Land Rover Defender: Engine and Ancillaries - Installation

ENGINE AND ANCILLARIES - INGENIUM I4 2.0L PETROL

INSTALLATION

SPECIAL TOOL(S)

303-680

Socket, Cylinder Head Temperature Sensor

310-198

Installer, Teflon Seal

JLR-303-1630

Locking Tool, Crankshaft Pulley

JLR-310-255

Guide pins threaded

JLR-310-256

Guide pins unthreaded

JLR-310-257

Teflon Seal Resize Tool

PART(S)

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.

1.

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

  Torque: 11.5Nm

2.

• Install the NVH material.
• Install the clip.

3.

• Install the NVH material.
• Install the 4 clips.

4.

• 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 pulley.
• Install the special tool.

  Special Tool(s): JLR-303-1630

5.

Install and tighten the 4 bolts.

Torque

• Stage1: 37Nm
• Stage2: 90º

6.

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.

• 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.

7.

• Install the drive plate.
• Install, but do not fully tighten the 8 new bolts.

  Renew Part: Drive plate bolts Quantity: 8.

8.

Tighten the 8 bolts in the illustrated sequence.

Torque

• Stage1: 30Nm
• Stage2: 120º

9. Remove the special tools.

Special Tool(s): JLR-303-1630

10.

• 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.

11.

Tighten the 7 bolts in the illustrated sequence.

Torque: 11.5Nm

12.

• 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.

13.

• Install the oil filter housing assembly.
• Install and tighten the 3 bolts.

  Torque: 11.5Nm

14.

Before installing the oil filter cap, check the by-pass valve (1) is installed and correctly secured on the locating tabs (2).

15.

• 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).

16.

Install and tighten the oil filter assembly.

Torque: 28Nm

17.

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: 10.5Nm

18.

Install and tighten a new cylinder block temperature sensor.

Renew Part: Engine block temperature sensor Quantity: 1.

Torque: 10.5Nm

19.

• 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: 11.5Nm

20.

• Install the bracket.
• Install and tighten the bolt.

  Torque: 11.5Nm

21.

• Install the bracket.
• Install and tighten the 2 bolts.

  Torque: 11.5Nm

22.

• 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: 8Nm

23.

• 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: 5Nm

24.

• 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: 11.5Nm

25.

NOTE: If equipped.

• Install a new gasket.

  Renew Part: Engine block heater manifold seal(s) Quantity: 1.

• Install and tighten the cylinder block heater.

  Torque: 55Nm

26.

CAUTION: Make sure that the mating faces are clean and free of foreign material.

• Install the knock sensor to the position noted in the removal step.
• Install and tighten the bolt.

  Torque: 20Nm

27.

CAUTION: Make sure that the mating faces are clean and free of foreign material.

• Install the knock sensor to the position noted in the removal step.
• Install and tighten the bolt.

  Torque: 20Nm

28.

• 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: 9Nm

29.

• 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: 8Nm

30.

• 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.

31.

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

32.

CAUTION: Make sure that the fuel injector Teflon seal groove is clean and free of foreign material.

Use the special tool 310-198 to install the Teflon seal to the fuel injector.

Special Tool(s): 310-198

33. Wait 2 minutes to allow the Teflon seal to recover its shape.

34.

• 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.

35.

Install a new fuel injector spring clamp.

36. Repeat steps 30 to 35 for the 3 remaining fuel injectors.

37.

Install the 4 fuel injectors to the fuel rail.

38.

Make sure the fuel injectors are correctly aligned.

39.

Make sure the fuel injectors are correctly aligned.

40.

• Install the wiring harness.
• Connect the 4 electrical connectors.
• Install the 4 wiring harness clips.

41.

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

42.

CAUTION: Tighten the fuel rail bolts one turn at a time until the correct torque figure is achieved.

• 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: 20Nm

43. Remove the special tools.

Special Tool(s): JLR-310-255, JLR-310-256

44.

CAUTION: Tighten the fuel rail bolts one turn at a time until the correct torque figure is achieved.

Install and tighten the 2 bolts.

Torque: 20Nm

45.

Tighten the 4 bolts in the illustrated sequence.

Torque: 30Nm

46.

• Install the 4 ignition coils.
• Install and tighten the 4 bolts.

  Torque: 8Nm

47.

• Lubricate the High Pressure (HP) fuel pump tappet with clean engine oil.
• Install the HP fuel pump tappet.

48.

CAUTION: Install the fuel pump evenly onto the camshaft cover surface by one turn on each bolt alternating until the required torque is achieved.

• 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: 11.5Nm

49.

• Install the HP fuel line.
• Tighten the 2 fuel line unions finger tight.

50.

• Tighten the 2 fuel line unions in the illustrated sequence.

  Torque: 20Nm

• Wait for 30 seconds and recheck the final torque of the 2 fuel line unions.

  Torque: 20Nm

51.

• Install the HP fuel line.
• Tighten the fuel line union finger tight.
• Install and tighten the 2 bolts.

  Torque

  • Stage1: 11.5Nm
  • Stage2: Loosen 90º

52.

• Tighten the fuel line union.

  Torque: 20Nm

• Tighten the 2 bolts.

  Torque: 11.5Nm

• Wait for 30 seconds and recheck the final torque of the fuel line union.

  Torque: 20Nm

53.

• Install the bracket.
• Install and tighten the 4 bolts.

  Torque

  • M10: 47.5Nm
  • M8: 25Nm

54.

