Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) / Installation

Land Rover Discovery (2009–2016) Service Manual / Powertrain / Engine / Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) / Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) / Installation

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Remove the component.

Special Tool(s): JLR-303-1627

NOTE:

Lubricate the seal with clean engine oil.

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

CAUTION:

Extreme cleanliness must be exercised when handling this component.

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

CAUTION:

Make sure that the area around the component is clean and free of foreign material.

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Torque: 25 Nm

CAUTION:

Make sure that the area around the component is clean and free of foreign material.

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Torque: 25 Nm

CAUTION:

Only tighten the nut and bolts finger tight at this stage.

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Special Tool(s): JLR-303-1627

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Loosen the bolts as indicated in the illustration.

Special Tool(s): JLR-303-1627

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Special Tool(s): JLR-303-1627

Torque: 80 Nm

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Remove the bolts.

Special Tool(s): JLR-303-1627

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Remove the special tool.

Special Tool(s): JLR-303-1627

NOTE:

Lubricate the O-ring seal with clean engine oil.

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Torque: 11 Nm

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

CAUTION:

Install a new high-pressure fuel supply pipe.

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Install the high-pressure fuel pipe and tighten the high-pressure fuel pipe union finger tight.

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Install the high-pressure fuel pipe to the fuel rail union finger tight.

NOTES:

  • Make sure the clamp tang sits in the recess of the cylinder head.
  • Make sure the mounting face of the clamp is flush to the cylinder head.

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

  1. Tighten the high-pressure fuel pipe clamp bolt.

Torque: 12 Nm

Loosen: 90º

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Tighten the high-pressure fuel pipe to the fuel pump union.

Torque: 15 Nm

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Tighten the high-pressure fuel pipe to the fuel pump union 60º. This is the equivalent of one flat on the fuel pipe union, as illustrated.

Torque: 60º

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Tighten the high-pressure fuel pipe to the fuel rail union.

Torque:

Stage 1: 10 Nm

Stage 2: 60º

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Tighten the high-pressure fuel pipe clamp bolt.

Torque: 12 Nm

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Torque: 11 Nm

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Torque: 9 Nm

NOTE:

Remove and discard the gasket.

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Torque: 11 Nm

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

NOTE:

Make sure that a new gasket and O-ring seal are installed.

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Torque:

M6x20 7 Nm

M6x25 11 Nm

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Torque: 11 Nm

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Fuel Pump (G1875960) Installation

Install the noise, vibration and harshness (NVH) material.

Refer to: Radiator (303-03B Engine Cooling - INGENIUM I4 2.0L Diesel, Removal and Installation).

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

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

CAUTION:

Bleed the fuel system by cranking the engine to purge the air from the system.

Bleed the fuel system.

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