Engine - INGENIUM I4 2.0L Petrol/INGENIUM I4 2.0L Petrol - PHEV (G2523514): Installation: Part(S)

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

STEP	PART NAME	QUALIFICATION	QUANTITY
Step 15	Air conditioning pipe to compressor O-ring seal(s)	All vehicles	2
Step 15	Air conditioning pipe O-ring seal(s)	All vehicles	1
Step 23	Halfshaft support bracket o-ring seal	All vehicles	1
Step 29	Air conditioning pipe to compressor O-ring seal(s)	Plug in hybrid electric vehicles only	2
Step 29	Air conditioning pipe O-ring seal(s)	Plug in hybrid electric vehicles only	1

WARNING:

If the vehicle has been powered down, do not power up the vehicle until all the bonding points have been tested.
It is the responsibility of the Electric Vehicle Senior Authorized Person (EVSAP) to make sure they comply with any local legislation for work on High Voltage (HV).
The approved Personal Protective Equipment (PPE) must be worn where indicated within this procedure and not removed unless indicated within a step. All items of PPE must be checked for signs of damage before each use, if damaged, replacement PPE must be obtained before doing this procedure.

NOTE:

All Permit To Work (PTW) documents must be kept for a minimum of 5 years.
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

Before working on the fuel system make sure to study the fuel system health and safety information.
Refer to: PETROL AND PETROL-ETHANOL FUEL SYSTEMS HEALTH AND SAFETY PRECAUTIONS .
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Install the special service tool, engine lifting bracket on a suitable hydraulic engine crane.

Special Tool(s): JLR-303-1633

General Equipment: Hydraulic jib crane
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Install the special service tool to the 3 engine lifting eye locations.

Special Tool(s): JLR-303-1633
WARNING: This step requires the aid of another technician.

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- Remove the 4 nuts from the engine stand bracket.
- Use the hydraulic engine crane to remove the engine assembly from the engine stand.
  General Equipment: Engine stand
  
  General Equipment: Hydraulic jib crane
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- Remove the 4 bolts.
- Remove the special tool.
  Special Tool(s): JLR-303-1673
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- Install the engine mount bracket.
- Install and tighten the 4 bolts.
  Torque : 60 Nm
WARNING: This step requires the aid of another technician.

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With assistance install the engine assembly.
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Install and tighten the right engine mount nut.

Torque : 60 Nm
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Install and tighten the left engine mount nut.

Torque : 60 Nm
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Remove the special service tool and hydraulic engine crane assembly.
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Connect the vacuum pipe to the left side engine mount.
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- Install the heat shield.
- Install the 2 bolts.
  Torque : 20 Nm
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- Secure the clip.
- Connect the vacuum pipe to the right side engine mount.
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- Connect the 2 electrical connectors.
- Install the upper wiring harness grommet.
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- Lubricate and install the 3 new O-ring seals to the Air Conditioning (A/C) pipes.
  Renew Part: Air conditioning pipe to compressor O-ring seal(s) Quantity: 2 .
  
  Renew Part: Air conditioning pipe O-ring seal(s) Quantity: 1 .
- Install the 2 A/C pipes to the A/C compressor.
- Install the A/C pipe to the A/C evaporator pipe.
- Install and tighten the nut and the 2 bolts.
  Torque : 20 Nm
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Secure the 4 clips.
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Install and tighten the nut.

Torque : 10 Nm
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Close the cover.
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- Install the charge air cooler bracket.
- Install and tighten the 2 front bolts.
  Torque : 40 Nm
- Install and tighten the 2 side nuts.
  Torque : 10 Nm
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Secure the 7 clips.
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- Position the radiator coolant hose assembly to the original location.
- Connect the radiator coolant hose assembly.
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- Install the radiator coolant hose.
- Connect the coolant hose connection.
- Connect the 2 coolant hose clips.
- Connect the electrical connector.
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- Install a new seal.
  Renew Part: Halfshaft support bracket o-ring seal Quantity: 1 .
- Install the halfshaft support bracket.
- Install and tighten the 3 bolts.
  Torque : 25 Nm
The following step(s) applies to:

Plug in hybrid electric vehicles only
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- Secure the 3 cable clips.
- Install the fir tree clip.
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Install and tighten the nut.

Torque : 10 Nm
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- Install the splash shield.
- Install the 3 push pins.
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Install and tighten the nut.

Torque : 10 Nm
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Close the cover.
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- Lubricate and install the 3 new O-ring seals to the A/C pipes.
  Renew Part: Air conditioning pipe to compressor O-ring seal(s) Quantity: 2 .
  
  Renew Part: Air conditioning pipe O-ring seal(s) Quantity: 1 .
- Install the 2 A/C pipes to the A/C compressor.
- Install the A/C pipe to the A/C evaporator pipe.
- Install and tighten the nut and the 2 bolts.
  Torque : 20 Nm
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- Install the lower radiator coolant hose assembly.
- Connect the 3 coolant hose connections.
- Connect the 2 coolant hose clips.
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Connect the coolant hose.

The following step(s) applies to:

All vehicles
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Install and tighten the ground cable bolt.

Torque : 10 Nm
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Install and tighten the transmission cooler hose bracket bolt.

Torque : 12 Nm
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- Install the coolant hose assembly.
- Connect the 5 coolant hose connections.
- Secure the 2 coolant hose clips.
- Secure the valve body clip.
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- Connect the vacuum pipe.
- Secure the 3 clips.
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- Install the coolant pipe.
- Connect the coolant pipe.
- Secure the 2 clips.
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- Position the 2 fuel pipes to the original location.
- Connect the 2 fuel lines.
- Secure the 2 clips.
Install both front halfshafts.
Refer to: FRONT HALFSHAFT .
Install the transmission.
Refer to: TRANSMISSION - INGENIUM I4 2.0L PETROL (G2784106) .

Refer to: TRANSMISSION - INGENIUM I4 2.0L PETROL - PHEV .
Install the charge air cooler.
Refer to: CHARGE AIR COOLER .
Install the charge air cooler outlet pipe.
Refer to: CHARGE AIR COOLER OUTLET PIPE .
Install the catalytic converter.
Refer to: CATALYTIC CONVERTER AND GASOLINE PARTICULATE FILTER ASSEMBLY - VEHICLES WITH: ROW SPECIFICATION .
Install the coolant expansion tank.
Refer to: COOLANT EXPANSION TANK .
Install the air cleaner.
Refer to: AIR CLEANER .
Install the cooling module.
Refer to: COOLING MODULE - VEHICLES WITH: NON-ELECTRIC VEHICLES (G2861046) .

Refer to: COOLING MODULE - VEHICLES WITH: PHEV (G2861047) .
Install the secondary bulkhead right inner panel.
Refer to: SECONDARY BULKHEAD RIGHT INNER PANEL - INGENIUM I4 2.0L PETROL .
Install the secondary bulkhead left outer panel.
Refer to: SECONDARY BULKHEAD LEFT OUTER PANEL .
Install the hood.
Refer to: HOOD .
Connect the 12V system.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT .

The following step(s) applies to:

Plug in hybrid electric vehicles only
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Power Up the HV system. Only technicians qualified to Electric Vehicle Authorized Person (EVAP) level are allowed to perform this procedure. It is mandated that all technicians involved with the steps in this procedure have read and understood the Electric Vehicle (EV) Safety Rules.

Refer to: PHEV POWER DOWN/UP - COMPLETE VEHICLE - PATHFINDER .