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Home >> Porsche >> 2018 >> Macan GTS >> Repair and Diagnosis >> External Pages >> Different car >> Section 487 (Engine - TDV6 3.0L Diesel - Gen 2/TDV6 3.0L Diesel -- Range Rover/L405) >> Engine - TDV6 3.0L Diesel - Gen 2/TDV6 3.0L Diesel >> Engine (Assembly) >> Assembly >> Part(S)

Engine (Assembly): Assembly: Part(S)

WARNING: This page is about a different car, the 2018 Land Rover Range Rover, 2017 Land Rover Range Rover, and 2016 Land Rover Range Rover. However, it is still accessible from the selected car via links, so may be relevant.
STEP PART NAME QUANTITY
Step 5 Engine coolant outlet upper O-ring seal 1
Step 20 Fuel injector O-ring seals 1
Step 20 Fuel injector washer(s) 1
Step 32 Timing belt tensioner 1
Step 33 Timing belt 1
Step 43 Fuel injector high pressure pipe(s) 3
Step 46 Fuel rail balance pipe 1
Step 47 Fuel injector high pressure pipe(s) 3
Step 63 Turbocharger oil supply tube to engine O-ring seal(s) 1
Step 64 Exhaust manifold studs 6
Step 64 Exhaust manifold gasket 1
Step 65 Turbocharger coolant pipe 1
Step 66 Exhaust manifold to cylinder head nuts 6
Step 68 Turbocharger oil feed pipe banjo bolt washers 2
Step 69 Turbocharger oil return pipe 1
Step 74 Exhaust manifold studs 6
Step 74 Exhaust manifold gasket 1
Step 75 Exhaust manifold to cylinder head nuts 6
Step 76 Turbocharger oil feed pipe banjo bolt washers 2
Step 78 Turbocharger oil return pipe gasket(s) 1
Step 78 Oil return pipe O-ring seal 1
Step 81 EGR pipe to exhaust manifold gasket 1
Step 85 Exhaust gas recirculation pipe gasket 1
Step 88 Engine Vent Oil Separator Seal(s) 2
Step 115 Flexplate bolts 10
NOTE: This procedure contains illustrations showing certain components removed to provide extra clarity.
  1. Always follow the Diesel fuel system health and safety precautions, when carrying out any repairs to the fuel system.

    Refer to: DIESEL FUEL SYSTEM HEALTH AND SAFETY PRECAUTIONS

    CAUTION: Make sure that the component is clean, free of foreign material and lubricant.
  2. G11756508
    • Install the Crankshaft Position (CKP) sensor.
    • Torque Specification: 5 Nm 
  3. G11756507
    • Install the CKP retaining bracket.

      Torque Specification: 32 Nm 

  4. G11756506
    • Install the coolant outlet channel.

      Torque Specification: 10 Nm 

  5. G11601943
    • Install a new gasket.

      Renew Part: Engine coolant outlet upper O-ring seal Quantity: 1  .

    • Install the coolant outlet assembly.

      Torque Specification: 10 Nm 

  6. G11601942

    Install the Camshaft Position (CMP) sensor.

    Torque Specification: 10 Nm 

  7. G11756503

    Install the fuel rail support bracket.

    Torque Specification: 24 Nm 

  8. G11756502

    Install the fuel pipe bracket.

    Torque Specification: 9 Nm 

  9. G11756501

    Install the pins.

  10. G11756500

    Install the bracket.

    Torque Specification: 9 Nm 

  11. G11756499

    Install the Noise, Vibration and Harshness (NVH) material.

  12. G11756498

    Install the fuel rail support bracket.

    Torque Specification: 24 Nm 

  13. G11756497

    Install the fuel pipe bracket.

    Torque Specification: 10 Nm 

  14. G11756496

    Install the pins.

  15. G11756495

    Install the NVH material.

  16. G11695858
    • Install the crankshaft pulley.
    • Torque Specification: 25 Nm 
  17. G11695857
    • Install the coolant pump pulley.
    • Torque Specification: 25 Nm 
  18. G11602198
    • Install the accessory drive belt idler pulley.
    • Torque Specification: 50 Nm 
  19. Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply lines, the fuel injectors and the fuel rail.

