Fuel injector — 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.

Caveats:

• 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.
• Be sure to perform the cleaning procedure before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may lead to the penetration of dirt into 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 workshop area where the vehicle is being worked on as clean and dust-free as possible. Dirt and dust from working on the clutch, brakes, or from machining or welding can contaminate the fuel system and lead to malfunctions later.

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. Remove the engine cover.

For more information, see chapter: Engine cover (501-05 Interior trim, Removal and installation).

3. Using a vacuum cleaner, remove foreign matter from the high pressure fuel supply lines, fuel manifolds and high pressure fuel pump.

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

4.

Caveats:

• Do not strike 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 feed lines and discard them.



5. Release the fuel injector harness.

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

6.

CAUTION: Plug all openings. Use new caps.

Release the fuel return line.

• Remove 2 clips.
• Remove and discard 2 o-rings.

7. Remove the fuel injector clamp cover.



8.

NOTE: Mark the location of the nozzle clamp pin.

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



9.

Caveats:

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

Remove the fuel injector.




10. Remove and discard 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 nozzles.



3.

NOTE: Remove and discard plugs.

Install fuel injectors.

4.

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

Install the fuel injector clamp.

• Stage 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 clamps.

7. Attach the fuel injector harness.

• 1. Connect the plug connectors of the fuel injectors.
• 2. Secure with clamps.

8.

NOTE: Remove and discard plugs.

Secure the high pressure fuel lines.

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

9. Replace the engine cover.

For more information, see chapter: Engine cover (501-05 Interior trim, Removal and installation).

10. 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).

11. Check the fuel system for leaks using the Land Rover approved diagnostic system.

12. Perform the Fuel Injector Calibration procedure using a Land Rover approved diagnostic system.