drain bolt LAND ROVER DEFENDER 1999 Owner's Manual

FUEL SYSTEM
5
REPAIR TURBOCHARGER
Service repair no - 19.42.01
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove 3 bolts and remove engine acoustic
cover.
4.Release clip and disconnect breather hose from
camshaft cover.
5.Release clips and disconnect air flow meter from
air filter.
6.Disconnect multiplug from air flow meter.
7.Loosen clip screw and remove air inlet hose
from turbocharger.
8.Remove 3 bolts and remove exhaust manifold
heat shield.
9.Release clip and disconnect vacuum hose from
turbocharger wastegate.
10.Loosen clip screw and release air outlet hose
from turbocharger.
11.Remove turbocharger oil feed banjo bolt and
discard sealing washers.
12.Remove 3 nuts and release exhaust front pipe
from turbocharger and discard gasket.
13.Remove 3 nuts securing turbocharger to exhaust
manifold.
14.Loosen and unscrew turbocharger drain pipe
union from cylinder block.
15.Remove turbocharger and discard gasket.
16.Remove 2 bolts and remove turbocharger oil
drain pipe. Discard gasket.
ProCarManuals.com

19FUEL SYSTEM
6
REPAIR Refit
17.Clean turbocharger and oil drain pipe mating
faces.
18.Using a NEW gasket, fit turbocharger drain pipe
and tighten bolts to10 Nm (7 lbf.ft).
19.Using a new gasket fit turbocharger to exhaust
manifold and tighten nuts to30 Nm (22 lbf. ft).
20.Position oil drain pipe to cylinder block and
tighten union.
21.Using new gasket, align exhaust front pipe and
tighten nuts to30 Nm (22 lbf.ft)
22.Fit banjo bolt to oil feed pipe using new sealing
washers and tighten to25 Nm (18 lbf.ft).
23.Position air outlet hose to turbocharger and
tighten clip screw.
24.Position and secure vacuum hose to
turbocharger wastegate.
25.Position exhaust manifold heat shield and
tighten M6 bolts to9 Nm (7 lbf.ft)and M8 bolt to
25 Nm (18 lbf.ft).
26.Position air inlet hose to turbocharger and
tighten clip screw.
27.Connect air flow meter to air filter and secure
clips.
28.Connect air flow meter multiplug.
29.Connect breather hose and secure clip.
30.Fit engine acoustic cover and secure with bolts.
31.Reconnect battery negative lead.
32.Fit battery cover.FILTER ASSEMBLY - AIR
Service repair no - 19.10.01
Remove
1.Loosen clip screw and release intake hose from
air filter.
2.Release 2 clips securing air flow meter.
3.Release air flow meter from air filter cover and
position aside.
4.Disconnect multiplug from AAP sensor.
5.Release air filter from 3 grommets, remove
assembly and discard’O’ring.
6.Remove 2 screws, remove AAP sensor and
discard’O’ring.
ProCarManuals.com

FUEL SYSTEM
7
REPAIR Refit
7.Clean air flow meter faces.
8.Fit new’O’ring to air filter.
9.Clean AAP sensor.
10.Using new’O’ring, fit AAP sensor and tighten
screws.
11.Position air filter assembly and secure in
grommets.
12.Position air flow meter and secure clips.
13.Position intake hose to air filter and tighten clip
screw.INJECTOR - SET
Service repair no - 19.60.12
Remove
1.Remove cooling fan.See COOLING SYSTEM,
Repair.
2.Remove rocker shaft.See ENGINE , Repair.
3.Position container to catch fuel spillage.
4.Disconnect quick release fuel hose connectors
from fuel connector block on cylinder head and
fuel cooler to drain fuel from cylinder head.
5.Disconnect 5 multiplugs from injectors.
6.Remove Torx bolt securing injector unit to
cylinder head.
ProCarManuals.com

19FUEL SYSTEM
12
REPAIR FUEL TANK
Service repair no - 19.55.01
Remove
1.Drain fuel tank.See Adjustment.
2.Raise rear of vehicle.
WARNING: Support on safety stands.
Vehicles fitted with tow bar
3.Remove 2 bolts securing support bars to drop
plate.
4.Loosen 2 nuts securing support bars to chassis.All Vehicles
5.Remove 2 nuts securing fuel tank support to rear
chassis member.
6.Remove 2 bolts securing fuel tank support plate
to chassis member.
7.Release clip securing filler hose and release
hose from filler neck.
ProCarManuals.com

19FUEL SYSTEM
14
REPAIR Refit
19.Clean fuel pump and mating face.
20.Fit new fuel pump sealing ring.
21.Fit fuel pump and secure with locking ring.
22.Fit breather hose and secure clip.
23.Position heat shield and secure with scrivits.
24.With assistance position fuel tank and support
plate.
25.Connect fuel hoses and multiplug to fuel pump.
26.Connect filler neck breather and secure clip.
27.Position vent hose and secure to chassis clips.
28.Raise fuel tank to its fitted position.
29.Fit nuts and bolts securing fuel tank and tighten
to25 Nm (18 lbf.ft).
30.Connect filler hose and secure clip.
Vehicles fitted with tow bar
31.Position support bar and tighten nuts and bolts.
32.Reconnect battery negative lead.
33.Fit battery cover.NECK - FUEL TANK FILLER
Service repair no - 19.55.07
Remove
1.Drain fuel tank.See Adjustment.
2.Loosen clip securing breather hose to fuel filler
neck and release hose.
3.Loosen clip securing fuel filler hose to neck and
release hose.
4.Remove screw and release earth lead from filler
neck.
5.Remove grommet securing filler neck to body.
6.Remove filler neck from body.
Refit
7.Fit filler neck to body.
8.Coat rubber grommet with soap solution.
9.Fit rubber grommet securing filler neck to body.
10.Connect earth lead and tighten screw.
11.Connect filler hose to neck and tighten clip.
12.Fit breather hose to filler neck and secure with
clip.
ProCarManuals.com