    Refer to: FUEL INJECTION COMPONENT CLEANING

  20. NOTE: Repeat this step for the remaining fuel injectors.
    G11695882
    • Install new O-ring seals.

      Renew Part: Fuel injector O-ring seals Quantity: 1  .

    • Install a new sealing washer.

      Renew Part: Fuel injector washer(s) Quantity: 1  .

  21. NOTE: Repeat this step for the remaining fuel injectors.
    G11709964

    Install the fuel injectors.

    NOTE: Repeat this step for the remaining fuel injectors.
  22. G11709985

    Install the fuel injectors retaining bolts.

    Torque Specification: 9 Nm 

  23. G11601803

    Remove the rubber gromet.

  24. G11601805

    Install the special tool.

    Special Tool(s): 303-1117 

  25. G11756487

    Install the fuel injection pump.

    Torque Specification: 10 Nm 

  26. G11756486

    Install the fuel injection pump retaining bracket.

    Torque Specification: 10 Nm 

  27. G11601331

    Install new fuel injection pump retaining bolts. (ADD FUEL PUMP BOLTS AS PART)

  28. G11756484

    Install the fuel injection pump pulley.

  29. G11756539

    Install the special tool.

    Special Tool(s): 310-139A 

  30. G11756482
    • Using the special tool install the fuel injection pump pulley nut.

      Torque Specification: 50 Nm 

    • Remove the special tool.
  31. NOTE: Do not loosen the bolts more than 2 turns.
    G11698041

    Release the camshaft rear pulley bolts.

  32. CAUTION: Make sure that the fuel pump belt tensioner tang is correctly located to the fuel pump belt rear cover. Failure to follow this instruction may result in damage to the engine.
    G11607827
    • Make sure that the fuel pump belt tensioner locking pin is not removed until the fuel pump belt tensioner is fully installed.
    • Install a new belt tensioner.

      Renew Part: Timing belt tensioner Quantity: 1  .

      Torque Specification: 23 Nm 

      CAUTION: Do not install the new fuel pump belt to the pulleys with the fuel pump belt tensioner installed. Failure to follow this instruction may result in damage to the fuel pump belt.
  33. NOTE: The camshaft and fuel pump pulleys rotates in a counter-clockwise direction when viewed from the rear of the engine.
    G11607829
    • Install the new fuel injection pump belt.

      Renew Part: Timing belt Quantity: 1  .

    • Make sure the new fuel pump belt is correctly seated onto the camshaft and fuel pump pulleys.
  34. G11607830

    Install the special tool.

    Special Tool(s): 310-212 

  35. G11607831

    Check the timing marks.

  36. G11607832

    Remove the locking pin from the tensioner.

  37. G11607833

    Tighten the 3 bolts.

    Torque Specification: 23 Nm 

  38. Remove the special tool.
  39. G11601805

    Remove the special tool.

  40. G11601803

    Install the rubber grommet.

  41. G11756478

    Install the Rear End Accessory Drive (READ) cover.

  42. NOTE: Only tighten the bolts finger-tight at this stage.
    G11601501

    Install the fuel rail.

  43. NOTE: Only tighten the bolts finger-tight at this stage.
    G11709984

    Install new fuel pipes.

    Renew Part: Fuel injector high pressure pipe(s) Quantity: 3  .

    NOTE: Only tighten the bolts finger-tight at this stage.
  44. G11756553

    Install the fuel rail.

  45. G11601329

    Tighten the fuel supply line union finger tight.

  46. NOTE: Only tighten the bolts finger-tight at this stage.
    G11756475

    Install a new fuel pipe.

    Renew Part: Fuel rail balance pipe Quantity: 1  .

  47. NOTE: Only tighten the bolts finger-tight at this stage.
    G11709957

    Install new fuel pipes.

    Renew Part: Fuel injector high pressure pipe(s) Quantity: 3  .

  48. G11601501
    • Tighten the bolts.
    • Torque Specification: 24 Nm 
  49. G11756473
    • Install the fuel pipe clamp.
    • Torque Specification: 9 Nm 
    • Tighten the high-pressure fuel unions.
    • Torque Specification: 15 Nm 
  50. G11756553

    Tighten the bolts.

