Land Rover Defender: Engine and Ancillaries - Removal

ENGINE AND ANCILLARIES - INGENIUM I4 2.0L PETROL

REMOVAL

SPECIAL TOOL(S)

100-012

Slide Hammer

100-012-01

Slide Hammer Adapter

JLR-303-1630

Locking Tool, Crankshaft Pulley

JLR-310-254

Injector Remover

1. Always follow the Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions, before any repairs are done to the fuel system.

2. Raise and support the vehicle on a suitable 2 post lift.

3. Disconnect the startup battery ground cable.

4. Remove the engine assembly.

5.

• Remove the drain plug and allow engine oil to drain into a suitable container.
• Install and tighten the drain plug.

  Torque: 23Nm

6.

• Remove the 3 clips.
• Remove the Noise, Vibration and Harshness (NVH) material.

7.

• Release the wiring harness clip.
• Remove the 2 bolts.
• Release the 2 engine coolant hose clamps.
• Remove the engine coolant pipe.

8.

• Disconnect the engine coolant pipe.
• Release the clip.
• Remove the engine coolant pipe.

9.

• Disconnect the 2 breather pipe connectors.
• Remove the breather pipe.

10.

• Remove the 2 bolts.
• Disconnect the engine coolant hose.
• Remove the engine coolant hose.

11.

• Disconnect the vacuum pipe connector.
• Release the 5 vacuum harness clips.
• Remove the vacuum harness.

12.

Remove the 2 bolts.

13.

• Disconnect the 2 electrical connectors.
• Release the 2 clips.
• Disconnect the breather pipe connector.
• Remove the purge valve assembly.

14.

• Remove the 3 bolts.
• Release the 2 engine coolant hose clamps.
• Remove the engine coolant hose.

15.

• Release the engine coolant hose clamp.
• Disconnect the engine coolant hose.
• Remove the 3 bolts.
• Remove the engine coolant hose assembly.
• Inspect the O-ring seal. Remove and discard the O-ring seal if damaged or worn.

16.

• Release the engine coolant hose clamp.
• Release the clip.
• Remove the bolt.
• Remove the engine coolant hose.
• Inspect the O-ring seal. Remove and discard the O-ring seal if damaged or worn.

17.

• Release the engine coolant hose clamp.
• Remove the engine coolant hose.
• Inspect the O-ring seal. Remove and discard the O-ring seal if damaged or worn.

18.

• Remove the 2 bolts.
• Remove the engine coolant degas separator.

19.

• Release the 3 wiring harnesses clips.
• Remove the bolt.
• Remove the oil level gauge assembly.
• Remove and discard the O-ring seal.

20.

• Remove the 2 covers.
• Release the 2 bolts.
• Remove the 2 pulleys.

21.

• Release the clamp.
• Remove the pipe.

22.

• Reposition the cover to get access to the nut.
• Remove the nut and disconnect the startup battery cable.
• Disconnect the electrical connector.
• Release the wiring harness clip.

23.

• Remove the 2 bolts.
• Remove the generator.

24.

Disconnect the 2 electrical connectors.

25.

• Disconnect the 4 electrical connectors.
• Remove the 2 bolts.
• Release the 2 wiring harness clips.

26.

• Disconnect the 2 electrical connectors.
• Remove the 2 bolts.

27.

• Disconnect the 2 electrical connectors.
• Release the 4 wiring harness clips.

28.

• Release the wiring harness clip.
• Disconnect the 2 electrical connectors.

29.

• Disconnect the 3 electrical connectors.
• Release the 4 wiring harness clips.

30.

• Release the 8 wiring harness clips.
• Disconnect the 4 electrical connectors.

31.

• Remove the 2 nuts.
• Release the 3 wiring harness clips.
• Remove the bolt.
• Disconnect the 11 electrical connectors.

32.

• Disconnect the 2 electrical connectors.
• Release the 2 wiring harness clips.

33.

Remove the wiring harness.

34.

• Remove the 3 bolts.
• Release the 2 wiring harnesses clips.
• Remove the wiring harness.

35.

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

• Remove the 3 bolts.
• Remove the engine coolant pump pulley.

36.

• Remove the 6 bolts.
• Remove the coolant pump.
• Inspect the gasket. If the gasket is damaged or worn, a new engine coolant pump must be installed.

37.

• Remove the 4 bolts.
• Remove the bracket.

38.

• Release the 2 banjo bolts.
• Remove the turbocharger oil supply pipe.

39.

• Cut and remove the 2 lower sealing washers.
• Remove and discard the 2 banjo bolts.
• Remove and discard the 4 sealing washers.

40.

• Remove the 4 bolts.
• Remove the heatshield.

41.

• Remove the bolt (1).
• Remove the and discard the bolt (2).
• Remove the heatshield.

42.

• Remove the bolt.
• Remove the heatshield.

43.

• Remove the bolt.
• Remove the turbocharger oil return pipe.
• Remove and discard the 2 O-ring seals.

44.

• Remove and discard the 4 nuts.
• Remove the turbocharger.

