Engine And Ancillaries - INGENIUM I4 2.0L Petrol (G2416435): Part(S)

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

STEP	PART NAME	QUANTITY
Step 17	Cylinder head temperature sensor	1
Step 7	Drive plate bolts	8
Step 25	Engine block heater manifold seal(s)	1
Step 18	Engine block temperature sensor	1
Step 10	Engine Vent Oil Separator Seal(s)	1
Step 61	Exhaust manifold gasket	1
Step 62	Exhaust manifold to turbocharger nuts	4
Step 30	Fuel Injector replacement kits	1
Step 55	Intake manifold seals	4
Step 58	Oil cooler gasket	1
Step 15	Oil filter and O-ring seal kit	1
Step 12	Oil filter housing drain port O-ring seal	1
Step 12	Oil filter housing inlet/outlet O-ring seals	4
Step 88	Oil level gauge O-ring seal	1
Step 64	Oil return pipe O-ring seal	2
Step 66	Turbocharger heatshield bolt(s)	1
Step 68	Turbocharger oil feed pipe banjo bolt washers	4
Step 68	Turbocharger oil supply pipe banjo bolt	2

WARNING:

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 openings must be sealed.

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 Noise, Vibration and Harshness (NVH) material.
- Install and tighten the bolt.
  Torque : 11.5 Nm
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- Install the NVH material.
- Install the clip.
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- Install the NVH material.
- Install the 4 clips.
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- Inspect the O-ring seal. Install a new O-ring seal if damaged or worn.
- Lubricate the O-ring seal with clean engine oil.
  Refer to: SPECIFICATIONS
- Install the crankshaft pulley.
- Install the special tool.
  Special Tool(s): JLR-303-1630
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Install and tighten the 4 bolts.

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.
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- Install the drive plate.
- Install, but do not fully tighten the 8 new bolts.
  Renew Part: Drive plate bolts Quantity: 8 .
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Tighten the 8 bolts in the illustrated sequence.

Torque

Stage 1: 30 Nm

Stage 2: 120°
Remove the special tools.
Special Tool(s): JLR-303-1630
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- Install a new gasket.
  Renew Part: Engine Vent Oil Separator Seal(s) Quantity: 1 .
- Install the engine vent oil separator.
- Install, but do not fully tighten the 7 bolts.
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Tighten the 7 bolts in the illustrated sequence.

Torque : 11.5 Nm
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- Lubricate the O-ring seals with clean engine oil.
- Install 5 new O-ring seals.
  Renew Part: Oil filter housing drain port O-ring seal Quantity: 1 .
  
  Renew Part: Oil filter housing inlet/outlet O-ring seals Quantity: 4 .
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- Install the oil filter housing assembly.
- Install and tighten the 3 bolts.
  Torque : 11.5 Nm
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Before installing the oil filter cap, check the by-pass valve (1) is installed and correctly secured on the locating tabs (2).
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- Install a new O-ring seal.
  Renew Part: Oil filter and O-ring seal kit Quantity: 1 .
- Install a new oil filter element.
- Lubricate the oil filter O-ring seal (1) with clean engine oil and install the oil filter element into the cap.
- Make sure the oil filter element is pushed correctly onto the bypass valve inside the oil filter cap (2).
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Install and tighten the oil filter assembly.

Torque : 28 Nm
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Use the special tool to install and tighten the new cylinder head temperature sensor.

Special Tool(s): 303-680

Renew Part: Cylinder head temperature sensor Quantity: 1 .

Torque : 10.5 Nm
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Install and tighten a new cylinder block temperature sensor.

Renew Part: Engine block temperature sensor Quantity: 1 .

