1996 LAND ROVER DEFENDER bonnet

19FUEL SYSTEM
12
REPAIR HEATER PLUG CONTROL UNIT
Service repair no - 19.60.33
Remove
1.Disconnect battery.
2.Remove screw securing control unit to bulkhead.
3.Disconnect multi-plug and release control unit.
Refit
4.Fit harness multi-plug to control unit.
5.Secure control unit to bulkhead.
6.Reconnect battery.AIR CLEANER
Service repair no - 19.10.01
Remove
1.Slacken hose clip and detach outlet hose.
2.Release clips and open air cleaner retaining
straps.
3.Lift up air cleaner, slacken hose clip and detach
inlet hose.
4.Remove air cleaner.
Refit
5.Position air cleaner and connect inlet hose.
6.Close air cleaner retaining straps and secure
lock clips.
7.Connect outlet hose.
NOTE: If an EGR fuel system is fitted,
ensure the modulator valve vacuum spill
pipe is secure in the outlet hose.
AIR CLEANER ELEMENT
Service repair no - 19.10.10
For remove and refit procedure.
See SECTION 10,
Maintenance, Under bonnet maintenance

19FUEL SYSTEM
14
REPAIR TURBOCHARGER INLET HOSE
Service repair no - 19.42.11
Remove
1.Disconnect battery.
2.Slacken retaining clip and disconnect intake
hose from turbocharger.
3.Slacken retaining clip and disconnect hose from
air cleaner.
4.If fitted, disconnect EGR modulator valve
vacuum spill pipe from inlet hose.
5.Slacken retaining clip and disconnect breather
valve hose from inlet hose.
6.Remove inlet hose.
Refit
7.Fit inlet hose to air cleaner.
8.Fit cyclone breather hose to inlet hose.
9.If applicable, fit vacuum spill pipe to inlet hose.
10.Fit inlet hose to turbocharger.
11.Reconnect battery.TURBOCHARGER OIL FEED PIPE
Service repair no - 19.42.14
Remove
1.Disconnect battery.
2.Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
front pipe
3.Remove banjo bolt securing oil feed pipe to
turbocharger and discard 2 joint sealing
washers.
4.Unscrew union and remove feed pipe from
cylinder block.
5.Plug connections to prevent ingress of dirt.
Refit
6.Using new joint washer, fit oil feed pipe to
cylinder block. Tighten union connector to
25
Nm (18 lbf/ft).
7.Fit a new joint washer to both sides of banjo and
secure feed pipe to turbocharger. Tighten banjo
bolt to
20 Nm (15 lbf/ft).
8.Fit exhaust front pipe.See MANIFOLD AND
EXHAUST SYSTEM, Repair, Exhaust front
pipe
9.Check/top-up engine oil level.See SECTION
10, Maintenance, Under bonnet maintenance
10.Reconnect battery.

FUEL SYSTEM
15
REPAIR TURBOCHARGER OIL DRAIN PIPE
Service repair no - 19.42.12
Remove
1.Disconnect battery.
2.Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
front pipe
3.Unscrew union and disconnect oil drain pipe
from cylinder block.
4.Remove 2 bolts securing oil drain pipe to
turbocharger.
5.Remove drain pipe and discard gasket.
6.Plug connections to prevent ingress of dirt.
Refit
7.Ensure mating surfaces of oil pipe, turbocharger
and engine block are clean.
8.Using new gasket, fit oil drain pipe to
turbocharger. Tighten bolts to
25 Nm (18 lbf/ft).
9.Fit drain pipe to cylinder block and tighten union
connector to
38 Nm (28 lbf/ft).
10.Fit exhaust front pipe.See MANIFOLD AND
EXHAUST SYSTEM, Repair, Exhaust front
pipe
11.Check/top-up engine oil level.See SECTION
10, Maintenance, Under bonnet maintenance
12.Reconnect battery.

19FUEL SYSTEM
16
REPAIR INTERCOOLER
Service repair no - 19.42.15
Remove
1.Disconnect battery.
2.Remove 2 nuts securing fan cowl to radiator top
cover.
3.Remove 4 bolts securing radiator top cover to
side covers.
4.Remove 2 bolts from both sides, securing
radiator top cover mounting brackets to bonnet
platform.
5.Detach radiator top cover, complete with
mounting brackets.
6.Slacken retaining clip and disconnect top hose
from intercooler.
7.Slacken 2 clips and disconnect bottom hose
from intercooler.
8.Manoeuvre intercooler upwards and remove
from vehicle.
9.Check condition of foam pads fitted to top and
bottom of intercooler and renew if necessary.
10.Check condition of intercooler locating grommets
in radiator top cover and renew if necessary.
Refit
11.Manoeuvre intercooler into position at LH side of
radiator.
12.Carefully lower intercooler and locate bottom
lugs into radiator bottom support frame.
13.Fit bottom and top hoses to intercooler.
14.Fit radiator top cover and secure mounting
brackets to bonnet platform.
15.Secure radiator top cover to side covers.
16.Fit fan cowl to top cover.
17.Reconnect battery.

