radiator LAND ROVER DEFENDER 1999 Owner's Manual

26COOLING SYSTEM
4
REPAIR
9.Remove 4 bolts securing RH and LH radiator
mounting brackets to body and remove brackets.
10.Release clip and release air hose from
turbocharger inlet pipe.11.Release bottom hose from bracket on lower
cooling fan cowl.
12.Remove radiator assembly and collect lower
mounting spacers.
13.Remove 2 bolts and remove intercooler from
radiator. Collect 2 nuts from radiator side
brackets.
14.Remove 2 rubber mountings from intercooler.
15.Remove 2 screws and remove lower cooling fan
cowl from radiator.
16.Remove 2 rubber mountings from bottom of
radiator.
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COOLING SYSTEM
5
REPAIR Refit
17.Fit rubber mountings to bottom of radiator.
18.Fit lower cooling fan cowl to radiator and secure
with screws.
19.Fit nuts to radiator side brackets.
20.Position intercooler to radiator and tighten bolts.
21.Fit rubber mountings to intercooler.
22.Position mounting spacers and fit radiator.
23.Fit bottom hose into bracket on lower cooling fan
cowl.
24.Position air hose to turbocharger pipe and
secure with clip.
25.Position LH and RH radiator mounting brackets
to body and radiator and tighten bolts.
26.Position coolant rail hose to radiator and secure
with clip.
27.Position fuel cooler hose to radiator and secure
with clip.
28.Position top hose to radiator and secure with
clip.
29.Position bleed hose to radiator and secure with
clip.
30.Position bonnet platform and tighten bolts.
31.Fit cooling fan.See this Section.
32.Fit front grille.See CHASSIS AND BODY,
Repair.
33.Fill cooling system.See Adjustment.
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CHASSIS AND BODY
5
REPAIR
13.Remove 4 bolts securing radiator mounting
bracket to wing.
14.Loosen screw and release bonnet lock inner
cable from bonnet lock.
15.Release bonnet lock outer cable from from
bonnet lock.
16.Push centre pins from studs securing wheel arch
extension to wing, remove studs and remove
wheel arch extension.
17.Remove bolt securing inner and outer wing to
chassis.
18.Remove nut and bolt securing support stay to
wing.
19.Remove 4 bolts securing wing to’A’post.
20.Remove bolt securing wing to bulkhead.
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CHASSIS AND BODY
7
REPAIR Refit
29.Fit bonnet cable grommet.
30.Fit side repeater lamp to wing.
31.Fit headlamp sealing ring, fit headlamp and
tighten screws.
32.Fit headlamp finisher, side and indicator lamps
and tighten screws.
33.Fit grille support bracket and tighten bolt.
34.With assistance, position and align wing to body
and locate bonnet cable to wing.
35.Connect headlamp, indicator, side lamp and side
repeater lamp multiplugs.
36.Fit bolt securing wing to bulkhead.
37.Fit bolts securing wing to’A’post.
38.Fit nut and bolt securing support stay to wing.
39.Fit bolt securing inner and outer wing to chassis.
40.Fit bolts securing radiator bracket to wing.
41.Fit bolts securing outer wing to inner wing.
42.Align wing and finally tighten all bolts.
43.Position wheel arch extension to wing, and fit
securing studs.
44.Position PAS reservoir to wing and tighten bolts.
45.Position expansion tank pipe and secure with
studs.
46.Position EGR solenoid and tighten bolts.
47.Position heater air intake seal and fit air intake.
48.Fit heater air intake bracket and tighten bolts.
49.Fit heater air intake grille and tighten screws.
50.Align air cleaner intake elbow, tighten screws
and fit grille.
51.Fit wheel arch liner.See this Section.
52.Position bonnet release cable to lock and tighten
screw.
53.Fit cooling fan cowl.
54.Fit front grille.See this Section.STEP - FOLDING - REAR DOOR
Service repair no - 76.10.41
Remove
1.Remove 2 bolts securing step to chassis
member, remove step and collect spacers.
Refit
2.Position step, fit spacer washers and tighten
bolts.
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PANEL REPAIRS
1
REPAIR WING LOWER FRONT
Remove
1.Disconnect both battery leads, negative lead
first. system.
2.Remove wheel arch eyebrow.
3.Remove wheel arch liner.
4. RH side:Remove aerial.
5.Remove air intake hose.
6.Remove bolts securing lower wing.
Refit
7.Prepare and clean panel joint faces.
8.Reverse removal procedure.HEADLAMP MOUNTING PANEL
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect all ECUs.
3.Remove radiator.See COOLING SYSTEM,
Repair.
4.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
5.Remove headlamp.See ELECTRICAL,
Repair.
6. LH side:Remove screen washer bottle.See
WIPERS AND WASHERS, Repair.
7. RH side:Position PAS reservoir aside.
8.Remove bolts and release welds securing panel,
remove panel.
