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PUBLISHED: 04-FEB-2020
2016.0 DISCOVERY SPORT (LC), 303-01B

ENGINE - INGENIUM I4 2.0L DIESEL

(G2094356)

S P E C I F I C AT I O N S

Lubricants, Fluids, Sealers and Adhesives

SPECIFICATIONS

Oil pan to block sealant Loctite 5970 BM Black

Engine Oil SAE 0W30 STJLR.03.5007

Capacities

LITERS

Service fill including filter - High Spec engines 7.02

Service fill including filter - Mid spec engines 6.52

General Specification

ITEM SPECIFICATION

Type 2.0 litre, inline 4, turbocharged and intercooled diesel

engine, twin overhead camshaft, 4 valves per cylinder

Cylinder arrangement Inline 4

Cylinder numbering No.1 from the accessory drive end

Bore - nominal 83.0 mm (3.270 in)

Stroke 92.4 mm (3.640 in)

Capacity 1999 cm³ (121.9 in³)

Firing order 1-3-4-2

Compression ratio 15.5:1

Direction of rotation Clockwise viewed at FEAD

Cylinder head maximum permitted warp (flatness specification) 0.2 mm (0.008 in)

Cylinder block maximum permitted warp (flatness specification) 0.15 mm (0.006 in)

Maximum power/torque - Eco spec

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ITEM SPECIFICATION

Maximum power 110 kW (150 ps) @ 4000rpm

Maximum Torque 380 Nm (280 lb/ft) @ 1750 - 2500rpm

Maximum power/torque - Mid spec

Maximum power 132 kW (180 ps) @ 4000rpm

Maximum Torque 430 Nm (317 lb/ft) @ 1750 - 2500rpm

Engine oil pressure*:

Note: For a Mid spec engine running with low load at 80 °C

engine oil temp, the minimum oil pressure requirement is:-

At 1750 rev/min 1.4 bar/140 kPa/20 lb/in²

At 4000 rev/min 2.9 bar/290 kPa/42 lb/in²

Crankshaft end play:

Minimum 0.15 mm

Maximum 0.35 mm

Main bearing clearance:

Minimum 0.030 mm

Maximum 0.054 mm

Main bearing Selection - Eco spec

BEARING GRADE COLOR CRANKSHAFT JOURNAL DIAMETER CYLINDER BLOCK BORE DIAMETER

Green 54.979 to 54.980 mm 59.031 to 59.032 mm

Blue 54.979 to 54.980 mm 59.014 to 59.032 mm

Yellow 54.981 to 54.996 mm 59.031 to 59.032 mm

Red 54.997 to 55.000 mm 59.014 to 59.017 mm

Main bearing Selection - Mid spec

BEARING GRADE COLOR CRANKSHAFT JOURNAL DIAMETER CYLINDER BLOCK BORE DIAMETER

Green 58.979 to 58.980 mm 63.031 to 63.032 mm

Blue 58.979 to 58.980 mm 63.014 to 63.032 mm

Yellow 58.981 to 58.996 mm 63.031 to 63.032 mm

Red 58.997 to 59.000 mm 63.014 to 63.017 mm

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Cylinder Head Gasket Selection

PISTON PROTRUSION THICKNESS OF COMPRESSED GASKET NUMBER OF HOLES/IDENTIFICATION MARKS

0.694 to 0.739 mm 1.30 mm 1

0.740 to 0.861 mm 1.40 mm 2

0.862 to 0.939 mm 1.50 mm 3

0.940 to 1.06 mm 1.60 mm 4

1.061 to 1.106 mm 1.70 mm 5

Torque Specifications

DESCRIPTION NM LB-FT

Crankshaft main bearing cap retaining bolts: *

Stage 1 25 18

Stage 2 58 43

Stage 3 135° 135°

Stage 4 Loosen retaining bolts Loosen retaining bolts

Stage 5 25 18

Stage 6 37 27

Stage 7 135° 135°

Intermediate gear retaining nut 92 68

Connecting rod cap retaining bolts:

Stage 1 20 15

Stage 2 125° 125°

Piston cooling jet retaining bolts 12 9

Windage tray retaining bolts 12 9

Oil pump retaining bolts 25 18

Oil pump chain tensioner retaining bolt 12 9

Oil pump pick-up pipe retaining bolts 12 9

Oil pump chain sprocket retaining bolt:

Stage 1 60 44

Stage 2 90° 90°

Engine oil drain plug 25 18

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DESCRIPTION NM LB-FT

Oil pan retaining bolts 25 18

Fuel pump retaining bolts 25 18

Fuel pump sprocket retaining nut * 80 59

Lower timing chain sprocket retaining bolt 35 26

Lower timing chain guide retaining bolts 25 18

Lower timing chain lever retaining nut 12 9

Lower timing chain tensioner retaining bolts 12 9

Lower timing chain cover retaining bolts 25 18

Piston cooling jet solenoid 12 9

Oil cooler retaining bolts 25 18

Engine mount bracket retaining bolts 63 46

Vacuum hose connection retaining bolt 5 4

Cylinder head retaining bolts A A

Camshaft cap retaining bolts 12 9

Camshaft carrier retaining bolts:

