Engine And Ancillaries - INGENIUM I4 2.0L Petrol - PHEV (G2748122): Part(S)

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

STEP	PART NAME	QUANTITY
Step 30	Camshaft position sensor O-ring seal	2
Step 23	Crank position sensor ring (CKP)	1
Step 6	Crankshaft pulley bolts	1
Step 58	Cylinder block coolant outlet O-ring seals	1
Step 24	Cylinder block vacuum connector bolt	1
Step 18	Cylinder head temperature sensor	1
Step 26	Engine block heater manifold seal(s)	1
Step 19	Engine block temperature sensor	1
Step 96	Engine coolant outlet upper O-ring seal	1
Step 11	Engine vent oil separator to valve cover gasket	1
Step 62	Exhaust manifold gasket	1
Step 63	Exhaust manifold to turbocharger nuts	4
Step 31	Fuel Injector replacement kits	1
Step 49	Fuel pump O-ring seal	1
Step 56	Intake manifold seals	4
Step 59	Oil cooler gasket	1
Step 20	Oil fill pipe O-ring seal	1
Step 16	Oil filter and O-ring seal kit	1
Step 13	Oil filter housing drain port O-ring seal	1
Step 13	Oil filter housing inlet/outlet O-ring seals	4
Step 93	Oil level gauge O-ring seal	1
Step 65	Oil return pipe O-ring seal	2
Step 25	Piston cooling oil jet solenoid O-ring seal	1
Step 55	Thermostat seal	1
Step 67	Turbocharger heatshield bolt(s)	1
Step 69	Turbocharger oil feed pipe banjo bolt washers	4
Step 69	Turbocharger oil supply pipe banjo bolt	2
Step 95	Turbocharger upper O-ring seals	1
Step 97	Turbocharger upper O-ring seals	1
Step 29	Variable Camshaft Timing (VCT) solenoid O-ring seals	2

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 Authorised 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.

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.
CAUTION: Make sure the crankshaft pulley is correctly installed.

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- Install the crankshaft pulley.
- Install the special tools.
  Special Tool(s): JLR-303-1630 , JLR-303-1686
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Before installing the new crankshaft damper bolts check the length of the thread as shown in the illustration. The new bolts must be 48mm in length.
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Working in a diagonal sequence, install and tighten the 4 new crankshaft pulley bolts.

Renew Part: Crankshaft pulley bolts Quantity: 1 .

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.
CAUTION:
- Do not insert or install the dual mass flywheel bolts into the crankshaft with the dual mass flywheel removed. Failure to follow this instruction will result in damage to the engine.
- Make sure the threads are clean and free from foreign material.
- Do not insert the tap more than the depth of the threaded holes (16 mm). Apply tape to the tap 16 mm 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.
NOTE: Align the dual mass flywheel with the locating dowel on the crankshaft.

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- Install the dual mass flywheel.
- Working diagonally, install and tighten the 8 bolts.
  Torque
  
  Stage 1: 30 Nm
  
  Stage 2: 120°
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Remove the special tools.

Special Tool(s): JLR-303-1686 , JLR-303-1630
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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.
- Install, but do not fully tighten the 7 bolts.
Fig 1: Engine Vent Oil Separator Bolts Tightening Sequence
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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 fitted 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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- Lubricate the O-ring seal with clean engine oil.
  Renew Part: Oil fill pipe O-ring seal Quantity: 1 .
- Install the new O-ring seal.
- 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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- Lubricate the O-ring seal with clean engine oil.
  Renew Part: Crank position sensor ring (CKP) Quantity: 1 .
- Install the new O-ring seal.
- Install the Crankshaft Position Sensor (CKP) sensor.
- Install and tighten the bolt.
  Torque : 8 Nm
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- Lubricate the O-ring seal with clean engine oil.
  Renew Part: Cylinder block vacuum connector bolt Quantity: 1 .
- Install the new O-ring seal.
- Install the vacuum pipe connector.
- Install and tighten the bolt.
  Torque : 5 Nm
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- Lubricate the O-ring seal with clean engine oil.
  Renew Part: Piston cooling oil jet solenoid O-ring seal Quantity: 1 .
- Install the new O-ring seal.
- 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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- Lubricate the 2 O-ring seals with clean engine oil.
  Renew Part: Variable Camshaft Timing (VCT) solenoid O-ring seals Quantity: 2 .
- Install the 2 new O-ring seals.
- Install the 2 Variable Camshaft Timing (VCT) solenoids.
- Install and tighten the 2 bolts.
  Torque : 9 Nm
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- Lubricate the 2 O-ring seals with clean engine oil.
  Renew Part: Camshaft position sensor O-ring seal Quantity: 2 .
- Install the 2 new O-ring seals.
- 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 fastener.
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
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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
Fig 2: Fuel Rail Bolts Tightening Sequence
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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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- Lubricate the O-ring seal with clean engine oil.
  Renew Part: Fuel pump O-ring seal Quantity: 1 .
- Install the new O-ring seal.
- 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.
Fig 3: Fuel Line Unions Tightening Sequence
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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
  
