 2 bolts.
  Torque : 24 Nm
Fully tighten the catalytic converter clamp.
Torque : 18 Nm
Fully tighten the 2 catalytic converter bracket bolts.
Torque : 25 Nm
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- Install the heatshield.
- Install and tighten the 2 bolts.
  Torque : 9 Nm
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- Install the heatshield.
- Install and tighten the 3 bolts.
  Torque : 9 Nm
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- Reposition the transmission wiring harness.
- Connect the 2 electrical connectors.
- Install the 3 wiring harness clips.
- Install and tighten the bolt.
  Torque : 10 Nm
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- Connect the 2 electrical connectors.
- Install the wiring harness clip.
- Install and tighten the bolt.
  Torque : 10 Nm
- Install the wiring harness connector retaining clip.
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- Install the charge air cooler.
- Secure the clip.
- Install and tighten the 4 bolts.
  Torque : 7 Nm
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- Install the charge air cooler inlet hose assembly.
- Install and tighten the bolt.
  Torque : 8 Nm
- Install and tighten the nut.
  Torque : 8 Nm
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- Install the air filter outlet pipe assembly.
- Connect the 4 hoses.
- Connect the electrical connector and secure the wiring harness with the clip.
- Connect the breather pipe.
- Install the 4 hose clips.
- Install and tighten the bolt.
  Torque : 8 Nm
The following step(s) applies to:

Mild Hybrid Electric Vehicles
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- Install the Belt Integrated Starter Generator (BISG).
- Install and tighten the 2 bolts.
  Torque : 47.5 Nm
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Install the accessory drive belt onto the BISG.
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- Install the accessory drive belt tensioner.
- Install and tighten the 3 bolts.
  Torque : 25 Nm
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- Release the accessory drive belt tensioner.
- Remove the accessory drive belt tensioner locking tool.
  Special Tool(s): JLR-308-1699
- Carefully allow the tensioner to make contact with the accessory drive belt.
The following step(s) applies to:

All vehicles
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- Install the 5-way manifold.
- Install and tighten the bolt.
  Torque : 7 Nm
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Connect the 2 coolant hoses.
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- Install the coolant hose assembly.
- Connect the 4 coolant hoses.
- Secure the coolant hose assembly with the 2 retainers.
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- Install the coolant hose assembly.
- Connect the 4 coolant hoses.
- Secure the coolant hose assembly with the 2 retainers.
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- Install the coolant hose and auxiliary coolant pump assembly.
- Connect the coolant hose.
- Install the wiring harness clip.
- Connect the electrical connector.
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- Install the coolant hose assembly.
- Connect the 2 coolant hoses.
WARNING: This step requires the aid of another technician.

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With the aid of another technician, carefully install the powertrain assembly.
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Install and tighten the 5 new bolts.

Renew Part: Engine mounting bracket to engine bolts Quantity: 5 .

Torque
1. Stage 1: 70 Nm
2. Stage 2: 120°
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Install and tighten the 3 new bolts.

Renew Part: Engine mounting bracket to engine bolts Quantity: 3 .

Torque
1. Stage 1: 70 Nm
2. Stage 2: 120°
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- Remove the hydraulic jib crane.
  General Equipment: Hydraulic jib crane
- Remove the 2 bolts.
- Remove the engine lifting bracket.
  Special Tool(s): JLR-303-1569
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- Reposition the breather pipe.
- Install the clip.
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- Install the bracket.
- Install and tighten the 2 bolts.
  Torque : 15 Nm
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- Reposition the wiring harness.
- Install the clip.
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- Install the bracket.
- Install and tighten the bolt.
  Torque : 10 Nm
- Connect the 2 electrical connectors.
- Secure the 2 wiring harnesses with the 2 clips.
- Install the wiring harness clip.
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Install the heatshield and secure with the 2 clips.
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Connect the breather pipe.
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- Install 6 new O-ring seals.
  Renew Part: Air conditioning pipe O-ring seal(s) Quantity: 6 .
- Install the 2 Air Conditioning (A/C) pipes.
- Install and tighten the 4 nuts.
  Torque : 24 Nm
NOTE: Repeat this step for the other side.

