service LAND ROVER DEFENDER 1999 Manual PDF

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.
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COOLING SYSTEM
1
ADJUSTMENT DRAIN AND REFILL
Service repair no - 26.10.01
WARNING: Hot coolant
Drain
1.Remove engine acoustic cover.
2.Visually check engine and cooling system for
signs of coolant leaks.
3.Examine hoses for signs of cracking, distortion
and security of connections.
4.Position drain tray to collect coolant.
5.Remove expansion tank filler cap.
6.Loosen clip screws securing air inlet hose to
intercooler and inlet manifold, release and
remove hose.
7.Release clip and disconnect bottom hose from
radiator.
8.Allow cooling system to drain.
9.Disconnect bottom hose from radiator.Refill
1.Flush system with water under low pressure.
2.Do not use water under high pressure as it could
damage the radiator.
3.Connect bottom hose to radiator and secure
hose with clip.
4.Prepare coolant to required concentration.
5.Position heater temperature control to maximum
hot position.
6.Remove bleed screw from top hose.
7.Fill system slowly through coolant expansion
tank until a steady flow of coolant is emitted from
the bleed hole in top hose.
8.Fit bleed screw to top hose.
9.Continue filling system until coolant level
reaches’MAX’mark on expansion tank.
10.Fit expansion tank filler cap.
11.Position air intake hose and tighten clip screws.
12.Start and run engine until normal running
temperature is reached.
13.If fitted, DO NOT operate air conditioning.
14.Switch off engine and allow to cool.
15.Check for leaks and top-up coolant to’MAX’
mark on expansion tank.
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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.
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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.
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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.
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MANIFOLD AND EXHAUST SYSTEM
1
REPAIR PIPE - EXHAUST - FRONT
Service repair no - 30.10.09
Remove
1.Remove engine acoustic cover.See ENGINE ,
Repair.
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 exhaust manifold
heat shield.
7.Remove 3 nuts, release front pipe from
turbocharger and discard gasket.
8.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
9.Remove 8 nuts and bolts and remove chassis
cross member.
10.Remove 2 nuts, release front pipe from
intermediate silencer.
11.Release front pipe from mounting rubber and
remove pipe.
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30MANIFOLD AND EXHAUST SYSTEM
2
REPAIR Refit
12.Clean front pipe and mating faces.
13.Position front pipe and using new gaskets, align
to intermediate pipe and turbocharger.
14.Connect mounting rubber to front pipe.
15.Fit and tighten exhaust flange nuts to27 Nm (20
lbf.ft).
16.Fit chassis cross member, and tighten bolts to
45 Nm (33 lbf.ft)
17.Fit underbelly panel.See CHASSIS AND
BODY, Repair.
18.Position new gasket and front pipe to
turbocharger and tighten nuts to27 Nm (20
lbf.ft).
19.Position exhaust manifold heat shield and
tighten M6 bolts to10 Nm (7 lbf.ft)and M8 bolt
to25 Nm(18 lbf.ft).
20.Position air inlet hose to turbocharger and
tighten clip screw.
21.Connect air flow meter to air filter and secure
clips.
22.Connect air flow meter multiplug.
23.Connect breather hose and secure clip.
24.Fit engine acoustic cover.See ENGINE ,
Repair.SILENCER - INTERMEDIATE
Service repair no - 30.10.11
Remove
1.Raise vehicle on a 4 post ramp.
2.Remove 2 nuts securing intermediate silencer to
front pipe.
3.Remove 3 nuts securing intermediate silencer to
tail pipe.
4.Release intermediate silencer from rubber
mountings and remove silencer.
5.Remove and discard gasket from tail pipe flange.
Refit
6.Clean intermediate silencer and mating faces.
7.Fit new gasket to tail pipe flange.
8.Position intermediate silencer to rubber
mountings and tail pipe flange.
9.Fit nuts securing intermediate silencer to front
pipe and tail pipe and tighten to25 Nm (18
lbf.ft).
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MANIFOLD AND EXHAUST SYSTEM
3
REPAIR EXHAUST - TAIL PIPE AND SILENCER
Service repair no - 30.10.22
Remove
1.Raise vehicle on ramp.
2.Remove 3 nuts securing silencer to tail pipe.
3.Release tail pipe from mounting and remove tail
pipe.
4.Collect silencer to tail pipe gasket.
Refit
5.Clean silencer and tail pipe mating faces.
6.Position tail pipe and secure on mounting
rubber.
7.Using a new gasket, align silencer to tail pipe.
8.Fit nuts to silencer and tighten to25 Nm (18
lbf.ft).GASKET - INLET MANIFOLD
Service repair no - 30.15.08
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove 3 bolts and remove engine acoustic
cover.
4.Release retainers and remove cooling fan cowl.