  Stage 1: M10 47.5 Nm
  
  Stage 2: M8 25 Nm
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- Install a new gasket.
  Renew Part: Thermostat seal Quantity: 1 .
- 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.
Fig 4: Intake Manifold Bolts Tightening Sequence
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Tighten the 7 bolts in the illustrated sequence.

Torque : 11.5 Nm
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- Install a new O-ring seal.
  Renew Part: Cylinder block coolant outlet O-ring seals Quantity: 1 .
- 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.
Fig 5:
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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 and connect the engine coolant hose.
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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 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
CAUTION: Inspect the coolant pump seal for damage. 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 Belt Integrated Starter Generator (BISG).
- 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 fastener.
  Torque : 7 Nm
CAUTION:
- Make sure the coolant pump drive belt is correctly aligned.
- Make sure the special tool is correctly aligned with the crankshaft pulley.
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- Install the new coolant pump drive belt to the engine coolant pump pulley.
- Install the special tool.
  Special Tool(s): JLR-303-1640
- Use the special tool to partially install the engine coolant pump drive belt around the crankshaft pulley by 90 degrees.
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- Use the special tool to rotate the crankshaft pulley in a clockwise direction until the coolant pump drive belt is correctly installed.
  Special Tool(s): JLR-303-1656
- Remove the special tools.
  Special Tool(s): JLR-303-1640 , JLR-303-1656
CAUTION: Make sure the BISG belt is correctly aligned.

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Install the BISG belt.
WARNING: Make sure the BISG belt tensioner is held securely before removing the locking tool

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- Install the BISG belt tensioner.
- Install and tighten the bolt.
  Torque : 47.5 Nm
- Remove the BISG belt tensioner locking tool.
  Special Tool(s): JLR-303-1669
- Slowly release the BISG belt tensioner.
WARNING: Make sure the BISG belt tensioner is held securely before removing the locking tool

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- Install the BISG belt tensioner.
- Install and tighten the bolt.
  Torque : 47.5 Nm
- Remove the BISG belt tensioner locking tool.
  Special Tool(s): JLR-303-1669
- Slowly release the BISG belt tensioner.
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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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- Install a new o-ring seal.
  Renew Part: Turbocharger upper O-ring seals Quantity: 1 .
- Install and connect the turbocharger coolant hose.
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- Install a new o-ring seal.
  Renew Part: Engine coolant outlet upper O-ring seal Quantity: 1 .
- Install the engine coolant hose.
- Install and tighten the bolt.
  Torque : 11.5 Nm
- Install and connect the engine coolant hose.
- Install the clip.
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- Install a new o-ring seal.
  Renew Part: Turbocharger upper O-ring seals Quantity: 1 .
- Install the engine coolant hose assembly.
- Install and tighten the 3 bolts.
  Torque : 11.5 Nm
- Install and connect the engine coolant hose.
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- Install the engine coolant hose.
- Install and connect the 2 engine coolant hoses.
- 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 pipe.
- 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.
- Install and connect the 2 engine coolant hoses.
- 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
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Power Up the HV system. Only technicians qualified to Electric Vehicle Authorised Person (EVAP) level or higher are allowed to complete this step of the procedure.

Refer to: PHEV POWER DOWN/UP - HANDHELD