Gas distribution mechanism drive cover (Defender 2007+)

Special tool(s)

Timing Belt Cover Installation Tool 303-682

Removal

1.

WARNING: Never work on a vehicle supported only by a jack. Always support the vehicle with special stands.

Raise and support the vehicle.

2. Disconnect the ground wire from the battery.

For more information, refer to the chapter: Disconnecting and connecting the battery (414-01 Battery, Battery Mounting and Cables, General Procedures).

3. Drain the cooling system.

For more information, refer to the chapter: Draining/filling coolant and bleeding air from the cooling system (303-03 Engine Cooling - ID4 2.4L Diesel Engine, General Procedures).

4. Remove the accessory drive element bracket.

For more information, refer to the chapter: Belt/Accessory Chain Tensioner Bracket (303-05 Accessory Drive - ID4 2.4L Diesel Engine, Removal and Installation).

5. Install the elbow pipe of the cylinder head cooling system.

• Remove the nut.
• Remove two bolts.
• Remove the sealing ring and dispose of it.

6. Remove the front crankshaft seal.



For more information, refer to the chapter: Front Crankshaft Seal (303-01 Engine - Diesel engine ID4 2.4L, On-car repair).

7. Reposition the coolant hose.

• Remove 4 bolts.
• Remove the gasket and dispose of it.

8. Using a suitable tool, remove and discard the timing belt cover.

• Remove 20 bolts.
• Unscrew 2 nuts.

Installation

1. Clean the mating surfaces of the engine timing cover.

2.

Warnings:

• Install a new timing cover. Failure to do so may result in damage to the vehicle.
• Install the engine timing cover within five minutes of applying the sealant. Failure to do so may result in damage to the vehicle.

NOTE: There may be some differences from what is shown in the pictures, but the basic information is correct.

Apply a 3mm bead of sealant to the four tees.



3. Apply a 3mm bead of sealant to the engine timing cover.



4.

CAUTION: Make sure the engine timing cover does not come into contact with the engine until the correct position is reached.

With the help of a second mechanic, install the engine timing cover.

5.

NOTE: Engine shown removed for clarity.

Using a special tool, adjust the position of the engine timing cover.

• Screw in and tighten the 2 engine timing cover bolts to 6 Nm.
• Install and tighten the remaining 16 engine timing cover bolts and install and tighten the 2 nuts to 6 Nm.
• Loosen the engine timing cover bolts and nuts 360 degrees.
• Install the special tool.

6. Tighten the engine timing cover nuts and bolts.

• Tighten the engine timing cover nuts and bolts to 3 Nm.
• Tighten the engine timing cover nuts and bolts in the following sequence:
• Tighten the 2 indicated bolts to 11 Nm.
• Tighten the remaining nuts and bolts to 10 Nm.

7.

NOTE: Clean the contact surfaces of the parts.

Secure the coolant pump.

• Install a new gasket.
• Tighten the bolts (tightening torque 22 Nm).

8.

NOTE: Clean the contact surfaces of the parts.

Install the elbow coolant pipe onto the cylinder head.

• Install a new O-ring.
• Tighten the nut (tightening torque 22 Nm).
• Tighten the bolts (tightening torque 22 Nm).

9. Install the accessory drive component bracket.

For more information, refer to the chapter: Belt/Accessory Chain Tensioner Bracket (303-05 Accessory Drive - ID4 2.4L Diesel Engine, Removal and Installation).

10. Connect the ground wire to the battery.

For more information, refer to the chapter: Connecting the Battery (414-01 Battery, Battery Mounting and Cables, General Procedures).

11. Fill the cooling system with coolant and bleed air from the system.

For more information, refer to the chapter: Draining/filling coolant and bleeding air from the cooling system (303-03 Engine Cooling - ID4 2.4L Diesel Engine, General Procedures).