1999 LAND ROVER DEFENDER AUX

26COOLING SYSTEM
8
DESCRIPTION AND OPERATION Coolant Pump
1.Drive lugs (hidden)
2.Housing
3.’O’rings4.Cover
5.Feed hose connection
6.Impeller
The coolant pump is attached on the left hand side of the engine, behind the PAS pump. A cast housing, bolted to
the cylinder block provides a common attachment point for both pumps. The housing has galleries which connect
the coolant pump to the cylinder block and the oil cooler housing. The coolant pump comprises a shaft, a housing
and a cover.
The shaft, which passes through the alloy housing, is supported at each end by bearings. Seals at each end of the
shaft protect the bearings from the coolant. The forward end of the shaft has two lugs which engage with the PAS
pump shaft. The opposite end of the shaft is fitted with an impeller which draws coolant from the feed pipe and
circulates it through galleries in the cylinder block. The shaft is driven by the auxiliary drive belt at the same
rotational speed as the crankshaft by a pulley attached to the PAS pump.
The pump is sealed in the cast housing with two’O’rings. An outer cover is positioned over the pump and secured
with six bolts and sealed to the pump with an’O’ring. The cover provides the attachment for the feed pipe
connecting hose.
ProCarManuals.com

COOLING SYSTEM
9
DESCRIPTION AND OPERATION Viscous Fan
1.Idler pulley drive attachment
2.Fan blades3.Bi-metallic coil
4.Body
The viscous fan provides a means of controlling the speed of the fan relative to the operating temperature of the
engine. The fan rotation draws air through the radiator, reducing engine coolant temperatures when the vehicle is
stationary or moving slowly.
The viscous fan is attached to an idler pulley at the front of the engine which is driven at crankshaft speed by the
auxiliary drive belt. The fan is secured to the pulley by a right hand threaded nut. The nut is positively attached to
the fan spindle which is supported on bearings in the fan body. The viscous drive comprises a circular drive plate
attached to the spindle and driven from the idler pulley. The drive plate and body have interlocking annular
grooves with a small clearance which provides the drive when silicone fluid enters the fluid chamber. A bi-metallic
coil is fitted externally on the forward face of the body. The coil is connected to and operates a valve in the body.
The valve operates on a valve plate with ports that connect the reservoir to the fluid chamber. The valve plate also
has return ports which, when the valve is closed, scoop fluid from the fluid chamber and push it into the reservoir
under centrifugal force.
Silicone fluid is retained in a reservoir at the front of the body. When the engine is off and the fan is stationary, the
silicone fluid level stabilises between the reservoir and the fluid chamber. This will result in the fan operating when
the engine is started, but the drive will be removed quickly after the fan starts rotating and the fan will’freewheel’.
ProCarManuals.com

MANIFOLD AND EXHAUST SYSTEM
5
REPAIR Refit
16.Clean inlet manifold and mating face.
17.Fit new gasket.
18.Fit inlet manifold, and working from the centre
outwards, tighten nuts and bolts to25 Nm (18
lbf.ft).
19.Position harness to sensors and connect
multiplugs.
20.Tighten harness clip bolts to camshaft carrier to
10 Nm (7 lbf.ft).
21.Clean dip stick tube and fit new’O’ring.
22.Fit dip stick tube and tighten bolt to10 Nm (7
lbf.ft).
23.Connect glow plug leads.
24.Fit alternator support bracket and tighten bolts to
45 Nm (33 lbf.ft).
25.Position fuel cooler. Apply Loctite 242 to bolts
and tighten to18 Nm (13 lbf.ft).
26.Fit new gasket, position EGR valve and tighten
bolts to9 Nm (7 lbf.ft).
27.Connect multiplug to MAP sensor.
28.Fit cooling fan cowl.
29.Fit engine acoustic cover.
30.Reconnect battery negative lead.
31.Fit battery cover.GASKET - EXHAUST MANIFOLD
Service repair no - 30.15.12
Remove
1.Remove turbocharger.See FUEL SYSTEM,
Repair.
2. Models with A/C:Remove auxiliary drive belt.
See ELECTRICAL, Repair.
3.Remove 4 bolts securing compressor and move
to one side.
All Models
NOTE: EU3 Model illustrated.
4.Remove and discard 2 Allen screws securing
EGR pipe to exhaust manifold.
5.Remove 10 nuts securing exhaust manifold to
cylinder head.
6.Remove exhaust manifold and gasket.
ProCarManuals.com

