Defender. Manual — part 68
Engine System - General Information - Valve Stem Diameter
General Procedures
1. Using a micrometer measure the diameter of the valve
stems.
If the measurements are not to specification, install a
new valve.
Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma -
Lubricants, Fluids and Sealers
Item
Specification
SAE 5W-30 engine oil
WSS-M2C913-B
Sealant — oil pan, camshaft carrier and engine front cover
WSE-M4G323-A4
Cylinder Head Dimensions
Description
mm
Maximum distortion — measured longitudinally and diagonally
0.10
Peak to valley height of mating surface
0.02
Cylinder head gasket thickness
Piston protrusion of 0.310 - 0.400 mm
1.1 (one tooth)
Piston protrusion of 0.401 - 0.450 mm
1.15 (two teeth)
Piston protrusion of 0.451 - 0.500 mm
1.2 (three teeth)
Oil pressure specifications
Description
bar
Minimum oil pressure at idle speed
1.25
Minimum oil pressure at 2000 rpm
2.0
Description
Nm
lb-ft
Transmission to engine bolts
40
30
Engine mount nuts
80
59
Engine mount bolts
80
59
Engine mount bracket bolts
63
46
Valve cover bolts
10
7
+ Rocker shaft bolts
Stage 1
10
7
Stage 2
Further 30 degrees
Timing chain guide bolts
15
11
Timing chain tensioner nut
15
11
Timing chain tensioner bolts
15
11
Oil pump chain tensioner bolts
22
16
Camshaft sprocket bolts
35
24
Fuel injection pump sprocket bolts
33
26
Generator bolts
48
35
Generator mounting bracket bolts
25
18
Exhaust gas recirculation (EGR) valve to EGR valve outlet tube bolts
10
7
EGR valve to EGR cooler bolts
23
17
Exhaust manifold to EGR cooler bolts
23
17
Intake manifold bolts
15
11
Intake manifold to EGR valve outlet tube bolts
10
7
Coolant pump bolts
23
17
Oil level indicator tube bolt
10
7
Oil pump pickup tube bolts
10
7
Oil filter housing assembly bolts
23
17
Oil pump bolts
10
7
Oil pan drain plug
23
17
Oil pressure switch
15
11
Oil pan bolts
Stage 1
7
5
Stage 2
14
10
Coolant manifold bolts
10
7
EGR cooler to cylinder head bolts
23
17
+ Cylinder head bolts
A
-
Engine front cover bolts
14
10
Engine front cover nuts
10
7
Glow plugs
10
7
Power steering pump bolts
23
17
Power steering pump bracket bolts
23
17
Exhaust manifold bolts
40
30
+ Exhaust manifold nuts
40
30
+ Exhaust manifold studs
20
15
Turbocharger oil return tube bolts
10
7
Turbocharger oil return tube clamp bolt
22
16
Turbocharger oil supply line banjo bolt
35
26
Engine lifting eye bolts
22
16
Crankshaft position sensor (CKP) bolt
7
5
+ Crankshaft pulley bolts
Stage 1
45
33
Stage 2
Further 120 degrees
Crankshaft rear oil seal carrier bolts
10
7
+ Flywheel bolts
Stage 1
25
18
Stage 2
40
30
Stage 3
Further 48 degrees
Crankshaft main bearing cap bolts
Stage 1
45
33
Stage 2
80
59
Stage 3
Further 105 degrees
Connecting rod bearing cap bolts
Stage 1
30
22
Stage 2
Further 100 degrees
Ladder frame bolts
23
17
Camshaft carrier bolts
A
-
Fuel injector clamp bolts
Stage 1
6
4
Stage 2
Further 180 degrees
+ New nuts/bolts/studs must be installed
A - Refer to the procedure in this section
Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma - Engine
Description and Operation
EXTERNAL VIEW
OVERVIEW
The 2.4 liter diesel engine is a 4 cylinder unit, direct injection, with 4 valves per cylinder, operated by 2 overhead
camshafts. The engine emissions comply with European Commission Directive (ECD) 4 legislative requirements and
employs a catalytic converter, electronic engine management control, positive crankcase ventilation and Exhaust Gas
Re-circulation (EGR) to limit the emission of pollutants. The unit is water cooled and turbocharged. The fuel injection
system features common rail technology.
The cylinder block is manufactured in Compacted Graphite Iron (CGI) and is coupled with a separate aluminum ladder
frame to provide a lightweight, compact and very stiff bottom end of the engine. The cylinder head is cast aluminum
with a moulded plastic camshaft cover. The single-piece oil sump is formed from pressed steel. The exhaust manifold is
cast iron and includes a connection for the turbocharger. A moulded plastic acoustic cover is fitted over the upper engine
to reduce engine-generated noise.
Engine Structure
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