Defender. Manual — part 83
Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma - Cylinder Head
In-vehicle Repair
Removal
1.
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the vehicle on safety
stands.
Raise and support the vehicle.
2. Disconnect the battery ground cable.
For additional information, refer to:
Battery Disconnect and
Connect
(414-01 Battery, Mounting and Cables, General
Procedures).
3. Remove the camshafts.
For additional information, refer to:
Camshafts
(303-01
Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma,
In-vehicle Repair).
4. Remove the intake manifold.
For additional information, refer to:
Intake Manifold
(303-01
Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma,
In-vehicle Repair).
5. NOTE: Engine shown removed for clarity.
Release the exhaust gas recirculation (EGR) cooler.
Remove the bolt.
6. Release the exhaust manifold.
Remove the 6 bolts.
Remove and discard the 2 nuts.
Remove and discard the 2 studs.
Remove and discard the gasket.
7. Release the glow plug wiring harness.
Remove the 4 nuts.
8.
CAUTION: The cylinder head must not be placed face
down. Failure to follow this instruction may result in damage to
the vehicle.
With assistance, carefully remove the cylinder head.
Remove and discard the bolts numbered 1 through 18.
Remove bolt 19.
Remove and discard the gasket.
9. NOTE: Do not dismantle further if component is removed for
access only.
Remove the 4 glow plugs.
Installation
1. Install the glow plugs.
Tighten the glow plugs to 12 Nm (9 lb.ft).
2. NOTE: Clean the component mating face.
• NOTE: Measure the piston protrusion of each cylinder at top
dead center (TDC).
Measure the distance between the piston crown and the
cylinder block at the points indicated.
3. Determine the cylinder head gasket thickness.
For additional information, refer to:
Specifications
(303-01
Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma,
Specifications).
4.
CAUTION: The thickness of the new cylinder head
gasket depends on the piston protrusion (hole/tooth marked).
Install a new cylinder head gasket.
CAUTION: Install new cylinder head bolts.
5.
CAUTION: Install new cylinder head bolts.
• NOTE: Clean the component mating face.
Install the cylinder head.
Tighten the bolts in the sequence shown in six stages.
Stage 1: Tighten bolts 1 through 10 to 20 Nm.
Stage 2: Tighten bolts 11 through 18 to 10 Nm.
Stage 3: Tighten bolts 1 through 10 to 40 Nm.
Stage 4: Tighten bolts 11 through 18 to 20 Nm.
Stage 5: Tighten bolts 1 through 10 to 180 degrees.
Stage 6: Tighten bolts 11 through 18 to 180 degrees.
Stage 7: Tighten the M6 bolt to 10 Nm (7 lb.ft).
6. Secure the glow plug wiring harness.
Tighten the nuts to 3 Nm (2 lb.ft).
7. NOTE: Clean the component mating faces.
Secure the exhaust manifold.
Install a new gasket.
Tighten the new studs to 20 Nm (15 lb.ft).
Tighten the new nuts to 40 Nm (30 lb.ft).
Tighten the bolts to 40 Nm (30 lb.ft).
8. Secure the EGR cooler.
Tighten the bolt to 20 Nm (15 lb.ft).
9. Install the intake manifold.
For additional information, refer to:
Intake Manifold
(303-01
Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma,
In-vehicle Repair).
10. Install the camshafts.
For additional information, refer to:
Camshafts
(303-01
Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma,
In-vehicle Repair).
11. Connect the battery ground cable.
For additional information, refer to:
Battery Connect
(414-01
Battery, Mounting and Cables, General Procedures).
Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma - Engine Mount
LH
In-vehicle Repair
Removal
1. Disconnect the battery ground cable.
For additional information, refer to:
Battery Disconnect and
Connect
(414-01 Battery, Mounting and Cables, General
Procedures).
2. Remove the hood.
For additional information, refer to:
Hood
(501-02 Front End
Body Panels, Removal and Installation).
3. Remove the cooling fan upper shroud.
Release the 6 clips.
4. Remove the air cleaner outlet pipe.
For additional information, refer to:
Air Cleaner Outlet Pipe
(303-12 Intake Air Distribution and Filtering - 2.4L Duratorq-
TDCi HPCR (103kW/140PS) - Puma, Removal and
Installation).
5. Remove the RH engine mount nut.
6. Disconnect the charge air cooler outlet hose.
Loosen the clip.
7. Remove the LH engine mount nut.
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