oil filter LAND ROVER DEFENDER 1999 Owner's Guide

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.
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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.
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COOLING SYSTEM
7
DESCRIPTION AND OPERATION Radiator
The 44 row radiator is located at the front of the vehicle in the engine compartment. The cross flow type radiator is
manufactured from aluminium with moulded plastic end tanks interconnected with tubes. The bottom four rows are
separate from the upper radiator and form the lower radiator for the fuel cooler. Aluminium fins are located
between the tubes and conduct heat from the hot coolant flowing through the tubes, reducing the coolant
temperature as it flows through the radiator. Air intake from the front of the vehicle when moving carries the heat
away from the fins. When the vehicle is stationary, the viscous fan draws air through the radiator fins to prevent
the engine from overheating.
Two connections at the top of the radiator provide for the attachment of the top hose from the outlet housing and
bleed pipe to the expansion tank. Three connections at the bottom of the radiator allow for the attachment of the
bottom hose to the thermostat housing and the return hose from the oil cooler and the feed hose to the fuel cooler.
The bottom four rows of the lower radiator are dedicated to the fuel cooler. The upper of the two connections at
the bottom of the radiator receives coolant from the oil cooler. This is fed through the four rows of the lower
radiator in a dual pass and emerges at the lower connection. The dual pass lowers the coolant temperature by up
to 24°C before being passed to the fuel cooler. Two smaller radiators are located in front of the cooling radiator.
The upper radiator is the intercooler for the air intake system and the lower radiator provides cooling of the
gearbox oil.
Pipes and Hoses
The coolant circuit comprises flexible hoses and metal formed pipes which direct the coolant into and out of the
engine, radiator and heater matrix. Plastic pipes are used for the bleed and overflow pipes to the expansion tank.
A bleed screw is installed in the radiator top hose and is used to bleed air during system filling. A drain plug to
drain the heater and cylinder block circuit of coolant is located on the underside of the coolant pump feed pipe.
Oil Cooler
The oil cooler is located on the left hand side of the engine block behind the oil centrifuge and oil filter. Oil from the
oil pump is passed through a heat exchanger which is surrounded by coolant in a housing on the side of the
engine.
Full water pump flow is directed along the cooler housing which also distributes the flow evenly along the block
into three core holes for cylinder cooling. This cools the engine oil before it is passed into the engine. A small
percentage of the coolant from the oil cooler passes into a metal pipe behind the engine. It then flows into the
lower radiator via a hose.
Fuel Cooler
The fuel cooler is located on the right hand side of the engine and is attached to the inlet manifold. The cooler is
cylindrical in design and has a coolant feed connection at its forward end. A’T’connection at the rear of the cooler
provides a connection for the coolant return from the heater matrix and coolant return from the fuel cooler.
The’T’connection houses a thermostat which opens at approximately 82°C. This prevents the cooler operating in
cold climates. Two quick release couplings on the cooler allow for the connection of the fuel feed from the
pressure regulator and return to the fuel tank. A counter flow system is used within the cooler.
Fuel flows around a coolant jacket within the cooler and flows from the back to the front of the cooler. As the hot
fuel cools travelling slowly forwards it meets progressively colder coolant travelling in the opposite direction
maintaining a differential cooling effect.
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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.
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STEERING
1
REPAIR STEERING COLUMN - UPPER - Td5
Service repair no - 57.40.01
Remove
1.Ensure road wheels and steering wheel are set
in the straight ahead position.
2.Loosen 2 clips securing air inlet pipe between
turbo and inlet air filter.
3.Remove air inlet pipe.
4.Mark relationship between the upper steering
column and the lower steering column universal
joint.
5.Remove bolt securing upper column to lower
column universal joint.
6.Remove steering colum nacelle.See this
Section.
7.Remove instrument pack.See
INSTRUMENTS, Repair.
8.Disconnect 3 column switch multiplugs.
9.Loosen column switch clamping screw.
10.Remove column switch assembly from steering
column.
11.Disconnect 4 Lucars from rear of ignition switch.
NOTE: Take note of Lucars correct fitted
position. Details can also be found in the
Electrical Reference Library.
12.Remove passive coil.See ELECTRICAL,
Repair.
13.Drill out 2 shear bolts securing ignition barrel to
column.
14.Remove ignition barrel.
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STEERING
3
REPAIR Refit
NOTE: The steering column is a
non-servicable component and can only
be serviced as a complete assembly.
29.Fit mounting bracket to column and manouvre
assembly into position.
NOTE: Ensure marks on upper and lower
columns are aligned.
