Defender. Manual — part 197
![](/vehicles/onond/qug/lecmbuttig/all.png)
4. Release the fuel return line from the clip.
5. Remove the fuel cooler.
Remove the 2 bolts.
Installation
1. Install the fuel cooler.
Tighten the bolts to 23 Nm (17 lb.ft).
2. Secure the fuel return line in the clip.
3. NOTE: Remove and discard the blanking caps.
Connect the fuel lines.
4. Bleed the fuel system.
For additional information, refer to:
Low-Pressure Fuel
System Bleeding
(310-00 Fuel System - General Information,
General Procedures).
5. Fill and bleed the cooling system.
For additional information, refer to:
Cooling System Draining,
Filling and Bleeding
(303-03 Engine Cooling - 2.4L Duratorq-
TDCi HPCR (103kW/140PS) - Puma, General Procedures).
![](/vehicles/onond/qug/lecmbuttig/xintevery.png)
Fuel Tank and Lines - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma -
Fuel Filter
Removal and Installation
Removal
• WARNINGS:
After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow this instruction
may result in personal injury.
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.
This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling
precautions. Failure to follow these instructions may result in personal injury.
Wash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop,
seek medical attention.
• 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 blanking plugs to
any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection
system.
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.
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. Remove the fuel filter cover.
Loosen the clip.
CAUTION: Make sure that the area around the
![](/vehicles/onond/qug/lecmbuttig/pyors.png)
3.
CAUTION: Make sure that the area around the
component is clean and free of foreign material.
Remove the fuel filter.
Position a container to collect the fluid spillage.
Installation
1.
CAUTION: Clean the component mating faces.
Install the fuel filter.
Remove the container.
2. Install the fuel filter cover.
Tighten the clip.
3. Bleed the fuel system.
For additional information, refer to:
Low-Pressure Fuel
System Bleeding
(310-00 Fuel System - General Information,
General Procedures).
![](/vehicles/onond/qug/lecmbuttig/zye.png)
Fuel Tank and Lines - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma -
Fuel Level Sender
Removal and Installation
Special Tool(s)
Wrench, Fuel tank
310-118
Removal
• WARNINGS:
After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow this instruction
may result in personal injury.
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.
This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling
precautions. Failure to follow these instructions may result in personal injury.
Wash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop,
seek medical attention.
• 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 blanking plugs to
any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection
system.
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.
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 fuel tank.
For additional information, refer to:
Fuel Tank
(310-01 Fuel
Tank and Lines - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma, Removal and Installation).
4. Remove the fuel level sender.
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