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ENGINE COOLING - INGENIUM I4 2.0L PETROL

T H E R M O STAT H O U S I N G - R B O M (G4424364)

PART(S)

ALL VEHICLES

Name Quantity Part Number

Intake manifold gasket(s) 4 -

Thermostat Housing (Main Component) 1 -

SPECIAL TOOL(S)

ALL VEHICLES

Adaptor, Cooling System Vacuum Refill Kit

JLR-303-1634

Coolant System Vacuum Refill Kit

HU-919

R E PA I R

Thermostat Housing (303-03B REMOVAL AND INSTALLATION G4231290)

PUBLISHED: 29-FEB-2024
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ENGINE COOLING - INGENIUM I4 2.0L PETROL

T H E R M O STAT H O U S I N G (G4231290)

R E M O VA L A N D I N S TA L L AT I O N

REMOVAL

NOTE:

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.

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

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

2. Remove the engine cover.

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

3. Partially drain the cooling system.

Refer to: Cooling System Draining and Vacuum Filling (303-03B Engine Cooling - INGENIUM I4 2.0L
Petrol, General Procedures).

4. Remove the intake manifold.

Refer to: Intake Manifold (303-01B Engine - INGENIUM I4 2.0L Petrol, Removal and Installation).
Refer to: Intake Manifold (303-01B Engine - INGENIUM I4 2.0L Petrol, Removal and Installation).

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5.

Remove the Noise, Vibration and Harshness (NVH) pad.

6.
CAUTIONS:

Be prepared to collect escaping coolant.

Mark the position of the components prior to removal.

Release the coolant hoses.

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7.

Remove the coolant outlet hose from the thermostat housing.

8.

Release the breather pipe.

Disconnect the electrical connector.

Remove the purge valve assembly.

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9.

Remove the coolant bypass hose from the thermostat housing.

10.

Disconnect the electrical connectors.

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11.

Remove the thermostat housing.

INSTALL ATION

1.
Install the thermostat housing.
Torque: 12Nm

2. Connect the 2 electrical connectors.

3.
Connect the coolant bypass hose to the thermostat housing.
Torque: 7Nm

4.
Install the purge valve assembly.

Install the breather pipe.

Connect the electrical connector.

5. Connect the coolant outlet hose to the thermostat housing.

6. Connect the 2 coolant hoses.

7. Install the NVH pad.

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8. Install the intake manifold.

Refer to: Intake Manifold (303-01B Engine - INGENIUM I4 2.0L Petrol, Removal and Installation).
Refer to: Intake Manifold (303-01B Engine - INGENIUM I4 2.0L Petrol, Removal and Installation).

9. Fill the cooling system.

Refer to: Cooling System Draining and Vacuum Filling (303-03B Engine Cooling - INGENIUM I4 2.0L
Petrol, General Procedures).

10. Install the engine cover.

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

CO O L I N G SYST E M D R A I N I N G A N D
VAC U U M F I L L I N G ( G 2 8 1 9 0 7 9 )

GENERAL PROCEDURES

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SPECIAL TOOL(S)

HU-919
Coolant System Vacuum Refill Kit

JLR-303-1634
Adaptor, Cooling System Vacuum Refill Kit

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DRAINING

WARNING:

Injury such as scalding could be caused by escaping steam or coolant. Make sure the vehicle cooling
system is cool prior to carrying out this procedure.

CAUTIONS:

The cooling system must be maintained with the correct concentration and type of engine coolant
solution to prevent corrosion and frost damage. Failure to follow this instruction may result in
damage to the engine.

Coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean
the area with water.

Never remove the coolant expansion tank cap under any circumstances while the engine is
operating. Failure to follow this instruction may result in damage to the engine.

NOTE:

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.

1. Complete the procedure from step 7 in the draining section up to step 35 in the filling section 3
times, filling the cooling system with clean water after the first 2 drains.

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

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

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3.
WARNING:

Release the cooling system pressure by slowly turning the coolant expansion tank cap a
quarter of a turn. Cover the coolant expansion tank cap with a thick cloth to prevent the
possibility of scalding. Failure to follow this instruction may result in personal injury.

CAUTION:

Be prepared to collect escaping coolant.

Remove the coolant expansion tank cap.

4. Remove 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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5.
NOTE:

If equipped.

Remove the front tow eye cover.

6. Remove the engine undershield.

Refer to: Engine Undershield (501-02 Front End Body Panels, Removal and Installation).

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7.
CAUTIONS:

Be prepared to collect escaping fluids.

Record the volume of coolant drained from the vehicle.

Remove the radiator drain plug and allow the coolant to drain into a suitable container.