    Torque Specification: 24 Nm 

  51. G11756474
    • Install the fuel pipe clamps.
    • Torque Specification: 9 Nm 
    • Tighten the high-pressure fuel unions.
    • Torque Specification: 15 Nm 
  52. G11756474
    • Tighten the high-pressure fuel unions.
    • Torque Specification: 35 Nm 
  53. G11756473
    • Tighten the high-pressure fuel unions.
    • Torque Specification: 35 Nm 
  54. G11601328
    • Tighten the high-pressure fuel unions.
    • Torque Specification: 15 Nm 
  55. G11601506
    • Tighten the high-pressure fuel unions.
    • Torque Specification: 15 Nm 
  56. G11756565
    • Tighten the high-pressure fuel unions.
    • Torque Specification: 15 Nm 
  57. G11601329
    • Tighten the high-pressure fuel unions.
    • Torque Specification: 35 Nm 
  58. G11756565
    • Tighten the high-pressure fuel unions.
    • Torque Specification: 35 Nm 
  59. G11601328
    • Tighten the high-pressure fuel unions.
    • Torque Specification: 35 Nm 
  60. G11601506
    • Tighten the high-pressure fuel unions.
    • Torque Specification: 35 Nm 
  61. G11756472

    Install the low-pressure fuel supply and return lines.

  62. G11756471

    Install the Air Conditioning (A/C) compressor support bracket.

    Torque Specification: 23 Nm 

  63. G11756470
    • Install a new O-ring seal.

      Renew Part: Turbocharger oil supply tube to engine O-ring seal(s) Quantity: 1  .

    • Torque Specification: 10 Nm 
  64. G11756463
    • Install new exhaust manifold studs.

      Renew Part: Exhaust manifold studs Quantity: 6  .

    • Install a new exhaust manifold gasket.

      Renew Part: Exhaust manifold gasket Quantity: 1  .

  65. G11607460

    Install a new coolant pipe.

    Renew Part: Turbocharger coolant pipe Quantity: 1  .

  66. NOTE: Tighten the retaining nuts in the sequence shown.
    Fig 1: Exhaust Manifold To Cylinder Head Nuts Tightening Sequence
    G11756575Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC
    • Install new nuts.

      Renew Part: Exhaust manifold to cylinder head nuts Quantity: 6  .

      Torque Specifications: 

      Stage 1: 5 Nm 

      Stage 2: 28 Nm 

  67. G11756455

    Install the exhaust manifold heatshield.

    Torque Specification: 10 Nm 

  68. G11756456
    • Install new sealing washers.

      Renew Part: Turbocharger oil feed pipe banjo bolt washers Quantity: 2  .

    • Install the turbocharger banjo bolt.
    • Torque Specification: 30 Nm 
  69. G11756460
    • Install a new oil return pipe.

      Renew Part: Turbocharger oil return pipe Quantity: 1  .

      Torque Specification: 9 Nm 

  70. G11607453

    Install the bolt.

    Torque Specification: 9 Nm 

  71. G11756458

    Install the turbocharger support bracket.

    Torque Specification: 32 Nm 

  72. G11607452

    Install the bolt.

    Torque Specification: 9 Nm 

  73. Fig 2: Generator Mounting Bracket Bolts Tightening Sequence
    G11602159Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC
    • Tighten the retaining bolts in the sequence shown.
    • Torque Specification: 22 Nm 
  74. G11756468
    • Install new exhaust manifold studs.

      Renew Part: Exhaust manifold studs Quantity: 6  .

    • Install a new exhaust manifold gasket.

      Renew Part: Exhaust manifold gasket Quantity: 1  .

  75. G11756467
    • Install new nuts.

      Renew Part: Exhaust manifold to cylinder head nuts Quantity: 6  .

      Torque Specification: 28 Nm 

  76. G11756456
    • Install new sealing washers.

      Renew Part: Turbocharger oil feed pipe banjo bolt washers Quantity: 2  .

    • Install the turbocharger banjo bolt.
    • Torque Specification: 30 Nm 
  77. G11756466

    Install the right turbocharger support bracket.

    Torque Specification: 24 Nm 

  78. G11607495
    • Install a new gasket.

      Renew Part: Turbocharger oil return pipe gasket(s) Quantity: 1  .

    • Install a new O-ring seal.

      Renew Part: Oil return pipe O-ring seal Quantity: 1  .

