Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual

							12ENGINE
16
REPAIR
NOTE: Non EU3 model illustrated.
17.Disconnect multiplug from fuel temperature
sensor.
18.Disconnect multiplug from CKP sensor. Remove
bolt securing CKP sensor, remove sensor and
discard’O’ring.
CAUTION: If fitted:- Retain CKP sensor
spacer.
19.Disconnect 4 glow plug leads.
20.Remove nut securing alternator lead and
disconnect multiplug.
NOTE: Non EU3 model illustrated.
21.Remove 2 bolts securing engine harness to
camshaft carrier.
22.Disconnect A/C compressor and ECT sensor
multiplugs. 
						

							ENGINE
17
REPAIR
23.Disconnect oil pressure switch multiplug.
24.Release engine harness from underside of inlet
manifold and tie aside.
25.Release clips and remove coolant top hose from
cylinder head and coolant rail.
26.Remove 4 bolts and move A/C compressor
aside.
27.Remove 3 bolts and remove PAS pump pulley.
28.Remove 4 bolts and move PAS pump aside.
29.Raise vehicle on ramp.
30.Remove 6 bolts securing gearbox housing to
engine.
31.Lower vehicle ramp.
32.Remove 2 upper bolts securing gearbox housing
to engine.
33.Remove bolt securing engine closing panel to
gearbox.
34.Release clip and coolant hose from engine oil
cooler. 
						

							12ENGINE
18
REPAIR
35.Remove 2 bolts and remove acoustic cover from
rear of cylinder head.
36.FitLRT-12-138to suitable lifting chains and
connect to lifting eyes on engine.
37.Remove 2 nuts from RH and LH front engine
mountings.
38.Fit trolley jack to support gearbox.
39.With assistance raise chains and remove engine
from vehicle.Refit
40.With assistance, raise engine from bench and
position in vehicle.
41.With assistance, align engine to gearbox input
shaft.
42.Position 2 upper bolts securing gearbox housing
to engine and tighten to50 Nm (37 lbf.ft).
43.Lower engine onto mountings and tighten nuts to
85 Nm (63 lbf.ft).
44.RemoveLRT-12-138from engine.
45.Fit and tighten bolt securing engine closing panel
to gearbox.
46.Raise vehicle on ramp.
47.Fit bolts securing gearbox housing to engine and
tighten to50 Nm (37 lbf.ft).
48.Lower ramp.
49.Fit acoustic cover to rear of cylinder head and
tighten bolts.
50.Position coolant hose to engine oil cooler and
secure clip.
51.Position PAS pump and tighten bolts to25 Nm
(18 lbf.ft).
52.Position PAS pulley and tighten bolts to25 Nm
(18 lbf.ft).
53.Position A/C compressor and tighten bolts to25
Nm (18 lbf.ft).
54.Route engine harness beneath inlet manifold
and connect multiplugs to oil pressure switch,
A/C compressor, and ECT sensor.
55.Fit and tighten bolts securing engine harness to
camshaft carrier.
56.Connect multiplug to alternator.
57.Connect battery lead to alternator and tighten
nut.
58.Clean CKP sensor and mating face.
CAUTION: If originally fitted:- Fit spacer to
CKP sensor.
59.Using a new’O’ring, fit CKP sensor, tighten bolt
to10 Nm (7 lbf.ft).
60.Connect CKP sensor multiplug.
61.Connect multiplugs to EGR solenoid, inlet
manifold sensor, injector harness, fuel
temperature sensor and CKP sensor.
62.Connect glow plug leads.
63.Connect multiplug to condensor cooling fan.
64.Connect vacuum hose to EGR valve.
65.Connect EGR vacuum hose to vacuum pipe.
66.Position pipe to vacuum pump and secure pipe
to acoustic cover clips.
67.Position fuel cooler. Apply Loctite 242 to bolts
and tighten to18 Nm (13 lbf.ft).
68.Disconnect fuel hose from connector block and
connect to fuel cooler.
69.Connect fuel hoses to fuel cooler and connector
block on cylinder head. 
						

