Defender. Manual — part 120
Fuel Charging and Controls - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma - Fuel Injector
Removal and Installation
Removal
• WARNINGS:
The spilling of fuel is unavoidable during this operation. Make sure that all necessary precautions are taken to
prevent fire and explosion.
Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable
vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related
components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result
in personal injury.
If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek immediate medical
attention.
Wash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop,
seek medical attention.
Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the system can
be as high as 2000 bar (29,008 lb-sq-in). Failure to follow this instruction may result in personal injury.
• CAUTIONS:
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 new blanking plugs
to any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection
system.
Always carry out the cleaning process before carrying out any repairs to the fuel injection system components.
Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
Do not disconnect the fuel injector electrical connectors with the engine running. Failure to follow this instruction
may result in serious damage to the engine.
Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible.
Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system
and may result in later malfunction.
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 engine cover.
For additional information, refer to:
Engine Cover
(501-05
Interior Trim and Ornamentation, Removal and Installation).
3. Using the pneumatic vacuum gun, vacuum foreign material
from the high-pressure fuel supply lines, the fuel rails and the
fuel injection pump.
For additional information, refer to:
Fuel Injection Component
Cleaning
(303-04A Fuel Charging and Controls - 2.4L
Duratorq-TDCi HPCR (103kW/140PS) - Puma, General
Procedures).
4. CAUTIONS:
4. CAUTIONS:
Do not allow the unions to hit the olive ends of the
high-pressure fuel supply line as this may damage the ends of
the line and allow foreign matter to enter the fuel injection
system.
Make sure that all openings are sealed. Use new
blanking caps.
Remove and discard the 2 high-pressure fuel supply lines.
5. Release the fuel injector wiring harness.
1. Disconnect the 2 fuel injector electrical
connectors.
2. Release the 2 clips.
6.
CAUTION: Make sure that all openings are sealed. Use
new blanking caps.
Release the fuel return line.
Remove the 2 clips.
Remove and discard the 2 O-ring seals.
7. Remove the fuel injector clamp cover.
8. NOTE: Note the position of the fuel injector clamp.
8. NOTE: Note the position of the fuel injector clamp.
Remove the fuel injector clamp.
Remove and discard the bolt.
9. CAUTIONS:
Make sure that all openings are sealed. Use new
blanking caps.
Make sure that both fuel injectors are removed. Failure
to follow this instruction may result in damage to the vehicle.
Remove the fuel injector.
10. Remove and discard the sealing washers from both fuel
injectors.
Installation
1. If a new fuel injector is to be installed, record the fuel
injector identification code.
2. Install new sealing washers to both fuel injectors.
3. NOTE: Remove and discard the blanking caps.
Install the fuel injectors.
4.
CAUTION: Make sure the fuel injector clamp is
installed correctly. Failure to follow this instruction may result
in damage to the vehicle.
Install the fuel injector clamp.
Stage 1: Tighten the new bolt to 6 Nm (4 lb.ft).
Stage 2: Tighten a further 180 degrees.
5. Install the fuel injector clamp cover.
6. NOTE: Remove and discard the blanking caps.
• NOTE: Clean the component mating faces.
Secure the fuel return line.
Install new O-ring seals.
Install the clips.
7. Secure the fuel injector wiring harness.
1. Connect the fuel injector electrical connectors.
2. Secure the clips.
8. NOTE: Remove and discard the blanking caps.
Secure the high-pressure fuel supply lines.
Stage 1: Tighten the unions to 5 Nm (4 lb.ft).
Stage 2: Tighten the unions to 35 Nm (26 lb.ft).
9. Install the engine cover.
For additional information, refer to:
Engine Cover
(501-05
Interior Trim and Ornamentation, Removal and Installation).
10. Connect the battery ground cable.
For additional information, refer to:
Battery Connect
(414-01
Battery, Mounting and Cables, General Procedures).
11. Carry out a fuel system leak test using the Land Rover
approved diagnostic system.
12. Carry out the fuel injector calibration procedure using the
Land Rover approved diagnostic system.
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