Long/Stripped Engine Assembly Renew (G3183749): Part(S)

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

STEP	PART NAME	QUANTITY
Step 21	Coolant pump bolts	3
Step 10	Crankshaft pulley bolts	4
Step 12	Drive plate bolts	8
Step 69	Engine block heater manifold seal(s)	1
Step 21	Engine coolant pump gasket	1
Step 14	Engine vent oil separator to valve cover gasket	1
Step 49	Exhaust manifold bolts	11
Step 51	Exhaust manifold bolts	2
Step 48	Exhaust manifold gasket	1
Step 74	Fuel Injection Pump retaining bolts	2
Step 27	Fuel Injector replacement kits	6
Step 74	Fuel pump O-ring seal	1
Step 39	Fuel rail bolt(s)	4
Step 40	Fuel rail bolt(s)	2
Step 71	Intake manifold seals	6
Step 56	Oil supply pipe sealing washers	2
Step 80	Throttle body to intake manifold seal	1
Step 54	Turbocharger coolant pipe O-ring seal	2
Step 55	Turbocharger oil return pipe seals	2

WARNING:

Be prepared to collect escaping coolant.
Be prepared to collect escaping oil.
Be prepared to collect escaping fuel.

NOTE:

This procedure contains illustrations showing certain components removed to provide extra clarity.
This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.

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- Install the special tools JLR-303-1676.
  Special Tool(s): JLR-303-1676
- Install and tighten the 4 bolts.
  Torque
  
  M8: 24 Nm
  
  M10: 47 Nm
- Install the special tool JLR-303-1591.
  Special Tool(s): JLR-303-1591
- Install and tighten the bolt.
  Torque : 10 Nm
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- Install the special tool.
  Special Tool(s): JLR-303-1673
- Install and tighten the 4 bolts.
  Torque : 40 Nm
CAUTION: Only operate the crane enough to align special tool JLR-303-1591. Do not apply lifting force to the engine.

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- Install a suitable hydraulic jib crane to the special tools and lifting bracket as illustrated.
  General Equipment: Hydraulic jib crane
- Operate the crane to align the special tool JLR-303-1591.
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- Fully tighten the bolt.
  Torque : 47 Nm
WARNING: This step requires the aid of another technician.

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With the aid of another technician, install the engine assembly to a suitable engine stand following the manufacturers instructions.
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Remove the hydraulic jib crane.

General Equipment: Hydraulic jib crane
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Remove the special tools.

Special Tool(s): JLR-303-1676 , JLR-303-1591
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Install the special tool as illustrated.

Special Tool(s): JLR-303-1659
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- Install the crankshaft damper pulley.
- Install the special tool.
  Special Tool(s): JLR-303-1659
CAUTION: Before installing the new crankshaft pulley bolts check the lengths of the threads as shown in the illustration. The new bolts must be 48mm in length.

NOTE: Tighten the bolts in a diagonal sequence.

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Install and tighten 4 new bolts.

Renew Part: Crankshaft pulley bolts Quantity: 4 .

Torque

Stage 1: 37 Nm

Stage 2: 90°
NOTE: Do not insert the bottoming tap more than the depth of the threaded holes (16mm). Apply tape to the bottoming tap 16mm from the end as a visual guide.

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- 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.
Fig 1: Drive Plate Bolts Tightening Sequence
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- Install the drive plate.
- Install and tighten the 8 new bolts in the sequence illustrated.
  Renew Part: Drive plate bolts Quantity: 8 .
  
  Torque
  
  Stage 1: 30 Nm
  
  Stage 2: 120°
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Remove the special tool.

Special Tool(s): JLR-303-1659
Fig 2: Engine Vent Oil Separator Bolts Tightening Sequence
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- Install a new gasket.
  Renew Part: Engine vent oil separator to valve cover gasket Quantity: 1 .
- Install the engine vent oil separator.
- Tighten the 11 bolts in the torque sequence illustrated.
  Torque : 12 Nm
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Install and tighten the 3 studs.

