Land Rover Discovery: Engine and Ancillaries (G1977459) / Installation

INSTALLATION

SPECIAL TOOL(S)

GENERAL EQUIPMENT

Engine hoist (1 tonne minimum capacity)

PART(S)

NOTES:

• In this procedure the EU6 Exhaust Gas Recirculation (EGR) assembly is shown. EU5, EU4 and NAS variants are similar.
• 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.

For the list of part numbers required for this job please refer to the specifications.

Refer to: Specifications (303-01B Engine - INGENIUM I4 2.0L Diesel, Specifications).

Install a new NVH pad.

Renew Part: Engine NVH pad.

Install new fuel injector seals.

Renew Part: Fuel injector O-ring seals.

• Install the fuel injector retaining clamps.
• Install new bolts.

Renew Part: Fuel injector clamp bolts.

Torque: 10 Nm

Loosen the 4 bolts 180 degrees.

• Tighten the 4 bolts.

Torque:

Stage 1: 11 Nm

Stage 2: 162º

NOTE:

New engines may be supplied with untapped bolt holes for some of the components. Bolts from the original engine can be used, as these are self tapping and will cut threads where required.

• Install the crankshaft position (CKP) sensor.

Torque: 8 Nm

NOTE:

New engines may be supplied with untapped bolt holes for some of the components. Bolts from the original engine can be used, as these are self tapping and will cut threads where required.

• Install a new gasket.

Renew Part: Engine vent oil separator to valve cover gasket.

• Install the engine vent oil separator.

Torque: 12 Nm

NOTE:

New engines may be supplied with untapped bolt holes for some of the components. Bolts from the original engine can be used, as these are self tapping and will cut threads where required.

• Install the camshaft position (CMP) sensor.

Torque: 8 Nm

NOTE:

New engines may be supplied with untapped bolt holes for some of the components. Bolts from the original engine can be used, as these are self tapping and will cut threads where required.

• Install the engine oil filler pipe.

Torque: 12 Nm

Install new O-ring seals.

Renew Part: Oil filter housing drain port O-ring seal.

Renew Part: Oil filter housing inlet / outlet O-ring seals.

NOTE:

New engines may be supplied with untapped bolt holes for some of the components. Bolts from the original engine can be used, as these are self tapping and will cut threads where required.

• Install the oil filter housing.

Torque: 12 Nm

Install the engine oil filter.

Refer to: Oil Filter Element (303-01B Engine - INGENIUM I4 2.0L Diesel, Removal and Installation).

NOTE:

New engines may be supplied with untapped bolt holes for some of the components. Bolts from the original engine can be used, as these are self tapping and will cut threads where required.

• Install a new gasket.

Renew Part: Oil cooler gasket.

• Install the oil cooler.

Torque: 12 Nm

• Install a new gasket.

Renew Part: Exhaust manifold gasket.

• Install new bolts and spacers.

Renew Part: Exhaust manifold bolts and spacers.

• Install the exhaust manifold.

Torque:

Stage 1: 15 Nm

Stage 2: 28 Nm

• Install the exhaust manifold heat shield.

Torque: 8 Nm

CAUTION:

Take care not to damage the O-ring seals during installation

• Install a new O-ring seal.

Renew Part: Low pressure exhaust gas recirculation valve to turbocharger seal.

• Install the EGR valve.

• Install a new gasket.

Renew Part: Turbocharger to exhaust manifold gasket.

• Install the turbocharger.

Torque: 25 Nm

Torque: 28 Nm

• Install new sealing washers.

Renew Part: Turbocharger oil supply tube to turbocharger sealing washers.

Torque: 18 Nm

• Install the turbocharger heat shield.

Torque: 8 Nm

NOTE:

New engines may be supplied with untapped bolt holes for some of the components. Bolts from the original engine can be used, as these are self tapping and will cut threads where required.

• Install the Variable Camshaft Timing (VCT) solenoid.

Torque: 9 Nm

• Install the EGR assembly.

Torque: 25 Nm

• Install a new gasket.

Renew Part: Exhaust manifold to EGR valve gasket.

Install the coolant hose.

• Install the new O-ring seals.

Renew Part: Oil return pipe O-ring seal.

• Push the oil drain tube into the engine and rotate it into position.
• Lift the oil drain tube into the turbocharger and secure it into position.

Torque: 10 Nm

NOTE:

New engines may be supplied with untapped bolt holes for some of the components. Bolts from the original engine can be used, as these are self tapping and will cut threads where required.

