Land Rover 90 110 Workshop Rover Manual
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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
n 42$B DEFENDER ELECTRICAL EQUIPMENT I86 I ALTERNATOR Service Repair No. 86.10.02 24% 4. ,: .. Remove and refit 1. Disconnect the battery. 2. Remove the air cleaner, see operation 19.10.01. 3. Remove the intercooler top hose assembly to the inlet manifold. 4. Remove the intercooler bottom hose assembly to the compressor housing. 5. Slacken the adjustment strap pivot bolt. 6. Remove the adjustment strap clamp bolt. 7. Remove the alternator two pivot bolts. 8. Release the drive belt from the alternator pulley. Note, to renew the drive belt, the power assisted steering pump and air conditioning compressor drive belts must first be removed. 9. Disconnect the electrical leads and remove the alternator. Refitting 10. Connect the electrical leads to the alternator before placing it in position on the common bracket. 11. Secure the alternator with the two pivot bolts and nuts, but leave slack at this stage. 12. Fit the adjustment strap clamp bolt and leave slack. 13. Fit the drive belt to the pulleys. 14. Tension the drive belt by levering the altemator away from the engine, taking care not to damage the alternator, and then tighten the adjustment strap c!amp bok. The tensicn is correct when the belt can be deflected 12mm (0.5ins.I at the the mid-point of the longest run between the pulleys. 15. Tighten the adjustment strap pivot bolt and the altemator two pivot nuts and bolts. 17. Reconnect the battery, run the engine and recheck the fan drive belt tension. 97