Land Rover Discovery Owners & Service Manuals

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

INSTALLATION

SPECIAL TOOL(S)

SPECIAL TOOL(S)

SPECIAL TOOL(S)

GENERAL EQUIPMENT

Engine hoist (1 tonne minimum capacity)

PART(S)

Engine and Ancillaries (G1977459) Installation

Engine and Ancillaries (G1977459) Installation

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).

Engine and Ancillaries (G1977459) Installation

Install a new NVH pad.

Renew Part: Engine NVH pad.

Engine and Ancillaries (G1977459) Installation

Install new fuel injector seals.

Renew Part: Fuel injector O-ring seals.

Engine and Ancillaries (G1977459) Installation

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

Renew Part: Fuel injector clamp bolts.

Torque: 10 Nm

Engine and Ancillaries (G1977459) Installation

Loosen the 4 bolts 180 degrees.

Engine and Ancillaries (G1977459) Installation

  • 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.

Engine and Ancillaries (G1977459) Installation

  • 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.

Engine and Ancillaries (G1977459) Installation

  • 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.

Engine and Ancillaries (G1977459) Installation

  • 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.

Engine and Ancillaries (G1977459) Installation

  • Install the engine oil filler pipe.

Torque: 12 Nm

Engine and Ancillaries (G1977459) Installation

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.

Engine and Ancillaries (G1977459) Installation

  • 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.

Engine and Ancillaries (G1977459) Installation

  • Install a new gasket.

Renew Part: Oil cooler gasket.

  • Install the oil cooler.

Torque: 12 Nm

Engine and Ancillaries (G1977459) Installation

  • 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

Engine and Ancillaries (G1977459) Installation

  • Install the exhaust manifold heat shield.

Torque: 8 Nm

CAUTION:

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

Engine and Ancillaries (G1977459) Installation

  • Install a new O-ring seal.

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

  • Install the EGR valve.

Engine and Ancillaries (G1977459) Installation

  • Install a new gasket.

Renew Part: Turbocharger to exhaust manifold gasket.

  • Install the turbocharger.

Torque: 25 Nm

Engine and Ancillaries (G1977459) Installation

Torque: 28 Nm

Engine and Ancillaries (G1977459) Installation

  • Install new sealing washers.

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

Torque: 18 Nm

Engine and Ancillaries (G1977459) Installation

  • 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.

Engine and Ancillaries (G1977459) Installation

  • Install the Variable Camshaft Timing (VCT) solenoid.

Torque: 9 Nm

Engine and Ancillaries (G1977459) Installation

  • Install the EGR assembly.

Torque: 25 Nm

  • Install a new gasket.

Renew Part: Exhaust manifold to EGR valve gasket.

Engine and Ancillaries (G1977459) Installation

Install the coolant hose.

Engine and Ancillaries (G1977459) Installation

  • 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.

Engine and Ancillaries (G1977459) Installation

Torque: 10 Nm

Engine and Ancillaries (G1977459) Installation

  • 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.

Engine and Ancillaries (G1977459) Installation

Torque: 25 Nm

Engine and Ancillaries (G1977459) Installation

  • Install the hoses.

Torque: 10 Nm

Engine and Ancillaries (G1977459) Installation

  • 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.

Engine and Ancillaries (G1977459) Installation

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

Renew Part: Fuel injector high pressure pipes.

Engine and Ancillaries (G1977459) Installation

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.

Engine and Ancillaries (G1977459) Installation

  • 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.

Engine and Ancillaries (G1977459) Installation

  • Install the new gaskets.

Renew Part: Intake manifold gaskets.

  • Install the inlet manifold complete with throttle body.

Torque: 12 Nm

Engine and Ancillaries (G1977459) Installation

Install the new engine number label.

CAUTION:

If accidentally dropped or knocked install a new glow plug.

Engine and Ancillaries (G1977459) Installation

  • Install the glow plugs.

