ECU LAND ROVER DEFENDER 1996 Repair Manual

26COOLING SYSTEM
2
REPAIR FAN COWL
Service repair no - 26.25.11
Remove
1.Disconnect battery.
2.Drain coolant.
See Adjustment, Drain and
refill cooling system.
3.Slacken retaining clips and remove radiator top
hose.
4.Slacken retaining clip and remove top hose from
intercooler.
NOTE: On vehicles fitted with EGR system,
remove complete intercooler top hose
assembly.
5.Remove viscous coupling and fan
See Viscous coupling and fan.
6.Remove 2 nuts securing top of fan cowl.
7.Release expansion tank hose from clips at base
of fan cowl.
8.Lift and remove cowl .
NOTE: On vehicles fitted with air
conditioning, it will be necessary to
remove the cowl and viscous fan unit
together to enable clearance of the compressor.Refit
9.Position fan cowl.
10.Fit viscous fan unit.
See Viscous coupling
and fan
11.Fit expansion tank hose into fan cowl clips.
12.Secure top of fan cowl to radiator top cover.
13.Fit intercooler top hose.
14.Fit radiator top hose.
15.Refill cooling system.
See Adjustment, Drain
and refill cooling system
16.Reconnect battery.
FAN PULLEY
Service repair no - 26.25.04.
Remove
1.Disconnect battery.
2.Remove viscous fan unit.
See Viscous
coupling and fan
3.Remove drive belt.See ELECTRICAL, Repair,
Auxiliary drive belt
4.Unscrew 4 bolts and remove pulley from adaptor
boss.
Refit
5.Fit fan pulley to adaptor boss. Tighten bolts to
25
Nm (18 lbf/ft).
6.Fit drive belt.See ELECTRICAL, Repair,
Auxiliary drive belt
7.Fit viscous fan unit.See Viscous coupling
and fan
8.Reconnect battery.

COOLING SYSTEM
3
REPAIR WATER PUMP
Service repair no - 26.50.01
Remove
1.Disconnect battery.
2.Drain cooling system.
See Adjustment, Drain
and refill cooling system
3.Remove radiator top hose.
4.Remove intercooler top hose.
5.Slacken water pump and power steering pump
pulley retaining bolts.
6.Remove drive belt.
See ELECTRICAL, Repair,
Auxiliary drive belt
7.Unscrew flange nut and remove belt tensioner.
8.Remove oil filler cap and remove rocker cover
insulation.
9.Slacken retaining clip and disconnect hose at
heater rail.
10.Unscrew 3 bolts and remove water pump pulley.
11.Unscrew 3 bolts and remove power steering
pump pulley.
12.Remove 8 bolts securing water pump, noting
location of 3 through bolts into cylinder block.
13.Withdraw pump and gasket from auxiliary
mounting bracket.
14.Clean all gasket material from mating faces.
Refit
15.Using new gasket, fit water pump to mounting
bracket. Tighten bolts to
25 Nm (18 lbf/ft).
16.Fit power steering pump pulley.
17.Fit water pump pulley. Tighten bolts of both
pulleys to
25 Nm (18 lbf/ft).
18.Fit drive belt.See ELECTRICAL, Repair,
Auxiliary drive belt
19.Fit hose at heater rail.
20.Fit rocker cover insulation and oil filler cap.
21.Fit drive belt tensioner. Tighten retaining nut to
45 Nm (33 lbf/ft).
22.Fit intercooler top hose.
23.Fit radiator top hose.
24.Refill cooling system.
See Adjustment, Drain
and refill cooling system
25.Reconnect battery.

26COOLING SYSTEM
4
REPAIRREV: 05/99 AUXILIARY MOUNTING BRACKET AND GASKET
Service repair no - 26.50.04
Remove
1.Disconnect battery.
2.Drain cooling system
See Adjustment, Drain
and refill cooling system
.
3.Remove radiator top hose.
4.Remove intercooler top hose.
5.Remove viscous fan unit.
See Viscous
coupling and fan
6.Remove fan cowl.See Fan cowl
7.Slacken power steering pump pulley retaining
bolts.
8.Remove drive belt.
See ELECTRICAL, Repair,
Auxiliary Drive belt
9.Unscrew 3 bolts and remove power steering
pump pulley.
10.Remove 4 bolts securing power steering pump
mounting bracket.
11.Lower pump and bracket. Do not disconnect fluid
pipes.
12.Remove generator.
See ELECTRICAL, Repair,
Generator
13.Unscrew retaining nut and remove drive belt
tensioner.
14.Release hose clip from bracket above water
pump.15.Disconnect bottom hose/heater return hose at
water pump and heater rail.
16.Disconnect by-pass hose from water pump and
thermostat housing.
17.Remove 5 bolts (one with nut) and single
retaining nut, securing auxiliary mounting
bracket to cylinder block.
18.Withdraw mounting bracket, complete with water
pump.
19.Remove gasket and clean mating faces.
Refit
20.Using 2 slave studs, fit new gasket.
NOTE: All fixing bolts and nuts should be
tightened to
25 Nm (18 lbf/ft)unless
otherwise stated.
21.Locate mounting bracket, complete with water
pump on slave studs and secure with 4 other
fixings.
22.Remove slave studs and fit remaining bolts/nuts.
23.Fit by-pass hose to thermostat housing and
water pump.
24.Fit bottom hose/heater return hose to water
pump and heater rail.
25.Fit heater hose clip to mounting bracket.
26.Fit drive belt tensioner. Tighten nut to
45 Nm (33
lbf/ft).
27.Fit generator.See ELECTRICAL, Repair,
Generator
Do not fit drive belt at this stage.

COOLING SYSTEM
5
REPAIR 28.Secure steering pump and bracket to auxiliary
mounting bracket.
29.Fit steering pump pulley.
30.Fit drive belt
See ELECTRICAL, Repair,
Auxiliary drive belt
.
31.Fit fan cowl
See Fan cowl.
32.Fit viscous fan unit
See Viscous coupling and
fan
.
33.Fit intercooler top hose.
34.Fit radiator top hose.
35.Refill cooling system.
See Adjustment, Drain
and refill cooling system
36.Reconnect battery.THERMOSTAT
Service repair no - 26.45.01
Remove
1.Partially drain cooling system, until coolant level
is below thermostat housing.
2.Disconnect top hose from outlet elbow.
3.Disconnect electrical connections to water
temperature switch.
4.Unscrew 2 bolts and remove outlet elbow.
5.Withdraw thermostat. Note 88°C rating of
thermostat.
6.Place thermostat in a container half full of water.
Heat water and observe temperature at which
thermostat begins to open. Thermostat is
satisfactory if it opens between 85°-89°C.
Refit
7.Fit thermostat with jiggle pin/vent hole upwards.
8.Secure outlet elbow to thermostat housing.
Tighten bolts to
25 Nm (18 lbf/ft).
9.Fit water temperature switch connections.
10.Fit top hose to outlet elbow.
11.Refill cooling system.
See Adjustment, Drain
and refill cooling system

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
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.