Land Rover Discovery: Engine and Ancillaries (G1977457) Removal

Removal

SPECIAL TOOL(S)

GENERAL EQUIPMENT

Engine hoist (1 tonne minimum capacity)

PART(S)

NOTES:

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

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

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

Disconnect the battery ground cable.

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

Remove the engine assembly.

Refer to: Engine (303-01B Engine - INGENIUM I4 2.0L Diesel, Removal).

1. Mount the engine stand to the lower timing cover.
2. Remove the special tool.

Special Tool(s): JLR-303-1633

General Equipment: Engine hoist (1 tonne minimum capacity)

CAUTIONS:

• Be prepared to collect escaping oil.
• Allow at least 10 minutes for the engine oil to drain.

Drain the engine oil.

• Install the oil pan plug removed in the previous step.

Torque: 23 Nm

Release the harness.

Release the harness.

Release the harness.

CAUTION:

Make sure the wiring harness and electrical connectors are not damaged during this operation.

NOTE:

Note the position of the wiring harnesses to aid installation.

Remove the engine wiring harness.

Remove the NVH insulation.

Remove the water pump pulley.

NOTES:

• This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.
• The coolant pump is to be fitted to the new engine.

Remove the coolant pump.

Remove the accessory drive component bracket.

Remove the accessory drive belt idler.

• Release the 3 clips.
• Remove the bolt.
• Remove the oil level indicator and vacuum tube.
• Discard the O-ring seal.

Renew Part: Oil level gauge O-ring seal.

Release the coolant hoses.

• Remove the thermostat and hose assembly.
• Remove and discard the gasket.

Renew Part: Thermostat to cylinder block gasket.

Release the coolant hose.

Remove the engine mount.

1. Remove the coolant pump inlet channel.
2. Remove and discard the O-ring seal.

Renew Part: Coolant pump inlet O-ring seal.

NOTE:

If equipped.

Remove the block heater.

• Remove the electrical harness clip.
• Remove the NVH pad.

Remove the 2 brackets.

• Remove the 5 bolts.

2. Remove the clips.

• Remove the EGR pipe.
• Discard the O-ring seal.
• Discard the gasket.

Renew Part: High pressure exhaust gas recirculation valve Oring seal.

Renew Part: High pressure exhaust gas recirculation valve gasket.

CAUTION:

If accidentally dropped or knocked install a new glow plug.

Remove the glow plugs.

Remove and discard the engine number label.

Renew Part: Engine number label.

NOTE:

This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

• Remove the inlet manifold complete with throttle body.
• Remove and discard the intake manifold gaskets.

Renew Part: Intake manifold gaskets.

CAUTIONS:

• Be prepared to collect escaping fuel.
• Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

• Remove and discard the high pressure fuel pipe.
• Install suitable blanking caps to the fuel lines and unions.

Renew Part: Fuel rail supply pipe.

Disconnect and release the fuel return pipes.

CAUTION:

Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

• Remove and discard the 4 high-pressure fuel supply lines.
• Install blanking caps to the exposed ports.

Renew Part: Fuel injector high pressure pipes.

• Remove the 2 bolts.
• Remove the fuel rail.

• Release the bracket.
• Release the 3 hoses.

NOTE:

This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

Release the EGR cooler.

1. Remove the EGR assembly.
2. Discard the gasket.

Renew Part: EGR cooler to EGR valve gasket.

NOTE:

This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

Remove the breather tube.

• Remove the bolt.
• Push the oil drain tube into the engine and release it from the turbocharger.
• Rotate the oil drain tube and remove it from the engine.
• Remove and discard the 2 O-ring seals.

Renew Part: Turbocharger oil return pipe seals.

Release the coolant hose.

1. Remove the EGR assembly.
2. Remove and discard the gasket.

Renew Part: High pressure exhaust gas recirculation valve gasket.

Remove the heat shield.

• Remove the banjo bolt.
• Remove and discard the sealing washers.

Renew Part: Turbocharger oil feed pipe banjo bolt washers

Release the turbocharger.

• Remove the turbocharger.
• Remove and discard the gasket.

Renew Part: Turbocharger to exhaust manifold gasket.

• Remove the EGR valve.
• Remove and discard the O-ring seal.

Renew Part: EGR valve to turbocharger O-ring seal.

• Remove the 2 bolts.
• Remove the exhaust manifold heat shield.

• Remove the 8 bolts.
• Discard the spacers and the bolts.
• Remove the exhaust manifold.
• Remove and discard the gasket.

Renew Part: Exhaust manifold bolts and spacers.

Renew Part: Exhaust manifold gasket.

NOTE:

This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

• Remove the 7 bolts.
• Remove the oil cooler.
• Discard the gasket.

Renew Part: Oil cooler gasket.

Remove the engine oil filter.

Refer to: Oil Filter Element (303-01B Engine - INGENIUM I4 2.0L Diesel, Removal and Installation).

NOTE:

This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

• Remove the 3 bolts.
• Remove the oil filter housing.

Remove and discard the 5 O-ring seals..

Renew Part: Oil filter housing inlet / outlet O-ring seals.

NOTE:

This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

• Remove the bolt.
• Remove the Crankshaft Position (CKP) sensor.

NOTE:

This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

Remove the oil filler cap and neck.

NOTE:

This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

• Remove the bolt.
• Remove the camshaft position (CMP) sensor.

NOTE:

This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

Remove the Variable Camshaft Timing (VCT) solenoid.

NOTE:

This component uses self tapping bolts. These bolts must be kept to cut the thread on the new engine as they may be supplied with untapped bolt holes.

• Remove the 8 bolts.
• Remove the engine vent oil separator.
• Remove and discard the gasket.

Renew Part: Engine vent oil separator to valve cover gasket.

• Remove and discard the 4 bolts.
• Remove the fuel injector retaining clamps.

Renew Part: Fuel injector clamp bolts.

• Special Tool(s): 100-012
• Special Tool(s): JLR-310-253

Using the special tool, remove the fuel injectors.

Remove and discard the fuel injector seal.

Renew Part: Fuel injector seal.

Engine - Ingenium i4 2.0l Diesel Engine and AncillariesEngine and Ancillaries (G1977459) / Installation

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