• Inspect the gasket. Install a new gasket if damaged or worn.
• Install the thermostat housing.
• Install and tighten the 4 bolts.

  Torque: 11.5Nm

55.

• 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.

56.

Tighten the 7 bolts in the illustrated sequence.

Torque: 11.5Nm

57.

• 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: 11.5Nm

58.

• Install a new gasket.

  Renew Part: Oil cooler gasket Quantity: 1.

• Install the oil cooler.
• Install, but do not fully tighten the 7 bolts.

59.

Tighten the 7 bolts in the illustrated sequence.

Torque

• Stage1: 15Nm
• Stage2: 25Nm

60.

• Install the engine coolant hose.
• Connect the 2 engine coolant hose clamps.

61.

Install a new exhaust manifold gasket.

Renew Part: Exhaust manifold gasket Quantity: 1.

62.

• Install the turbocharger.
• Install, but do not fully tighten the 4 new nuts.

  Renew Part: Exhaust manifold to turbocharger nuts Quantity: 4.

63.

Tighten the 4 nuts in the illustrated sequence.

Torque

• Stage1: 18Nm
• Stage2: 25Nm

64.

• 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: 10.5Nm

65.

• Install the heatshield.
• Install and tighten the bolt.

  Torque: 9Nm

66.

• Install the heatshield.
• Install and tighten the bolt (1).

  Torque: 9Nm

• Install and tighten the new bolt (2).

  Renew Part: Turbocharger heatshield bolt(s) Quantity: 1.

  Torque: 9Nm

67.

• Install the heatshield.
• Install and tighten the 4 bolts.

  Torque: 9Nm

68.

• 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: 18Nm

69.

• Install the bracket.
• Install and tighten the 4 bolts.

  Torque: 60Nm

70.

• Install the engine coolant pump.
• Install and tighten the 2 bolts.

  Torque: 6Nm

71.

• Install the remaining 4 bolts.
• Tighten the 6 bolts.

  Torque: 11.5Nm

72.

NOTE: If required, use a suitable tool to prevent the pulley from rotating.

• Install the engine coolant pump pulley.
• Install and tighten the 3 bolts.

  Torque: 25Nm

73.

• Install the wiring harness.
• Install the 2 wiring harness clips.
• Install and tighten the 3 bolts.

  Torque: 10Nm

74.

Install the wiring harness.

75.

• Connect the 2 electrical connectors.
• Install the 2 wiring harness clips.

76.

• Install and tighten the 2 nuts.

  Torque: 10Nm

• Install the 3 wiring harness clips.
• Install and tighten the bolt.

  Torque: 10Nm

• Connect the 11 electrical connectors.

77.

• Install the 8 wiring harness clips.
• Connect the 4 electrical connectors.

78.

• Connect the 3 electrical connectors.
• Install the 4 wiring harness clips.

79.

• Connect the 2 electrical connectors.
• Install the wiring harness clip.

80.

• Connect the 2 electrical connectors.
• Install the 4 wiring harness clips.

81.

• Connect the 2 electrical connectors.
• Install and tighten the 2 bolts.

  Torque: 10Nm

82.

• Connect the 4 electrical connectors.
• Install and tighten the 2 bolts.
• Install the 2 wiring harness clips.

83.

Connect the 2 electrical connectors.

84.

• Install the generator.
• Install and tighten the 2 bolts.

  Torque: 47.5Nm

85.

• Install the wiring harness clip.
• Connect the electrical connector.
• Connect the startup battery positive cable.
• Install and tighten the nut.

  Torque: 12Nm

• Reposition the cover.

86.

• Install the pipe.
• Tighten the clamp.

87.

• Install the 2 pulleys.
• Install and tighten the 2 bolts.

  Torque

  • M10: 47.5Nm
  • M8: 25Nm
• Install the 2 covers.

88.

• 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: 7Nm

• Install the 3 wiring harness clips.

89.

• Install the engine coolant degas separator.
• Install and tighten the 2 bolts.

  Torque: 11.5Nm

90.

• 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.

91.

• 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: 11.5Nm

• Connect the engine coolant hose and install the clamp.
• Install the clip.

92.

• 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: 11.5Nm

• Connect the engine coolant hose and install the clamp.

93.

• Install the engine coolant hose.
• Connect the 2 engine coolant hoses and install the 2 clamps.

  Install and tighten the 3 bolts.

• Torque: 7Nm

94.

• Install the purge valve assembly.
• Connect the breather pipe connector.
• Install the 2 clips.
• Connect the 2 electrical connectors.

95.

Install and tighten the 2 bolts.

Torque: 11.5Nm

96.

• Install the vacuum harness.
• Install the 5 vacuum harness clips.
• Connect the vacuum pipe connector.

97.

• Install the engine coolant hose.
• Connect the engine coolant hose.
• Install and tighten the 2 bolts.

  Torque: 11.5Nm

98.

• Install the breather pipe.
• Connect the 2 breather pipe connectors.

99.

• Install the engine coolant pipe.
• Install the clip.
• Connect the engine coolant pipe.

100.

• Install the engine coolant pipe.
• Connect the 2 engine coolant hoses and install the 2 clamps.
• Install and tighten the 2 bolts.

  Torque: 25Nm

• Install the wiring harness clip.

101.

• Install the NVH material.
• Install the 3 clips.

102. Install the engine assembly.

103. Fill the engine with clean engine oil.

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