Defender. Manual — part 81
12.
CAUTION: Make sure the colored links align to the
timing marks. Failure to follow this instruction may result in
damage to the vehicle.
Install both of the camshaft sprockets and the timing chain.
13.
CAUTION: Make sure the timing chain tensioner is
fully retracted before installation. Failure to follow this
instruction may result in damage to the vehicle.
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).
14. Using a suitable 6 mm bar, lock the camshaft sprockets.
Loosely install the camshaft sprocket bolts.
15. Loosen the 4 bolts on the fuel injection pump sprocket.
15. Loosen the 4 bolts on the fuel injection pump sprocket.
16. NOTE: Make sure the timing chain tensioner is completely
released.
Unlock the timing chain tensioner.
Remove the pin.
17. 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).
18. Remove the special tool.
19. Remove the 6 mm bars.
20. CAUTIONS:
Make sure that new bolts are installed.
Make sure that the oil supply holes in the rocker shafts
point downwards. Failure to follow this instruction may result in
damage to the vehicle.
• NOTE: Tighten the bolts in the stages shown.
Install the rocker shafts.
Stage 1: Tighten the bolts to 13 Nm (10 lb.ft).
Stage 2: Tighten the bolts a further 45 degrees.
21. Rotate the crankshaft clockwise 2 complete revolutions.
22.
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.
23. Check the camshaft timing by inserting a suitable 6 mm
bar through the holes in the camshaft sprockets
24. Remove the special tool.
25. Remove the 6 mm bars.
26. 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).
27. 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).
28. Install the valve cover.
For additional information, refer to:
Valve Cover
(303-01
Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma,
In-vehicle Repair).
29. Connect the battery ground cable.
For additional information, refer to:
Battery Connect
(414-01
Battery, Mounting and Cables, General Procedures).
Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma - Crankshaft
Pulley
In-vehicle Repair
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. Remove the cooling fan.
For additional information, refer to:
Cooling Fan
(303-03
Engine Cooling - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma, Removal and Installation).
3. Release the tension from the accessory drive belt.
Rotate the accessory drive belt tensioner clockwise.
4. Remove the crankshaft pulley.
Remove and discard the 3 bolts.
Installation
1.
CAUTION: New crankshaft pulley bolts must be
installed.
• NOTE: New crankshaft pulley bolts must be installed.
• NOTE: Clean the component mating faces.
Install the crankshaft pulley.
Stage 1: Tighten the bolts to 45 Nm (33 lb.ft).
Stage 2: Tighten the bolts a further 90 degrees.
2. Secure the accessory drive belt.
Rotate the accessory drive belt tensioner clockwise.
3. Install the cooling fan.
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