Torque : 10 Nm
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- Inspect the 2 O-ring seals and replace if damaged.
- Lubricate the 2 O-ring seals with clean engine oil.
  Refer to: SPECIFICATIONS
- Install the 2 Variable Camshaft Timing (VCT) solenoids.
- Install and tighten the 4 bolts.
  Torque : 9 Nm
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- Inspect the O-ring seal and replace if damaged.
- Lubricate the O-ring seal with clean engine oil.
  Refer to: SPECIFICATIONS
- Install the Crankshaft Position Sensor (CKP) sensor.
- Install and tighten the bolt.
  Torque : 8 Nm
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Install and tighten the Continuous Variable Valve Lift (CVVL) oil temperature sensor.

Torque : 18 Nm
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- Inspect the O-ring seal and replace if damaged.
- Lubricate the O-ring seal with clean engine oil.
  Refer to: SPECIFICATIONS
- Install the 2 Camshaft Position Sensor (CMP) sensors.
- Install and tighten the 2 bolts.
  Torque : 8 Nm
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Install and tighten the oil pressure and temperature sensor.

Torque : 15 Nm
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- Install a new O-ring seal.
  Renew Part: Engine coolant pump gasket Quantity: 1 .
- Install the coolant pump.
- Install and tighten the 3 new bolts.
  Renew Part: Coolant pump bolts Quantity: 3 .
  
  Torque : 25.5 Nm
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- Install the coolant pump pulley.
- Install but do not fully tighten the 3 bolts.
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- Install the bracket.
- Install and tighten the 4 bolts.
  Torque : 25 Nm
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- Install the viscous cooling fan drive pulley.
- Install and tighten the 3 bolts.
  Torque : 25 Nm
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- Install the idler pulley.
- Install and tighten the bolt.
  Torque : 25 Nm
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- Inspect the 2 O-ring seals and replace if damaged.
- Install the coolant pipe.
- Install and tighten the 2 bolts.
  Torque : 11.5 Nm
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- Install the new spacer washer.
- Install the new O-ring seal.
  Renew Part: Fuel Injector replacement kits Quantity: 6 .
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Install the special tool to the fuel injector with the 'T' symbol towards the top of the fuel injector as illustrated.

Special Tool(s): JLR-310-257
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Use the special tool to install the new Teflon™ seal to the fuel injector.

Special Tool(s): 310-198
Wait 2 minutes to allow the Teflon™ seal to recover its shape.
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- Remove the special tool.
  Special Tool(s): JLR-310-257
- Make sure the Teflon™ seal is correctly installed.
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Install the new fuel injector spring clamp.
Repeat steps 25- 30 for the remaining 5 fuel injectors.
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Install the 6 fuel injectors into the fuel rail.
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Make sure the fuel injectors are correctly installed.
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Make sure the fuel injectors are correctly installed.
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Install the appropriate special tools. If a new cylinder head has not been installed then the special tool JLR- 310-255 with the threaded section must be used. If a new cylinder head has been installed then the special tool JLR-310-256 without the threaded section must be used.

Special Tool(s): JLR-310-255 , JLR-310-256
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Install the fuel rail and injector assembly allowing guide pins to control position.
NOTE: Tighten each of the bolts 1 turn at a time until the fuel rail is fully installed.

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- Install and tighten the 4 bolts.
  Renew Part: Fuel rail bolt(s) Quantity: 4 .
  
  Torque : 15 Nm
- Remove the special tools.
  Special Tool(s): JLR-310-255 , JLR-310-256
NOTE: Tighten each of the bolts 1 turn at a time until the fuel rail is fully installed.

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Install and tighten the 2 bolts.

Renew Part: Fuel rail bolt(s) Quantity: 2 .

Torque : 15 Nm
NOTE: Tighten each of the bolts 1 turn at a time until the fuel rail is fully installed.

Fig 3: Fuel Rail Bolts Removal Sequence
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Tighten the 6 bolts in the sequence illustrated.

