Land Rover Defender 90 110 Workshop Book 6 Supplement Rover

							..1:;:: ... . , .>.:. ,. . ... .. 
Gl%B DEFENDER FUEL SYSTEM 
14. Fit the  turbo  charger  and secure  with the four 
nuts  and tighten  evenly to the  correct  torque. 
15.  connect  the 
oil feed and retum  pipes to the 
turbo  charger  and tighten  the 
feed pipe clamp. 
16.  Connect  the boost  pressure pipe to the 
T 
piece  and secure  with the clip. 
17. Connect the  intercooler hose to the  turbo 
inlet. 
18.  Fit the  hose  to air  cleaner  and turbo  charger. 
19. Fit the  turbo  charger  elbow. 
20.  Connect  the exhaust  front pipe to the  elbow 
using 
Holts Firegum to  seal  the joint. 
21.  Fit the  heat  shield  and secure  at the 
two fixing 
points. 
22. Fit  the  bonnet  and connect  the battery. 
INTERCOOLER 
Service Repair No. 19.42.15 
Remove,  clean and refit. 
1. Remove  the fan and  viscous  coupling 
assembly, 
see operation  26.25.1 9. 
2. Remove  the fan cowl, see operation  26.25.11. 
3. Disconnect  the top and bottom hoses  from 
the  Intercooler. 
4. Remove  the four  bolts (two each  side) 
retaining  the radiator  top support  brackets. 
5. Remove  the four bolts (two each  end) securing 
the  radiator  surround  top panel,  and remove 
the  panel. 
6.  Lift  out  the Intercooler. 
ST2928M 
Cleaning. 
7. Flush  the intercooler  with ICI GENKLENE 
propriety  cleaner,  following  the manufacturers 
instructions. 
no liquid  remains  in the  element. 
8. Dry the Intercooler  completely  ensuring  that 
Refitting. 
9. Slide the htercooler into position  taking care 
not  to damage the  insulation material on the 
sides. 
10.  Fit the  radiator  surround  top panel  and secure 
with  the four bolts. 
11. Fit the two top  brackets  and secure  with the 
four bolts. 
12.  Connect  the top and bottom  hoses. 
13.  Fit the  fan 
cowl. 
14. Fit the  fan and coupling  assembly. 
I .i . :. .$! . .. . !, ... 
87  
						

							COOLING SYSTEM DEFENDER 
COOLING SYSTEM 
Engine protection 
To prevent corrosion of aluminium  engine parts it is 
vital that the cooling  system is filled with  a solution 
of clean water  and  anti-freeze winter  and summer. 
Never 
fill or  top-up  with  water  only. always  add 
anti
-freeze.  Never  use salt water otherwise  corrosion 
will  occur.  In certain  territories  where the only 
available  water supply may  have some  salt content, 
use  only  clean  rain water  or distilled  water, with 
anti
- freeze  added. 
Use  only  Universal  anti
-freeze or permanent  type 
ethylene base, without methanol,  containing, a 
suitable  inhibitor 
for aluminiium  engine parts. Use 
one part of anti-freeze  to one  part  water. 
Anti
-freeze  should  be used  even  in climates  where it 
is not necessary. 
Anti
-freeze  can remain  in the  cooling  system  and 
will  provide  adequate  protection 
for two years 
provided  that the 
specific gravity of the coolant is 
checked  before the onset of the second  winter and 
topped
-up  with  new anti- freeze as required. 
Land  Rovers  leaving  the factory  have the cooling 
system 
filled with  a 50% anti- freeze  mixture.  This 
gives  protection  down to minus 
47 degrees 
Centigrade  (minus 
53 degrees  Fahrenheit). 
After  the second  winter the system  should be 
drained  and thoroughly  flushed. 
Before adding  new 
anti
-freeze  examine  all joints  and  renew  defective 
hoses  to make  sure  that the system  is leak  proof. 
See  section 
09 for protection  quantities. 
Service Repair No. 26.10.01 
Refilling. 
5. Make up a solution of anti-freeze  and water  in 
a  separate  container  in the  concentration 
required. 
To allow for topping-up,  and  for 
filling  the expansion  tank, prepare  a quantity  in 
excess 
of the  cooling  system capacity. 
6. Remove  the radiator filler cap  and fill the 
radiator  until the coolant  level 
is just below  the 
filler neck and refit  the cap. 
7. Fill the  expansion  tank to approximately  half 
full  and  refit  the cap. 
8. Connect  the battery  and run the engine  until 
normal  operating temperature 
is attained. 
Allow the engine  to cool completely  and 
removethe  radiator and expansion  tank caps. 
If 
necessary,  top-up the  the radiator  to just 
below  the filler  neck.  Top
-up the  expansion 
tank  to about  half full.  Fit both 
filler caps. 
Drain  and refil 
. 
WARNING: Do not remove  the radiator or 
expansion  tank filler  cap when  the engine is 
hot  because  the cooling  system is 
pressurized  and personal  scalding could 
result. 
1. Disconnect  the battery. 
2. Disconnect  the bottom  coolant hose from the 
radiator.  Allow to drain  and reconnect the 
hose. 
3. To drain  the cylinder  block,  remove the drain 
plug  which  is situated  on the  left hand 
side of 
the engine  immediately  below front core plug. 
Refit  the plug,  with  a  new washer,  when the 
draining 
is completed. 
4. To drain  the expansion  tank, remove  the cap 
and  disconnect  the expansion  hose from the 
radiator  and allow  it to  drain  into a suitable 
container.  Flush the tank  with  clean water  and 
reconnect  the hose. 
\- \- _,’ 
ST3032M 
88  
						