26COOLING SYSTEM
6
REPAIR RADIATOR
Service repair no - 26.40.01
Remove
1.Disconnect radiator bottom hose and drain
cooling system.
See Adjustment, Drain and
refill cooling system
2.Disconnect radiator top hose.
3.Remove viscous fan unit.
See Viscous
coupling and fan
4.Remove fan cowl.See Fan cowl
5.Disconnect oil cooler pipes. Plug all connections
to prevent oil spillage and ingress of dirt.
6.Disconnect top and bottom intercooler hoses.
7.Disconnect bleed hose at radiator.
8.Remove 2 bolts from both sides securing
radiator mounting brackets to bonnet platform.
9.Lift and remove radiator/intercooler assembly
from vehicle.
10.Remove 2 bolts from both sides and detach
radiator top cover from side covers.
11.Lift and remove radiator from intercooler and RH
side frame.
12.Check condition of locating grommets in radiator
top cover and lower mounting bushes. Renew if
necessary.Refit
13.Position radiator between intercooler and RH
side frame.
14.Fit radiator top cover to side covers.
15.Lower radiator/intercooler assembly into
position.
16.Secure radiator mounting brackets to bonnet
platform.
17.Fit radiator bleed hose.
18.Fit top and bottom intercooler hoses.
19.Fit oil cooler pipes.
20.Fit fan cowl
See Fan cowl.
21.Fit viscous fan unit.
See Viscous coupling
and fan
22.Fit radiator top hose.
23.Fit radiator bottom hose and refill cooling
system.
See Adjustment, Drain and refill
cooling system

COOLING SYSTEM
7
REPAIR EXPANSION TANK
Service repair no - 26.15.01
Remove
1.Position container to collect coolant spillage.
2.Slacken retaining clips and disconnect both
hoses from base of expansion tank.
3.Remove 3 bolts securing expansion tank to
inside wing and mounting bracket.
4.Remove expansion tank.
Refit
5.Fit expansion tank to inside wing and mounting
bracket.
6.Fit both hoses to base of tank.
7.Check and top up cooling system
See
SECTION 10, Maintenance, Under bonnet
maintenance

STEERING
1
REPAIR STEERING COLUMN
Service repair no - 57.40.01
Remove
1.Remove bonnet.
2.Set road wheels and steering wheel in straight
ahead position.
3.Mark relationship of steering column inner shaft
to top universal joint.
NOTE: collapsible shaft can be
disconnected from steering column only, if
required, by removing bolts from top
universal joint and slackening top bolt of lower
universal joint.
4.Remove 2 bolts from top universal joint and
lower bolt of bottom universal joint. Slacken top
bolt of lower universal joint and withdraw shaft.5.Prise centre cap from steering wheel.
6.Remove steering wheel retaining nut and
withdraw wheel from column spline.
7.Disconnect battery.
8.Remove 4 screws securing instrument panel and
pull panel away from facia to enable
speedometer cable to be disconnected.
9.Disconnect multi-plugs, electrical leads and
connections to vehicle alarm system, if fitted.
See ELECTRICAL, Repair, Vehicle
immobilisation and alarm system
.
10.Withdraw panel complete with instruments.
11.Remove 5 screws and 2 self-tapping screws to
remove top half of nacelle.
12.Ease bottom half of nacelle from switch
gaiters/grommets and remove.

57STEERING
6
REPAIR POWER STEERING SYSTEM - BLEED
Service repair no - 57.15.02
1.Check that fluid level is at maximum level
See
MAINTENANCE , Under bonnet maintenance.
2.Run engine to normal operating temperature.
3.Recheck reservoir fluid level, top up if necessary
NOTE: During operations 4 to 6, maintain
maximum fluid level in reservoir. Do not
increase engine speed or move steering
wheel.
4.With engine at idle speed, slacken bleed screw.
When fluid seeps past bleed screw retighten
screw.
5.Check fluid level.
6.Clean away fluid around bleed screw.
7.Check hose connections, pump and steering box
for fluid leaks by holding steering on full lock in
both directions.
CAUTION: Do not maintain this pressure
for more than 30 seconds in any one
minute to avoid overheating fluid and
possibly damaging seals.
8.Carry out road test.POWER STEERING FLUID RESERVOIR
Service repair no - 57.15.08
Remove
1.Position drain tin beneath reservoir.
2.Slacken mounting bracket clamp bolt and raise
reservoir to gain access to feed and return hose
retaining clips.
3.Slacken clips, disconnect hoses from reservoir,
allow fluid to drain.
4.Remove reservoir.
CAUTION: Plug connections to prevent
ingress of dirt.
CAUTION: Discard fluid drained from
system. Do not allow fluid to contact
paintwork, if spilled, remove fluid and
clean area with warm water.
Refit
5.Position reservoir, connect feed and return
hoses and tighten clips to
3 Nm (2 lbf/ft).
6.Fit reservoir in clamp, tighten clamp bolt.
7.Fill reservoir between upper mark and end of
dipstick with power steering fluid
See
MAINTENANCE , Under bonnet maintenance
.
8.Bleed power steering system
See Power
steering system - bleed
.