Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Engine - Ingenium i4 2.0l Diesel Flexplate (G1875884) / Removal and Installation

Land Rover Discovery (2009–2016) Service Manual / Powertrain / Engine / Engine - Ingenium i4 2.0l Diesel Flexplate (G1875884) / Removal and Installation

SPECIAL TOOL(S)

SPECIAL TOOL(S)

PART(S)

PART(S)

PART(S)

REMOVAL

CAUTION:

Under no circumstances should the flexplate retaining bolts be inserted into the crankshaft with the flexplate removed. Failure to follow this instruction will result in damage to the engine.

NOTE:

  • Some variation in the illustrations may occur, but the essential information is always correct.
  • Some illustrations may show the engine removed for clarity.

Disconnect the battery ground cable.

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

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

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

Remove the charge air cooler.

Refer to: Charge Air Cooler (303-12C Intake Air Distribution and Filtering - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV, Removal and Installation).

Refer to: Transmission - INGENIUM I4 2.0L Diesel (307-01 Automatic Transmission/Transaxle, Removal).

Engine - Ingenium i4 2.0l Diesel Flexplate (G1875884) / Removal and Installation

  1. Disconnect the electrical connector.
  2. Release the wiring harness clips.

Engine - Ingenium i4 2.0l Diesel Flexplate (G1875884) / Removal and Installation

  1. Release the wiring harness clip.
  2. Remove the charge air cooler mounting bracket nuts.

Engine - Ingenium i4 2.0l Diesel Flexplate (G1875884) / Removal and Installation

Remove the charge air cooler mounting bracket.

CAUTION:

  • Only rotate the crankshaft clockwise.
  • The four locating pegs of the special tool must be installed correctly into the crankshaft pulley.

Engine - Ingenium i4 2.0l Diesel Flexplate (G1875884) / Removal and Installation

Install the special tool onto the crankshaft pulley.

Special Tool(s): JLR-303-1630

CAUTION:

Remove and discard the flexplate bolts.

Engine - Ingenium i4 2.0l Diesel Flexplate (G1875884) / Removal and Installation

Remove the flexplate.

INSTALLATION

CAUTION:

Under no circumstances should the flexplate retaining bolts be inserted into the crankshaft with the flexplate removed.

Failure to follow this instruction will result in damage to the engine.

NOTE:

Do not insert the bottoming tap more than the depth of the threaded holes (16mm). Apply tape to the bottoming tap 16mm from the end as a visual guide.

Engine - Ingenium i4 2.0l Diesel Flexplate (G1875884) / Removal and Installation

  1. Using a suitable bottoming tap, clean out the threads.
  2. Using suitable brake cleaner, remove any foreign material from the threads.

NOTES:

  • The flexplate will only locate in one position.
  • Make sure that new flexplate bolts are installed.

Engine - Ingenium i4 2.0l Diesel Flexplate (G1875884) / Removal and Installation

  1. Install the flexplate.
  2. Install and tighten the bolts in the sequence illustrated.

Renew Part: Flexplate bolts.

Torque:

Stage 1: 30 Nm

Stage 2: 120º

Remove the special tool.

Special Tool(s): JLR-303-1630

  1. Install the charge air cooler mounting bracket

Torque: 40 Nm

NOTE:

Make sure the wiring harness is routed correctly.

  1. Remove the charge air cooler mounting bracket nuts.

Torque: 12 Nm

  1. Secure the wiring harness clip.
  1. Connect the electrical connector.
  2. 2. Secure the wiring harness clips.

Refer to: Transmission - INGENIUM I4 2.0L Diesel (307-01 Automatic Transmission/Transaxle, Installation).

Install the charge air cooler.

Refer to: Charge Air Cooler (303-12C Intake Air Distribution and Filtering - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV, Removal and Installation).

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