Torque: 10 Nm

• Install a new gasket.

Renew Part: Exhaust gas recirculation outlet pipe to exhaust gas recirculation valve gasket.

• Install the EGR assembly.

Torque: 25 Nm

NOTE:

New engines may be supplied with untapped bolt holes for some of the components. Bolts from the original engine can be used, as these are self tapping and will cut threads where required.

Torque: 25 Nm

• Install the hoses.

Torque: 10 Nm

• Install the fuel rail.

Torque: 25 Nm

CAUTION:

Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

• Install the new high-pressure fuel injector supply lines.

Renew Part: Fuel injector high pressure pipes.

Install the fuel return pipes.

CAUTION:

Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

• Install a new high-pressure fuel supply line.

Renew Part: Fuel rail supply pipe.

Torque:

Fuel pipe connections

• Stage 1: 15 Nm
• Stage 2: 60º

Bolt 10 Nm

NOTE:

New engines may be supplied with untapped bolt holes for some of the components. Bolts from the original engine can be used, as these are self tapping and will cut threads where required.

• Install the new gaskets.

Renew Part: Intake manifold gaskets.

• Install the inlet manifold complete with throttle body.

Torque: 12 Nm

Install the new engine number label.

CAUTION:

If accidentally dropped or knocked install a new glow plug.

• Install the glow plugs.

Torque: 12 Nm

• Install a new O-ring seal.

Renew Part: EGR outlet pipe to throttle body gasket.

• Install a new gasket.

Renew Part: Exhaust gas recirculation outlet pipe to exhaust gas recirculation valve gasket.

• Install the EGR pipe.

Torque:

Inlet Manifold 8 Nm

EGR Valve 10 Nm

• Install the 2 brackets.

Torque: 12 Nm

• Install the NVH pad.
• Install the harness clip.

NOTE:

If equipped.

• Install the block heater.

Torque: 55 Nm

• Install the engine mount bracket.
• Tighten the bolts in the sequence shown in two stages.

Torque:

Stage 1: 50 Nm

Stage 2: 125º

Install the coolant hose.

• Install the new gasket.

Renew Part: Thermostat to cylinder block gasket.

• Install the thermostat.

Torque: 12 Nm

Install the coolant hoses.

• Install a new O-ring seal.

Renew Part: Oil level gauge O-ring seal.

• Install the oil level indicator and vacuum tube.

Torque: 8 Nm

• Secure the 3 clips.

• Install the accessory drive belt idler.

Torque: 48 Nm

• Install the accessory drive component bracket.

Torque: 48 Nm

CAUTION:

During the installation, make sure that all components are clean and free from foreign material.

• Install the crankshaft pulley.
• Install the special tool.

Special Tool(s): JLR-303-1630

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.

• Install new bolts.

Renew Part: Crankshaft pulley bolts.

Torque:

• Stage 1: 40 Nm
• Stage 2: 90º

NOTES:

• New engines may be supplied with untapped bolt holes for some of the components. Bolts from the original engine can be used, as these are self tapping and will cut threads where required.
• The coolant pump from the previous engine is to be installed.

Install the coolant pump.

Torque: 12 Nm

• Install the water pump pulley.

Torque: 26 Nm

1. Install the coolant pump inlet channel.
2. Install a new O-ring seal.

Renew Part: Coolant pump inlet O-ring seal.

Install the NVH insulation.

CAUTION:

Make sure the wiring harness and electrical connectors are not damaged during this operation.

Install the engine wiring harness.

Install the engine wiring harness.

Install the engine wiring harness.

Install the engine wiring harness.

• Remove the special tool.

Special Tool(s): JLR-303-1630

Install the special tool.

Special Tool(s): JLR-303-1633

General Equipment: Engine hoist (1 tonne minimum capacity)

Remove the engine from the engine stand.

Install the engine assembly.

Refer to: Engine (303-01B Engine - INGENIUM I4 2.0L Diesel, Installation).

Connect the battery ground cable.

Refer to: Specifications (414-01 Battery, Mounting and Cables, Specifications).

Remove the engine oil level indicator.

Fill the engine with oil.

Refer to: Specifications (303-01C Engine - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV, Specifications).

Clean any residual engine oil from the oil filler cap area.

Using the oil level indicator, check the engine oil level.

• Start the engine and allow to run for 10 minutes, stop the engine.
• Check for leaks.
• Check the engine oil level.

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