Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

REMOVAL

SPECIAL TOOL(S)

SPECIAL TOOL(S)

SPECIAL TOOL(S)

GENERAL EQUIPMENT

Engine hoist (1 tonne minimum capacity)

CAUTION:

Make sure that all openings are sealed. Use new blanking caps.

NOTES:

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

All vehicles

Remove the engine cover.

Refer to: Engine Cover - INGENIUM I4 2.0L Diesel (501-05 Interior Trim and Ornamentation, Removal and Installation).

Remove the battery.

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

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the battery tray.

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

Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

Drain the coolant system.

Refer to: Cooling System Partial Draining and Vacuum Filling (303- 03A Engine Cooling - TD4 2.2L Diesel, General Procedures).

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  1. Disconnect the electrical connector.
  2. Release the air pipe from the air cleaner.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  1. Remove the clean air duct.
  2. Remove and discard the O-ring seal.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the air cleaner.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

CAUTION:

Be prepared to collect escaping fuel.

  1. Disconnect the electrical connector.
  2. Disconnect the fuel pipes.

CAUTION:

Be prepared to collect escaping fuel.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the fuel filter.

CAUTION:

Be prepared to collect escaping fuel.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Disconnect the fuel supply pipes.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the fuel filter housing.

NOTE:

Repeat the step for the other side.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Release the clip.

CAUTION:

Be prepared to collect escaping fluids.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Release the washer hose.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the cowl panel.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Disconnect the electrical connector.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the bolts.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the Battery Junction Box (BJB) cover.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the BJB.

CAUTION:

Be prepared to collect escaping coolant.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Disconnect the coolant pipes.

CAUTION:

Be prepared to collect escaping coolant.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Disconnect the coolant pipes.

CAUTION:

Be prepared to collect escaping coolant.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the coolant pipes from the fuel cooler.

CAUTION:

Be prepared to collect escaping fuel.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the fuel pipe assembly.

CAUTION:

Be prepared to collect escaping fuel.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the fuel cooler.

Vehicles with manual transmission

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  1. Disconnect the electrical connectors.
  2. Remove the bracket.

NOTE:

Neutral must be selected before the cables are released to allow the cables to be correctly set on the install.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Disconnect the cables.

All vehicles

Raise the vehicle.

Remove the front subframe.

Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  1. Disconnect the electrical connectors from the glow plug module.
  2. Disconnect the electrical connector from the wiring harness.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the glow plug module

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  1. Remove the wiring harness from the glow plug module support bracket.
  2. Remove the glow plug module support bracket.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Push the engine wiring harness through the body in to the engine compartment.

CAUTION:

Do not use air tools to remove the nut.

NOTE:

Repeat this step for the other side.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove and discard the hub nut.

CAUTION:

Do not use a hammer to detach the halfshaft from the hub assembly, failure to follow this instruction may result in damage to the halfshaft.

NOTE:

Repeat this step for the other side.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Using the special tool remove the halfshaft.

Special Tool(s): 205-857

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the nuts.

NOTE:

Repeat this step for the other side.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  1. Move the wheel knuckle and brake assembly aside.\
  2. Remove the halfshaft.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  1. Disconnect the electrical connector.
  2. Remove the exhaust clamp.

CAUTION:

To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  1. Mark the driveshaft to Power Transfer Unit (PTU) flange.
  2. Remove the driveshaft from the PTU and tie aside.
  3. Discard the bolts.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  1. Disconnect the electrical connectors.
  2. Remove the differential pressure sensor assembly.

CAUTION:

To avoid damage to the Diesel Particulate Filter (DPF) and components, do not allow the exhaust to hang.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  1. Remove and discard the nuts and gasket.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Insert a suitable tool, where illustrated, to prevent tension being applied to the accessory belt.

NOTE:

Note the fitted position of the accessory drive belt.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the accessory drive belt.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  1. Disconnect the electrical connector.
  2. Remove the bolts.
  3. Remove the compressor from the cylinder block and tie aside.

Lower the vehicle.

CAUTION:

Make sure the engine and transmission is stable on the wooden block.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Position a suitable wooden block under the engine.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the bolts from the engine mount.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the nuts.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the bolts.

CAUTIONS:

  • Raise the vehicle body slowly. Make sure no components are damaged.
  • Make sure the engine and transmission is stable on the wooden block as the vehicle is raised.

NOTE:

This step requires the aid of another technician.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Carefully raise the vehicle on the lift.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  1. Install the special tool.

Special Tool(s): JLR-303-1633

  1. Use the engine hoist to support the engine.

General Equipment: Engine hoist (1 tonne minimum capacity)

Do not disassemble further if the engine assembly is removed for access only.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

CAUTION:

Be prepared to collect escaping coolant.

  1. Disconnect the electrical connector.
  2. Remove the coolant pipe assembly.

CAUTION:

Be prepared to collect escaping coolant.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the coolant pipe assembly.

CAUTION:

Be prepared to collect escaping coolant.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the coolant pipe assembly

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the nut.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the generator.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  1. Disconnect the electrical connector.
  2. Remove the charge air cooler.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the air intake duct.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  1. Remove the Exhaust Gas Recirculation (EGR) inlet.
  2. Remove and discard the gasket.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the heatshield.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  1. Remove the bracket.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the bolt.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  1. Disconnect the electrical connector.
  2. Remove the catalytic converter.
  3. Remove and discard the gasket.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the Power Transfer Unit (PTU) mounting bracket.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the PTU.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the turbocharger outlet duct.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the charge air cooler intake duct.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the nut.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Disconnect the electrical connector

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the breather pipe.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the starter motor.

Vehicles with automatic transmission

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  1. Disconnect the electrical connectors.

CAUTION:

Only rotate the crankshaft clockwise.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove and discard the bolts.

NOTES:

  • Automatic transmission is shown, manual is similar.
  • This step requires the aid of another technician.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the transmission

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Remove the drive plate.

Vehicles with manual transmission

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

Slacken the bolts of the clutch pressure plate each two turns at a time in the sequence shown.

Remove and discard the 6 bolts.

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) Removal

  • Remove and discard the 8 bolts.
  • Remove the flywheel.

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