Stage 1 7 5

Stage 2 (M8x40) 15 11

Stage 3 (M8x80) 25 18

Upper timing chain guide retaining bolt 25 18

Upper timing chain tensioner 55 41

Intake camshaft sprocket retaining bolt:

Stage 1 10 7

Stage 2 Loosen ¼ of a turn Loosen ¼ of a turn

Stage 3 80 59

Stage 4 90° 90°

Variable camshaft unit retaining bolt: *

Stage 1 10 7

Stage 2 Loosen ¼ of a turn Loosen ¼ of a turn

Stage 3 25 18

Stage 4 40° 40°

Engine front cover retaining bolts 12 9

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DESCRIPTION NM LB-FT

Idler pulley retaining bolt 25 18

Coolant pump retaining bolts 12 9

Crankshaft pulley bolts:

Stage 1 37 27

Stage 2 90° 90°

Camshaft position (CMP) sensor retaining bolt 8 6

Upper timing chain cover retaining bolts 12 9

Variable camshaft timing solenoid retaining bolts 9 7

Glow plug 18 13

Fuel injector clamp retaining bolts:

Stage 1 11 8

Stage 2 162° 162°

Fuel rail retaining bolts 25 18

Fuel rail high-pressure fuel line unions:

Stage 1 10 7

Stage 2 62° 62°

Valve cover retaining bolts 12 9

oil filter housing retaining bolts 12 9

Cylinder head temperature (CHT) sensor 11 8

Intake manifold retaining bolts 12 9

Intake manifold support retaining bolts 12 9

Fuel pump to fuel rail fuel line bracket retaining bolt 10 7

Fuel pump high-pressure fuel line union:

Stage 1 15 11

Stage 2 62° 62°

Cylinder block temperature sensor 11 8

Thermostat retaining bolts 12 9

Coolant pump intake elbow retaining bolts 25 18

Lower pressure exhaust gas recirculation (EGR) cooler retaining bracket bolts 12 9

Exhaust manifold retaining bolts 18 13

Exhaust manifold heatshield retaining bolts 9 7

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DESCRIPTION NM LB-FT

Turbocharger to exhaust manifold retaining nuts 27 20

Turbocharger heatshield retaining bolts 9 7

Turbocharger support bracket retaining bolts:

Stage 1 (M8x20) 7 5

Stage 2 (M8x20) 25 18

Stage 3 (M8x25) 25 18

Stage 4 (M6x14) 9 7

Turbocharger oil feed pipe unions 18 13

Turbocharger oil drain tube retaining bolt 12 9

High pressure EGR valve retaining bolts 12 9

EGR crossover pipe retaining bolts:

Stage 1 12 9

Stage 2 Loosen ¼ of a turn Loosen ¼ of a turn

Stage 3 12 9

High pressure EGR pipe to intake manifold retaining bolts:

Stage 1 7 5

Stage 2 Loosen ¼ of a turn Loosen ¼ of a turn

Stage 3 7 5

High pressure EGR pipe to high pressure EGR valve retaining bolts:

Stage 1 12 9

Stage 2 Loosen ¼ of a turn Loosen ¼ of a turn

Stage 3 12 9

High pressure EGR cooler clamp 4 3

High pressure EGR cooler upper retaining bolt:

Stage 1 12 9

Stage 2 Loosen ¼ of a turn Loosen ¼ of a turn

Stage 3 12 9

High pressure EGR cooler to high pressure EGR valve retaining bolts:

Stage 1 12 9

Stage 2 Loosen ¼ of a turn Loosen ¼ of a turn

Stage 3 12 9

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DESCRIPTION NM LB-FT

High pressure EGR cooler lower retaining bolt:

Stage 1 7 5

Stage 2 Loosen ¼ of a turn Loosen ¼ of a turn

Stage 3 7 5

Low pressure EGR cooler retaining bolt:

Stage 1 25 18

Stage 2 Loosen ¼ of a turn Loosen ¼ of a turn

Stage 3 25 18

Low pressure EGR valve retaining bolts 25 18

Turbocharger support bracket retaining bolts 25 18

Turbocharger intake pipe retaining bolts 25 18

Coolant pump inlet elbow retaining bolts 25 18

Low pressure EGR temperature sensor 3 2.2

High pressure EGR temperature sensor 3 2.2

EGR pressure sensor retaining bolt 12 9

Turbocharger outlet temperature sensor 3 2.2

Throttle body retaining screws 12 9

Exhaust temperature sensor 35 26

Breather hose retaining bolts 12 9

Oil level indicator retaining bolt 7 5

Oil filler neck retaining bolt 12 9

Vacuum pipe assembly retaining bolt 40 30

Coolant pump pulley retaining bolts 25 18

Flywheel/flexplate retaining bolts:

Stage 1 30 22

Stage 2 120° 120°

Crankshaft position (CKP) sensor retaining bolt 12 9

* New nuts/bolts must be installed

A = refer to procedure for correct torque sequence

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