Head cover — removal and installation (Defender 2007+)

Removing

Warnings:

• Some fuel will inevitably spill during this operation. Ensure that all necessary precautions have been taken to prevent fire and explosion.
• Do not carry or use a cell phone while working on or in the vicinity of any fuel related items. There is a danger of ignition of flammable vapours. Failure to follow these instructions may result in injury.
• Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. There is a danger of ignition of flammable vapours. Failure to follow these instructions may result in injury.
• If fuel gets in your eyes, rinse them with cold water or special eyewash solution and seek immediate medical attention.
• Wash your hands thoroughly after handling fuel as prolonged skin contact with fuel may cause irritation. Seek medical attention if irritation occurs.
• Do not carry out any repairs to the fuel system while the engine is running. The 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 close clearances. Therefore, when working with these nodes, absolute cleanliness is required. Be sure to install new plugs in all open holes and piping. Failure to follow this instruction may lead to the penetration of dirt into the fuel injection system.

1. 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).


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



3. Remove the fuel injectors.

For more information, see chapter: Fuel injector (303-04A Fuel supply and controls - Diesel engine ID4 2.4L, 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.

• Completely loosen 12 bolts.
• Remove the gasket and send it for recycling.

Installation

1.

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

Reinstall the elements in reverse order.

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

2. 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).