Land Rover Defender: Engine Wiring Harness - Ingenium I4 2.0l Petrol

REMOVAL AND INSTALLATION

REMOVAL

CAUTIONS:

• Take extra care not to damage the wiring harness clips.
• Make sure that the wiring harness is not twisted or damaged on removal. Failure to follow this instruction may result in damage to the vehicle.

NOTES:

• Note the position of the wiring harnesses to aid installation.
• This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
• This procedure contains illustrations showing certain components removed to provide extra clarity.

1. Disconnect the startup battery ground cable.

2. Remove the air filter outlet pipe.

3. Remove the intake manifold.

4. Remove the electric thermostat.

5.

WARNING: Be prepared to collect escaping coolant.

• Release the clamp.
• Release the 2 clips.
• Remove the 2 bolts.
• Remove the coolant pipe assembly.

6.

• Disconnect the 2 electrical connectors from the coolant pump.
• Disconnect the electrical connector from the bypass valve.
• Release the clip.

7.

• Remove the 2 bolts.
• Disconnect the electrical connector from the oil pressure and temperature sensor.
• Disconnect the cylinder head temperature sensor electrical connector.
• Disconnect the link harness electrical connector.
• Release the 2 clips.

8.

• Disconnect the 2 electrical connectors from the Camshaft Position Sensor (CMP) sensors.
• Remove the 2 bolts.

9.

Remove the charge air cooler outlet pipe.

10.

• Disconnect the electrical connector from the Air Conditioning (A/C) compressor.
• Disconnect the electrical connector from the Manifold Absolute Pressure and Temperature sensor (MAPT) sensor.
• Disconnect the electrical connector from the link harness.
• Release the 3 clips.

11.

• Release the 4 clips.
• Disconnect the electrical connector from the Crankshaft Position Sensor (CKP) sensor.
• Disconnect the electrical connector from the variable flow oil pump with integral vacuum pump.

12.

Release the 5 clips from the engine oil level gauge.

13.

• Disconnect the electrical connector from the knock sensor.
• Disconnect the electrical connector from the piston cooling oil jet solenoid.
• Disconnect the electrical connector from the cylinder block temperature sensor.
• Release the 4 clips.

14.

• Release the 2 clamps.
• Disconnect the 5 coolant hoses.
• Remove the 2 bolts.
• Remove the coolant degas separator.

15.

• Disconnect the 2 electrical connectors from the Variable Camshaft Timing (VCT) solenoids.
• Disconnect the electrical connector from the exhaust back pressure sensor.
• Disconnect the electrical connector from the Electronic Vacuum Regulating Valve (EVRV).
• Release the 8 clips.

16.

• Disconnect the 4 electrical connectors from the Continuous Variable Valve Lift (CVVL) units.
• Disconnect the electrical connector from the CVVL oil temperature sensor.
• Disconnect the 4 electrical connectors from the ignition coil on-plugs.
• Disconnect the electrical connector from the fuel injector wiring harness.
• Disconnect the electrical connector from the fuel rail pressure sensor.
• Remove the bolt.
• Release the 3 clips.
• Remove the 2 nuts.

17.

• Disconnect the electrical connector from the High Pressure (HP) fuel pump.
• Disconnect the electrical connector from the turbocharger actuator.
• Disconnect the electrical connector from the link harness.
• Release the 8 clips.

18.

• Disconnect the electrical connector from the Engine Control Module (ECM).
• Disconnect the electrical connector from the engine compartment wiring harness.
• Release the grommet.

19.

Remove the engine wiring harness.

INSTALLATION

CAUTION: If any clips were damaged during the removal process, make sure they are replaced and installed in the original location and orientation.

1. Install the engine wiring harness.

2.

• Connect the electrical connector to the Engine Control Module (ECM).
• Connect the electrical connector to the engine compartment harness.
• Install the grommet.

3.

• Connect the electrical connector to the HP fuel pump.
• Connect the electrical connector to the turbocharger actuator.
• Connect the electrical connector to the link harness.
• Install the 8 clips.

4.

• Connect the 4 electrical connectors to the Continuous Variable Valve Lift (CVVL) units.
• Connect the electrical connector to the CVVL oil temperature sensor.
• Connect the 4 electrical connectors to the ignition coil on-plugs.
• Connect the electrical connector to the fuel injector wiring harness.
• Connect the electrical connector to the fuel rail pressure sensor.
• Install and tighten the bolt.

  Torque: 9Nm

• Install the 3 clips.
• Install and tighten the 2 nuts.

  Torque: 9Nm

5.

• Connect the 2 electrical connectors to the Variable Camshaft Timing (VCT) solenoids.
• Connect the electrical connector to the exhaust back pressure sensor.
• Connect the electrical connector to the Electronic Vacuum Regulating Valve (EVRV).
• Install the 8 clips.

6.

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

  Torque: 10Nm

• Connect the 5 coolant hoses.
• Install the 2 clamps.

7.

• Connect the electrical connector to the knock sensor.
• Connect the electrical connector to the piston cooling oil jet solenoid.
• Connect the electrical connector to the cylinder block temperature sensor.
• Install the 4 clips.

8. Install the 5 wiring harness clips to the engine oil level gauge.

9.

• Connect the electrical connector to the CKP sensor.
• Connect the electrical connector to the variable flow oil pump with integral vacuum pump.
• Install the 4 clips.

10.

• Connect the electrical connector to the A/C compressor.
• Connect the electrical connector to the MAPT sensor.
• Connect the electrical connector to the link harness.
• Release the 3 clips.

11. Install the charge air cooler outlet pipe.

12.

• Install and tighten the 2 bolts.

  Torque: 9Nm

• Connect the 2 electrical connectors to the CMP sensors.

13.

• Install and tighten the 2 bolts.

  Torque: 9Nm

• Connect the electrical connector to the oil pressure and temperature sensor.
• Connect the cylinder head temperature sensor electrical connector.
• Connect the link harness electrical connector.
• Install the 2 clips.

14.

• Connect the 2 electrical connectors to the coolant pump.
• Connect the electrical connector to the bypass valve.
• Install clip.

15.

• Install the coolant pipe assembly.
• Install the clamp.
• Install and tighten the 2 bolts.

  Torque: 10Nm

• Install the 2 clips.

16. Install the electric thermostat.

17. Install the intake manifold.

18. Install the air filter outlet pipe.

19. Connect the startup battery ground cable.

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