Engine disassembly (Defender 2007+)

Disassembly

1. Install the engine on a suitable engine stand.

2. Drain the engine oil.

• Place a container to collect engine oil.
• Remove the drain plug.
• Let the engine oil drain.

3. Disconnect the electrical connector of the crankshaft position sensor (CKP).



4. Remove the SKR sensor. Turn out a bolt.



5. Remove the CKP sensor bracket. Turn out two bolts.




6.

CAUTION: Loosen the clutch pressure plate bolts by backing out two turns at a time in the sequence shown.

Remove the driven and pressure plates of the clutch. Turn out 6 bolts.



7. Remove the flywheel. Remove and discard 8 bolts.



8. Remove and discard the crankshaft rear oil seal. Remove 8 bolts.




9. Install the EGR valve assembly with the heat exchanger.

• Disconnect the EGR valve electrical connector.
• Turn out 5 bolts.
• Discard two gaskets.

10. Disconnect the camshaft position sensor electrical connector (CMP).



11. Release the engine wiring harness. Release the clamp.




12.

iCAUTION: Plug all openings. Use new caps.

Remove the high pressure fuel pump feed line. Turn out a bolt.



13. Release the EGR valve outlet pipe. Turn out a bolt.



14. Remove the EGR valve outlet pipe and intake manifold assembly.

• Completely loosen 9 bolts.
• Remove eight seals and discard.

15. Release the engine wiring harness. Release 3 clamps.




16. Disconnect the engine oil pressure sensor electrical connector (EOP).



17. Disconnect the electrical connectors for the fuel metering valve and fuel temperature sensor.



18. Disconnect the coolant hose. Release the clamp.



19. Release the coolant manifold.

• Remove 8 bolts.
• Remove the gasket and send it for recycling.

20. Release the coolant pump.

• Turn out 4 bolts.
• Remove the gasket and send it for recycling.

21. Remove the coolant pump and coolant manifold assembly.

22. Remove the power steering pump bracket. Turn out 3 bolts.



23. Remove the left engine mount bracket. Turn out 4 bolts.



24.

CAUTION: Plug all openings. Use new caps.

Remove the oil filter housing assembly.

• Turn out 6 bolts.
• Remove the gasket and send it for recycling.

25. Remove the A/C compressor pulley cover.

• Turn out two bolts.
• Remove the nut.
• Remove the accessory drive belt.

26. Remove the engine lift bracket. Turn out 3 bolts.



27. Disconnect the AC compressor electrical connector.



28. Remove the air conditioning compressor. Turn out 3 bolts.



29. Disconnect the positive battery cable from the alternator. Remove the nut.



30. Disconnect the electrical connector of the generator.



31. Remove the generator. Turn out 3 bolts.



32. Release the turbocharger heat shield bracket. Turn out a bolt.



33. Remove the turbocharger heat shield bracket. Turn out a bolt.



34. Remove the generator support bracket. Remove 8 bolts.



35. Release the wiring harness of the mass air flow sensor (MAF). Cut the clamp.



36. Disconnect the turbocharger drive electrical connector.



37. Disconnect the breather line. Release the clamp.



38.

CAUTION: Plug all openings. Use new caps.

Disconnect the turbocharger oil supply line.

• Turn out a hollow bolt.
• Remove the sealing washers and discard them.

39.

CAUTION: Plug all openings. Use new caps.

Remove the oil level indicator tube and oil level indicator.

• Turn out a bolt.
• Disconnect the wiring harness.
• Remove the O-ring and send it for recycling.

40. Disconnect the turbocharger oil return line.

• Turn out two bolts.
• Remove the gasket and send it for recycling.

41. Remove the exhaust manifold assembly with the turbocharger.

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

42. Remove the right engine mount bracket. Turn out 4 bolts.



43.

CAUTION: Plug all openings. Use new caps.

Remove the turbocharger oil return line.

• Turn out a bolt.
• Remove clamp.
• Remove the O-ring and send it for recycling.

44. Remove the engine cover. Turn out two bolts.



45. Disconnect the fuel rail pressure sensor electrical connector (FRP).



46. Disconnect the four electrical connectors for the injectors.

• Disconnect the injector wiring harness.
• Release 7 clamps.

47. Install the engine wiring harness support bracket.

• Remove the nut.
• Turn out a bolt.

48. Release the glow plug harness. Remove four nuts.



49. Remove the engine wiring harness.

50.

CAUTION: Plug all openings. Use new caps.

Remove the high pressure fuel supply line and discard it. Release two clamps.



51.

CAUTION: Plug all openings. Use new caps.

Remove the 4 injector high pressure fuel lines and discard them.



52.

CAUTION: Plug all openings. Use new caps.

Disconnect the injector fuel return line. Remove 4 clips.



53. Remove 2 injector clip covers.



54. Remove 2 nozzle clips. Turn out two bolts.



55. Remove 4 nozzles. Remove and discard the sealing washer.



56. Remove the fuel rail.

• Turn out two bolts.
• Remove the bracket.

57. Remove the accessory drive belt idler pulley. Turn out 5 bolts.



58. Remove the cylinder block coolant outlet elbow.

• Remove the nut.
• Turn out two bolts.
• Remove the O-ring and send it for recycling.

59. Remove the crankshaft pulley. Remove and discard 3 bolts.



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

• Remove 20 bolts.
• Remove two nuts.

61. Remove the cylinder head cover.

• Turn out 12 bolts.
• Remove the gasket and send it for recycling.

62. Remove the rocker axles. Loosen and discard 10 bolts.



63. Loosen the 6 camshaft sprocket bolts.



64. Loosen the 4 injection pump sprocket bolts.



65. Loosen and lock the timing chain tensioner.

• 1. Take the dog away.
• 2. Push in the latch.
• 3. Insert the pin.

66. Remove the timing chain tensioner and right timing chain guide.

• Turn out two bolts.
• Remove the nut.

67. Remove the upper timing chain guide. Turn out two bolts.



68. Remove the camshaft sprockets the timing chain. Turn out 6 bolts.



69. Remove the high pressure fuel pump sprocket. Turn out 4 bolts.



70. Remove the high pressure fuel pump.

• Turn out two bolts.
• Remove the O-ring and send it for recycling.

71.

CAUTION: Remove the bolts in the sequence shown. Failure to do so may result in vehicle damage.

Remove the camshaft housing. Remove 25 bolts.



72. Remove camshafts.



73.

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

Remove the cylinder head.

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

74. Remove and discard the oil pan.

• Remove 11 bolts.
• Loosen 5 nuts.
• Remove 5 pins.

75. Remove the oil pump chain tensioner.

• 1. Insert the bolt and secure the tensioner.
• 2. Lock the tensioner by inserting the pin.
• 3. Remove the leaf spring from the stud.
• Turn out a bolt.

76. Remove the oil pump intake pipe.

• Turn out two bolts.
• Remove the O-ring and send it for recycling.

77. Remove the oil pump.

• Turn out 4 bolts.
• Disconnect the chain from the crankshaft sprocket.

78.

CAUTION: Remove the step frame bolts in the sequence shown.

Remove the step frame.

• Remove 22 bolts.
• Discard the gasket.

79. Remove the connecting rod bearing caps. Remove 8 bolts.



80. Remove connecting rods and pistons.

81. Remove the crankshaft main bearing caps. Remove 10 bolts.



82. Remove the crankshaft.

• Remove the crankshaft thrust rings.
• Remove the crankshaft main bearing shells.