Defender. Manual — part 121
Fuel Charging and Controls - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma - Fuel Injection Pump
Removal and Installation
Special Tool(s)
Remover/Installer, Crankshaft Oil
Seal
303-679
Locking Tool, Fuel Pump Sprocket
303-1151
Remover Crankshaft Damper Pulley
303-1149
Remover Fuel Pump
303-1333
Removal
• WARNINGS:
The spilling of fuel is unavoidable during this operation. Make sure that all necessary precautions are taken to
prevent fire and explosion.
Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable
vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related
components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result
in personal injury.
If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek immediate medical
attention.
Wash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop,
seek medical attention.
Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the system can
be as high as 2000 bar (29,008 lb-sq-in). Failure to follow this instruction may result in personal injury.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
therefore essential that absolute cleanliness is observed when working with these components. Always install new
blanking plugs to any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the
fuel injection system.
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 accessory drive component bracket.
For additional information, refer to:
Accessory Drive
Component Bracket
(303-05 Accessory Drive - 2.4L Duratorq-
TDCi HPCR (103kW/140PS) - Puma, Removal and
Installation).
3. Remove the brake vacuum pump.
For additional information, refer to:
Brake Vacuum Pump
(206-07 Power Brake Actuation, Removal and Installation).
4.
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.
For additional information, refer to:
Lifting
(100-02 Jacking
and Lifting, Description and Operation).
5. Drain the cooling system.
For additional information, refer to:
Cooling System Draining,
Filling and Bleeding
(303-03 Engine Cooling - 2.4L Duratorq-
TDCi HPCR (103kW/140PS) - Puma, General Procedures).
6. Release the water pump.
Remove the 4 bolts.
Remove and discard the gasket.
7. Release the wiring harness.
8. Using the pneumatic vacuum gun, vacuum foreign material
from the high-pressure fuel supply lines, the fuel rails and the
fuel injection pump.
For additional information, refer to:
Fuel Injection Component
Cleaning
(303-04A Fuel Charging and Controls - 2.4L
Duratorq-TDCi HPCR (103kW/140PS) - Puma, General
Procedures).
9.
CAUTION: Make sure that all openings are sealed. Use
new blanking caps.
Release the fuel injection pump high-pressure fuel line.
1. Remove the 2 bolts.
2. Release the fuel pump high-pressure fuel line
union.
CAUTION: Make sure that all openings are sealed.
10.
CAUTION: Make sure that all openings are sealed.
Use new blanking caps.
Disconnect the fuel injector to fuel injection pump line.
11.
CAUTION: Make sure that all openings are sealed.
Use new blanking caps.
Disconnect the fuel return line.
12. Disconnect the fuel metering valve and the fuel
temperature sensor.
13.
CAUTION: Make sure that all openings are sealed.
Use new blanking caps.
Remove and discard the fuel injection pump high-pressure
fuel line.
14. Using the special tool, remove the fuel injection pump
14. Using the special tool, remove the fuel injection pump
drive gear cover.
15. Install the special tools.
16. Release the fuel injection pump drive gear.
1. Remove the nut.
2. Remove the 2 bolts.
17. Remove 2 bolts from the fuel injection pump.
18. Using the special tool, release the fuel injection pump.
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