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

SPECIAL TOOL(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).

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

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

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.

Install the special tool onto the crankshaft pulley.

Special Tool(s): JLR-303-1630

CAUTION:

Remove and discard the flexplate bolts.

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.

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.

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

4. 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

2. 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).

Engine - Ingenium i4 2.0l Diesel Engine Upper Support Insulator (G1923644) / Removal and InstallationEngine - Ingenium i4 2.0l Diesel Flywheel (G1875896) / Removal and Installation

READ NEXT: