air filter LAND ROVER DEFENDER 1999 User Guide

ENGINE
19
REPAIR 70.Connect coolant hoses to fuel cooler and coolant
rail and secure clips.
71.Fit air intake hose to intake elbow and tighten
clip screw.
72.Fit starter motor.See ELECTRICAL, Repair.
73.Fit turbocharger.See FUEL SYSTEM, Repair.
74.Fit radiator.See COOLING SYSTEM, Repair.
75.Fit air filter.See FUEL SYSTEM, Repair.
76.Fill engine with oil.
77.Fit underbelly panel.See CHASSIS AND
BODY, Repair.MOUNTING - FRONT - LH
Service repair no - 12.45.01
Remove
1.Remove centrifuge assembly.See this
Section.
2.Remove 3 bolts, remove oil filter adaptor
housing and discard gasket.
3.Fit suitable lifting chains to support engine.
4.Remove 2 nuts securing engine mounting to
chassis.
5.Remove 4 bolts securing engine mounting
bracket to cylinder block.
6.Remove nut securing mounting to mounting
bracket.
7.Remove mounting and mounting bracket.
8.Remove mounting shield.
ProCarManuals.com

12ENGINE
20
REPAIR Refit
9.Fit shield to mounting ensuring cut-away portion
is correctly aligned.
10.Fit mounting and mounting bracket.
11.Fit mounting bracket to cylinder block bolts and
tighten to48 Nm (35 lbf.ft).
12.Fit nuts securing mounting to chassis and tighten
to85 Nm (63 lbf.ft).
13.Fit mounting to mounting bracket nut and tighten
to85 Nm (63 lbf.ft).
14.Remove engine support chains.
15.Clean oil filter adaptor housing and mating face.
16.Fit oil filter adaptor housing using a new gasket
and tighten bolts to25 Nm (18 lbf.ft).
17.Fit centrifuge assembly.See this Section.MOUNTING - FRONT - RH
Service repair no - 12.45.03
Remove
1.Remove engine acoustic cover.See this
Section.
2.Remove fixings, remove battery cover.
3.Disconnect battery negative lead.
4.Raise front of vehicle.
WARNING: Support on safety stands.
5.Remove 4 bolts, move fuel cooler to one side.
6.Fit suitable lifting chains to support engine.
7.Remove 2 nuts securing engine mounting to
chassis.
8.Remove 4 bolts securing engine mounting
bracket to cylinder block.
9.Remove nut securing mounting to mounting
bracket.
10.Remove mounting and mounting bracket.
ProCarManuals.com

ENGINE
23
REPAIR FILTER - OIL
Service repair no - 12.60.04
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Release clip and disconnect breather hose from
camshaft cover.
3.Release clips and disconnect air flow meter from
air filter.
4.Disconnect multiplug from air flow meter.
5.Loosen clip screw and remove air inlet hose
from turbocharger.
6.Remove 3 bolts and remove manifold heat
shield.
7.Clean area around filter head and place a
container beneath engine.
8.Using a strap wrench, unscrew and discard filter.
Refit
9.Clean mating face of filter head.
10.Lubricate sealing ring of new filter with clean
engine oil.
11.Fit filter and tighten by hand until it seats then
tighten a further half turn.
12.Start and run engine to check for leaks.
13.Stop engine, wait a few minutes, then check oil
level.
14.Top up engine oil.
15.Position exhaust manifold heat shield and
tighten 3 bolts.
16.Position air inlet hose to turbocharger and
tighten clip screw.
17.Connect air flow meter to air filter and secure
clips.
18.Connect air flow meter multiplug.
19.Connect breather hose and secure with clip.
20.Position engine acoustic cover.
ProCarManuals.com

12ENGINE
28
REPAIR SWITCH - OIL PRESSURE
Service repair no - 12.60.50
Remove
1.Remove fixings and remove engine acoustic
cover.
2.Release clip and disconnect breather hose from
camshaft cover.
3.Release clips and disconnect air flow meter from
air filter.
4.Disconnect multiplug from air flow meter.
5.Release clip screw and remove air inlet hose
from turbocharger.
6.Remove 3 bolts and remove exhaust manifold
heat shield.
7.Disconnect multiplug from oil pressure switch.
8.Position container below switch to catch oil
spillage.
9.Remove oil pressure switch.
Refit
10.Clean oil pressure switch threads.
11.Fit oil pressure switch and tighten to9Nm(7
lbf.ft).
12.Connect switch multiplug.
13.Position exhaust manifold heat shield and
tighten M6 bolts to10 Nm (7 lbf.ft)and M8 bolt
to25 Nm (18 lbf.ft).
14.Position air inlet hose to turbocharger and
tighten clip screw.
15.Connect air flow meter to air filter and secure
clips.
16.Connect air flow meter multiplug.
17.Connect breather hose and secure clip.
18.Fit and secure engine acoustic cover.
19.Top up engine oil.
ProCarManuals.com

ENGINE
29
REPAIR VALVE - RELIEF - OIL PRESSURE
Service repair no - 12.60.56
Remove
1.Remove sump gasket.See this Section.
2.Remove and discard oil pressure relief valve
plug from oil pump housing.
3.Remove spring and valve.
Refit
4.Clean valve and spring.
5.Clean valve seating inside oil pump housing.
6.Lubricate valve and seating.
7.Fit valve and spring to pump.
8.Apply Loctite 243 sealant to threads of a new
plug.
9.Fit plug and tighten to23 Nm ( 17 lbf.ft).
10.Fit sump gasket.See this Section.
11.Check engine oil level, top-up if necessary.COOLER - ENGINE OIL
Service repair no - 12.60.68
Remove
1.Drain cooling system.See COOLING
SYSTEM, Adjustment.
2.Remove centrifuge assembly.See this
Section.
3.Remove clutch housing bolt and release coolant
pipe from rear of engine.
4.Release clip and coolant hose from oil cooler.
5.Disconnect oil pressure switch multiplug.
6.Remove oil filter element using a suitable strap
wrench.
7.Remove 3 bolts, remove oil filter adaptor and
discard gasket.
8.Remove 7 bolts, remove oil cooler and discard
gasket.
9.Remove oil pressure switch.
ProCarManuals.com

12ENGINE
30
REPAIR Refit
10.Clean oil cooler and mating faces.
11.Fit oil pressure switch and tighten to9Nm(7
lbf.ft).
12.Position oil cooler using a new gasket and
tighten bolts to25 Nm (18 lbf.ft).
13.Position oil filter adaptor, fit new gasket and
tighten bolts to25 Nm (18 lbf.ft).
14.Position oil filter element hand tight then a
further half turn.
15.Position coolant hose to oil cooler and secure
clip.
16.Position coolant pipe and tighten clutch housing
bolt to50 Nm (37 lbf.ft).
17.Connect oil pressure switch multiplug.
18.Fit centrifuge assembly.See this Section.
19.Refill cooling system.See COOLING SYSTEM,
Adjustment.
20.Top up engine oil.CENTRIFUGE ASSEMBLY
Service repair no - 12.60.90
Remove
1.Remove fixings and remove underbelly panel.
See CHASSIS AND BODY, Repair.
2.Remove 2 bolts securing centrifuge drain pipe to
engine sump and discard gasket.
3.Remove turbocharger.See FUEL SYSTEM,
Repair.
Models with air conditioning only
4.Remove auxiliary drive belt.See
ELECTRICAL, Repair.
5.Remove 4 bolts securing compressor and move
to one side.
ProCarManuals.com

12ENGINE
20
OVERHAUL GASKET - ENGINE SUMP
Service repair no - 12.60.38.01
Remove
1.Remove 2 bolts securing centrifuge oil drain pipe
to sump, remove and discard gasket.
2.Using sequence shown and noting their fitted
positions, remove 20 bolts securing sump to
cylinder block.
3.Remove sump, remove and discard gasket.
CAUTION: Do not lever between sump and
cylinder block.Refit
1.Clean sump and mating faces, ensure bolt holes
in cylinder block are clean and dry.
2.Using suitable solvent, remove all traces of
sealant from joint faces of timing chain cover and
crankshaft rear oil seal housing.
3.Clean centrifugal filter oil drain pipe and mating
faces.
4.Apply a bead of sealant, Part No. STC 3254 to
joint faces of timing chain cover and crankshaft
rear oil seal housing.
CAUTION: Assembly and bolt tightening
must be completed within 20 minutes of
applying sealant.
5.Position new sump gasket.
CAUTION: Gasket must be fitted dry.
6.Position sump, fit and lightly tighten bolts
ensuring they are in their original fitted positions.
ProCarManuals.com

17 - EMISSION CONTROL
CONTENTS
Page
DESCRIPTION AND OPERATION
EGR SYSTEM COMPONENTS - TYPE 1 2............................................................
EGR SYSTEM COMPONENTS - TYPE 2 4............................................................
EMISSION CONTROL SYSTEMS 6.......................................................................
CRANKCASE EMISSION CONTROL 7..................................................................
EXHAUST GAS RECIRCULATION 8.....................................................................
EGR MODULATOR 9..............................................................................................
INLET THROTTLE (ILT) MODULATOR 10.............................................................
EGR VALVE 11.......................................................................................................
INLET THROTTLE (ILT) VALVE 12........................................................................
IN-LINE AIR FILTER - PRE EU´ u MODELS 13........................................................
EGR SYSTEMS 14.................................................................................................
REPAIR
VALVE - EGR - NON EU3 MODELS 1...................................................................
VALVE - EGR - EU3 MODELS 2............................................................................
INLET THROTTLE (ILT) MODULATOR 3...............................................................
SOLENOID - VALVE - EGR 3.................................................................................
ProCarManuals.com

EMISSION CONTROL
3
DESCRIPTION AND OPERATION 1.EGR Solenoid
2.Vacuum hose (light brown)
3.T-piece
4.Vacuum hose to brake servo
5.Non-return valve
6.Brake servo
7.Inlet manifold
8.Exhaust manifold
9.EGR pipe
10.Vacuum pump/alternator assembly
11.Air intake hose from intercooler
12.EGR valve assembly
13.Vacuum hose to vacuum pump
14.Vacuum hose to EGR valve suction port (blue)
15.To atmosphere
16.In-line filter
17.Vent hose - EGR solenoid to in-line filter (green)
ProCarManuals.com

EMISSION CONTROL
5
DESCRIPTION AND OPERATION
CAUTION: Inset A shows the Pre-EU3 condition for the EGR pipe. Inset B shows the Pre-EU3
condition filter and venting.
1.ILT valve modulator
2.ILT modulator vacuum hose (brown)
3.EGR valve modulator
4.EGR modulator vacuum hose (brown)
5.Vent hose - EGR modulator to in-line filter (green)
6.Vacuum hose to ILT valve suction port (blue)
7.Vacuum hose to EGR valve suction port (blue)
8.’T’-piece (4-way)
9.Vacuum hose to brake servo
10.Non-return valve
11.Brake servo
12.Inlet manifold
13.Exhaust manifold
14.ILT valve
15.EGR cooler - EU-3 models
16.Vacuum pump/alternator assembly
17.Air intake hose from intercooler
18.EGR valve (incorporating ILT valve) assembly
19.Vacuum hose to vacuum pump
20.Vent hose - ILT valve modulator to in-line filter (green)
21.3-way connector
22.Vent hose to air cleaner
23.ILT modulator harness connector (green)
24.EGR modulator harness connector (black)
25.To atmosphere - Pre-EU3 models
26.In-line filter - Pre-EU3 models
27.EGR pipe - Pre-EU3 models
ProCarManuals.com