Torque : 10.5 Nm
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- Inspect the O-ring seal. Remove and discard the O-ring seal if damaged or worn.
- Lubricate the O-ring seal with clean engine oil.
- Install the oil filler.
- Install and tighten the bolt.
  Torque : 11.5 Nm
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- Install the bracket.
- Install and tighten the bolt.
  Torque : 11.5 Nm
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- Install the bracket.
- Install and tighten the 2 bolts.
  Torque : 11.5 Nm
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- Inspect the O-ring seal. Install a new O-ring seal if damaged or worn.
- Lubricate the O-ring seal with clean engine oil.
- Install the Crankshaft Position Sensor (CKP) sensor.
- Install and tighten the bolt.
  Torque : 8 Nm
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- Inspect the O-ring seal. Install a new O-ring seal if damaged or worn.
- Lubricate the O-ring seal with clean engine oil.
- Install the vacuum pipe connector.
- Install and tighten the bolt.
  Torque : 5 Nm
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- Inspect the O-ring seal. Install a new O-ring seal if damaged or worn.
- Lubricate the O-ring seal with clean engine oil.
- Install the piston cooling oil jet solenoid.
- Install and tighten the bolt.
  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 cylinder block heater.
  Torque : 55 Nm
CAUTION: Make sure that the mating faces are clean and free of foreign material.

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- Install the knock sensor to the position noted in the removal step.
- Install and tighten the bolt.
  Torque : 20 Nm
CAUTION: Make sure that the mating faces are clean and free of foreign material.

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- Install the knock sensor to the position noted in the removal step.
- Install and tighten the bolt.
  Torque : 20 Nm
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- Inspect the O-ring seal. Install a new O-ring seal if damaged or worn.
- Lubricate the 2 O-ring seals with clean engine oil.
- Install the 2 variable valve timing (VVT) solenoids.
- Install and tighten the 2 bolts.
  Torque : 9 Nm
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- Inspect the 2 O-ring seals. Install a new O-ring seal if damaged or worn.
- Lubricate the 2 O-ring seals with clean engine oil.
- Install the 2 Camshaft Position Sensor (CMP) sensors.
- Install and tighten the 2 bolts.
  Torque : 8 Nm
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- Install a new fuel injector O-ring seal and washer.
  Renew Part: Fuel Injector replacement kits Quantity: 1 .
- Lubricate the O-ring seal with clean engine oil.
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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
CAUTION: Make sure that the fuel injector Teflon seal groove is clean and free of foreign material.

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Use the special tool 310-198 to install the 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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- Make sure the Teflon™ seal is correctly installed.
- As illustrated, remove the special tool JLR-310-257 from the fuel injector to create the final shape of the Teflon™ seal.
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Install a new fuel injector spring clamp.
Repeat steps 30 to 35 for the 3 remaining fuel injectors.
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Install the 4 fuel injectors to the fuel rail.
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Make sure the fuel injectors are correctly aligned.
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Make sure the fuel injectors are correctly aligned.
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- Install the wiring harness.
- Connect the 4 electrical connectors.
- Install the 4 wiring harness clips.
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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
CAUTION: Tighten the fuel rail bolts one turn at a time until the correct torque figure is achieved.

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- Install the fuel rail and fuel injector assembly. Use the special tool guide pins to control the position.
- Install and tighten the 2 bolts.
  Torque : 20 Nm
Remove the special tools.
Special Tool(s): JLR-310-255 , JLR-310-256
CAUTION: Tighten the fuel rail bolts one turn at a time until the correct torque figure is achieved.

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Install and tighten the 2 bolts.

Torque : 20 Nm
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Tighten the 4 bolts in the illustrated sequence.

Torque : 30 Nm
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- Install the 4 ignition coils.
- Install and tighten the 4 bolts.
  Torque : 8 Nm
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- Lubricate the High Pressure (HP) fuel pump tappet with clean engine oil.
- Install the HP fuel pump tappet.
CAUTION: Install the fuel pump evenly onto the camshaft cover surface by one turn on each bolt alternating until the required torque is achieved.