							G83 DEFENDER COOLING SYSTEM 
FAN COWL 
26 
Service Repair No. 26.25.11 
Remove  and refit. 
1. Follow  instructions 1 to 7 operation  26.25.19. 
2. Remove the cowl  from the engine 
compartment. 
Refitting. 
3. Reverse  instructions 1 and 2. 
FAN AND  COUPLING ASSEMBLY 
Service  Repair No. 26.25.19 
Remove  and refit. 
1. Disconnect  the battery  for safety  reasons. 
2.  Drain  the coolant  by disconnecting  the radiator 
bottom  hose and reconnect  when  coolant  has 
drained. 
3. Remove  the top  hose. 
4. Using  a  cranked  open ended  spanner and a 
restraining  bar  in the  hole  in the  pulley  hub, 
release  anti
-clockwise,  the viscous  coupling 
from  the water  pump  spindle. 
Lower the fan 
and  coupling  assembly into the base 
of the 
cowl. 
5. Remove  the two nuts securing  the cowl  to the 
radiator. 
Refitting 
8. 
9. 
10. 
11. 
12. 
Insert  the fan and  coupling into  the base of 
the  cowl  reversing  the removal  procedure. 
Fit  the  coupling  to the  water  pump  spindle 
noting  that  it has  a  left  hand thread.  Tighten 
the  coupling  using the restraining  bar and 
cranked  spanner. 
Fit  the  cowl  and secure  with the 
two nuts. 
Ensure  that the cowl  fits properly  in its  lower 
location.  Fit  the  top  hose  and refill  the cooling  system 
with  the correct concentration 
of anti-freeze 
and  water. 
Connect  the battery,  run the engine and  check 
for coolant leaks. 
6. Lift the cowl  to release it from its lower 
location. 
7. Move  the cowl  forward,  towards the engine 
236 ii4ihbixi the faii aiid coiipling ii~~e~bly 
from  the gap  created between the cowl and 
radiator. 
89  
						

							RADIATOR 
Service  Repair 
No. 26.40.01 
Remove and refit 
1. Remove  the fan and  viscous  coupling 
assembly, 
see operation  26.25.19. 
2.  Remove  the fan 
cowl, see operation 26.25.11. 
3. Disconnect  the hoses  from the intercooler. 
4. Disconnect  the expansion  tank hose  from the 
radiator. 
5. Disconnect  the oil cooler pipes from the 
radiator  and  cover  the ends 
to prevent  entry of 
dirt. 
6. Disconnect  the bottom  hose from the radiator. 
7. Remove  the four bolts, two each side, 
retaining  the radiator  top securing  brackets, 
and  remove the  brackets. 
intercooler. 
8. Lift  out  the radiator  complete  with the 
4;--  
						

