Land Rover Defender: Cylinder Head

REMOVAL AND INSTALLATION

SPECIAL TOOL(S)

JLR-303-1653

Cylinder Head Bolt Remover/Installer

PART(S)

REMOVAL

CAUTION: Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.

NOTE:

• This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
• This procedure contains illustrations showing certain components removed to provide extra clarity.

1. Raise and support the vehicle on a suitable 2 post lift.

2. Disconnect the startup battery ground cable.

3. Remove and discard the oil filter element.

4. Remove the intake manifold.

5. Remove the turbocharger.

6. Remove the camshaft carrier.

7.

• Remove the bolt.
• Disconnect the electrical connector from the link harness.
• Disconnect the electrical connector from the cylinder head temperature sensor.
• Disconnect the electrical connector from the oil pressure and temperature sensor.

8.

Remove and discard the cylinder head temperature sensor.

9.

CAUTION: Be prepared to collect escaping coolant.

• Remove the 2 bolts.
• Remove the coolant pipe assembly.

10.

WARNING: Be prepared to collect escaping oil.

• Remove the 3 bolts.
• Remove the oil filter housing.

11.

• Remove the 2 pipes.
• Remove and discard the 5 O-ring seals.

12.

CAUTION: Be prepared to collect escaping coolant.

• Remove the bolt.
• Disconnect the coolant pipe from the cylinder head.

13.

Remove the front Noise, Vibration and Harshness (NVH) material.

14.

Remove the left NVH material.

15.

CAUTION:

• Mark each camshaft follower and hydraulic lash adjuster. Make sure each component is returned to its original installed position.
• Make sure that the components are clean, dry and free from corrosion and foreign material.
• Inspect the components for wear and replace if necessary.

• Remove the 8 camshaft followers.
• Remove the 8 hydraulic lash adjusters.

16.

Remove the 3 bolts.

17.

Remove the bolt.

18.

• Use the special tool to remove the 10 bolts in the illustrated sequence.

  Special Tool(s): JLR-303-1653

• Discard the 10 bolts.

19.

WARNING: Be prepared to collect escaping fluids.

CAUTION:

• Take extra care not to damage the surrounding components.
• Take extra care not to damage the edges of the component.

With the aid of another technician, remove the cylinder head.

20.

Remove and discard the cylinder head gasket.

21.

CAUTION: Make sure that the dowels and dowel holes are clean and free from debris and foreign material.

Remove the 2 dowels.

22.

CAUTION: Only use a plastic scraper to clean off the old gasket.

Clean and inspect the cylinder head and cylinder block.

INSTALLATION

1. Check the cylinder head face for distortion.

2.

CAUTION: Make sure that the dowels and dowel holes are clean and free from debris and foreign material.

Install the 2 dowels.

3.

CAUTIONS:

• Make sure that the mating surfaces are clean and free from debris and foreign material.
• The cylinder head gasket must be installed over the cylinder head to the 2 dowels.

Install a new cylinder head gasket.

Renew Part: Cylinder head gasket Quantity: 1.

4.

CAUTION: Make sure that the component is correctly located on the locating dowels.

With the aid of another technician, install the cylinder head.

5.

• Use the special tool to install and tighten 10 new cylinder head bolts in the illustrated sequence.

  Special Tool(s): JLR-303-1653 Renew Part: Cylinder head bolts Quantity: 10.

  Torque: 20Nm

6.

• Use the special tool to tighten the 10 bolts in the illustrated sequence.

  Special Tool(s): JLR-303-1653
  Torque

  • Stage1: 90º
  • Stage2: 180º
• Remove the special tool.

  Special Tool(s): JLR-303-1653

7.

Install and tighten the bolt.

Torque: 25Nm

8.

Install and tighten the 3 bolts.

Torque: 12Nm

9.

CAUTION:

• Make sure that the components are clean, dry and free from corrosion and foreign material.
• Inspect the components for wear and replace if necessary.

NOTE: Make sure that these components are installed to the noted removal position.

• Install the 8 hydraulic lash adjusters.
• Install the 8 camshaft followers.

10. Install the front Noise, Vibration and Harshness (NVH) material.

11. Install the left NVH material.

12.

• Connect the coolant pipe to the cylinder head.
• Install and tighten the bolt.

  Torque: 8Nm

13.

• Install 5 new O-ring seals.

  Renew Part: Oil filter housing inlet / outlet O-ring seals Quantity: 1.

  Renew Part: Oil filter housing drain port O-ring seal Quantity: 1.

• Install the 2 pipes to the oil filter housing.

14.

• Install the oil filter housing.
• Install and tighten the 3 bolts.

  Torque: 12Nm

15.

• Install the coolant pipe assembly.
• Install and tighten the 2 bolts.

  Torque: 12Nm

16.

• Install and tighten a new cylinder head temperature sensor.

  Renew Part: Cylinder head temperature sensor Quantity: 1.

  Torque: 11Nm

17.

• Connect the electrical connector to the oil pressure and temperature sensor.
• Connect the electrical connector to the cylinder head temperature sensor.
• Connect the electrical connector to the link harness.
• Install and tighten the bolt.
• Torque: 7Nm

18. Install the camshaft carrier.

19. Install the turbocharger.

20. Install the intake manifold.

21. Install a new oil filter element.

22. Connect the startup battery ground cable.

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