Install the radiator drain plug.

Torque: 3.5Nm

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8.
CAUTIONS:

Be prepared to collect escaping fluids.

Record the volume of coolant drained from the vehicle.

Disconnect the right side auxiliary radiator hose and allow the coolant to drain into a suitable
container.

Connect the right side auxiliary radiator hose.

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9.
CAUTIONS:

Be prepared to collect escaping fluids.

Record the volume of coolant drained from the vehicle.

Disconnect the left side auxiliary radiator hose and allow the coolant to drain into a suitable
container.

Connect the left side auxiliary radiator hose.

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10.
CAUTIONS:

Be prepared to collect escaping fluids.

Record the volume of coolant drained from the vehicle.

Disconnect the charge air cooler radiator hose and allow the coolant to drain into a suitable
container.

Connect the charge air cooler radiator hose.

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11.
CAUTIONS:

Be prepared to collect escaping fluids.

Record the volume of coolant drained from the vehicle.

Disconnect the transmission oil cooler inlet hose from the radiator and allow the coolant to
drain into a suitable container.

Connect the transmission oil cooler inlet hose.

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12.
CAUTIONS:

Be prepared to collect escaping fluids.

Record the volume of coolant drained from the vehicle.

Disconnect the heater core hose and allow the coolant to drain into a suitable container.

Connect the heater core hose.

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13.
CAUTIONS:

Be prepared to collect escaping fluids.

Record the volume of coolant drained from the vehicle.

Disconnect the radiator top hose and allow the coolant to drain into a suitable container.

Connect the radiator top hose.

14. Record the total volume of coolant drained from the vehicle.

FILLING

The following step(s) applies to:

 All vehicles

1. Install the front tow eye cover.

Torque: 7Nm

2.
NOTE:

The drained coolant can be reused.

Prepare a sufficient amount of coolant to the specified concentration.

Refer to: Specifications (303-03B Engine Cooling - INGENIUM I4 2.0L Petrol, Specifications).

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3.
CAUTION:

Make sure the air ejecting from the vac fill tool is pointed away from the vehicle.

NOTES:

Make sure the coolant volume in the container is greater than the amount of coolant the
vehicle requires.

Make sure the coolant supply valve is in the closed position on the special tool.

The special tool needs an air pressure of 6 to 8 bar (87 to 116 psi) to operate correctly.

Small diameter or long airlines may restrict airflow to the coolant vacuum fill tool.

Install the special tools.

Special Tool(s): JLR-303-1634, HU-919

Connect the hose from the vacuum refill adapter into a container of clean coolant, making
sure the hose is submerged in coolant at all times during the fill operation.

Connect a regulated compressed air supply to the venturi tube assembly.

Install the cooling system vacuum refill adapter to the expansion tank.

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4.
NOTE:

Make sure the coolant supply valve is in the closed position on the vacuum filler
gauge assembly.

The coolant vacuum fill tool needs an air pressure of 6 to 8 bar (87 to 116 psi) to
operate correctly.

Small diameter or long airlines may restrict airflow to the coolant vacuum fill tool.

Open the air supply valve until -0.8 (-12 psi) Bar is shown on the gauge.

5.

Close the air supply valve.

Allow 1 minute to check the vacuum is held.

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6.

Open the coolant supply valve and allow the coolant to be drawn into the system until the header
tank is at least half full and no further fluid is entering the tank. If the fill process appears to stop
and the header tank is not yet half full then stop the fill process, remove the tool and restart the
cooling system draining and vacuum filling procedure.

7. Remove the special tools.

8. Check and top-up the coolant to MAX.

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9.
CAUTIONS:

Make sure that the mating faces are clean and free of foreign material.

Do not exceed 1.0 bar (15 psi) when pressurizing the cooling system.

NOTE:

If the pressure continues to drop after the initial tolerance, there is a coolant leak.

Using the correct adapter connect the cooling system pressure test kit to the vehicle
expansion tank.

Slowly pressurize the cooling system until the pressure gauge reads 1.0 bar (15 psi).

Make sure the cooling system holds pressure, and continue to step 10 to bleed coolant from
the bleed points.

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The following step(s) applies to:

 Vehicles built 2021 onwards

10.
NOTES:

Make sure the hood is open.

Make sure the engine is not running.

1. Switch the Ignition ON and select the park position (car in Parking (P) or Neutral (N)
mode).

2. Open the driver’s door.

3. Fully press the accelerator pedal for 10 seconds.

4. Fully release the accelerator pedal.

5. Electric coolant pump will be activated for 5 minutes.

6. Monitoring the engine coolant level in the engine coolant expansion tank.

7. After 5 minutes, increase the system pressure until 1 bar is showed in the gauge, if
needed.

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The following step(s) applies to:

 All vehicles

11.