30.Loosely fit bolts securing mounting bracket to
bulkhead.
31.Fit upper clamp and rubber packing to column.
32.Loosely fit bolts securing upper clamp to
mounting bracket.
33.Loosely fit bolts securing 2 halves of upper
clamp.
34.Loosely fit bolts securing column lower mounting
bracket.
35.Fit bolt securing upper tie bar to steering column
and tighten to22 Nm (16 lbf.ft).
36.Tighten mounting bracket to bulkhead bolts,
clamp bolts, and lower mounting bolts.
M6 bolts =9 Nm (6 lbf.ft)
M8 bolts =22 Nm (16 lbf.ft)
37.Manouvre brake pedal box assembly and NEW
gasket into position in vehicle.
38.Tighten bolts securing brake pedal box to
bulkhead to25 Nm (18 lbf.ft)
39.Connect brake pedal switch Lucars.
40.Reposition mat to underside of fascia.
41.Secure ABS modulator multiplug to side of brake
pedal box.
42.Fit brake servo.See BRAKES, Repair.
43.Fit ignition switch to steering column, ensuring
inner shaft slot aligns with steering lock plunger.
44.Evenly tighten clamp bolts, but DO NOT shear at
this stage.
45.Temporarily fit steering wheel and check for
correct operation of switch and lock.
46.Remove steering wheel.
47.Fully tighten ignition switch bolts until heads
shear.48.Connect Lucars to rear of ignition switch.
49.Fit passive coil to ignition switch and connect
multiplug.
50.Fit switch assembly to steering column and
tighten clamping screw.
51.Connect column switch multiplugs.
52.Fit instrument pack.See INSTRUMENTS,
Repair.
53.Fit steering column nacelle.See this Section.
54.Fit bolt securing upper column to lower column
universal joint and tighten to25 Nm (18 lbf.ft).
55.Fit air inlet pipe between turbo and inlet air filter
and secure with clips.
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AIR CONDITIONING
1
ADJUSTMENT REFRIGERANT RECOVERY, RECYCLING,
RECHARGING
Service repair no - 82.30.02
WARNING: The air conditioning system is
charged with a high pressure, potentially
toxic refrigerant. Repairs or servicing must
only be carried out by an operator familiar with
both the vehicle system and the charging and
testing equipment.
WARNING: All operations must be carried
out in a well ventillated area away from
open flame and heat sources.
WARNING: Wear eye and hand safety
protection.
CAUTION: Overcharging air conditioning
system will cause excessive head
pressure.
An air conditioning portable Refrigerant Recovery
Recycling Recharging Station for use with R134a
refrigerant incorporates all the features necessary to
recover R134a refrigerant from the air conditioning
system; to filter and remove moisture; to evacuate and
recharge with the reclaimed refrigerant. The unit can
also be used for performance testing and air
conditioning system analysis.
The operator must adhere to the equipment
manufacturer’s instructions.
Refrigerant Recovery
1.Remove dust caps from high and low pressure
connectors.
2.Connect high and low pressure hoses to
appropriate connections.
3.Open valves on connectors.
4.Turn valves on refrigerant station to correct
positions.
NOTE: Operate the refrigerant station in
accordance with the manufacturers
instructions.
5.Turn Process switch to correct position.
6.Turn Main switch to’ON’.
7.Allow station to recover refrigerant from system.8.Close valves on refrigerant station.
9.Turn Main switch to’OFF’.
10.Close valves on connectors.
11.Disconnect high and low pressure hoses from
connectors.
12.Fit dust caps to connectors.
13.Open tap at rear of station to drain refrigerant oil
recovered from system.
14.Measure and record quantity of refrigerant oil
recovered from system.
15.Close tap at rear of station.
Evacuation
CAUTION: Whenever the refrigerant
system is opened, the receiver/drier must
be renewed immediately before evacuating
and recharging the system.
1.Remove dust caps from high and low pressure
connectors.
2.Connect high and low pressure hoses to
appropriate connections.
3.Open valves on connectors.
4.Turn valves on refrigerant station to correct
positions.
5.Turn Process switch to correct position.
6.Turn Main switch to’ON’.
7.Allow station to evacuate system.
NOTE: If the vacuum reading is below
700mmHg after 15 minutes, suspect a leak
in the system. Partially recharge the
system and check for leaks using an electronic
leak tester. Check suction lines first, then run the
compressor for 5 minutes. Next check the high
pressure lines.
NOTE: The system must be evacuated
immediately before recharging
commences. Delay between evacuation
and recharging is not permitted.
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