Refit
9.Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown.
10.Reverse removal procedure.
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77PANEL REPAIRS
2
REPAIR WING UPPER - LH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove headlamp.See ELECTRICAL,
Repair.
3.Remove headlamp mounting panel.See this
Section.
4.Remove radiator.See COOLING SYSTEM,
Repair.
5.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
6.Remove receiver drier.See AIR
CONDITIONING, Repair.
7.Remove relevant A/C pipes.
8.Remove relevant heater intake pipes.
9.Remove screen washer bottle.
10.Remove wheel arch liner.See CHASSIS AND
BODY, Repair.
11.Remove bolts and release welds securing panel,
remove panel.
Refit
12.Prepare and clean panel joint faces.
13.Reverse removal procedure.
14.Align headlamps.See ELECTRICAL,
Adjustment.WING UPPER - RH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove headlamp.See ELECTRICAL,
Repair.
3.Remove headlamp mounting panel.See this
Section.
4.Remove radiator.See COOLING SYSTEM,
Repair.
5.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
6.Remove relevant A/C pipes.
7.Position PAS reservoir aside.
8.Remove wheel arch liner.See CHASSIS AND
BODY, Repair.
9.Remove aerial.
10.Remove vacuum solenoid valve.
11.Release clips securing coolant reservoir.
12.Remove bolts and release welds securing panel,
remove panel.
Refit13.Prepare and clean panel joint faces.
NOTE: LH panel shown
14.Reverse removal procedure.
15.Align headlamps.See ELECTRICAL,
Adjustment.
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PANEL REPAIRS
3
REPAIR WHEEL ARCH - FRONT
Remove
The procedure to change the Inner Front Wheelarch is
the same as for the Wing Upper, except for removal of
the ABS sensors and shield, if fitted.
BULKHEAD ASSEMBLY
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove front lower wing.See this Section.
3.Remove RH and LH front upper wing.See this
Section.
4.Remove headlamp mounting panels.See this
Section.
5.Remove screen aperture.See this Section.
6.Remove both front doors.
7.Remove lower fascia panel.See CHASSIS
AND BODY, Repair.
8. Models with A/C:Remove relevant A/C pipes.
9.Remove front grille.
10.Drain cooling system.See COOLING
SYSTEM, Adjustment.
11.Remove radiator and intercooler.
12. Models with A/C:Remove condensor.
13.Remove air cleaner assembly.
14.Remove heater unit.See HEATING AND
VENTILATION, Repair.
15.Remove brake servo assembly.
16.Remove heater ducts.
17.Remove both front seats.
18.Remove front carpets.
19.Release all relevant harnesses and position
aside.
20.Remove facia support bracket.
Refit
21.Prepare and clean panel joint faces. Ensure all
necessary grommets and sealant is applied to
new bulkhead.
22.Reverse removal procedure.
23.Bleed brake system.See BRAKES,
Adjustment.
24.Align headlamps.See ELECTRICAL,
Adjustment.
25.Water test after refitting.
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82AIR CONDITIONING
2
REPAIR MOTOR - CONDENSER FAN
Service repair no - 82.15.01
Remove
1.Remove 6 screws and remove radiator grille.
2.Disconnect fan multiplug and release multiplug
holder from retaining clip.
3.With assistance remove 4 nuts and bolts
securing motor to condenser.
4.Remove motor.
Refit
5.Position motor to condenser and with assistance
tighten nuts and bolts to8 Nm (6 lbf.ft).
6.Connect motor multiplug.
7.Position radiator grille and secure with screws.RECEIVER DRIER
Service repair no - 82.17.03
Remove
1.Recover refrigerant from A/C system.See
Adjustment.
2.Remove 2 bolts securing pipe unions to receiver
drier.
3.Release pipes and discard’O’rings.
CAUTION: Immediately cap all air
conditioning pipes to prevent ingress of
dirt and moisture into the system.
4.Remove 2 bolts securing receiver drier mounting
bracket to chassis.
5.Remove receiver drier, slacken clamp bolt and
remove bracket.
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ELECTRICAL
3
REPAIR ALTERNATOR
Service repair no - 86.10.02
Remove
1.Remove auxilliary drive belt.See this Section.
2.Release cover and remove nut securing lead to
alternator.
3.Disconnect alternator multiplug.
4.Remove bolt (LH thread) and remove auxiliary
drive belt tensioner.
5.Remove bolt securing support stay to alternator.
6.Release clip securing lubrication drain hose to
vacuum pump.
7.Loosen vacuum pump lubrication pipe from
cylinder head and discard’O’ring.
8.Remove bolt securing alternator and release
from mounting bracket.
9.Disconnect hose from vacuum pump.
10.Remove alternator taking care not to damage
radiator cooling fins.
11.Remove 4 bolts, and remove vacuum pump from
alternator.
CAUTION: Plug the connections.
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