							9. Check that the  rubber  grommets on the 
radiator  locating  pegs and beneath  the radiator 
mounting  brackets on the  chassis  cross 
member  are 
in position. 
10.  Lower  the radiator  into position  ensuring  that 
the  pegs  locate  in the  mounting  brackets. 
lO----;-ii;LT 
ZI - 
ST3033M 
11. Fit the  radiator  top mounting  brackets and 
secure  with the four  bolts. 
12. Connect the radiator  bottom hose. 
13.  Fit the  oil cooler  pipes to the  radiator. 
14. Connect  the expansion  tank hose. 
15. Connect  the top  and  bottom  hoses to the 
intercooler. 
16. Place  the fan cowl in  position but do  not 
secure  at this  stage. 
17.  Fit  the 
fan and viscous  coupling  and secure the 
cowl with  the two nuts. 
18. Check that all the  coolant  hose clips are tight 
and  refill  the cooling  system with the correct 
concentration 
of water  and anti-freeze, see 
operation  26.10.01. 
91  
						

							. 
26 
WATER PUMP 
Service Repair No. 26.50.01 
Remove  and refit 
DEFENDER COOLING SYSTEM 
1. 
2. 
3. 
4. 
1 
Remove  the fan and  coupling  assembly 
operation  2. 25.19. 
Remove  the fan 
cowl operation  26.25.11. 
Slacken  the fan belt  tension  and remove  it 
from  the pulley. 
Remove  the four  bolts securing  pulley to hub. 
5. 
6. 
7. 
8.  Remove 
the thermostat  housing  to water 
pump  hose. 
Disconnect  the bottom hose  from the water 
pump- Remove  the six bolts and one  nut  securing  the 
water  pump  to the  front  cover  plate. 
Remove  the water  pump  and gasket.  Refitting 
9. 
10. 
11. 
12. 
13. 
14. 
15. 
16. 
17. 
18. 
19.  Clean 
the water  pump  and front  cover  plate 
mating  faces. 
Lightly  grease  a new  gasket and  place in 
position  on the 
cover plate. 
Clean  the threads 
of the water  pump  retaining 
bolts and  apply Loctite  572 thread  lubricant 
sealant  to the  threads 
of all the  bolts. 
Fit  the pump 
to the  engine  and secure  with 
the  six bolts  and one  nut in accordance  with 
the  chart  below.  Tighten the fixings  evenly  and 
to  the  correct  torque. 
Connect  the bottom  hose to the  water  pump. 
Fit  the  pulley  to the  water  pump  hub and 
secure  with the four  bolts. 
Fit  and  tension  the water 
pump/aiternator belt. 
Fit  the  fan cowl. 
Fit  the  fan and  coupling  assembly. 
Check  that all the  coolant  hose clips are tight 
and 
refill the  cooling  system  with the correct 
re 5 %. ., v concentration of water  and anti-freeze,  see 
operation 
26.10.01. 
Connect  the battery,  run the engine and check 
for coolant  leaks. 
92  
						

							DEFENDER MANIFOLDS AND EXHAUST 130 I 
EXHAUST AND INLET MANIFOLDS 
Service Repair No. 30.15.01 
Remove  and refit 
Note: 
to remove  the inlet manifold,  the exhaust 
mainifold  must 
be removed first. 
1. Disconnect  the battery. 
2. Remove  the air cleaner to turbo  charger  inlet 
hose  from  the turbo  charger. 
3. Disconnect  hose from turbo  charger  to 
intercooler. 
4. Remove  the turbo  charger  heat shield. 
5. Disconnect  from the turbo  charger,  the oil 
feed pipe. 
6. Disconnect  the front  exhaust  pipe  from the 
turbo charger  elbow. 
ST2938M 
7. Release the front  exhaust pipe  bracket from 
the  cylinder  block. 
8. Disconnect  the front  exhaust pipe from the 
forward  silencer pipe. 
9. Release the heater  rail from  the exhaust 
manifold  studs. 
10.  Disconnect  the boost  pressure 
pipe from the 
turbo  charger. 
11.  Disconnect  the turbo  charger 
oil drain pipe 
from  the cylinder  block. 
12.  Remove  the exhaust 
mainfold nuts  and 
withdraw  the manifold  complete  with the 
turbo  charger. 
Inlet manifold 
13.  Disconnect  hose from  inlet  manifold 
14.  Remove  the 
two bolts and two nuts and 
withdraw  the inlet  manifold. 
15.  Remove  the common  gasket. 
Continued 
93  
						

