Head cover — removal and installation (Defender 2007+)

Removal

Warnings:

• Some fuel will inevitably spill during this operation. Make sure that all necessary precautions are taken to prevent fire and explosion.
• Do not carry or use a cell phone while working with or in the immediate vicinity of any fuel related components. There is a risk of ignition of flammable vapors. Failure to follow these instructions may result in injury.
• Do not smoke or carry a lighted cigarette or open flame of any type when working on or near fuel-related components. There is a risk of ignition of flammable vapors. Failure to follow these instructions may result in injury.
• If fuel gets into your eyes, rinse them with cold water or a special eye wash solution and seek medical attention immediately.
• Wash your hands thoroughly after handling fuel, as prolonged contact with the skin may cause irritation. If irritation occurs, seek medical attention.
• Do not perform any repairs to the fuel system while the engine is running. Fuel pressure in the system can reach 2000 bar. Failure to follow this instruction may result in injury.

CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very small clearances. Therefore, absolute cleanliness is required when working on these components. Be sure to insert new plugs into all open ports and lines. Failure to do so may result in dirt entering the fuel injection system.

1. 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).



2. Disconnect the positive crankcase ventilation (PCV) hose.



3. Remove the fuel injectors.

For more information, refer to the chapter: Fuel Injector (303-04A Fuel Supply and Controls - ID4 2.4L Diesel Engine, Removal and Installation).

4. Release the fuel line.



5.

CAUTION: Plug all openings. Use new caps.

Disconnect the fuel return line.



6.

CAUTION: Plug all openings. Use new caps.

Disconnect the fuel return line.



7.

CAUTION: Plug all openings. Use new caps.

Remove the fuel return line.



8. Disconnect the engine wiring harness from the cylinder head cover.



9. Remove the cylinder head cover.

• Loosen the 12 bolts completely.
• Remove the gasket and dispose of it.

Installation

1.

CAUTION: Tighten the bolts in the order shown in the illustration.

Install the elements back in place in reverse order.

• Install a new gasket.
• Tighten the bolts to 10 Nm.

2. Connect the ground wire to the battery.

(The original text can be found at: lrman.ru)

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