Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Engine - Ingenium i4 2.0l Diesel Engine (G1880415) / Installation

INSTALLATION

SPECIAL TOOL(S)

SPECIAL TOOL(S)

SPECIAL TOOL(S)

GENERAL EQUIPMENT

Engine hoist (1 tonne minimum capacity)

PART(S)

PART(S)

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

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).

If the engine assembly has been removed for access only then proceed to step 31.

NOTE:

This step requires the aid of another technician.

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

  1. Install the special tool.

Special Tool(s): JLR-303-1633

General Equipment: Engine hoist (1 tonne minimum capacity)

CAUTION:

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

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

Lower the engine on to a suitable wooden block.

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

  • Install the special tool.

Special Tool(s): JLR-303-1630

Vehicles with automatic transmission

NOTE:

The driveplate will only locate in one position.

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

  • Install the driveplate.
  • Install new bolts.

Renew Part: Flexplate bolts.

  • Torque:

Stage 1: 30 Nm

Stage 2: 120º

Vehicles with manual transmission

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

  • Install the flywheel.
  • Install new bolts.

Renew Part: Flywheel bolts.

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

Tighten the retaining bolts in the sequence shown.

Torque:

Stage 1: 30 Nm

Stage 2: 120º

NOTE:

Using a suitable tool make sure the clutch assembly is installed in the released state.

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

  • Install new bolts.

Renew Part: Clutch pressure plate bolts.

  • Follow the indicated sequence and tighten the bolts of the clutch pressure plate each two turns at a time until the specified tightening torque is achieved.

Torque: 29 Nm

Remove the special tool.

All vehicles

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

  • Remove the special tool.

NOTES:

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

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

Install the transmission

Torque: 65 Nm

Vehicles with automatic transmission

CAUTION:

Only rotate the crankshaft clockwise.

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

Install new torque converter bolts.

Renew Part: Torque converter bolts.

Torque: 62 Nm

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

  1. Connect the electrical connectors.

All vehicles

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

Install the starter motor.

Torque: 48 Nm

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

Install the breather pipe.

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

Connect the electrical connector.

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

Install the nut.

Torque: 10 Nm

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

Install the charge air cooler intake duct.

Torque: 8 Nm

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

Install the turbocharger outlet duct.

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

Install the Power Transfer Unit (PTU).

Torque: 60 Nm

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

Install the PTU mounting bracket.

Torque: 60 Nm

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

  1. Connect the electrical connector.
  2. Install a new gasket.

Renew Part: Exhaust pipe to turbocharger gasket.

  1. Install the catalytic converter clamp

Torque: 10 Nm

  1. Install the bolt.

Torque: 24 Nm

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

Install the bolt.

Torque: 24 Nm

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

  1. Install the bracket.

Torque: 24 Nm

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

Install the heatshield.

Torque: 8 Nm

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

  1. Install the Exhaust Gas Recirculation (EGR) inlet.

Torque: 24 Nm

  1. Install a new gasket.

Renew Part: EGR inlet pipe to EGR valve gasket.

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

Install the air intake duct.

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

Install the charge air cooler.

Torque: 7 Nm

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

Install the generator.

Torque: 47 Nm

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

Install the nut.

Torque: 12 Nm

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

Install the coolant pipe assembly

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

Install the coolant pipe assembly.

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

  1. Connect the electrical connector.
  2. Install the coolant pipe assembly.

CAUTION:

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

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

  1. Remove the special tool.

Special Tool(s): JLR-303-1633

CAUTIONS:

  • Lower the vehicle body slowly. Make sure no components are damaged.
  • Make sure the engine and transmission is stable as the vehicle is lowered.

NOTE:

This step requires the aid of another technician.

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

Carefully lower the vehicle on the lift.

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

Install the bolts.

Torque: 175 Nm

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

Install the nuts.

Torque:

M12 80 Nm

M8 25 Nm

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

Install the bolts.

Torque: 175 Nm

  1. Raise the vehicle.
  2. Remove the wooden block

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

  1. Connect the electrical connector.
  2. Install the compressor.

Torque: 25 Nm

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

Install the accessory drive belt.

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

  1. Install the Diesel Particulate Filter (DPF).

Torque: 24 Nm

  1. Install new nuts and a new gasket.

Renew Part: Exhaust downpipe RH to DPF gasket.

Renew Part: Exhaust manifold nuts.

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

  1. Install the differential pressure sensor assembly.

Torque: 6 Nm

  1. Connect the electrical connectors.

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

  1. Install the exhaust clamp.

Torque: 10 Nm

  1. Connect the electrical connector.

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

  1. Install new driveshaft bolts.

Renew Part: Driveshaft flange bolts.

Torque: 40 Nm

NOTE:

Repeat this step for the other side.

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

Install the halfshaft.

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

Install the nuts.

Torque: 25 Nm

CAUTION:

Do not use air tools to install the nut.

NOTE:

Repeat this step for the other side.

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

Install new hub nuts.

Renew Part: Front halfshaft nut.

Torque:

Stage 1: 100 Nm

Stage 2: 90º

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

Push the engine wiring harness through the engine compartment in to the front left wheel arch.

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

  1. Install the glow plug module support bracket.

Torque: 10 Nm

  1. Install the wiring harness on to the glow plug module support bracket.

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

Install the glow plug module.

Torque: 10 Nm

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

  1. Connect the electrical connector on to the wiring harness.
  2. Connect the electrical connectors on to the glow plug module.

Install the front subframe.

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

Vehicles with manual transmission

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

Connect the cables.

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

  1. Connect the electrical connectors.
  2. Install the bracket.

Torque: 10 Nm

All vehicles

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

Install the fuel cooler.

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

Install the fuel pipe assembly.

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

Install the coolant pipes from the fuel cooler.

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

Connect the coolant pipes.

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

Connect the coolant pipes.

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

Install the Battery Junction Box (BJB)

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

Install the BJB cover.

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

Install the bolts.

Torque: 10 Nm

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

Connect the electrical connectors.

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

Install the cowl panel.

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

Connect the washer hose.

NOTE:

Repeat the step for the other side.

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

Install the clip.

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

Install the fuel filter housing.

Torque: 24 Nm

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

Connect the fuel supply pipes.

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

Install the fuel filter.

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

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

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

Install the air cleaner.

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

  1. Install the clean air duct.
  2. Install a new O-ring seal.

Renew Part: Turbocharger inlet pipe seal.

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

  1. Install the air pipe to the air cleaner.
  2. Connect the electrical connector.

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

Install the battery tray.

Torque: 10 Nm

Install the battery.

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

Fill the coolant system.

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

Install the engine cover.

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

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