							ENGINE
19
REPAIR 70.Connect coolant hoses to fuel cooler and coolant
rail and secure clips.
71.Fit air intake hose to intake elbow and tighten
clip screw.
72.Fit starter motor.See ELECTRICAL, Repair.
73.Fit turbocharger.See FUEL SYSTEM, Repair.
74.Fit radiator.See COOLING SYSTEM, Repair.
75.Fit air filter.See FUEL SYSTEM, Repair.
76.Fill engine with oil.
77.Fit underbelly panel.See CHASSIS AND
BODY, Repair.MOUNTING - FRONT - LH
Service repair no - 12.45.01
Remove
1.Remove centrifuge assembly.See this
Section.
2.Remove 3 bolts, remove oil filter adaptor
housing and discard gasket.
3.Fit suitable lifting chains to support engine.
4.Remove 2 nuts securing engine mounting to
chassis.
5.Remove 4 bolts securing engine mounting
bracket to cylinder block.
6.Remove nut securing mounting to mounting
bracket.
7.Remove mounting and mounting bracket.
8.Remove mounting shield. 
						

							12ENGINE
20
REPAIR Refit
9.Fit shield to mounting ensuring cut-away portion
is correctly aligned.
10.Fit mounting and mounting bracket.
11.Fit mounting bracket to cylinder block bolts and
tighten to48 Nm (35 lbf.ft).
12.Fit nuts securing mounting to chassis and tighten
to85 Nm (63 lbf.ft).
13.Fit mounting to mounting bracket nut and tighten
to85 Nm (63 lbf.ft).
14.Remove engine support chains.
15.Clean oil filter adaptor housing and mating face.
16.Fit oil filter adaptor housing using a new gasket
and tighten bolts to25 Nm (18 lbf.ft).
17.Fit centrifuge assembly.See this Section.MOUNTING - FRONT - RH
Service repair no - 12.45.03
Remove
1.Remove engine acoustic cover.See this
Section.
2.Remove fixings, remove battery cover.
3.Disconnect battery negative lead.
4.Raise front of vehicle.
WARNING: Support on safety stands.
5.Remove 4 bolts, move fuel cooler to one side.
6.Fit suitable lifting chains to support engine.
7.Remove 2 nuts securing engine mounting to
chassis.
8.Remove 4 bolts securing engine mounting
bracket to cylinder block.
9.Remove nut securing mounting to mounting
bracket.
10.Remove mounting and mounting bracket. 
						

							ENGINE
21
REPAIR Refit
11.Fit mounting and mounting bracket.
12.Fit mounting bracket to cylinder block bolts and
tighten to48 Nm (35 lbf.ft).
13.Fit nuts securing mounting to chassis and tighten
to85 Nm (63 lbf. ft).
14.Fit mounting to mounting bracket nut and tighten
to85 Nm (63 lbf.ft).
15.Remove engine support chains.
16.Position fuel cooler. Apply Loctite 242 to bolts
and tighten to18 Nm (13 lbf.ft).
17.Remove stand(s) and lower vehicle.
18.Reconnect battery negative lead.
19.Fit engine acoustic cover.See this Section.MOUNTING - GEARBOX - REAR - LH
Service repair no - 12.45.07
Remove
1.Raise vehicle on ramp.
2.Position jack to support gearbox.
3.Remove 4 bolts securing mounting bracket to
transfer gearbox.
4.Remove 2 nuts, remove mounting and mounting
bracket.
5.Remove heat shield from mounting.
Refit
6.Clean mounting and mating faces.
7.Position heat shield to mounting.
8.Position mounting and mounting bracket and
tighten nuts to48 Nm (35 lbf.ft)and bolts to85
Nm (63 lbf. ft).
9.Lower support jack.
10.Lower vehicle. 
						

							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. 
						

							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. 
						

							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. 
						

							ENGINE
25
REPAIR
6.Using sequence shown, remove and discard 22
bolts securing oil pump and stiffener assembly.
7.Remove oil pump and stiffener assembly.
NOTE: Dowel located.
8.Remove and discard’O’ring.Refit
9.Clean mating faces of oil pump and stiffener
assembly to main bearing caps and cylinder
block.
10.Fit new’O’ring to oil pump housing.
11.Position oil pump and stiffener assembly on to
cylinder block ensuring 2 dowels are correctly
located.
12.Fit new bolts and using sequence shown, tighten
to13 Nm (10 lbf.ft).
13.Lubricate a new’O’ring with engine oil and fit to
oil pick-up strainer.
14.Fit oil pick-up strainer, apply Loctite 242 to
threads of Torx screws; fit screws and tighten to
10 Nm (7 lbf.ft).