Torque : 30 Nm
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- Install the wiring harness.
- Connect the 6 electrical connectors.
- Install the 5 clips.
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Install the Noise, Vibration and Harshness (NVH) material.
WARNING:
- Make sure that the spark plug ceramic insulator and terminal pin are wiped/cleaned dry using a soft clean cloth.
- Make sure that the ignition coil-on-plug rubber boot is pushed down fully over the spark plug ceramic insulator. Double check by installing the ignition coil-on-plug as usual and then pushing on the ignition coil-on-plug head gently for a second time to make sure that the ignition coil-on-plug rubber boot has seated correctly over the spark plug insulator.
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- Install the 6 ignition coils.
- Install and tighten the 6 bolts.
  Torque : 8 Nm
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- Install the NVH material.
- Install the 5 clips.
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- Inspect the O-ring seal, replace if damaged.
- Install the coolant pipe.
- Install and tighten the bolt.
  Torque : 11.5 Nm
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Use an M8 x 1.25 bottoming tap to clean the threads.
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Install the appropriate special tools. If a new cylinder head has not been installed then the special tool JLR-303-1449-01 with the threaded section must be used. If a new cylinder head has been installed then the special tool JLR-303-1449-02 without the threaded section must be used.

Special Tool(s): 303-1449-01 , 303-1449-02

Renew Part: Exhaust manifold gasket Quantity: 1 .
Fig 4: Turbocharger Bolts Tightening Sequence
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- Install the turbocharger.
- Use the special tool to install and tighten the 11 new bolts, spacers and washers in the sequence illustrated.
  Special Tool(s): JLR-303-1683
  
  Renew Part: Exhaust manifold bolts Quantity: 11 .
  
  Torque : 8 Nm
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Remove the special tools.

Special Tool(s): 303-1449-01 , 303-1449-02
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Use the special tool to install and tighten the 2 new bolts, spacers and washers in the sequence illustrated.

Special Tool(s): JLR-303-1683

Renew Part: Exhaust manifold bolts Quantity: 2 .

Torque : 8 Nm
CAUTION: When fully tightened, allow 4 hours for the thread locking compound to cure. Do not start the engine within 4 hours of completing this step.

Fig 5: Exhaust Manifold Bolts Tightening Sequence
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Use the special tool to tighten the 13 bolts in the sequence illustrated.

Special Tool(s): JLR-303-1683

Torque

Stage 1: 8 Nm

Stage 2: 12 Nm

Stage 3: 15 Nm

Stage 4: 135°

Stage 5: 24 Nm
Fig 6: Bracket Bolts Tightening Sequence
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- Install the bracket.
- Install and tighten the 3 bolts in the sequence illustrated.
  Torque
  
  Stage 1: 11.5 Nm
  
  Stage 2: 25 Nm
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- Install 2 new O-ring seals.
  Renew Part: Turbocharger coolant pipe O-ring seal Quantity: 2 .
- Install the 2 coolant pipes.
- Install and tighten the bolt.
  Torque : 11.5 Nm
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- Install the 2 new O-ring seals.
  Renew Part: Turbocharger oil return pipe seals Quantity: 2 .
- Lubricate the 2 O-ring seals with clean engine oil.
  Refer to: SPECIFICATIONS
- Install the pipe.
- Install and tighten the bolt.
  Torque : 10.5 Nm
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- Install 2 new sealing washers.
  Renew Part: Oil supply pipe sealing washers Quantity: 2 .
- Install and tighten the banjo bolt.
  Torque : 18 Nm
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Install the heatshield.
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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 bolt.
  Torque : 9 Nm
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- Install the heatshield.
- Install and tighten the 5 bolts.
  Torque
  
  M6 x 14 mm: 6.5 Nm
  
  M6 x 18 mm: 9 Nm
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- Install the bracket.
- Install, but do not fully tighten the nut.
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Install the 4 supercharger mounting rubbers.
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- Inspect the O-ring seal and replace if damaged.
- Install the supercharger assembly.
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Install and tighten the 2 bolts.

Torque : 25 Nm
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Fully tighten the nut.

Torque : 11.5 Nm
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Install and tighten the 2 bolts.