COOLING SYSTEM
1
REPAIR COUPLING - COOLING FAN
Service repair no - 26.25.19
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove 3 bolts and remove engine acoustic
cover.
4.Remove cooling fan cowl.
NOTE: Thread is RH.
5.Remove cooling fan usingLRT-12-093and
LRT-12-094.
Refit
6.Position cooling fan and tighten using
LRT-12-093andLRT-12-094.
7.Fit cooling fan cowl.
8.Fit engine acoustic cover.
9.Reconnect battery negative lead.
10.Fit battery cover.THERMOSTAT
Service repair no - 26.45.09
Remove
1.Drain cooling system.See Adjustment.
2.Remove cooling fan.See this Section.
3.Release 3 clips and disconnect coolant hoses
from thermostat.
4.Remove thermostat.
Refit
5.Position thermostat, connect hoses and secure
with clips.
6.Fit cooling fan.See this Section.
7.Fill cooling system.See Adjustment.
ProCarManuals.com

26COOLING SYSTEM
2
REPAIR PUMP - COOLANT
Service repair no - 26.50.01
Remove
1.Drain cooling system.See Adjustment.
2.Remove centrifuge.See ENGINE , Repair.
3.Release clip and hose from coolant pump cover.
4.Remove 5 bolts securing coolant pump cover.
5.Remove cover and coolant pump from housing
and discard’O’rings.Refit
6.Clean coolant pump housing and mating faces.
7.Fit new’O’rings to coolant pump and cover.
8.Fit coolant pump and cover and tighten bolts to9
Nm (7 lbf.ft).
9.Connect hose to pump cover and secure clip.
10.Refit centrifuge.See ENGINE , Repair.
11.Refill cooling system.See Adjustment.
ProCarManuals.com

COOLING SYSTEM
3
REPAIR RADIATOR
Service repair no - 26.40.01
Remove
1.Remove front grille.See CHASSIS AND
BODY, Repair.
2.Drain cooling system.See Adjustment.
3.Remove cooling fan.See this Section.
4.Remove 5 bolts and move bonnet platform
aside.
5.Release clip and disconnect bleed hose from
radiator.
6.Release clip and disconnect top hose from
radiator.
7.Release clip and disconnect fuel cooler hose
from radiator.
8.Release clip and disconnect coolant rail hose
from radiator.
ProCarManuals.com

37MANUAL GEARBOX
8
REPAIR
12.Remove 13 screws securing tunnel cover.
13.Release and remove tunnel cover.
14.Remove cooling fan.See COOLING SYSTEM,
Repair.
15.Remove air filter.See FUEL SYSTEM, Repair.
16.Remove 2 upper bolts securing clutch housing to
engine.
17.Remove bolt securing shim to clutch housing.
18.Release gearbox breather pipes from clips on
heater hose.
19.Remove starter motor.See ELECTRICAL,
Repair.
20.Remove exhaust front pipe.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
21.Drain gearbox oil.See Adjustment.
22.Drain transfer gearbox oil.See
MAINTENANCE ,
23.Remove 3 nuts securing intermediate silencer to
tail pipe.
24.Release silencer from mounting rubbers, remove
silencer and discard gasket.
25.Mark front and rear propeller shaft to transfer
gearbox flanges for reassembly purposes.
ProCarManuals.com

TRANSFER GEARBOX
1
REPAIR BOTTOM COVER - TRANSFER GEARBOX -
RESEAL
Service repair no - 41.20.06
1.Raise vehicle on ramp.
2.Remove 6 bolts securing rear underbelly panel
and remove panel.
3.Drain transfer gearbox oil.
4.Remove 10 bolts securing bottom cover to
transfer gearbox and remove cover.
Refit
5.Clean bottom cover and mating face on transfer
gearbox.
6.Clean bolt threads.
7.Apply Loctite 290 to bolt threads.
8.Apply Hylosil RTV sealant to bottom cover
sealing face.
9.Position bottom cover, fit bolts and tighten to25
Nm (18 lbf.ft).
10.Fill transfer gearbox with oil.
11.Fit rear underbelly panel and tighten bolts.
12.Lower vehicle on ramp.TRANSFER GEARBOX
Service repair no - 41.20.25.99
Remove
1.Position vehicle on a’4 post’ramp
2.Remove battery cover.
3.Disconnect battery negative lead.
4.Select low range gear and leave vehicle in
neutral.
5.Remove gear lever knobs.
6.Remove gearbox tunnel carpet.
7.Remove gear lever cover.
8.Release and remove insulation pad.
9.Remove cubby box.See CHASSIS AND
BODY, Repair.
10.Remove 4 screws securing access panel,
diagnostic plug mounting bracket and place
aside.
11.Remove trim stud and lift up handbrake gaiter for
access to clevis pin.
12.Remove split pin, washer, clevis pin and
disconnect cable from handbrake lever.
ProCarManuals.com