cooling LAND ROVER DEFENDER 1999 Repair Manual

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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AIR CONDITIONING
1
REPAIR COMPRESSOR
Service repair no - 82.10.20
Remove
1.Remove engine acoustic cover.See ENGINE ,
Repair.
2.Depressurise A/C system.See Adjustment.
3.Remove auxiliary drive belt.See
ELECTRICAL, Repair.
4.Drain cooling system.See COOLING
SYSTEM, Adjustment.
5.Disconnect multiplug from compressor.
6.Remove 2 bolts securing air conditioning pipes
to compressor and discard’O’rings.
CAUTION: Immediately cap all air
conditioning pipes to prevent ingress of
dirt and moisture into the system.
7.Release clips and disconnect top hose from
coolant elbow and heater pipe.
8.Remove 4 bolts securing compressor to
mounting bracket.
9.Remove compressor.Refit
10.Position compressor to mounting bracket and
tighten bolts to25 Nm (18 lbf.ft).
11.Remove caps from compressor and pipe
connections.
12.Clean compressor and pipe connections.
13.Lubricate new’O’rings with refrigerant oil and fit
to compressor.
14.Position A/C pipes to compressor and tighten
bolts to9 Nm (7 lbf.ft).
15.Connect multiplug to compressor.
16.Position top hose and secure with clips.
17.Refill cooling system.See COOLING SYSTEM,
Adjustment.
18.Fit auxiliary drive belt.See ELECTRICAL,
Repair.
19.Recharge A/C system.See Adjustment.
20.Fit engine acoustic cover.See ENGINE ,
Repair.
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86ELECTRICAL
26
DESCRIPTION AND OPERATION PASSENGER COMPARTMENT FUSE BOX
FROM 02MY
The increase in electrical systems on Defender 02MY vehicles has necessitated an increase in the number of
fuses required.
The passenger compartment fuse box now contains three rows of fuses instead of the previous two rows and
relays to control the CDL system, heated front screen, headlamps, anti-theft alarm ECU and seat heaters and
window lift system.
1.Fuse 8 - Anti-theft alarm ECU/BBUS (10A)
2.Fuse 9 - Front wiper motor and washer pump
(15A)
3.Fuse 10 - Rear wiper relay (10A)
4.Fuse 11 - ABS ECU (10A)
5.Fuse 12 - Engine Control Module (10A)
6.Fuse 13 - Brake pedal switch (10A)
7.Fuse 14 - Reverse lamp switch/Glowplugs (10A)
8.Fuse 15 - Miscellaneous relay control. See
Electrical Library (5A)
9.Fuse 16 - Cigar lighter/Heater blower (20A)
10.Fuse 17 - Radio (5A)
11.Fuse 18 - LH side lamps/trailer pick up (10A)
12.Fuse 19 - RH side lamps/trailer pick up (10A)
13.Fuse 20 - Headlamp levelling/Illumination (10A)
14.Fuse 21 - Direction indicators (10A)
15.Fuse 22 - RH headlamp dip beam (10A)
16.Fuse 23 - LH headlamp dip beam (10A)
17.Fuse 24 - RH headlamp main beam (10A)
18.Fuse 25 - LH headlamp main beam (10A)19.Fuse 26 - Rear fog lamp ECU (10A)
20.Fuse 27 - Alarm relay (10A)
21.Fuse 28 - Air conditioning blower relay (30A)
22.Fuse 29 - Air conditioning compressor
relay/cooling fan relay (20A)
23.Fuse 30 - Interior lamps/radio/alarm
LED/clock/diagnostic socket/tachometer (South
African vehicles only) (5A)
24.Fuse 31 - Hazard warning lamps (15A)
25.Fuse 32 - Heated rear window (20A)
26.Fuse 33 - Seat heat relay (20A)
27.Fuse 34 - RH window lift switch (20A)
28.Fuse 35 - LH window lift switch (20A)
29.Fuse 36 - Heated front screen (30A)
30.Relay - Heated Front Screen
31.Relay - Starter motor
32.Relay - Heated Rear Window
33.Relay - Headlamps
34.Relay - Anti-theft alarm
35.Relay - Seat heat/window lift
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ELECTRICAL
1
REPAIR BELT - AUXILLARY DRIVE
Service repair no - 86.10.03
Remove
1.Remove cooling fan.See COOLING SYSTEM,
Repair.
2.Release drive belt tensioner using a 15 mm ring
spanner and release belt from pulleys.
Refit
3.Clean drive belt pulley grooves and ensure
grooves are not damaged.
4.Fit new drive belt around pulleys, ensure belt is
correctly aligned in pulley grooves.
5.With assistance, hold tensioner fully clockwise
and fit drive belt around remaining pulley.
6.Fit cooling fan.See COOLING SYSTEM,
Repair.HARNESS - INJECTORS
Service repair no - 86.70.22
Remove
1.Remove camshaft cover gasket.See ENGINE ,
Repair.2.Disconnect engine harness from injector
harness.
3.Disconnect multiplugs from injectors.
4.Release injector harness from camshaft carrier
and remove harness.
Refit
5.Fit new’O’rings to injector harness connector.
6.Position harness and locate connector to
camshaft carrier.
7.Connect injector and engine harness multiplugs.
8.Fit camshaft cover gasket.See ENGINE ,
Repair.
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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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