Torque : 11.5 Nm
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- Install the bracket.
- Install and tighten the nut.
  Torque : 11.5 Nm
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- Install the ground cable.
- Install and tighten the 2 nuts.
  Torque : 11.5 Nm
NOTE: If equipped.

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- Install a new gasket.
  Renew Part: Engine block heater manifold seal(s) Quantity: 1 .
- Install and tighten the block heater.
  Torque : 50 Nm
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- Inspect the 2 O-ring seals and replace if damaged.
- Install the 2 coolant pipes.
- Install and tighten the 2 bolts.
  Torque : 11.5 Nm
NOTE: The bolts will remain captive.

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- Install 6 new O-ring seals.
  Renew Part: Intake manifold seals Quantity: 6 .
- Install the intake manifold.
- Install, but do not fully tighten the 9 bolts.
Fig 7: Intake Manifold Bolts Tightening Sequence
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Tighten the 9 bolts in the sequence illustrated.

Torque : 11.5 Nm
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Install the High Pressure (HP) fuel pump Camshaft follower.
NOTE: Tighten each of the bolts a half turn at a time until the fuel pump is fully installed.

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- Install a new O-ring seal.
  Renew Part: Fuel pump O-ring seal Quantity: 1 .
- Lubricate the O-ring seal with clean engine oil.
  Refer to: SPECIFICATIONS
- Install the HP fuel pump.
- Install and tighten the 2 bolts.
  Renew Part: Fuel Injection Pump retaining bolts Quantity: 2 .
  
  Torque : 14.5 Nm
CAUTION: Fuel lines may only be reused one time. After final tightening, clean the fuel line and apply a paint mark to identify reuse. If the fuel line is already paint marked, a new fuel line must be installed.

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- Install the HP fuel line.
- Finger tighten the 2 unions.
- Tighten the 2 unions.
  Torque : 20 Nm
- Install and tighten the 2 M6 Hex stud bolts.
  Torque : 11.5 Nm
- Fully loosen the 2 fuel line unions.
- Finger tighten the 2 unions.
- Tighten the 2 fuel line unions.
  Torque : 20 Nm
- Wait for 30 seconds and recheck the final torque.
- Install and tighten the M6 Torx bolt.
  Torque : 11.5 Nm
CAUTION: Fuel lines may be used a maximum of 4 times, paint mark fuel line after each full tightening sequence.

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- Install the Low Pressure (LP) fuel line.
- Finger tighten the union.
- Install and tighten the bolt.
  Torque : 11.5 Nm
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- Tighten the union.
  Torque : 20 Nm
- Wait 10 seconds.
- Loosen the union.
  Torque : 1 turn(s)
- Tighten the union.
  Torque : 20 Nm
- Wait 10 seconds.
- Tighten the union.
  Torque : 20 Nm
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Install the NVH material.
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- Install the bracket.
- Install and tighten the nut.
  Torque : 11.5 Nm
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- Install a new O-ring seal.
  Renew Part: Throttle body to intake manifold seal Quantity: 1 .
- Install the throttle body.
- Install, but do not fully tighten the 4 bolts.
Fig 8: Throttle Body Bolts Tightening Sequence
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Tighten the 4 bolts in the sequence illustrated.

Torque : 11.5 Nm
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- Install the purge valve assembly.
- Connect the breather pipe.
- Install the 3 clips.
- Install and tighten the bolt.
  Torque : 7 Nm
CAUTION: Failure to follow this instruction could cause damage to the thermostat housing.

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Make sure the thermostat housing is installed correctly as illustrated.
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- Inspect the 2 O-ring seals and replace if damaged.
- Install the coolant hose assembly.
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- Install and tighten the 2 bolts.
  Torque : 11.5 Nm
- Install the clip.
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- Connect the coolant hose.
- Install and tighten the 3 bolts.
  Torque
  
  M6 x 25 mm: 11.5 Nm
  
  M6 x 20 mm: 7 Nm
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Install and tighten the 2 bolts.

