Fuel injector — 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.

Warnings:

• Diesel fuel injection equipment is manufactured to very precise tolerances and very small clearances. Therefore, absolute cleanliness is required when working with these components.
• Be sure to install new plugs in all open ports and lines. Failure to do so may result in dirt entering the fuel injection system.
• Always perform the cleaning procedure before performing any repairs to fuel injection system components. Failure to do so may result in dirt entering the fuel injection system.
• Do not disconnect the fuel injector electrical connectors while the engine is running. Failure to do so may result in serious engine damage.
• Keep the area of the service station where the vehicle is being worked on as clean and dust-free as possible. Dirt and dust from clutch, brake, machining, or welding work can contaminate the fuel system and cause problems later.

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. Remove the engine cover.

For more information, refer to the chapter: Engine Cover (501-05 Interior trim, Removal and installation).

3. Using a vacuum cleaner, remove foreign material from the high-pressure fuel supply lines, fuel rails and high-pressure fuel pump.

For more information, refer to the chapter: Cleaning the fuel injection system components (303-04A Fuel Delivery and Controls - ID4 2.4L Diesel Engine, General Procedures).

4.

Warnings:

• Avoid striking the sealing lens of the high-pressure fuel supply line, as this may damage the ends of the line and allow dirt to enter the fuel injection system.
• Plug all openings. Use new caps.

Remove the 2 high pressure fuel supply lines and discard them.



5. Release the fuel injector wiring harness.

• 1. Disconnect the electrical connectors of the fuel injectors (2 pcs.).
• 2. Release the two clamps.

6.

CAUTION: Plug all openings. Use new caps.

Release the fuel return line.

• Remove 2 clamps.
• Remove and discard the 2 O-rings.

7. Remove the fuel injector clamp cover.



8.

NOTE: Mark the location of the injector retaining pin.

Remove the fuel injector clamp. Unscrew and discard the bolt.



9.

Warnings:

• Plug all openings. Use new caps.
• Make sure the fuel injectors are removed. Failure to do so may result in damage to the vehicle.

Remove the fuel injector.





10. Remove and discard the sealing washers from both fuel injectors.

Installation

1. If a new injector needs to be installed, record the fuel injector identification code.



2. Install new sealing washers on both injectors.



3.

NOTE: Remove and discard plugs.

Install the fuel injectors.

4.

CAUTION: Make sure the fuel injector clamp is installed correctly. Failure to do so may result in damage to the vehicle.

Install the fuel injector clamp.

• Step 1: Tighten the new bolt to 6 Nm.
• Stage 2: Tighten another 180 degrees.

5. Install the fuel injector clamp cover.

6.

NOTE: Remove and discard plugs.

NOTE: Clean the contact surfaces of the parts.

Connect the fuel return line.

• Install new O-rings.
• Install the clamps.

7. Secure the fuel injector wiring harness.

(Details can be found on the website: lrman.ru)

• 1. Connect the fuel injector plugs.
• 2. Secure with clamps.

8.

NOTE: Remove and discard plugs.

Secure the high pressure fuel lines.

• Step 1: Tighten the connection (tightening torque 5 Nm).
• Step 2: Tighten the connection (tightening torque 35 Nm).

9. Replace the engine cover.



For more information, refer to the chapter: Engine Cover (501-05 Interior trim, 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. Check the fuel system for leaks using a Land Rover approved diagnostic system.

12. Perform the fuel injector calibration procedure using the Land Rover approved diagnostic system.