							301 MANIFOLDS AND EXHAUST DEFENDER 
Ref ittng 
15. 
16. 
17. 
18. 
19. 
20. 
- 21. 
22. 
23. 
24. 
25. 
26. 
27. Place  a 
new gasket  in position  and fit the  inlet 
manifold  and secure  with the 
two bolts  and 
two nuts and  tighten to the  correct  torque. 
Fit  the  exhaust  manifold  complete  with turbo 
charger  and secure  with the nuts. 
Fit  the  heater  rail to the  manifold  studs. 
Connect  the turbo  charger 
oil drain pipe to 
the  cylinder  block. 
Connect  the boost  pressure  pipe to the turbo 
charger.  Using 
HOLTS FIRE GUM fit the  front 
exhaust  pipe to the  turbo  charger  elbow and 
secure  with the clamp.  Note, before  fitting the 
pipe  to the  elbow  make sure that the securing 
clamp 
is above  the inlet  manifold  since the clip 
will  not 
pass between  the front  pipe and 
manifold. 
Connect  the front  pipe to the  forward  silencer. 
Fit
-the  front  pipe support  bracket to the 
cylinder 
block with  the single bolt. 
Connect  the turbo  charger 
oil feed pipe. 
Fit  the  intercooler  to turbo  charger  hose. 
Fit  the  air cleaner  to turbo  charger hose. 
Fit  the  turbo  charge  heat shield. 
Connect  the battery,  run the engine  and check 
for exhaust gas leaks. 
94  
						

							DEFENDER STEERING n 57 
POWER STEERING PUMP 
Service Repair No. 57.20.14 
, 2- - . 
Remove  and  refit 
1. Working from beneath  the vehicle, release the 
drive  belt tension  by slackening  the 
two 
adjustment  clamp bolts and the single  pivot 
bolt  and remove  the belt. 
ST3050M \y 
1 
2. Disconnect  from the pump,  the supply hose 
from  the fluid reservoir and  drain  into a 
suitable  container. 
3.  Remove  the banjo  union  bolt from  the rear 
of 
the  pump  and allow  fluid to drain  into a 
container. 
4. Remove  the three  bolts slackened  in 
instruction 
1 and  remove  the pump  complete 
with  adjustment  plate and pulley. 
5. Remove  the four bolts to release the drive 
pulley  from the pump  hub. 
6. Since the adjustment  plate can be fitted  in 
more  than 
one position  on the  pump,  mark 
the  relationship 
of the pump to the plate 
before  removing  the four  attachment  bolts. 
. 
Refitting 
7. Fit the  adjustment  plate to the pump  aligning 
the  marks  made when  dismantling  and secure 
with  the four  bolts. 
screw. 
engine  bracket  and loosely  secure with the 
pivot  bolt and 
two adjustment  clamp bolts. 
10.  Fit the  drive  belt and  lever  the pump  away 
from  the engine  to tension  the belt  and 
tighten  the 
two clamp bolts and single  pivot 
bolt.  The belt 
is correctly  tensioned  when, at 
the  mid-point 
of its run  it can  be deflected  by 
thumb  pressure 
12 (. 5ins.) 
8. Fit the  drive  pulley  and retain  with the four 
9. Fit the  pump  and adjustment  plate to the 
CAUTION: Do not  apply  any pressure 
against  the pumpcasing  when tensioning 
the  drive  belt since  it will  damage  the 
casing permanently,  beyond repair. 
11. Connect  the fluid  hose  and secure  with the 
clip. 
12. Fit  the  banjo  bolt ensuring  that a special  steel 
washer 
is fitted  each side of the banjo. 
13. Top  up the  fluid  reservoir  with the correct 
make  and grade 
of fluid, see section 09. 
14.  Run the engine  and turn  the steering  from lock 
to lock.  Re-check  the fluid  level  and the drive 
belt  tension. 
Also examine for fluid  leaks. 
1. Pulley 6. Washer(specia1) 
2. Adjustment  plate 7. Banjo 
3. Pump 8. Washer(specia1) 
4. inlet hose 9. bolt 
5. 0 rings  10. Union  nut 
ST3051 M 1 
95