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- Inspect the O-ring seal. Install a new O-ring seal if damaged or worn.
- Lubricate the O-ring seal with clean engine oil.
- Install the HP fuel pump.
- Install and tighten the 2 bolts.
  Torque : 11.5 Nm
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- Install the HP fuel line.
- Tighten the 2 fuel line unions finger tight.
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- Tighten the 2 fuel line unions in the illustrated sequence.
  Torque : 20 Nm
- Wait for 30 seconds and recheck the final torque of the 2 fuel line unions.
  Torque : 20 Nm
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- Install the HP fuel line.
- Tighten the fuel line union finger tight.
- Install and tighten the 2 bolts.
  Torque
  
  Stage 1: 11.5 Nm
  
  Stage 2: Loosen 90°
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- Tighten the fuel line union.
  Torque : 20 Nm
- Tighten the 2 bolts.
  Torque : 11.5 Nm
- Wait for 30 seconds and recheck the final torque of the fuel line union.
  Torque : 20 Nm
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- Install the bracket.
- Install and tighten the 4 bolts.
  Torque
  
  M10: 47.5 Nm
  
  M8: 25 Nm
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- Inspect the gasket. Install a new gasket if damaged or worn.
- Install the thermostat housing.
- Install and tighten the 4 bolts.
  Torque : 11.5 Nm
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- Install the 4 new O-ring seals.
  Renew Part: Intake manifold seals Quantity: 4 .
- Install the intake manifold.
- Install, but do not fully tighten the 7 bolts.
- Connect the engine coolant hose and install the clamp.
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Tighten the 7 bolts in the illustrated sequence.

Torque : 11.5 Nm
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- Inspect the O-ring seal. Install a new O-ring seal if damaged or worn.
- Install the engine coolant pipe.
- Install and tighten the 2 bolts.
  Torque : 11.5 Nm
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- Install a new gasket.
  Renew Part: Oil cooler gasket Quantity: 1 .
- Install the oil cooler.
- Install, but do not fully tighten the 7 bolts.
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Tighten the 7 bolts in the illustrated sequence.

Torque

Stage 1: 15 Nm

Stage 2: 25 Nm
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- Install the engine coolant hose.
- Connect the 2 engine coolant hose clamps.
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Install a new exhaust manifold gasket.

Renew Part: Exhaust manifold gasket Quantity: 1 .
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- Install the turbocharger.
- Install, but do not fully tighten the 4 new nuts.
  Renew Part: Exhaust manifold to turbocharger nuts Quantity: 4 .
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Tighten the 4 nuts in the illustrated sequence.

Torque

Stage 1: 18 Nm

Stage 2: 25 Nm
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- Install 2 new O-ring seals.
  Renew Part: Oil return pipe O-ring seal Quantity: 2 .
- Install the turbocharger oil return pipe.
- Install and tighten the bolt.
  Torque : 10.5 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 bolt (1).
  Torque : 9 Nm
- Install and tighten the new bolt (2).
  Renew Part: Turbocharger heatshield bolt(s) Quantity: 1 .
  
  Torque : 9 Nm
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- Install the heatshield.
- Install and tighten the 4 bolts.
  Torque : 9 Nm
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- Install the turbocharger oil feed pipe.
- Install 4 new sealing washers.
  Renew Part: Turbocharger oil feed pipe banjo bolt washers Quantity: 4 .
- Install and tighten the 2 new banjo bolts.
  Renew Part: Turbocharger oil supply pipe banjo bolt Quantity: 2 .
  
  Torque : 18 Nm
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- Install the bracket.
- Install and tighten the 4 bolts.
  Torque : 60 Nm
NOTE:
- New engines may be supplied with untapped bolt holes for some of the components. Use the bolts from the original engine, as these are self tapping and will cut threads where required.
- The coolant pump from the previous engine is to be installed.
- Inspect the coolant pump seal. If any damage is visible, a new coolant pump must be installed.
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- Install the engine coolant pump.
- Install and tighten the 2 bolts.
  Torque : 6 Nm
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- Install the remaining 4 bolts.
- Tighten the 6 bolts.
  Torque : 11.5 Nm
NOTE: If required, use a suitable tool to prevent the pulley from rotating.

