LAND ROVER DEFENDER 1996 Workshop Manual

26COOLING SYSTEM
6
REPAIR RADIATOR
Service repair no - 26.40.01
Remove
1.Disconnect radiator bottom hose and drain
cooling system.
See Adjustment, Drain and
refill cooling system
2.Disconnect radiator top hose.
3.Remove viscous fan unit.
See Viscous
coupling and fan
4.Remove fan cowl.See Fan cowl
5.Disconnect oil cooler pipes. Plug all connections
to prevent oil spillage and ingress of dirt.
6.Disconnect top and bottom intercooler hoses.
7.Disconnect bleed hose at radiator.
8.Remove 2 bolts from both sides securing
radiator mounting brackets to bonnet platform.
9.Lift and remove radiator/intercooler assembly
from vehicle.
10.Remove 2 bolts from both sides and detach
radiator top cover from side covers.
11.Lift and remove radiator from intercooler and RH
side frame.
12.Check condition of locating grommets in radiator
top cover and lower mounting bushes. Renew if
necessary.Refit
13.Position radiator between intercooler and RH
side frame.
14.Fit radiator top cover to side covers.
15.Lower radiator/intercooler assembly into
position.
16.Secure radiator mounting brackets to bonnet
platform.
17.Fit radiator bleed hose.
18.Fit top and bottom intercooler hoses.
19.Fit oil cooler pipes.
20.Fit fan cowl
See Fan cowl.
21.Fit viscous fan unit.
See Viscous coupling
and fan
22.Fit radiator top hose.
23.Fit radiator bottom hose and refill cooling
system.
See Adjustment, Drain and refill
cooling system

COOLING SYSTEM
7
REPAIR EXPANSION TANK
Service repair no - 26.15.01
Remove
1.Position container to collect coolant spillage.
2.Slacken retaining clips and disconnect both
hoses from base of expansion tank.
3.Remove 3 bolts securing expansion tank to
inside wing and mounting bracket.
4.Remove expansion tank.
Refit
5.Fit expansion tank to inside wing and mounting
bracket.
6.Fit both hoses to base of tank.
7.Check and top up cooling system
See
SECTION 10, Maintenance, Under bonnet
maintenance

MANIFOLD AND EXHAUST SYSTEM
1
DESCRIPTION AND OPERATION MANIFOLDS AND EXHAUST SYSTEM
Description
The exhaust systems fitted on all models with the
300Tdi engine comprise three sections; front pipe
assembly, intermediate silencer assembly, and tail
pipe and silencer assembly. All sections, including
silencers, are manufactured from luminised steel to
give the system a durable working life under all
conditions. Special clamps are provided to ensureleak proof jointing between the various sections,
which are supported by flexible rubber mountings.
Catalytic convertor
When fitted, the catalytic converter is integral with the
front pipe assembly, which also incorporates a flexible
joint. The catalyst forms part of the engine emission
control that can also include an EGR valve system
See FUEL SYSTEM, Repair, EGR valve
Exhaust system - 90
1.Gasket
2.Front pipe
3.Front pipe with catalytic converter
4.Front mounting bracket
5.Intermediate silencer6.Intermediate mounting brackets
7.Tail pipe silencer*
8.Tail pipe silencer mounting
9.Tail pipe mounting
* Deleted on later models

30MANIFOLD AND EXHAUST SYSTEM
2
DESCRIPTION AND OPERATION The catalyst comprises platinum coated ceramic
elements. The Hydrocarbons (HC), Oxides of nitrogen
(NOx) and Carbon monoxide (CO) emitted by the
engine react with the catalytic element and exhaust
temperature to convert the toxic gas into Nitrogen
(N
2), Carbon dioxide (CO2) and water vapour.
Exhaust system - 110/130
1.Gasket
2.Front pipe
3.Front pipe with catalytic converter
4.Front mounting bracket
5.Intermediate silencer6.Intermediate mounting brackets
7.Tail pipe silencer
8.Tail pipe silencer mounting
9.Tail pipe mounting

