Land Rover Defender Workshop Rover Manual

							FUELSYSTEM
11
REPAIR
HEATER
PLUGS
Service repairno-19.60.31
Remove 1. Disconnect battery.
No.1 heater plug-air conditioning models:
2.Release drivebeltfrom compressor pulley.See
AIR CONDITIONING, Repair,Compressor
drive belt
3.Remove 4bolts securing compressor tofront
cover, movecompressor aside.
No.3 heater plug:
4. Remove retaining boltand withdraw breather
valve fromrocker cover.Remove anddiscard O
ring.
All heater plugs:
5. Remove terminalnutand disconnect wirefrom
heater plugterminal.
6. Unscrew heaterplug.
Refit 7. Clean heater plugandseating.
8. Coat threads ofheater plugwithsuitable
anti-seize compound operational toa
temperature of1000 °C.
9. Fitheater plug,tighten to
23Nm (17lbf/ft).
10. Connect wiretoheater plugterminal andsecure
with nut.
NOTE: Feedwiremust beconnected to
No. 4heater plugterminal.
No. 3heater plug:
11. Lubricate newOring with engine oiland fitto
breather valve.
12. Fitvalve torocker cover,tighten tobolt to
15Nm
(11 lbf/ft).
No. 1heater plug-air conditioning models
13. Position compressor tofront cover, fitbolts and
tighten to
25Nm (18lbf/ft).
14. Fitdrive belttocompressor pulleyandadjust
tension.
See AIRCONDITIONING, Repair,
Compressor drivebelt
Allmodels:
15. Reconnect battery.     
						

							19FUEL
SYSTEM
12 REPAIR
HEATER
PLUGCONTROL UNIT
Service repairno-19.60.33
Remove 1. Disconnect battery.
2.Remove screwsecuring controlunittobulkhead.
3. Disconnect multi-plugandrelease controlunit.
Refit 4. Fitharness multi-plug tocontrol unit.
5. Secure controlunittobulkhead.
6. Reconnect battery. AIR
CLEANER
Service repairno-19.10.01
Remove
1. Slacken hoseclipand detach outlethose.
2. Release clipsandopen aircleaner retaining
straps.
3. Lift upaircleaner, slackenhoseclipand detach
inlet hose.
4. Remove aircleaner.
Refit 5. Position aircleaner andconnect inlethose.
6. Close aircleaner retaining strapsandsecure
lock clips.
7. Connect outlethose.
NOTE: Ifan EGR fuelsystem isfitted,
ensure themodulator valvevacuum spill
pipe issecure inthe outlet hose.
AIR CLEANER ELEMENT
Service repairno-19.10.10
For remove andrefitprocedure.
See SECTION 10,
Maintenance, Underbonnet maintenance   
						

							FUELSYSTEM
13
REPAIR
THROTTLE
CABLE
Service repairno-19.20.06
Remove 1. Disconnect battery.
2.Remove splitpinand clevis pinsecuring throttle
cable toinjector pumpthrottle lever.
3. Depress ferruleretaining tags,release ferrule
from abutment bracketandwithdraw throttle
cable.
4. Release throttlecablefromcliponbulkhead.
5. Remove pinand clevis pinsecuring throttle
cable topedal lever.
6. Release grommet frombulkhead.
7. Withdraw throttlecablefromengine
compartment. Refit
8. Feed throttle cablethrough bulkhead from
engine compartment andfitgrommet.
9. Secure throttlecabletopedal lever.Usenew
split pintosecure clevis.
10. Secure throttlecableinbulkhead clip.
11. Guide throttle cablethrough abutment bracket
and fitferrule.
12. Secure cabletoinjection pumpthrottle lever.
Use new splitpintosecure clevis.
13. Adjust throttle cable.
SeeAdjustment,
Throttle cable
THROTTLE PEDAL
Service repairno-19.20.01
Remove 1. Remove throttlecablefrompedal.
See Throttle
cable
2. Remove 6bolts securing throttlepedalassembly
to engine bulkhead.
3. Remove pedalassembly fromfootwell, complete
with trimretainer.
4. Release returnspring frompedal lever.
5. Remove rollpin securing pivotshaft topedal
assembly.
6. Withdraw pivotshaft andremove pedalfrom
mounting bracket.
7. Remove returnspring frompedal boss.
Refit 8. Fitreturn spring topedal boss.
9. Fitpedal tomounting bracketandlocate return
spring.
10. Fitpivot shaft topedal assembly andsecure with
roll pin.
11. Locate returnspring onpedal lever.
12. Secure throttlepedalassembly andtrimretainer
to bulkhead. Tightenboltsto
9Nm (7 lbf/ft).
13. Fitthrottle cabletopedal.See Throttle cable
14.Adjust pedal,ifnecessary.See Adjustment,
Throttle pedaladjustment    
						

