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

REMOVAL

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).

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).

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

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

Remove the air cleaner.

CAUTION:

Be prepared to collect escaping fuel.

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

CAUTION:

Be prepared to collect escaping fuel.

Remove the fuel filter.

CAUTION:

Be prepared to collect escaping fuel.

Disconnect the fuel supply pipes.

Remove the fuel filter housing.

NOTE:

Repeat the step for the other side.

Release the clip.

CAUTION:

Be prepared to collect escaping fluids.

Release the washer hose.

Remove the cowl panel.

Disconnect the electrical connector.

Remove the bolts.

Remove the Battery Junction Box (BJB) cover.

Remove the BJB.

CAUTION:

Be prepared to collect escaping coolant.

Disconnect the coolant pipes.

CAUTION:

Be prepared to collect escaping coolant.

Disconnect the coolant pipes.

CAUTION:

Be prepared to collect escaping coolant.

Remove the coolant pipes from the fuel cooler.

CAUTION:

Be prepared to collect escaping fuel.

Remove the fuel pipe assembly.

CAUTION:

Be prepared to collect escaping fuel.

Remove the fuel cooler.

Vehicles with manual transmission

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.

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).

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

Remove the glow plug module

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

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.

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.

Using the special tool remove the halfshaft.

Special Tool(s): 205-857

Remove the nuts.

NOTE:

Repeat this step for the other side.

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

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.

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

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.

1. Remove and discard the nuts and gasket.

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.

Remove the accessory drive belt.

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.

Position a suitable wooden block under the engine.

Remove the bolts from the engine mount.

Remove the nuts.

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.

Carefully raise the vehicle on the lift.

1. Install the special tool.

Special Tool(s): JLR-303-1633

2. 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.

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.

Remove the coolant pipe assembly.

CAUTION:

Be prepared to collect escaping coolant.

Remove the coolant pipe assembly

Remove the nut.

Remove the generator.

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

Remove the air intake duct.

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

Remove the heatshield.

1. Remove the bracket.

Remove the bolt.

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

Remove the Power Transfer Unit (PTU) mounting bracket.

Remove the PTU.

Remove the turbocharger outlet duct.

Remove the charge air cooler intake duct.

Remove the nut.

Disconnect the electrical connector

Remove the breather pipe.

Remove the starter motor.

Vehicles with automatic transmission

1. Disconnect the electrical connectors.

CAUTION:

Only rotate the crankshaft clockwise.

Remove and discard the bolts.

NOTES:

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

Remove the transmission

Remove the drive plate.

Vehicles with manual transmission

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

Remove and discard the 6 bolts.

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

Engine - Ingenium i4 2.0l Diesel Engine (G1880413) / (G1880415)Engine - Ingenium i4 2.0l Diesel Engine (G1880415) / Installation

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