Defender. Manual — part 73
Item
Part Number
Description
1
-
Exhaust camshaft sprocket
2
-
Inlet camshaft sprocket
3
-
Primary drive chain
4
-
Primary drive chain guide
5
-
High-pressure fuel injection pump sprocket
6
-
Bolt (4 off)
7
-
Primary drive chain guide
8
-
Bolt (2 off)
9
-
Crankshaft sprocket
10
-
Secondary drive chain
11
-
Bolt (2 off)
12
-
Automatic tensioner
13
-
Primary drive chain tensioner arm
14
-
Bolt (4 off)
15
-
Primary drive chain guide
A multiple link primary drive chain transmits the drive from the sprocket on the crankshaft to the exhaust camshaft, the
inlet camshaft and the high-pressure fuel pump. The secondary drive chain transmits drive from the sprocket on the
crankshaft to the oil pump located on the underside of the ladder frame.
One bolt locates the drive sprocket on the crankshaft and 3 bolts are used to mount the crankshaft's torsional vibration
damper to the crankshaft via holes in the drive sprocket. The inlet and exhaust camshaft sprockets are aligned on their
respective camshafts using a spigot tool and a timing peg. Once they are in their correct position, 3 bolts are used to
secure each camshaft sprocket to their camshaft.
Each chain has a hydraulic tensioner operated by engine oil. The primary chain is lubricated via an oil squirt tube
located centrally at the front of the engine block. Oil from the ladder frame and oil pan assembly splash lubricates the
secondary chain. The primary chain tensioner acts on a pivoting flexible tensioner blade. The secondary chain tensioner
acts directly on the chain. Guide rails are installed on the drive side of the primary chains.
Front Cover
Item
Part Number
Description
1
-
Bolt (20 off)
2
-
Front cover
3
-
Locating pins
4
-
Guide pin
5
-
Nut (2 off)
6
-
Alignment tool
7
-
Water outlet
8
-
Bolt (2 off)
9
-
Nut
10
-
Stud
The pressed steel front cover is bolted to the front of the cylinder block, the cylinder head and the ladder frame with 20
bolts and sealed with a bead of Room Temperature Vulcanizing (RTV) silicon sealant.
When installing the front cover, a special locating tool is required, which fits in the crankshaft sprocket aperture, to aid
the alignment of the front cover.
CYLINDER HEAD COMPONENTS
The main cylinder head components are:
Cylinder head and valves
Camshafts
Cylinder head gasket
Glow plugs
Fuel injectors
Cylinder Head Temperature (CHT) sensor
High-pressure fuel rail
Inlet manifold
Exhaust manifold
Camshaft carrier
Hydraulic lash adjusters
Camshaft Position (CMP) sensor
Camshaft and engine cover
Cylinder Head and Valves
Item
Part Number
Description
1
-
Cylinder head
2
-
Outer cylinder head bolt (8 off)
3
-
Inner cylinder head bolt (10 off)
4
-
Intake valves (16 off)
5
-
Valve collets (32 off)
6
-
Spring retainer (16 off)
7
-
Valve spring (16 off)
8
-
Valve stem oil seal (16 off)
9
-
Exhaust valve (8 off)
10
-
Intake valve (8 off)
11
-
Valve guide (16 off)
12
-
Cylinder head gasket
13
-
Valve assembly
The cylinder head is made of gravity die cast aluminum. Four valves per cylinder provides improved cylinder charging, a
compact combustion chamber, and vertical fuel injectors guarantee optimum distribution of the fuel in the combustion
chamber.
Eighteen deep-seated bolts help reduce distortion and secure the cylinder head to the cylinder block. The 8 cylinder
head outer bolts are shorter than the inner bolts and are located beneath the camshafts, 4 under the inlet camshaft and
4 under the exhaust camshaft. Two hollow dowels align each cylinder head with the cylinder block.
The cylinder head has four ports machined at each cylinder location, 2 exhaust ports and 2 inlet ports. One of the inlet
ports is helical and functions as a swirl port, the other is arranged laterally as a tangential port and functions as a
charge port.
• NOTE: The cylinder head cannot be reworked.
All valves are supported in sintered metal seats and guide inserts. Collets, valve collars and spring seats locate single
valve springs on both intake and exhaust valves. Valve stem seals are integrated into the spring seats.
Camshafts
Item
Part Number
Description
1
-
Inlet camshaft
2
-
Exhaust camshaft
The camshafts are of a hollow steel tube construction, with pressed on sintered lobes and have a machined face at the
front to accept the camshaft gear sprocket. The camshafts are retained in the cylinder head by the camshaft carrier. The
reluctor, machined towards the rear of the inlet camshaft, enables the Camshaft Position (CMP) sensor to provide a
signal, which enables the ECM to determine the position of the camshaft relative to the crankshaft.
For additional information, refer to:
Electronic Engine Controls
(303-14 Electronic Engine Controls - 2.4L Duratorq-TDCi
HPCR (103kW/140PS) - Puma, Description and Operation).
Cylinder Head Gasket
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