							19FUEL
SYSTEM
14 REPAIR
TURBOCHARGER
INLETHOSE
Service repairno-19.42.11
Remove 1. Disconnect battery.
2.Slacken retaining clipand disconnect intake
hose fromturbocharger.
3. Slacken retaining clipand disconnect hosefrom
air cleaner.
4. Iffitted, disconnect EGRmodulator valve
vacuum spillpipe from inlethose.
5. Slacken retaining clipand disconnect breather
valve hosefrominlethose.
6. Remove inlethose.
Refit 7. Fitinlet hose toair cleaner.
8. Fitcyclone breather hosetoinlet hose.
9. Ifapplicable, fitvacuum spillpipe toinlet hose.
10. Fitinlet hose toturbocharger.
11. Reconnect battery. TURBOCHARGER
OILFEED PIPE
Service repairno-19.42.14
Remove 1. Disconnect battery.
2. Remove exhaustfrontpipe.
SeeMANIFOLD
AND EXHAUST SYSTEM,Repair,Exhaust
front pipe
3.Remove banjoboltsecuring oilfeed pipeto
turbocharger anddiscard 2joint sealing
washers.
4. Unscrew unionandremove feedpipefrom
cylinder block.
5. Plug connections toprevent ingressofdirt.
Refit 6. Using newjointwasher, fitoil feed pipeto
cylinder block.Tighten unionconnector to
25
Nm (18lbf/ft).
7.Fitanew jointwasher toboth sides ofbanjo and
secure feedpipetoturbocharger. Tightenbanjo
bolt to
20Nm (15lbf/ft).
8.Fitexhaust frontpipe.SeeMANIFOLD AND
EXHAUST SYSTEM,Repair,Exhaust front
pipe
9. Check/top-up engineoillevel.See SECTION
10, Maintenance, Underbonnet maintenance
10.Reconnect battery.   
						

							FUELSYSTEM
15
REPAIR
TURBOCHARGER
OILDRAIN PIPE
Service repairno-19.42.12
Remove 1. Disconnect battery.
2. Remove exhaustfrontpipe.
SeeMANIFOLD
AND EXHAUST SYSTEM,Repair,Exhaust
front pipe
3.Unscrew unionanddisconnect oildrain pipe
from cylinder block.
4. Remove 2bolts securing oildrain pipeto
turbocharger.
5. Remove drainpipeanddiscard gasket.
6. Plug connections toprevent ingressofdirt.
Refit 7. Ensure matingsurfaces ofoil pipe, turbocharger
and engine blockareclean.
8. Using newgasket, fitoil drain pipeto
turbocharger. Tightenboltsto
25Nm (18lbf/ft).
9.Fitdrain pipetocylinder blockandtighten union
connector to
38Nm (28lbf/ft).
10. Fitexhaust frontpipe.SeeMANIFOLD AND
EXHAUST SYSTEM,Repair,Exhaust front
pipe
11. Check/top-up engineoillevel.See SECTION
10, Maintenance, Underbonnet maintenance
12.Reconnect battery.   
						

							19FUEL
SYSTEM
16 REPAIR
INTERCOOLER Service
repairno-19.42.15
Remove 1. Disconnect battery.
2.Remove 2nuts securing fancowl toradiator top
cover.
3. Remove 4bolts securing radiatortopcover to
side covers.
4. Remove 2bolts frombothsides, securing
radiator topcover mounting bracketstobonnet
platform.
5. Detach radiator topcover, complete with
mounting brackets.
6. Slacken retaining clipand disconnect tophose
from intercooler.
7. Slacken 2clips anddisconnect bottomhose
from intercooler.
8. Manoeuvre intercoolerupwardsandremove
from vehicle.
9. Check condition offoam padsfittedtotop and
bottom ofintercooler andrenew ifnecessary.
10. Check condition ofintercooler locatinggrommets
in radiator topcover andrenew ifnecessary.
Refit
11. Manoeuvre intercoolerintoposition atLH side of
radiator.
12. Carefully lowerintercooler andlocate bottom
lugs intoradiator bottomsupport frame.
13. Fitbottom andtophoses tointercooler.
14. Fitradiator topcover andsecure mounting
brackets tobonnet platform.
15. Secure radiator topcover toside covers.
16. Fitfan cowl totop cover.
17. Reconnect battery.   
						