45.

Remove and discard the exhaust manifold gasket.

46.

• Disconnect the 2 engine coolant hose clamps.
• Remove the engine coolant hose.

47.

• Remove the 7 bolts.
• Remove the engine oil cooler.
• Remove and discard the gasket.

48.

• Remove the 2 bolts.
• Remove the engine coolant pipe.
• Inspect the O-ring seal. Remove and discard the O-ring seal if damaged or worn.

49.

NOTE: The bolts will remain captive.

• Release the engine coolant hose clamp and disconnect the engine coolant hose.
• Release the 7 bolts.
• Remove the intake manifold.
• Remove and discard the 4 O-ring seals.

50.

• Remove the 4 bolts.
• Remove the thermostat housing.
• Inspect the gasket. Remove and discard the gasket if damaged or worn.

51.

• Remove the 4 bolts.
• Remove the bracket.

52.

CAUTION: Fuel lines may be used a maximum of 4 times, paint mark fuel line after each full tightening sequence.

• Release the High Pressure (HP) fuel line union.
• Remove the 2 bolts.
• Remove the HP fuel line.

53.

CAUTION: Fuel lines may be used a maximum of 4 times, paint mark fuel line after each full tightening sequence.

• Release the 2 HP fuel line unions.
• Remove the HP fuel line.

54.

CAUTION: Loosen each of the bolts 1 turn at a time until the spring tension is fully released.

• Remove the 2 bolts.
• Remove the HP fuel pump.
• Inspect the O-ring seal. Remove and discard the O-ring seal if damaged or worn.

55.

Remove the HP fuel pump tappet.

56.

• Remove the 4 bolts.
• Remove the 4 ignition coils.

57.

Release the 4 wiring harness clips.

58.

• Remove the 4 bolts.
• Remove the fuel rail.

59.

• Disconnect the 4 electrical connectors.
• Remove the wiring harness.

60.

Remove and discard the 4 fuel injector spring clamps.

61.

Install the special tool.

Special Tool(s): JLR-310-254

62.

Use the special tool to remove the fuel injector.

Special Tool(s): 100-012, 100-012-01, JLR-310-254

63.

Remove and discard the fuel injector O-ring seal and washer.

64.

Remove and discard the Teflon seal.

65. Repeat steps 61 to 64 for the 3 remaining fuel injectors.

66.

• Remove the 2 bolts.
• Remove the 2 Camshaft Position Sensor (CMP) sensors.
• Inspect the 2 O-ring seals. Remove and discard the O-ring seals if damaged or worn.

67.

• Remove the 4 bolts.
• Remove the 2 variable valve timing (VVT) solenoids.
• Inspect the 2 O-ring seals. Remove and discard the O-ring seals if damaged or worn.

68.

CAUTION: Note the installed position of the component(s) prior to removal.

• Remove the bolt.
• Remove the knock sensor.

69.

CAUTION: Note the installed position of the component(s) prior to removal.

• Remove the bolt.
• Remove the knock sensor.

70.

NOTE: If equipped.

• Remove the cylinder block heater.
• Remove and discard the gasket.

71.

• Remove the bolt.
• Remove the piston cooling oil jet solenoid.
• Inspect the O-ring seal. Remove and discard the O-ring seal if damaged or worn.

72.

• Remove the bolt.
• Remove the vacuum pipe connector.
• Inspect the O-ring seal. Remove and discard the O-ring seal if damaged or worn.

73.

• Remove the bolt.
• Remove the Crankshaft Position Sensor (CKP) sensor.
• Inspect the O-ring seal. Remove and discard the O-ring seal if damaged or worn.

74.

• Remove the 2 bolts.
• Remove the bracket.

75.

• Remove the bracket.
• Remove the bolt.

76.

• Remove the bolt.
• Remove the oil filler.
• Inspect the O-ring seal. Remove and discard the O-ring seal if damaged or worn.

77.

• Remove the oil filter element cap.
• Remove and discard the oil filter element.
• Remove and discard the O-ring seal.

78.

• Remove the 3 bolts.
• Remove the oil filter housing.

79.

Remove and discard the 5 O-ring seals.

80.

NOTE: The bolts will remain captive.

• Release the 7 bolts.
• Remove the engine vent oil separator.
• Remove and discard the gasket.

81.

Install the special tools.

Special Tool(s): JLR-303-1630

82.

• Remove and discard the 8 bolts.
• Remove the drive plate.

83.

CAUTION: The bolts can only be used a maximum of 4 times. Mark the bolts with a center punch. If 3 punch marks are visible, discard the bolts.

Remove the 4 bolts.

84.

• Remove the special tools.

  Special Tool(s): JLR-303-1630

• Remove the crankshaft pulley.
• Inspect the O-ring seal. Remove and discard the O-ring seal if damaged or worn.

85.

• Remove the 4 clips.
• Remove the NVH material.

86.

• Remove the clip.
• Remove the NVH material.

87.

• Remove the bolt.
• Remove the NVH material.

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