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- Install the bracket.
- Install and tighten the 3 nuts.
  Torque : 15 Nm
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With the aid of another technician, install the cooling module assembly.
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Install and tighten the 4 nuts on the left side.

Torque : 50 Nm
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Install and tighten the 4 nuts on the right side.

Torque : 50 Nm
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Install the clip.
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Install and tighten the 3 bolts on the left side.

Torque : 170 Nm
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Install and tighten the 3 bolts on the right side.

Torque : 170 Nm
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- Install the lower active grille air shutter.
- Install and tighten the 7 bolts.
  Torque : 4.1 Nm
- Connect the electrical connector.
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- Install the radiator lower air deflector.
- Install and tighten the 2 screws.
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Install the 2 clips.
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- Install the 2 horn assemblies.
- Install and tighten the 2 bolts.
  Torque : 10 Nm
- Connect the 2 electrical connectors.
- Secure the horn wiring harness on both sides.
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- Install the upper active grille air shutter.
- Install and tighten the 3 bolts.
  Torque : 4.1 Nm
- Install the 2 clips.
- Connect the electrical connector.
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Connect the 3 left side coolant hoses.
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Connect the 3 right side coolant hoses.
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- Connect the electrical connector.
- Secure the clip.
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Secure the 6 clips.
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- Reposition the auxiliary coolant pump.
- Install and tighten the bolt.
  Torque : 10 Nm
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- Install 2 new O-ring seals.
  Renew Part: Air conditioning pipe O-ring seal(s) Quantity: 2 .
- Connect the 2 A/C pipes.
- Install and tighten the 2 nuts.
  Torque : 24 Nm
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Connect the electrical connector.

The following step(s) applies to:

Mild Hybrid Electric Vehicles
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- Reposition the wiring harness.
- Install and tighten the 2 nuts.
  Torque : 10 Nm
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- Connect the 2 cables.
- Install the clip.
- Install and tighten the 2 nuts.
  Torque : 12 Nm
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Close the cover.
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- Install the wiring harness clip.
- Connect the electrical connector.
The following step(s) applies to:

All vehicles
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- Install the clip.
- Connect the vacuum pipe.
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Connect the 3 coolant hoses.
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- Reposition the wiring harness.
- Install the 2 wiring harness clips.
- Install the wiring harness mounting grommet.
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- Connect the 3 electrical connectors.
- Install and tighten the locking bolt.
  Torque : 8 Nm
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- Install the auxiliary radiator.
- Install and tighten the 4 bolts.
  Torque : 24 Nm
- Connect the 2 coolant hoses.
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- Install the auxiliary radiator duct.
- Install and tighten the bolt.
CAUTION: To avoid damage to the joint, do not allow the driveshaft to hang.

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- Install the driveshaft.
- Install and tighten the 6 new bolts.
  Renew Part: Driveshaft flange bolts Quantity: 6 .
  
  Torque : 40 Nm
Install the cowl panel.
Refer to: COWL PANEL .
Install the coolant expansion tank.
Refer to: COOLANT EXPANSION TANK .
Install the exhaust system.
Refer to: EXHAUST SYSTEM .
Install the hood latch panel.
Refer to: HOOD LATCH PANEL .
Install the front right halfshaft.
Refer to: FRONT LEFT HALFSHAFT .
Install the front left halfshaft.
Refer to: FRONT RIGHT HALFSHAFT .
Vacuum fill the cooling system.
Refer to: COOLING SYSTEM DRAINING AND VACUUM FILLING .
Charge the A/C system.
Refer to: AIR CONDITIONING SYSTEM RECOVERY, EVACUATION AND CHARGING .
Install both front headlamps.
Refer to: HEADLAMP ASSEMBLY .

The following step(s) applies to:

Mild Hybrid Electric Vehicles
Power Up the Mild Hybrid Electric Vehicle (MHEV) system.
Refer to: MHEV POWER DOWN/UP .

The following step(s) applies to:

All vehicles
Install the startup battery tray.
Refer to: STARTUP BATTERY TRAY .
Install the engine cover.
Refer to: ENGINE COVER - INGENIUM I4 2.0L PETROL .
Connect the startup battery ground cable.
Refer to: 12V SYSTEM DISCONNECT .