Open the bleed screw, when coolant is visible from the outlet close the bleeding point.
Torque: 2Nm

12.

Open the bleed screw, when coolant is visible from the outlet close the bleeding point.
Torque: 2Nm

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13.

Open the bleed screw, when coolant is visible from the outlet close the bleeding point.
Torque: 2Nm

14.

Release the front finisher and position to one side.

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15.

Open the bleed screw, when coolant is visible from the outlet close the bleeding point.
Torque: 2Nm

16.

Reposition the front finisher in the correct location and install the retaining clip.

Install the 3 retaining bolts and tighten to the correct torque

Torque: 9Nm

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17.

Depressurize and remove the cooling system pressure tester.

Check and top-up the coolant to MAX.

18.
CAUTION:

Correct installation of the coolant expansion tank cap can be obtained by tightening the
cap until 3 audible clicks are heard.

Install the coolant expansion tank cap.

19. Connect exhaust extraction hoses to the tail pipes.

20.
Select sand driving/dynamic mode if available.

Make sure the interior heater is switched off.

21. Start and run the engine and allow to idle for 30 seconds.

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22.
CAUTION:

Make sure to observe the coolant level at all times and top up to the MAX mark as
required.

Hold the engine speed at 3500 rpm until the cooling fan starts to run and the thermostat opens,
this will be evident as the radiator side coolant temperature will rise as coolant starts to flow around
the radiator.

23. Switch the engine off and allow the engine to cool.

24.
WARNING:

Release the cooling system pressure by slowly turning the coolant expansion tank cap a
quarter of a turn. Cover the expansion tank cap with a thick cloth to prevent the possibility
of scalding. Failure to follow this instruction may result in personal injury.

Remove the coolant expansion tank pressure cap.

Maintain the coolant level in the coolant expansion tank at the MAX mark.

25.
CAUTION:

Correct installation of the coolant expansion tank cap can be obtained by tightening the
cap until 3 audible clicks are heard.

Install the coolant expansion tank cap.

26. Install the engine undershield.

Refer to: Engine Undershield (501-02 Front End Body Panels, Removal and Installation).
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ENGINE - INGENIUM I4 2.0L PETROL

I N TA K E M A N I F O L D (G2029661)

R E M O VA L A N D I N S TA L L AT I O N

GENERAL EQUIPMENT

EQUIPMENT NAME

2 post lift

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PART(S)

STEP PART NAME QUANTITY

Installation Step 3 Intake manifold seals 1

Installation Step 1 Throttle body to intake manifold seal 4

REMOVAL

WARNING:

Be prepared to collect escaping coolant.

NOTE:

This procedure contains some variation in the illustration depending on the vehicle specification,
but essential information is always correct.

This procedure contains illustrations showing certain components removed to provide extra
clarity.

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

Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
General Equipment: 2 post lift

2. Disconnect the startup battery ground cable.

Refer to: Startup Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General
Procedures).

3. Drain the coolant system.

Refer to: Cooling System Draining and Vacuum Filling (303-03B Engine Cooling - INGENIUM I4 2.0L
Petrol, General Procedures).

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4.

Remove the engine cover.

5.

Remove the front Noise, Vibration and Harshness (NVH) material.

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6.
NOTE:

If equipped.

Remove the NVH material.

7.

Remove the breather.

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8.

Disconnect the upper coolant hose.

9.

Remove the upper coolant pipe.

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10.

Remove the purge valve.

11.

Release the vacuum pipe.

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12.

Remove the lower coolant pipe.

13.

Disconnect and release the wiring harness.

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14.

Disconnect and release the wiring harness.

15.

Disconnect the charge air pipe.

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16.

Disconnect the oil level gauge from the intake manifold assembly.

17.

Disconnect the coolant hose from the thermostat assembly.

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18.

Release the 7 bolts and then remove the intake manifold.

19.

Remove and discard the intake manifold gaskets.

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20.
NOTE:

Do not disassemble further if the component is removed for access only.

Remove the manifold absolute pressure sensor.

21.

Remove the throttle body. Discard the seal.

INSTALL ATION

NOTE:

Only perform steps 1 and 2 if the components were previously removed.

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1. Install the throttle body. Renew the seal.

Renew Part: Throttle body to intake manifold seal Quantity: 4.
Torque: 12Nm

2.
CAUTION:

Inspect the seal and renew the component if damaged or worn.

Install the manifold absolute pressure sensor.

