Defender. Manual — part 138
Engine Emission Control - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma - Exhaust Gas Recirculation (EGR) Cooler
Removal and Installation
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.
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.
3. NOTE: Position a container to collect the fluid spillage.
Disconnect the exhaust gas recirculation (EGR) cooler LH
coolant hose.
Clamp the hose to minimize coolant loss.
Release the clip.
4. Release the EGR cooler from the EGR valve and from the
EGR cooler bracket.
Remove the 4 bolts.
Remove and discard the gasket.
5. Disconnect the EGR cooler RH coolant hose.
Clamp the hose to minimize coolant loss.
Release the clip.
Release the coolant hoses from the EGR cooler.
6. Reposition the coolant expansion tank.
6. Reposition the coolant expansion tank.
Remove the bolt.
7. NOTE: Engine shown removed for clarity.
Remove the EGR cooler.
Remove the 2 bolts.
Remove and discard the gasket.
Installation
1. NOTE: Clean the component mating faces.
Install the EGR cooler.
Install a new gasket.
Tighten the bolts to 23 Nm (17 lb.ft).
2. Secure the coolant expansion tank.
Tighten the bolt to 10 Nm (7 lb.ft).
3. Connect the EGR cooler RH coolant hose.
Secure with the clip.
Secure the coolant hoses to EGR cooler.
Remove the hose clamp.
4. Secure the EGR cooler to the EGR valve and the EGR cooler
bracket.
Install a new gasket.
Tighten the bolts to 23 Nm (17 lb.ft).
5. Connect the EGR cooler LH coolant hose.
Secure with the clip.
Remove the hose clamp.
Remove the container.
6. Connect the battery ground cable.
For additional information, refer to:
Battery Connect
(414-01
Battery, Mounting and Cables, General Procedures).
7. Check and top up the coolant.
Engine Emission Control - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma - Exhaust Gas Recirculation (EGR) Valve
Removal and Installation
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. Disconnect the exhaust gas recirculation (EGR) valve
electrical connector.
3. NOTE: Engine shown removed for clarity.
Remove the EGR valve.
Remove the 4 bolts.
Remove and discard the 2 gaskets.
Installation
1. Install the EGR valve.
Clean the component mating faces.
Install new gaskets.
Tighten the M6 bolts to 10 Nm (7lb.ft).
Tighten the M8 bolts to 23 Nm (17lb.ft).
2. Connect the EGR valve electrical connector.
3. Connect the battery ground cable.
For additional information, refer to:
Battery Connect
(414-01
Battery, Mounting and Cables, General Procedures).
Intake Air Distribution and Filtering - 2.4L Duratorq-TDCi HPCR
(103kW/140PS) - Puma -
Torque Specifications
Description
Nm
lb-ft
Air cleaner bolts
13
10
A/C compressor low-pressure and high-pressure refrigerant lines bolt
30
22
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
Air cleaner outlet pipe clips
3
2
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