5.Disconnect multiplug from manifold air pressure
sensor and release 4 glow plug leads.
6.Remove 4 bolts, release EGR valve from inlet
manifold and discard gasket.
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MANIFOLD AND EXHAUST SYSTEM
5
REPAIR Refit
16.Clean inlet manifold and mating face.
17.Fit new gasket.
18.Fit inlet manifold, and working from the centre
outwards, tighten nuts and bolts to25 Nm (18
lbf.ft).
19.Position harness to sensors and connect
multiplugs.
20.Tighten harness clip bolts to camshaft carrier to
10 Nm (7 lbf.ft).
21.Clean dip stick tube and fit new’O’ring.
22.Fit dip stick tube and tighten bolt to10 Nm (7
lbf.ft).
23.Connect glow plug leads.
24.Fit alternator support bracket and tighten bolts to
45 Nm (33 lbf.ft).
25.Position fuel cooler. Apply Loctite 242 to bolts
and tighten to18 Nm (13 lbf.ft).
26.Fit new gasket, position EGR valve and tighten
bolts to9 Nm (7 lbf.ft).
27.Connect multiplug to MAP sensor.
28.Fit cooling fan cowl.
29.Fit engine acoustic cover.
30.Reconnect battery negative lead.
31.Fit battery cover.GASKET - EXHAUST MANIFOLD
Service repair no - 30.15.12
Remove
1.Remove turbocharger.See FUEL SYSTEM,
Repair.
2. Models with A/C:Remove auxiliary drive belt.
See ELECTRICAL, Repair.
3.Remove 4 bolts securing compressor and move
to one side.
All Models
NOTE: EU3 Model illustrated.
4.Remove and discard 2 Allen screws securing
EGR pipe to exhaust manifold.
5.Remove 10 nuts securing exhaust manifold to
cylinder head.
6.Remove exhaust manifold and gasket.
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33CLUTCH
6
DESCRIPTION AND OPERATION DESCRIPTION
General
The clutch system is a diaphragm type clutch operated by a hydraulic cylinder. The drive plate is of the rigid centre
type with no integral damping springs. The flywheel is of the dual mass type with damping springs integral with the
flywheel. The clutch requires no adjustment to compensate for wear.
Hydraulic Clutch
The hydraulic clutch comprises a master cylinder, slave cylinder and a hydraulic reservoir. The master and slave
cylinders are connected to each other hydraulically by plastic and metal pipes. The plastic section of the pipe
allows ease of pipe routing and also absorbs engine movements and vibrations.
The master cylinder comprises a body with a central bore. Two ports in the body connect the bore to the hydraulic
feed pipe to the slave cylinder and the fluid reservoir. The bore is also connected to a damper which prevents
engine pulses being transferred hydraulically to the clutch pedal. A piston is fitted in the bore and has an external
rod which is attached to the clutch pedal with a pin. Two coil springs on the clutch pedal reduce the effort required
to depress the pedal.
The master cylinder is mounted on the bulkhead and secured with two bolts. The cylinder is connected to the
shared brake/clutch reservoir on the brake servo by a braided connecting hose.
The slave cylinder is located on the left hand side of the gearbox housing and secured with two bolts. A heat
shield is fitted to protect the underside of the slave cylinder from heat generated from the exhaust system. The
slave cylinder comprises a cylinder with a piston and a rod. A port in the cylinder body provides the attachment for
the hydraulic feed pipe from the master cylinder. A second port is fitted witha bleed nipple used for removing air
from the hydraulic system after servicing. The piston rod locates on a clutch release lever located in the gearbox
housing. The rod is positively retained on the release lever with a clip.
Clutch Mechanism
The clutch mechanism comprises a flywheel, drive plate, pressure plate, release lever and a release bearing. The
clutch mechanism is fully enclosed at the rear of the engine by the gearbox housing.
A clutch release bearing sleeve is attached in the gearbox housing with two bolts and located on two dowels. A
spigot with a ball end is formed on the release bearing sleeve and provides a mounting and pivot point for the
clutch release lever. A dished pivot washer is located on the ball of the spigot. When the release lever is located
on the ball, the pivot washer seats against the rear face of the release lever. A spring clip is located on the lever
and the pivot washer and secures the lever on the spigot. A small bolt retains the spring clip in position.
The release lever is forked at its inner end and locates on the clutch release bearing carrier. The outer end of the
release lever has a nylon seat which locates the slave cylinder piston rod. A second nylon seat, positioned
centrally on the release lever, locates on the ball spigot of the release bearing sleeve and allows the release lever
to pivot freely around the ball.
The clutch release bearing locates on the clutch release lever and release bearing sleeve. The bearing is retained
on a carrier which has two flats to prevent the carrier rotating on the release lever. A clip retains the release lever
on the carrier. The bearing and carrier are not serviceable individually.
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