Cylinder head cover (Freelander 2)

Special tool

303-1270 Timing Pin, Crankshaft

303-1277 Timing Pin, Camshaft

NOTE: The valve cover and cylinder head are machined as an assembly and cannot be serviced separately.

Removal

1. Remove the cover and disconnect the ground cable from the battery. Refer to procedure: Specifications (414-00 Charging System - General Information, Specifications).

2. Remove the air cleaner assembly. Refer to procedure: Air Cleaner (303-12A Intake Air Distribution and Filtration - 3.2L NA - I6, Removal and Installation).

3. Raise and support the vehicle.

WARNING: Ensure that the vehicle is supported securely.

4. Remove the camshaft seal. Refer to procedure: Camshaft Seal (303-01B Engine - 2.2L Duratorq - Td4, Removal and Installation).

5. Remove the fuel rail. Refer to procedure: Fuel Rail (303-04B Fuel Delivery and Controls - 2.2L Duratorq - Td4, Removal and Installation).

6. Remove the fuel injectors. Refer to procedure: Fuel Injector (303-04B Fuel Delivery and Controls - 2.2L Duratorq - Td4, Removal and Installation).

7. Remove the intake manifold. Refer to procedure: Intake Manifold (303-01B Engine - 2.2L Duratorq - Td4, Removal and Installation).









8.

NOTE: Discard the mounting clip.

9. Remove and discard the hose clamps.







10.

CAUTION: Discard valve stem seals.

11.

CAUTION: Plug all openings.

12.

CAUTION: Discard the seal.

13.

Clean the area around the element and remove any foreign particles. Plug all openings. Use new plugs.

14.

CAUTION: The O-ring can be reused if it is not damaged.

NOTE: Make sure the fuel pump drive remains in place when removing the fuel pump.

15. Remove the injection timing tool. Special tool: 303-1270

NOTE: The engine is now in the SAFE position.

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16. Turn the crankshaft 90 degrees.

17. Move and lock the camshaft drive chain tensioner.





18.

NOTE: Discard the gasket.

Installation

1. Apply a thin bead of sealant to one side. Refer to procedure: Specifications (303-01B Engine - 2.2L Duratorq - Td4, Specifications).

CAUTION: Clean mating surfaces of any foreign material.

2. Temporarily install the camshaft pulley and pulley mounting stud. Special tool: 303-1277





3. Install and tighten the bolts in the sequence shown in the figure.

CAUTION: Lubricate bearing surfaces with clean engine oil.

NOTE: Install a new gasket.

4. Tighten the bolts in the sequence shown in the figure. Tightening torque: 10 Nm

5. Loosen the chain tensioner.

6. Turn the crankshaft and install the injection timing tool. Special tool: 303-1270

7. Remove the camshaft pulley.

8. Secure the EGR cooler.



9. Install the nuts, bolts and washers, but do not tighten them at this stage.



10. Tighten the nuts in the sequence shown. Tightening torque: 6 Nm

11. Tighten the bolts in the order shown in the figure. Tightening torque: 10 Nm

12. Install the fuel pump. Tightening torque: 22 Nm

Extreme cleanliness is required when handling this component. Clean mating surfaces of any foreign material. Ensure that the seal is installed correctly.

13. Connect the fuel shut-off valve electrical connector.

14. Connect the supply and return fuel line fittings to the fuel pump.

WARNING: Before installing components, ensure that the area around contact surfaces and connections is clean and dry.

15. Install the vacuum pump. Tightening torque: 9 Nm

Clean mating surfaces from foreign material. Make sure the seal is installed correctly.

16. Secure the oil filler tube. Tightening torque: 9 Nm

17. Connect the vacuum system lines to the vacuum pump. Secure the fuel lines.

CAUTION: Clean mating surfaces of any foreign material.

18. Install the valve cover vent oil separator. Tightening torque: 9 Nm

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

NOTE: Install new seals.

19. Insert a 7.5mm drill bit between the cylinder head cover and the CMP sensor as shown to ensure proper alignment of the CMP sensor. Tightening torque: 4 Nm

CAUTION: Incorrect installation of the camshaft position (CMP) sensor can result in engine damage.

20. Install the cylinder head cover breather.

NOTE: Install new mounting clips.

21. Connect the CMP sensor electrical connector.

22. Connect and secure the engine ventilation line.

NOTE: Install a new clamp.

23. Install the oxygen sensor (HO2S) harness bracket. Tightening torque: 9 Nm

24. Secure the oxygen sensor (HO2S) harness.

25. Install the ventilation duct.

26. Install the intake manifold. Refer to procedure: Intake Manifold (303-01B Engine - 2.2L Duratorq - Td4, Removal and Installation).

27. Install the fuel injectors. Refer to procedure: Fuel Injector (303-04B Fuel Delivery and Controls - 2.2L Duratorq - Td4, Removal and Installation).

28. Install the fuel rail. Refer to procedure: Fuel Rail (303-04B Fuel Delivery and Controls - 2.2L Duratorq - Td4, Removal and Installation).

29. Install the camshaft seal. Refer to procedure: Camshaft Seal (303-01B Engine - 2.2L Duratorq - Td4, Removal and Installation).

30. Reinstall the air cleaner. Refer to procedure: Air Cleaner (303-12A Intake Air Distribution and Filtration - 3.2L NA - I6, Removal and Installation).

31. Connect the ground cable to the battery and install the cover. Refer to Procedure: Specifications (414-00 Charging System - General Information, Specifications).