service LAND ROVER DEFENDER 1999 Owner's Guide

12ENGINE
22
REPAIR MOUNTING - GEARBOX - REAR - RH
Service repair no - 12.45.09
Remove
1.Remove LH rear gearbox mounting.See this
Section.
2.Remove 4 bolts securing mounting bracket to
transfer gearbox.
3.Remove 2 nuts, remove mounting and mounting
bracket.
Refit
4.Clean mounting and mating faces.
5.Position mounting and mounting bracket and
tighten nuts to48 Nm (35 lbf.ft)and bolts to85
Nm (63 lbf.ft).
6.Fit LH rear gearbox mounting.See this
Section.FLYWHEEL
Service repair no - 12.53.07
Remove
1.Remove clutch assembly.See CLUTCH,
Repair.
2.Remove and discard 8 bolts securing flywheel to
crankshaft and remove flywheel.
NOTE: Dowel located.
Refit
3.Clean flywheel and crankshaft mating face.
4.Position flywheel to crankshaft.
5.Fit new flywheel retaining bolts and tighten by
diagonal selection to:
Stage 1 -40 Nm (30 lbf.ft)
Stage 2 -Further 90°
CAUTION: Do not carry out stages 1 and 2
in one operation.
6.Fit clutch assembly.See CLUTCH, Repair.
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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.
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12ENGINE
24
REPAIR STRAINER - OIL PICK-UP
Service repair no - 12.60.20
Remove
1.Remove sump gasket.See this Section.
2.Remove 3 Torx screws securing oil pick-up
strainer.
3.Remove and discard’O’ring.
Refit
4.Clean oil pick-up strainer faces.
5.Fit new’O’ring to oil pick-up strainer.
6.Fit oil pick-up strainer, apply Loctite 242 to
threads of Torx screws; fit screws and tighten to
10 Nm (7 lbf.ft).
7.Fit new sump gasket.See this Section.PUMP - OIL
Service repair no - 12.60.26
Remove
1.Remove sump gasket.See this Section.
2.Remove bolt securing oil pump sprocket to oil
pump drive spindle.
3.Remove sprocket from oil pump.
4.Remove 3 Torx screws securing oil pick-up
strainer; remove strainer.
5.Remove and discard’O’ring.
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12ENGINE
26
REPAIR
15.Position oil pump drive sprocket and chain on to
oil pump ensuring that the’D’shape on the drive
sprocket is located on flat on the oil pump drive
shaft.
16.Clean oil pump drive sprocket retaining bolt and
apply Loctite 242 to bolt threads.
17.Fit oil pump drive sprocket retaining bolt and
tighten to25 Nm (18 lbf.ft).
18.Fit new sump gasket.See this Section.GASKET - ENGINE TO SUMP
Service repair no - 12.60.38
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove exhaust front pipe.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
4.Drain engine oil.
5.Loosen 4 bolts securing sump to gearbox bell
housing.
6.Remove 2 bolts securing centrifuge drain pipe to
sump and discard gasket.
7.Using sequence shown and noting their fitted
position, remove 20 bolts securing sump.
8.Remove sump, remove and discard gasket.
CAUTION: Do not lever between sump and
cylinder block.
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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.
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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.
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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.
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12ENGINE
32
REPAIR ROTOR - CENTRIFUGE
Service repair no - 12.60.91
Remove
1.Remove 2 bolts and remove centrifuge cover.
2.Remove and discard’O’ring and rotor
Refit
3.Clean centrifuge body and cover.
4.Fit new rotor.
5.Fit centrifuge cover using new’O’ring and
tighten bolts to9 Nm (7 lbf.ft).OIL SEAL - TIMING COVER
Service repair no - 12.65.05
Remove
1.Remove crankshaft pulley.See this Section.
2.PositionLRT-12-092into crankshaft front oil seal
and discard seal.
Refit
3.Using a lint free cloth, thoroughly clean oil seal
recess and the running surface on crankshaft
pulley.
4.Position new seal into timing chain housing. Drift
seal into place usingLRT-12-156.
5.RemoveLRT-12-156.
6.Fit crankshaft pulley.See this Section.
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ENGINE
33
REPAIR TIMING CHAIN AND SPROCKETS
Service repair no - 12.65.13
Remove
1.Remove crankshaft front oil seal.See this
Section.
2.Remove cylinder head gasket.See this
Section.
3.Remove sump gasket.See this Section.
4.Release clip securing vacuum pump drain hose
to timing chain cover.
5.Remove 8 bolts securing timing chain cover.
6.Remove cover.
7.Remove timing chain and camshaft sprocket.
8.Remove 2 bolts and remove timing chain fixed
guide.
9.Remove bolt and remove timing chain adjustable
guide.
10.Remove bolt securing oil pump drive sprocket.
11.Remove crankshaft sprocket, oil pump drive
chain and sprocket.
12.Remove bolt and remove timing chain lubrication
jet.
Refit
13.Clean timing chain lubrication jet.
14.Fit lubrication jet and tighten bolt to10 Nm (7
lbf.ft).
15.Clean oil pump drive sprocket bolt threads.
16.Clean timing sprockets and chain guides.
17.Ensure that crankshaft is set to TDC firing No. 1
cylinder.
18.Fit oil pump drive chain to crankshaft sprocket
and fit sprocket to crankshaft.
19.Fit sprocket to oil pump.
20.Apply Loctite 242 to oil pump sprocket bolt
threads and tighten bolt to25 Nm (18 lbf.ft).
21.Fit timing chain fixed guide and tighten M10 bolt
to45 Nm (34 lbf.ft)and M6 bolt to10 Nm (7
lbf.ft).
22.Fit timing chain adjustable guide and tighten bolt
to25 Nm (18 lbf.ft).
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ENGINE
1
OVERHAUL GASKET - INLET MANIFOLD
Service repair no - 30.15.08.01
Remove
NOTE: The following procedure covers
both EU3 and non EU3 engines
NOTE: EU3 Engine in main illustration, Pre
EU3 condition shown in inset.
1.Remove and discard 2 Allen screws securing
EGR pipe or EGR cooler to exhaust manifold.
2.Remove bolt securing EGR pipe to cylinder
head, (if fitted)
3.Disconnect multiplug from IAT and MAP sensor.
4.Remove 4 bolts securing fuel cooler to inlet
manifold. and remove cooler.
5.Remove bolt securing engine dipstick tube to
camshaft carrier.
6.Release and remove engine dipstick tube.
7.Remove’O’ring from dip stick tube.
8.Disconnect 4 leads from glow plugs.
9.Remove 2 nuts and 8 bolts and remove inlet
manifold.
10.Remove manifold gasket.Refit
1.Clean inlet manifold and mating face, clean
mating faces of EGR pipe, exhaust manifold and
EGR cooler (if fitted).
2.Fit new gasket.
3.Position inlet manifold and working from the
centre outwards, fit inlet manifold nuts and bolts
and tighten to25 Nm (18 lbf.ft).
4.Connect glow plug leads.
5.Clean engine dipstick tube.
6.Fit new’O’ring to dipstick tube.
7.Fit engine dipstick tube to camshaft carrier and
tighten bolt to10 Nm (7 lbf.ft).
8.Position fuel cooler and tighten bolts to25 Nm
(18 lbf.ft).
9.Connect multiplug to IAT and MAP sensor.
10.Position EGR pipe or EGR cooler to exhaust
manifold and using new Allen screws tighten to
10 Nm (7 lbf.ft).
11.Fit EGR pipe clamp to cylinder head, (if fitted)
and tighten bolt to10 Nm (7 lbf.ft).
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