MANIFOLD AND EXHAUST SYSTEM
1
REPAIR INDUCTION MANIFOLD
Service repair no - 30.15.02
Remove
1.Disconnect battery.
2.Remove oil filler cap and remove rocker cover
insulation.
3.Remove hose intercooler to induction manifold. If
fitted, remove EGR valve.
See FUEL SYSTEM,
Repair, EGR valve
4.Remove 2 screws and release heat shield from
induction manifold.
5.Slacken induction manifold lower securing nuts,
located below exhaust manifold.
6.Remove induction manifold upper securing bolts.
7.Remove induction manifold. Plug apertures in
cylinder head with clean rag to prevent any items
falling into engine.
8.Check gasket is satisfactory for further use.
Refit
9.Clean induction manifold mating face.
10.Position induction manifold and secure with
upper and lower fixings.
11.Tighten securing nuts and bolts to
25 Nm (18
lbf/ft).
12.Fit manifold heat shield.
13.Fit hose intercooler to induction manifold.
14.Fit rocker cover insulation.
15.Reconnect battery.INDUCTION/EXHAUST MANIFOLD GASKET
Service repair no - 30.15.15
Remove
1.Remove induction manifold
See Induction
manifold
.
2.Remove turbocharger outlet hose.
3.Raise vehicle and slacken exhaust front pipe to
intermediate silencer flange nuts. Ensure pipe is
free to turn.
NOTE: If removing exhaust manifold and
turbocharger assembly from vehicle,
remove manifold to exhaust front pipe
nuts while working under vehicle.
4.Remove exhaust manifold securing nuts,
removing centre lower nut first.
5.Move heater rail clear of exhaust manifold.
6.With exhaust manifold and turbocharger still
attached to exhaust front pipe, withdraw from
head by turning front pipe until sufficient access
is gained to remove gasket.
7.Suitably support exhaust manifold and
turbocharger assembly to prevent damage.
8.Remove induction manifold lower nuts.
9.Remove gasket.
10.Clean mating faces.

30MANIFOLD AND EXHAUST SYSTEM
2
REPAIR Refit
11.Fit new gasket over manifold studs.
12.Loosely fit induction manifold lower nuts to
studs.
13.Fit exhaust manifold and secure with central
upper and lower nuts.
14.Locate heater rail to its correct position and
secure with outer exhaust manifold nuts.
15.Tighten all exhaust manifold nuts to
45 Nm (33
lbf/ft).
16.Tighten exhaust front pipe to intermediate
silencer nuts to
50 Nm (37 lbf/ft).
17.Fit turbocharger outlet pipe.
18.Fit induction manifold
See Induction manifold
.EXHAUST MANIFOLD/TURBOCHARGER
ASSEMBLY
Service repair no - 30.15.10
Remove
1.Remove induction manifold
See Induction
manifold
.
2.Disconnect turbocharger inlet hose.
3.Disconnect boost pressure pipe at turbocharger.
4.Remove intercooler bottom hose.
5.Place suitable container under engine and
disconnect turbocharger oil feed and return
pipes at cylinder block.
6.Remove 3 nuts securing exhaust front pipe to
manifold flange.
7.Remove 7 nuts and lift exhaust manifold and
turbocharger assembly from cylinder head.
8.Discard manifold gasket.
Refit
9.Fit new manifold gasket.
10.Position exhaust manifold assembly onto
location studs and secure to cylinder head.
Tighten nuts to
45 Nm (33 lbf/ft).
11.Secure exhaust front pipe to manifold flange.
Tighten fixings to
50 Nm (37 lbf/ft).
12.Reconnect turbocharger oil feed and return
pipes at cylinder block.
13.Fit intercooler bottom hose.
14.Fit boost pressure pipe at turbocharger.
15.Fit turbocharger inlet hose.
16.Fit induction manifold
See Induction manifold
.

MANIFOLD AND EXHAUST SYSTEM
3
REPAIR EXHAUST FRONT PIPE
Service repair no - 30.10.09
Remove
1.Disconnect battery.
2.Raise vehicle on ramp.
3.Remove 3 securing nuts at exhaust manifold
flange.
4.Remove through bolt securing front pipe
mounting bracket to chassis.
5.Remove bracket and rubber mounting from
exhaust pipe.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray
See
CHASSIS AND BODY, Repair, Front undertray or
See CHASSIS AND BODY, Repair, Rear undertray
.
6.Remove flange nuts securing front pipe to
intermediate silencer assembly and separate
flanges.
7.Release front pipe at manifold and remove
gasket.
8.Move front pipe rearwards, lower front end and
at the same time twist toward propeller shaft.
Move pipe forward and withdraw from under
vehicle.
Refit
9.Manouvre front pipe into position and secure to
intermediate silencer flange. Do not fully tighten
fixings at this stage.
10.Fit new gasket and secure front pipe to exhaust
manifold. Tighten fixings to
50 Nm (37 lbf/ft).
11.Fit front pipe bracket and mounting rubber to
chassis.
12.Fully tighten front pipe to intermediate silencer
flange nuts to
30 Nm (22 lbf/ft).
13.Lower vehicle ramp and reconnect battery.