Torque: 5Nm

3. Install the intake manifold assembly. Renew the seals.

Renew Part: Intake manifold seals Quantity: 1.
Torque: 12Nm

4. Connect the coolant pipe to the thermostat assembly.

5. Install the oil level gauge.

Torque: 8Nm

6. Connect the charge air pipe.

7. Connect and secure the wiring harnesses.

8. Install the vacuum pipe.

9. Install the purge valve.

10. Install the lower coolant pipe.

Torque: 10Nm

11. Install the upper coolant pipe.

Torque: 10Nm

12. Connect the upper coolant hose.

13. Install the breather.

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14.
NOTE:

If equipped.

Install the rear NVH material.

Torque: 8Nm

15. Install the front NVH material.

16. Install the engine cover.

17. Fill the coolant system.

Refer to: Cooling System Draining and Vacuum Filling (303-03B Engine Cooling - INGENIUM I4 2.0L
Petrol, General Procedures).

18. Connect the battery startup ground cable.

Refer to: Startup Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General
Procedures).

19. Lower the vehicle.

ai1tYXJxODY7MjAyNS0wMS0zMVQxODoxNTozNi4zMzRaOzE4MS4xMTguNTMuMzU7

PUBLISHED: 19-JAN-2017
2 0 1 9 . 0 R A N G E R O V E R V E L A R ( LY ) , 5 0 1 - 0 5

INTERIOR TRIM AND ORNAMENTATION

E N G I N E COV E R - I N G E N I U M I 4 2 . 0 L
PETROL (G2020024)

R E M O VA L A N D I N S TA L L AT I O N

REMOVAL

NOTES:

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.

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1.

Remove the engine cover.

2.

Remove the Noise, Vibration and Harshness (NVH) pad.

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INSTALL ATION

1.
CAUTION:

Make sure that the component is correctly located.

Install the NVH pad.

2. Install the engine cover.

ai1tYXJxODY7MjAyNS0wMS0zMVQxODoxNTozNi45MjRaOzE4MS4xMTguNTMuMzU7

PUBLISHED: 25-JUN-2019
2 0 1 9 . 0 R A N G E R O V E R V E L A R ( LY ) , 1 0 0 - 0 2

JACKING AND LIFTING

LIFTING (G2005995)

D E S C R I P T I O N A N D O P E R AT I O N

LIFTING AND SUPPORT POINTS

CAUTIONS:

Do not allow the hoist adapters to contact the steering linkage, suspension arms, stabilizer bar,
rear subframe stabilizer brackets or to compress the lower suspension arm stabilizer bar insulator.
Damage to the suspension, exhaust and steering linkage components may occur if care is not
exercised when positioning the hoist adapters of two-post hoists prior to lifting the vehicle.

Never use the differential housing as a lift point. Damage to the differential housing and cover
may occur.

When using a floor jack, a cushioned pad must be utilized to avoid body damage.

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1 Twin-post hoist and floor jack points

2 Axle stand support points

VEHICLE RECOVERY

NOTE:

Prior to vehicle recovery, make sure that the vehicle keys are available and the security system is
disarmed.

Vehicle recovery methods are:

By flat-bed transporter.

By rear suspended tow.

By rear suspended tow.

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TRANSPORTER OR TRAILER RECOVERY

When the vehicle is being recovered by transporter or trailer:

The parking brake must be applied and the wheels chocked.

The gear selector lever must be in Neutral. Do not select Park on automatic transmission vehicles, as the
parking lock mechanism may be damaged by the forward and backward rocking motion of the vehicle.

The vehicle must be securely tied down to the transporter or trailer.

REAR SUSPENDED TOW

When the vehicle is being recovered by rear suspended tow:

The ignition key must be removed from the ignition switch to lock the steering.

The rear wheels must be correctly positioned in the lifting cradle and securely tied down.

EMERGENCY TOWING

WARNING:

If the engine is not running, the steering will become heavy and the force necessary to effectively
apply the brakes will be greatly increased.

CAUTION:

A vehicle with a defective transmission must be towed by rear suspended tow.

When the vehicle is being towed on its own wheels:

Local regulations for the towing of vehicles must be followed. In some countries the registration number of
the towing vehicle and an On Tow sign or warning triangle must be displayed at the rear of the towed

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vehicle.

The gear selector lever must be in Neutral.

The ignition switch must be in position II to release the steering lock and make the direction indicators,
horn and stop lamps operate.

A distance of 0,8 km (0.5 mile) must not be exceeded.

A speed of 48 km/h (30 mph) must not be exceeded.

The tow rope must be attached to the front towing eye.

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