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- Install the engine coolant pump pulley.
- Install and tighten the 3 bolts.
  Torque : 25 Nm
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- Install the wiring harness.
- Install the 2 wiring harness clips.
- Install and tighten the 3 bolts.
  Torque : 10 Nm
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Install the wiring harness.
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- Connect the 2 electrical connectors.
- Install the 2 wiring harness clips.
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- Install and tighten the 2 nuts.
  Torque : 10 Nm
- Install the 3 wiring harness clips.
- Install and tighten the bolt.
  Torque : 10 Nm
- Connect the 11 electrical connectors.
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- Install the 8 wiring harness clips.
- Connect the 4 electrical connectors.
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- Connect the 3 electrical connectors.
- Install the 4 wiring harness clips.
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- Connect the 2 electrical connectors.
- Install the wiring harness clip.
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- Connect the 2 electrical connectors.
- Install the 4 wiring harness clips.
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- Connect the 2 electrical connectors.
- Install and tighten the 2 bolts.
  Torque : 10 Nm
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- Connect the 4 electrical connectors.
- Install and tighten the 2 bolts.
- Install the 2 wiring harness clips.
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Connect the 2 electrical connectors.
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- Install the generator.
- Install and tighten the 2 bolts.
  Torque : 47.5 Nm
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- Install the wiring harness clip.
- Connect the electrical connector.
- Connect the startup battery positive cable.
- Install and tighten the nut.
  Torque : 12 Nm
- Reposition the cover.
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- Install the pipe.
- Tighten the clamp.
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- Install the 2 pulleys.
- Install and tighten the 2 bolts.
  Torque
  
  M10: 47.5 Nm
  
  M8: 25 Nm
- Install the 2 covers.
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- Install a new O-ring seal.
  Renew Part: Oil level gauge O-ring seal Quantity: 1 .
- Lubricate the O-ring seal with clean engine oil.
- Install the oil level gauge assembly.
- Install and tighten the bolt.
  Torque : 7 Nm
- Install the 3 wiring harness clips.
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- Install the engine coolant degas separator.
- Install and tighten the 2 bolts.
  Torque : 11.5 Nm
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- Inspect the O-ring seal. Install a new O-ring seal if damaged or worn.
- Install the engine coolant hose.
- Connect the engine coolant hose and install the clamp.
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- Inspect the O-ring seal. Install a new O-ring seal if damaged or worn.
- Install the engine coolant hose.
- Install and tighten the bolt.
  Torque : 11.5 Nm
- Connect the engine coolant hose and install the clamp.
- Install the clip.
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- Inspect the O-ring seal. Install a new O-ring seal if damaged or worn.
- Install the engine coolant hose assembly.
- Install and tighten the 3 bolts.
  Torque : 11.5 Nm
- Connect the engine coolant hose and install the clamp.
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- Install the engine coolant hose.
- Connect the 2 engine coolant hoses and install the 2 clamps.
- Install and tighten the 3 bolts.
  Torque : 7 Nm
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- Install the purge valve assembly.
- Connect the breather pipe connector.
- Install the 2 clips.
- Connect the 2 electrical connectors.
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Install and tighten the 2 bolts.

Torque : 11.5 Nm
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- Install the vacuum harness.
- Install the 5 vacuum harness clips.
- Connect the vacuum pipe connector.
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- Install the engine coolant hose.
- Connect the engine coolant hose.
- Install and tighten the 2 bolts.
  Torque : 11.5 Nm
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- Install the breather pipe.
- Connect the 2 breather pipe connectors.
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- Install the engine coolant pipe.
- Install the clip.
- Connect the engine coolant pipe.
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- Install the engine coolant pipe.
- Connect the 2 engine coolant hoses and install the 2 clamps.
- Install and tighten the 2 bolts.
  Torque : 25 Nm
- Install the wiring harness clip.
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- Install the NVH material.
- Install the 3 clips.
Install the engine assembly.
Refer to: INSTALLATION .
Fill the engine with clean engine oil.
Refer to: SPECIFICATIONS