    • Torque Specification: 9 Nm 
  79. G11607497

    Install the exhaust manifold heatshield.

    Torque Specification: 10 Nm 

  80. G11756464
    • Install the oil extraction tube.
    • Torque Specification: 9 Nm 
  81. G11756451
    • Install a new Exhaust Gas Recirculation (EGR) inlet pipe gasket.

      Renew Part: EGR pipe to exhaust manifold gasket Quantity: 1  .

      Torque Specification: 10 Nm 

    • Install the right EGR valve.

      Torque Specification: 10 Nm 

  82. G11756450

    Install the heat shield.

    Torque Specification: 10 Nm 

  83. G11756449

    Connect the EGR inlet hose.

  84. G11756445
    • Install the Left EGR valve.

      Torque Specification: 10 Nm 

    • Connect the EGR valve outlet pipe.
  85. G11756444

    Install a new gasket.

    Renew Part: Exhaust gas recirculation pipe gasket Quantity: 1  .

  86. G11756443

    Install the retaining bolt.

    Torque Specification: 9 Nm 

  87. G11756442

    Connect the hose.

  88. G11756447
    • Install the new O-ring seals.

      Renew Part: Engine Vent Oil Separator Seal(s) Quantity: 2  .

    • Install the engine vent oil separator.
  89. G11756446

    Install the engine vent tube.

    Torque Specification: 10 Nm 

  90. G11756448

    Install the vacuum harness.

    Torque Specification: 10 Nm 

  91. G11756441

    Install the engine wiring harness.

  92. G11756440

    Install the engine wiring harness and connect the electrical connectors.

  93. G11756439

    Install the idler pulley.

    Torque Specification: 23 Nm 

  94. G11756438
    • Install the engine wiring harness and connect the electrical connectors.
    • Install the bolt.

      Torque Specification: 9 Nm 

  95. G11756437
    • Install the engine wiring harness and connect the electrical connectors.
  96. NOTE: Repeat this step for the LH side.
    G11602223

    Install the Noise Vibration Harshness (NVH) material.

  97. G11756606

    Install the retaining bolt to the crankcase ventilation pipe.

    Torque Specification: 10 Nm 

  98. G11756109
    • Install the engine wiring harness and connect the electrical connectors.
  99. G11756608
    • Install the engine wiring harness and connect the electrical connectors.
  100. G11756249
    • Install the engine wiring harness and connect the electrical connectors.
  101. G11756433
    • Install the engine wiring harness and connect the electrical connectors.
  102. G11756431
    • Install the engine wiring harness and connect the electrical connectors.
  103. G11756430
    • Install the engine wiring harness and connect the electrical connectors.
  104. G11756429
    • Install a new gasket.
    • Install the EGR inlet pipe.

      Torque Specification: 10 Nm 

  105. G11756427

    Install the engine wiring harness as illustrated.

  106. G11756426
    • Install the engine wiring harness and connect the electrical connectors.
  107. G11607499

    Install the vacuum hose.

  108. G11607498

    Connect the electrical connector.

  109. G11598652

    Install the generator.

    Torque Specification: 47 Nm 

  110. G11756422
    • Connect the wiring harness.
  111. G11698022
    • Install the accessory drive belt tensioner.
    • Torque Specification: 47 Nm 
  112. G11756418
    • Install the special tool.
    • Special Tool(s): 303-1123 
  113. G11756622

    Use an M10 X 1mm tap to clean the threads.

  114. Remove the engine from the engine stand.
    CAUTION: Apply Loctite 243 to the bolts.
    NOTE: Make sure that all the component mating faces are clean.
  115. G11756623
    • Install the new bolts finger tight.

      Renew Part: Flexplate bolts Quantity: 10  .

    • Tighten the retaining bolts working diagonally.
    • Torque Specifications: 

      Stage 1: 45 Nm 

      Stage 2: 90° 

  116. G11756418
    • Remove the special tool.
  117. Install the engine.

    Refer to: ENGINE (INSTALLATION) 

  118. Install the throttle body.

    Refer to: INTAKE AIR SHUTOFF THROTTLE

  119. Fill the engine with oil.

    Refer to: ENGINE OIL DRAINING AND FILLING 

  120. Connect the primary battery ground cable.

    Refer to: SPECIFICATIONS

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