Cylinder head — removal and installation (Defender 2007+)

Removing

1.

WARNING: It is forbidden to carry out work on a vehicle standing on only one jack. Always support the vehicle with jack stands.

Raise and support the vehicle.

2. Disconnect the wire "masses" from the battery.

For more information, see the chapter: Disconnecting and connecting the battery (414-01 Battery, Battery Mount and Wires, General Procedures).

3. Remove camshafts.

For more information, refer to the chapter: Camshafts (303-01 Engine - Diesel engine ID4 2.4L, Car repair).

4. Remove the intake manifold.

For more information, refer to the chapter: Intake Manifold (303-01 Engine - Diesel engine ID4 2.4L, Car repair).

5. NOTE: Engine shown removed for clarity.

Remove the EGR heat exchanger (EGR). Turn out a bolt.



6. Remove the exhaust manifold.

• Turn out 6 bolts.
• Loosen and discard 2 nuts.
• Remove and discard two pins.
• Remove the gasket and send it for recycling.

7. Release the glow plug harness. Loosen 4 nuts.




8.

CAUTION: Do not lay the cylinder head face down. Failure to do so may result in vehicle damage.

With the help of another mechanic, remove the cylinder head.

• Remove and discard bolts 1 to 18.
• Remove bolt 19.
• Remove the gasket and send it for recycling.

9.

NOTE: Do not proceed with further dismantling if the element is removed only for access.

Remove 4 glow plugs.

Installation

1. Install glow plugs. Tighten the glow plugs to 12 Nm.


2.

NOTE: Clean the mating surface of the element.

NOTE: Measure the piston protrusion in each cylinder at top dead center (w.m.t.).

Measure the distance between the piston crown and the cylinder block at the indicated points.



3. Determine the thickness of the cylinder head gasket.

For more information, please refer to the chapter: Specifications (303-01 Engine - Diesel engine ID4 2.4L, Specifications).

4.

CAUTION: The thickness of the new cylinder head gasket depends on the piston protrusion (marked hole/prong).

Install a new cylinder head gasket.

5.

CAUTION: Install new cylinder head bolts.

NOTE: Clean the mating surface of the element.

Install the cylinder head.

• Tighten the bolts in six steps in the sequence shown.
• Stage 1: Tighten bolts 1 to 10 to 20 Nm.
• Stage 2: Tighten bolts 11 to 18 to 10 Nm.
• Stage 3: Tighten bolts 1 to 10 to 40 Nm.
• Stage 4: Tighten bolts 11 to 18 to 20 Nm.
• Stage 5: Tighten bolts 1-10 180 degrees.
• Stage 6: Tighten bolts 11 - 18 180 degrees.
• Step 7: Tighten the M6 bolt to 10 Nm.

6. Secure the glow plug harness. Tighten nuts (tightening torque 3 Nm).


7.

NOTE: Clean the contact surfaces of the elements.

Attach the exhaust manifold.

• Install a new gasket.
• Tighten the new studs to 20 Nm.
• Tighten new nuts (tightening torque 40 Nm).
• Tighten the bolts (tightening torque 40 Nm).

8. Fix the EGR heat exchanger. Tighten the bolt to 20 Nm.

9. Reinstall the intake manifold.

For more information, refer to the chapter: Intake Manifold (303-01 Engine - Diesel engine ID4 2.4L, Car repair).

10. Install camshafts.

For more information, refer to the chapter: Camshafts (303-01 Engine - Diesel engine ID4 2.4L, Car repair).

11. Connect the wire "masses" to the battery.

For more information, see the chapter: Connecting the Battery (414-01 Battery, Battery Mount and Wires, General Procedures).