Land Rover Defender: Upper Timing Chain

REMOVAL AND INSTALLATION

SPECIAL TOOL(S)

JLR-303-1630

Locking Tool, Crankshaft Pulley

JLR-303-1635

Camshaft Setting Tool

JLR-303-1636

Locking Tool, Variable Camshaft Timing Actuator / Unit

JLR-303-1656

Crank Rotation Tool

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 the hood.

4. Remove the upper timing cover.

5. Remove the charge air cooler.

6.

• Release the 4 clips.
• Reposition the wiring harness away form the charge air cooler bracket.
• Remove the nut.
• Repostion the 2 coolant pipes away from the charge air cooler bracket.

7.

• Remove the nut.
• Remove the 2 bolts.
• Remove the charge air cooler bracket.

8.

• Install the special tool.

  Special Tool(s): JLR-303-1656

• Use the special tool to rotate the crankshaft clockwise until the timing marks align as illustrated.

9.

• Install the special tool.

  Special Tool(s): JLR-303-1635

• Install and tighten the 2 bolts.

  Torque: 13Nm

10.

• Install the special tool.

  Special Tool(s): JLR-303-1636

• Install and tighten the 2 bolts.

  Torque: 13Nm

11.

• Install the special tool.

  Special Tool(s): JLR-303-1630

• Install and tighten the 2 bolts.

12.

Loosen, but do not fully remove the 2 bolts.

13.

Remove and discard the upper timing chain tensioner.

14.

• Remove the 2 bolts.
• Remove the special tool.

  Special Tool(s): JLR-303-1636

15.

CAUTION: Note the location of the Variable Camshaft Timing (VCT) units prior to removal. Each VCT unit is matched to a specific camshaft.

• Remove and discard the 2 bolts.
• Remove the 2 VCT actuators.

16.

• Remove the 2 bolts.
• Remove and discard the upper timing chain guide.

17.

• Remove the bolt.
• Remove and discard the upper timing chain guide.

18.

Remove and discard the upper timing chain guide.

19.

Remove the upper timing chain.

INSTALLATION

1.

NOTE: Maintain tension on the chain to prevent the coloured link from disengaging with its sprocket position.

• Install the upper timing chain.
• Make sure the colored link is aligned with the timing mark on the idler sprocket.

2.

NOTE: Maintain tension on the chain to prevent the coloured link from disengaging with its sprocket position.

• Install a new upper timing chain guide.

  Renew Part: Upper timing chain guide Quantity: 1.

• Install and tighten the bolt.

  Torque: 25Nm

3.

CAUTION: Make sure that the upper timing chain does not come off the idler sprocket and stays in the correct position.

• Install the intake camshaft Variable Camshaft Timing (VCT) actuator. Make sure that the correct VCT actuator is installed as noted in the removal steps.
• Make sure the dowel is correctly installed to the VCT actuator as illustrated.
• Install and tighten the new bolt.

  Renew Part: Variable camshaft timing actuator bolts Quantity: 1.

  Torque

  • Stage1: 10Nm
  • Stage2: Loosen 90º
• Make sure the timing mark is aligned with the center of the colored link.

4.

NOTE: Maintain tension on the chain to prevent the coloured link from disengaging with its sprocket position.

Install a new upper timing chain guide.

Renew Part: Upper timing chain guide Quantity: 1.

5.

CAUTION: Make sure that the upper timing chain does not come off the idler sprocket and stays in the correct position.

• Install the exhaust camshaft VCT actuator. Make sure that the correct VCT actuator is installed as noted in the removal steps.
• Make sure the dowel is correctly installed to the VCT actuator as illustrated.
• Install and tighten the new bolt.

  Renew Part: Variable camshaft timing actuator bolts Quantity: 1.

  Torque

  • Stage1: 10Nm
  • Stage2: Loosen 90º
• Make sure the groove on the exhaust VCT actuator is aligned with the center of the colored link.

6.

CAUTION: Make sure that the upper timing chain does not come off the idler sprocket and stays in the correct position.

• Install a new upper timing chain guide.

  Renew Part: Upper timing chain guide Quantity: 1.

• Install and tighten the 2 bolts.

  Torque: 11Nm

7.

• Install the special tool.

  Special Tool(s): JLR-303-1636

• Install and tighten the 2 bolts.

  Torque: 13Nm

8.

Install and tighten a new upper timing chain tensioner.

Renew Part: Upper timing chain tensioner Quantity: 1.

Torque: 55Nm

9.

CAUTION: Do not directly touch the timing chain tensioner at this stage.

• Push and release the upper timing chain guide to release the upper timing chain tensioner.
• Make sure the upper timing chain is correctly released.

10.

Tighten the 2 bolts.

Torque

• Stage1: 25Nm
• Stage2: 60º

11.

• Remove the 2 bolts.
• Remove the special tool.

  Special Tool(s): JLR-303-1636

12.

• Remove the 2 bolts.
• Remove the special tool.

13. Install the upper timing cover.

14.

• Remove the 2 bolts.
• Remove the special tool.

  Special Tool(s): JLR-303-1630

15.

• Install the charge air cooler bracket.
• Install and tighten the 2 bolts.

  Torque: 47Nm

• Install and tighten the nut.

  Torque: 9Nm

16.

• Reposition the 2 coolant pipes in the correct location.
• Install and tighten the nut.

  Torque: 9Nm

• Install the 4 clips.

17. Install the charge air cooler.

18. Install the hood.

19. Connect the startup battery ground cable.

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