30MANIFOLD AND EXHAUST SYSTEM
4
REPAIR INTERMEDIATE PIPE - 90
Service repair no - 30.10.11
Remove
1.Raise vehicle on ramp.
2.Release intermediate pipe from front mounting
rubber, see J6243.
3.Remove 2 flange nuts securing intermediate
pipe to tail pipe.
4.Release intermediate pipe from rear mounting
rubber.
5.Remove 2 flange nuts securing intermediate
pipe to front pipe.
6.Release intermediate pipe from front and tail
pipe and remove.
Refit
7.Fit intermediate pipe to front and tail pipes.
8.Secure intermediate pipe to front and rear
mounting rubbers.
9.Secure intermediate pipe to front pipe. Tighten
nuts to
30 Nm (22 lbf/ft).
10.Secure intermediate pipe to tail pipe. Tighten
nuts to
30 Nm (22 lbf/ft).
11.Lower vehicle.INTERMEDIATE PIPE - 110/130
Service repair no - 30.10.11
Remove
1.Raise vehicle on ramp.
2.Release intermediate pipe from mounting
rubber, see J6244.
3.Remove 2 flange nuts securing intermediate
pipe to tail pipe.
4.Remove 2 flange nuts securing intermediate
pipe to front pipe.
5.Release intermediate pipe from front and tail
pipe and remove.
Refit
6.Fit intermediate pipe to front and tail pipes.
7.Secure intermediate pipe to mounting rubbers.
8.Secure intermediate pipe to front pipe. Tighten
nuts to
30 Nm (22 lbf/ft).
9.Secure intermediate pipe to tail pipe. Tighten
nuts to
30 Nm (22 lbf/ft).
10.Lower vehicle.

MANIFOLD AND EXHAUST SYSTEM
5
REPAIR TAILPIPE - 90
Service repair no - 30.10.22
Remove
1.Raise vehicle on ramp.
2.Remove 2 flange nuts securing tail pipe to
intermediate pipe, see J6243.
3.Release tail pipe from inboard mounting rubber.
4.Release tail pipe from outboard mounting rubber
and remove.
Refit
5.Fit tail pipe to intermediate pipe.
6.Secure tail pipe to mounting rubbers.
7.Secure tail pipe to intermediate pipe. Tighten
nuts to
30 Nm (22 lbf/ft).
8.Lower vehicle.TAILPIPE - 110/130
Service repair no - 30.10.22
Remove
1.Raise vehicle on ramp.
2.Remove 2 flange nuts securing tail pipe to
intermediate pipe, see J6244.
3.Release tail pipe from front mounting rubber.
4.Release tail pipe from rear mounting rubber.
5.Release tail pipe from intermediate pipe and
feed over rear axle.
6.Remove tail pipe.
Refit
7.Feed tail pipe over rear axle and connect to
intermediate pipe.
8.Secure tail pipe to mounting rubbers.
9.Secure tail pipe to intermediate pipe. Tighten
nuts to
30 Nm (22 lbf/ft).
10.Lower vehicle.

CLUTCH
1
DESCRIPTION AND OPERATION DESCRIPTION
The clutch unit comprises a single dry plate friction
disc and diaphragm spring clutch unit, secured to the
engine flywheel.OPERATION
The unit is operated hydraulically by the clutch master
cylinder (12) and a slave cylinder (13) attached to the
transmission bell housing.
Clutch components
1.Crankshaft and flywheel
2.Friction plate
3.Clutch cover
4.Diaphragm spring
5.Pressure plate
6.Fulcrum posts (9) for diaphragm spring
7.Bearing rings (2) for diaphragm spring
8.Retraction links and bolts (3) for pressure plate
9.Release bearing10.Release lever
11.Release lever pivot post
12.Master cylinder
13.Slave cylinder
14.Master cylinder pedal pushrod
15.Primary shaft and taper bearing (in gearbox)
16.Gearbox front cover
17.Primary shaft flywheel bush
18.Pedal pivot and return spring