Torque : 11.5 Nm
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- Connect the coolant hose.
- Install the clip.
- Install and tighten the bolt.
  Torque : 11.5 Nm
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- Install the coolant hose assembly.
- Install and tighten the nut.
  Torque : 11.5 Nm
- Connect the 2 coolant hoses.
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Install the wiring harness.
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- Connect the electrical connector.
- Install the 2 clips.
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- Connect the 3 electrical connectors.
- Install the 3 clips.
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- Connect the electrical connector.
- Install the 2 clips.
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- Connect the electrical connector.
- Install the 3 clips.
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- Connect the 7 electrical connectors.
- Install the 2 clips.
- Install and tighten the bolt.
  Torque : 10 Nm
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- Connect the electrical connector.
- Install the 2 clips.
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- Connect the 3 electrical connectors.
- Install the 2 clips.
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- Connect the 6 electrical connectors.
- Install the 4 clips.
- Install and tighten the bolt.
  Torque : 11.5 Nm
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- Connect the 3 electrical connectors.
- Install the 3 clips.
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- Connect the 13 electrical connectors.
- Install the 3 clips.
- Install and tighten the 2 bolts.
  Torque : 10 Nm
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- Install the bracket.
- Install and tighten the 4 bolts.
  Torque : 25 Nm
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- Install the Air Conditioning (A/C) compressor.
- Install and tighten the 3 bolts.
  Torque : 25 Nm
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- Connect the electrical connector.
- Install the 2 clips.
- Install and tighten the bolt.
  Torque : 10 Nm
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- Install the coolant hose assembly.
- Connect the 2 coolant hoses.
- Install the 2 clips.
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- Install the vacuum pipe.
- Install the 3 clips.
- Connect the vacuum pipe.
- Install the coolant pipe.
- Connect the coolant pipe.
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- Install the Belt Integrated Starter Generator Belt Integrated Starter Generator (BISG).
- Install and tighten the 2 bolts.
  Torque : 47.5 Nm
- Connect the electrical connector.
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Install the accessory drive belt.
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- Install the accessory drive belt tensioner.
- Install and tighten the 3 bolts.
  Torque : 25 Nm
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- Use a suitable tool to release the accessory drive belt tension as illustrated.
- Remove the special tool.
  Special Tool(s): JLR-303-1669
- Tension the accessory drive belt.
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Tighten the 3 bolts.

Torque : 25 Nm
NOTE: Make sure the pulley is in the position illustrated before removing the belt.

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Install the viscous cooling fan drive belt.
NOTE:
- During the rotation of the pulley, expect the pulley to snap down into position.
- If the pulley does not snap down into the correct position, loosen the bolts half a turn.
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Use a suitable tool to rotate the pulley to the position illustrated.
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Install the illustrated bolt finger tight.
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- Use the special tool to prevent the pulley from rotating when tightening the 4 bolts.
  Special Tool(s): JLR-303-1667
- Fully tighten the 4 bolts.
  Torque : 25 Nm
CAUTION: This step must be completed, failure to complete this step may result in damage to the viscous cooling fan bracket.

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- Measure the gap between the viscous cooling fan pulley and the viscous cooling fan bracket.
- If the gap is 0.15 mm or less, continue to step 6.
- If the gap is greater than 0.15 mm, re-adjust the viscous cooling fan belt.
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Install the NVH material.
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Install the breather pipe.
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- Install the coolant hose assembly.
- Connect the 2 coolant hoses.
- Install the 2 clips.
- Install and tighten the bolt.
  Torque : 11.5 Nm
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- Install the coolant hose assembly.
- Connect the 2 coolant hoses.
- Install the 2 clips.
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Install the breather pipe assembly.
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Install the charge air cooler assembly.
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- Connect the 2 coolant hoses.
- Install the 3 clips.
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Connect the 2 coolant hoses.
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Connect the 2 coolant hoses.
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- Install the Emergency Park Release (EPR) cable.
- Install and tighten the bolt.
  Torque : 7 Nm
- Install the 3 clips.
Install the engine assembly.
Refer to: ENGINE ASSEMBLY REMOVE FOR ACCESS
Connect the 12 V system.
Refer to: SPECIFICATIONS