							FUELSYSTEM
17
REPAIR
EGR
VALVE
Service repairno-17.45.01
Remove
1. Disconnect multi-plugfromEGR valve.
2. Disconnect vacuumpipefrom EGR valve.
3. Remove 2Allen screws securing EGRvalve to
exhaust manifold.
4. Remove 2bolts securing airinlet delivery tubeto
EGR valve.
5. Remove EGRvalve anddiscard gaskets.
Refit 6. Clean mating facesofEGR valve andexhaust
manifold.
7. Position newgaskets andfitEGR valve to
delivery tubeandexhaust manifold. Tighten
bolts to
25Nm (18lbf/ft).
8.Fitvacuum pipeandmulti-plug toEGR valve. EGR
VALVE MODULATOR
Service repairno-17.45.04
Remove
1. Disconnect multi-plugfrommodulator.
2. Disconnect spillpipe (green), modulator toair
cleaner hose.
3. Disconnect vacuumpipe(blue), modulator to
EGR valve.
4. Disconnect vacuumpipe(white), modulator to
brake servopipe.
5. Unscrew 2nuts securing modulator toflexible
mountings.
6. Remove modulator.
Refit 7. Fitmodulator toflexible mountings andtighten
nuts to
8Nm (6 lbf/ft).
8. Fitmodulator pipes,ensuring theyareconnected
to correct ports.
9. Connect modulator multi-plug.    
						

							19FUEL
SYSTEM
18 REPAIR
EGR
THROTTLE POSITIONSENSOR
Service repairno-17.45.08
Remove
1. Remove 2screws securing throttleposition
sensor mounting platetoinjection pump.
2. Disconnect sensormulti-plug.
3. Remove sensorassembly.
Refit 4. Position sensorassembly oninjection pumpand
secure withscrews.
5. Connect multi-plug.
6. Adjust sensor
SeeAdjustment, EGRthrottle
sensor
EGR CONTROL UNIT
Service repairno-17.45.07
Remove 1. Raise centre seat,orcubby box
SeeCHASSIS
AND BODY, Repair, Cubbybox
togain access
to EGR control unitharness.
2.Disconnect controlunitmulti-plug andremove
centre seatorcubby box.
3. Remove 4screws anddetach controlunitfrom
seat orcubby boxbase.
Refit 4. Secure EGRcontrol unittobase ofcentre seat
or cubby box.
5. Position centreseatorcubby boxand connect
control unitmulti-plug.
6. Fitcentre seat,orcubby box.
SeeCHASSIS
AND BODY, Repair, Cubbybox   
						

							COOLINGSYSTEM
1
DESCRIPTION
ANDOPERATION
ENGINE
COOLING SYSTEM
Description The complete coolingsystemofthe 300Tdi engine
incorporates threeindependent functions:-Engine
(coolant) cooling;Turbo(charge air)intercooling;
Engine oilcooling. The
intercooler isaseparate aluminium unit,located
on the LHside ofthe engine compartment adjacentto
the radiator, sharingthesame upper andlower
mountings. Fordetails ofturbo intercooling
See
FUEL SYSTEM, Description andoperation,
Operation
. The oilcooler matrixisan integral partof
the radiator. Pre-formed pipes/hoses areused tolink
the components withintheseparate systemsas
shown below.
Engine cooling system
1. Radiator
2. Thermostat housing
3. Radiator bottomhose
4. Viscous fan
5. Water pump
6. Radiator tophose
7. Heater returnhose
8. Coolant supplyhose
9. By-pass hose
10. Radiator bleed(purge) hose
11. Bleed (purge) hose,thermostat housing
12. Ypiece ejector
13. Expansion tank 14.
Heater rail
15. Heater unit
16. Heater feedhose
17. Intercooler
18. Aircleaner
19. Airfeed hose
20. Turbocharger
21. Charge airsupply pipe/hose
22. Cooled chargeairsupply hose
23. Exhaust manifold
24. Engine oilcooler
25. Feed pipe,engine oilcooler
26. Return pipe,engine oilcooler
27. Oilfilter   
						

							26COOLING
SYSTEM
2 DESCRIPTION
ANDOPERATION
ENGINE
(COOLANT) COOLING
Description The 300Tdi engineusesapressurised coolingsystem
and cross flowradiator whichissupplied withcoolant
from anexpansion tankmounted onthe RH side of
the engine compartment. Abelt driven centrifugal
water pump, fittedtoan auxiliary mounting assembly, pumps
coolant tothe engine crankcase, cylinderhead
and vehicle heaterunit.
An eleven bladed fan,incorporating aviscous
coupling, isdriven byan independent pulleysecured
to the front cover plate.Thethermostat housing,
bolted tothe front ofthe cylinder head,isfitted witha
vent valve thatpurges excessive airpressure and
coolant backtothe expansion tank.
Enginecoolant circulation (enginewarm-thermostat open).
1. Radiator
2. Thermostat/housing
3. Radiator bottomhose
4. Viscous fan
5. Water pump
6. Radiator tophose
7. Heater returnhose
8. Coolant supplyhose 9.
By-pass hose
10. Radiator bleed(purge) hose
11. Thermostat housingbleed(purge) hose
12. Ypiece ejector
13. Expansion tank
14. Heater rail
15. Heater unit
16. Heater feedhose