Defender. Manual — part 91
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12. Remove the timing chain.
Installation
1.
CAUTION: Make sure the colored links align to the
timing marks. Failure to follow this instruction may result in
damage to the vehicle.
Install the timing chain.
2.
CAUTION: Make sure the timing chain tensioner is fully
retracted before installation. Failure to follow this instruction
may result in damage to the vehicle.
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Install the timing chain tensioner and the timing chain guides.
Tighten the bolts to 15 Nm (11 lb.ft).
Tighten the nut to 15 Nm (11 lb.ft).
3. NOTE: Make sure the timing chain tensioner is completely
released.
Unlock the timing chain tensioner.
Remove the pin.
4. Secure the camshaft sprockets and the fuel injection pump
sprocket.
Tighten the camshaft sprocket bolts to 35 Nm (24 lb.ft).
Tighten the fuel injection sprocket bolts to 33 Nm (26
lb.ft).
5. Remove the special tool.
6. Remove the 6 mm bars.
7. Rotate the crankshaft clockwise 2 complete revolutions.
8.
CAUTION: Make sure the special tool is fully located in
the flywheel.
Check the timing by inserting the special tool in the CKP
sensor hole.
9. Check the camshaft timing by inserting a suitable 6 mm bar
through the holes in the camshaft sprockets
10. Remove the special tool.
11. Remove the 6 mm bars.
12. Install the CKP sensor.
For additional information, refer to:
Crankshaft Position (CKP)
Sensor
(303-14 Electronic Engine Controls - 2.4L Duratorq-
TDCi HPCR (103kW/140PS) - Puma, Removal and
Installation).
13. Install the timing cover.
For additional information, refer to:
Timing Cover
(303-01
Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma,
In-vehicle Repair).
14. Connect the battery ground cable.
For additional information, refer to:
Battery Connect
(414-01
Battery, Mounting and Cables, General Procedures).
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Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma - Valve Cover
In-vehicle Repair
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.
CAUTION: 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.
1. Disconnect the battery ground cable.
For additional information, refer to:
Battery Disconnect and
Connect
(414-01 Battery, Mounting and Cables, General
Procedures).
2. Disconnect the positive crankcase ventilation (PCV) hose.
3. Remove the fuel injectors.
For additional information, refer to:
Fuel Injector
(303-04A
Fuel Charging and Controls - 2.4L Duratorq-TDCi HPCR
(103kW/140PS) - Puma, Removal and Installation).
4. Release the fuel line.
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4. Release the fuel line.
5.
CAUTION: Make sure that all openings are sealed. Use
new blanking caps.
Disconnect the fuel return line.
6.
CAUTION: Make sure that all openings are sealed. Use
new blanking caps.
Disconnect the fuel return line.
7.
CAUTION: Make sure that all openings are sealed. Use
new blanking caps.
Remove the fuel return line.
8. Release the engine wiring harness from the valve cover.
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