Defender. Manual — part 107
Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma - Engine
Installation
Installation
All vehicles
1. With assistance, carefully install the engine.
Clean the component mating faces.
2. Secure the engine to the transmission.
Tighten the bolts to 40 Nm (30 lb.ft).
Remove the hydraulic jack supporting the transmission.
3. Install the LH engine mount.
4. Install the RH engine mount.
5. Secure both of the engine mounts.
Lower the engine on to its mounts.
Tighten the bolts to 80 Nm (59 lb.ft).
Tighten the nuts to 80 Nm (59 lb.ft).
6. Connect the exhaust gas recirculation (EGR) cooler coolant
hose.
Secure with the clip.
Secure the coolant hoses to EGR cooler.
7. Connect the heater coolant hose to the heater control valve.
Secure with the clip.
8. NOTE: Remove and discard the blanking caps.
Connect the fuel lines.
Secure with the clip.
Secure the fuel return line in the clip.
9. Secure the power steering pump.
Remove and discard the tie-strap.
Tighten the bolts to 23 Nm (17 lb.ft).
10. Secure the accessory drive belt around the power steering
pump pulley.
11. Connect the brake booster vacuum line to the brake
vacuum pump.
12. Connect the coolant hoses to the coolant pump housing.
Secure with the clips.
13. Connect the radiator upper coolant hose.
Secure with the clip.
14. Secure the engine wiring harness.
Connect the engine control module (ECM) electrical
connectors.
Secure in the clips.
15. Connect the glow plug electrical connector.
16. Connect the engine wiring harness electrical connector.
17. Install the charge air cooler outlet hose.
Tighten the clips.
18. Install the charge air cooler inlet hose.
Tighten the clips.
Vehicles with air conditioning
19. NOTE: Remove and discard the blanking caps.
Connect the air conditioning (A/C) compressor high-pressure
line.
Install new O-ring seals.
All vehicles
20. Install the air cleaner.
For additional information, refer to:
Air Cleaner
(303-12
Intake Air Distribution and Filtering - 2.4L Duratorq-TDCi
HPCR (103kW/140PS) - Puma, Removal and Installation).
21. Connect the coolant hose to the EGR cooler.
Secure with the clip.
22. Connect the coolant hose to the engine oil cooler.
Secure with the clip.
23. Connect the reverse light switch electrical connector.
24. Secure the crankshaft position (CKP) sensor and reverse
light switch wiring harness to the transmission.
Secure the clips.
25. Install the starter motor.
For additional information, refer to:
Starter Motor
(303-06
Starting System - 2.4L Duratorq-TDCi HPCR (103kW/140PS)
- Puma, Removal and Installation).
26. Install the catalytic converter.
For additional information, refer to:
Catalytic Converter
(309-
00 Exhaust System - 2.4L Duratorq-TDCi HPCR
(103kW/140PS) - Puma, Removal and Installation).
27. Install the cooling fan shroud.
For additional information, refer to:
Cooling Fan Shroud
(303-
03 Engine Cooling - 2.4L Duratorq-TDCi HPCR
(103kW/140PS) - Puma, Removal and Installation).
28. Connect the battery ground cable.
For additional information, refer to:
Battery Connect
(414-01
Battery, Mounting and Cables, General Procedures).
29. Install the hood.
For additional information, refer to:
Hood
(501-02 Front End
Body Panels, Removal and Installation).
Engine Cooling - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma -
Item
Specification
Anti-freeze
WAS-M97B44-D
Anti-freeze concentration - Will provide frost protection to -40°C (-40°F)
50%
Specific gravity of coolant at 20°C (68°F), to protect against frost down to -40°C (-40°F)
1.068
Item
Capacity
Cooling System
10 Liters (17.6 pints) (10.6 quarts)
Radiator
2.3 Liters (4 pints) (2.4 quarts)
Coolant Expansion Tank (To Cold Level)
1.2 Liters (2.1 pints) (1.3 quarts)
Item
Description
Cooling system type
Pressurized, thermostatically controlled with coolant expansion tank
Radiator
Cross flow
Coolant expansion tank
Remote with cold level fill mark
Pressure cap rating
100 kPa (1 bar) (15.9 lbf/in!)
Thermostat: Starts to open
82° C (180°F)
Thermostat: Fully open
96° C (205°F)
Cooling fan
Viscous
Cooling fan control
Bi-metallic
Cooling fan diameter
475 mm (18.70 inches)
Cooling fan direction of rotation
Clockwise when viewed from front of engine
Coolant pump
Centrifugal flow impeller, belt driven from the crankshaft
Torque Specifications
Description
Nm
lb-ft
Heater hose air bleed screw
2
1
Coolant pump bolts
23
17
Coolant pump outlet manifold
10
7
Coolant pump hose clip
3
2
Viscous coupling bolts
10
7
Expansion tank bolt
10
7
Charge air cooler to radiator bolts
20
15
Charge air cooler inlet and outlet hose clips
3
2
Charge air cooler bracket bolts
9
7
Power steering reservoir nuts
4
3
Engine Cooling - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma -
Engine Cooling
Description and Operation
COMPONENT LOCATION
Item
Part Number
Description
1
-
Radiator top hose
2
-
Cooling fan top cowl
3
-
Expansion tank
4
-
Passenger compartment heater connections
5
-
Exhaust Gas Recirculation (EGR) cooler
6
-
EGR cooler outlet hose
7
-
Expansion tank hose
8
-
Fuel cooler
9
-
Engine oil cooler
10
-
Coolant pump
11
-
Fuel cooler feed and return hoses
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