Torque: 12 Nm

Engine and Ancillaries (G1977459) Installation

  • 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

Engine and Ancillaries (G1977459) Installation

  • Install the 2 brackets.

Torque: 12 Nm

Engine and Ancillaries (G1977459) Installation

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

NOTE:

If equipped.

Engine and Ancillaries (G1977459) Installation

  • Install the block heater.

Torque: 55 Nm

Engine and Ancillaries (G1977459) Installation

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

Torque:

Stage 1: 50 Nm

Stage 2: 125º

Engine and Ancillaries (G1977459) Installation

Install the coolant hose.

Engine and Ancillaries (G1977459) Installation

  • Install the new gasket.

Renew Part: Thermostat to cylinder block gasket.

  • Install the thermostat.

Torque: 12 Nm

Engine and Ancillaries (G1977459) Installation

Install the coolant hoses.

Engine and Ancillaries (G1977459) Installation

  • 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.

Engine and Ancillaries (G1977459) Installation

  • Install the accessory drive belt idler.

Torque: 48 Nm

Engine and Ancillaries (G1977459) Installation

  • 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.

Engine and Ancillaries (G1977459) Installation

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

Special Tool(s): JLR-303-1630

Engine and Ancillaries (G1977459) Installation

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.

Engine and Ancillaries (G1977459) Installation

  • 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.

Engine and Ancillaries (G1977459) Installation

Install the coolant pump.

Torque: 12 Nm

Engine and Ancillaries (G1977459) Installation

  • Install the water pump pulley.

Torque: 26 Nm

Engine and Ancillaries (G1977459) Installation

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

Renew Part: Coolant pump inlet O-ring seal.

Engine and Ancillaries (G1977459) Installation

Install the NVH insulation.

CAUTION:

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

Engine and Ancillaries (G1977459) Installation

Install the engine wiring harness.

Engine and Ancillaries (G1977459) Installation

Install the engine wiring harness.

Engine and Ancillaries (G1977459) Installation

Install the engine wiring harness.

Engine and Ancillaries (G1977459) Installation

Install the engine wiring harness.

Engine and Ancillaries (G1977459) Installation

  • Remove the special tool.

Special Tool(s): JLR-303-1630

Engine and Ancillaries (G1977459) Installation

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).

Engine and Ancillaries (G1977459) Installation

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).

Engine and Ancillaries (G1977459) Installation

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

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

Engine and Ancillaries (G1977459) Installation

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

    READ NEXT:

     Engine Front Cover (G1875898) / Removal and Installation

    REMOVAL NOTES: Some variation in the illustrations may occur, but the essential information is always correct. Removal steps in this procedure may contain installation details. WARNING: Make sure

     Engine Mount (G1913572) / Removal and Installation

    PART(S) REMOVAL WARNING: Make sure to support the vehicle with axle stands. Raise and support the vehicle. Refer to: Cooling System Draining, Filling and Bleeding (303-03B Engine Cooling - INGENIUM I

     Engine - Ingenium i4 2.0l Diesel Engine Mount Alignment (G1815586) / General Procedures

    ADJUSTMENT Transmission mounting WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. Raise and support the vehicle. Using a suitable hydr

    SEE MORE:

     Front end Sheet Metal Repairs Fender Apron Panel (G1770873) / Removal and installation

    REMOVAL NOTE: The fender apron panel is installed in conjunction with: Front bumper cover Hood Hood hinge Hood latch panel Front fender Fender splash shield Front door A-pillar outer panel The fender apron panel is serviced as indicated. Before commencing this procedure make sure that

     Trailer Lamps

    PRINCIPLES OF OPERATION For a detailed description of the Trailer Lamps, refer to the relevant Description and Operation section in the workshop manual. REFER to: Exterior Lighting (417-01 Exterior Lighting, Description and Operation). INSPECTION AND VERIFICATION CAUTION: Diagnosis by substitution f

    © 2019-2024 Copyright www.lrdisc.com