30MANIFOLD AND EXHAUST SYSTEM
6
REPAIR Refit
7.Clean exhaust manifold and mating face.
8.Fit exhaust manifold with new gasket and tighten
nuts to25 Nm (18 lbf.ft).
9. Models with A/C:Position compressor and
tighten bolts to25 Nm (18 lbf.ft).
10. All Models:Position EGR valve pipe, fit new
allen screws and tighten to10 Nm (7 lbf.ft).
11.Fit turbocharger.See FUEL SYSTEM, Repair.
12. Models with A/C:Fit auxiliary drive belt.See
ELECTRICAL, Repair.
ProCarManuals.com

76 - CHASSIS AND BODY
CONTENTS
Page
DESCRIPTION AND OPERATION
FRONT SEAT RECLINE - FROM 02MY 1..............................................................
SOFT TOP - FROM 02MY 1...................................................................................
TAIL DOOR - FROM 02MY 2..................................................................................
ADJUSTMENT
TAIL DOOR STRIKER 1.........................................................................................
REPAIR
PANEL - UNDERBELLY - FRONT AND CENTRE 1...............................................
CUBBY BOX 1........................................................................................................
TRIM CASING - TAIL DOOR - UP TO 02MY 2.......................................................
LATCH - TAIL DOOR - UP TO 02MY 3..................................................................
CARPET - LUGGAGE COMPARTMENT 3.............................................................
WING - FRONT 4....................................................................................................
STEP - FOLDING - REAR DOOR 7........................................................................
LINER - FRONT WHEEL ARCH 8..........................................................................
FRONT BUMPER 9.................................................................................................
DOOR - REAR 9.....................................................................................................
DOOR - TAIL - REMOVE 10...................................................................................
GLASS/SEALING RUBBER - TAIL DOOR - UP TO 02MY 11................................
SEAT BELT - FRONT 12........................................................................................
SEAT BELT - CENTRE - REAR 13.........................................................................
SEAT BELT - REAR - SIDE 13...............................................................................
SEAT - REAR 14.....................................................................................................
COVER - CUSHION - REAR SEAT 15...................................................................
COVER - SQUAB - REAR SEAT 16.......................................................................
REGULATOR - REAR DOOR GLASS 16...............................................................
TRIM CASING - REAR DOOR 17...........................................................................
AUXILLIARY SWITCH PANEL 18...........................................................................
LOWER FASCIA PANEL - UP TO 02MY 19...........................................................
PANEL - MOUNTING - FRONT DOOR - FROM 02MY 23.....................................
PANEL - MOUNTING - REAR DOOR - FROM 02MY 25........................................
FACIA CONSOLE - FROM 02MY 27......................................................................
GLASS - REAR DOOR - FROM 02MY 29..............................................................
GLASS/SEALING RUBBER - TAIL DOOR - FROM 02MY 30................................
TRIM CASING - FRONT DOOR - FROM 02MY 31................................................
TRIM CASING - TAIL DOOR - FROM 02MY 33.....................................................
PLASTIC SHEET - FRONT DOOR - FROM 02MY 34............................................
ProCarManuals.com

76CHASSIS AND BODY
18
REPAIR AUXILLIARY SWITCH PANEL
Service repair no - 76.46.38
Remove
1.Remove 2 screws securing axilliary switch panel
to fascia and collect nuts and washers.
2.Disconnect multiplug from headlamp Levelling
switch.
3.Disconnect multiplug and Lucar from cigar
lighter.
4.Noting their fitted position, disconnect 4 Lucars
from rear wash wipe switch.
5.Remove switch panel.Do not carry out further dismantling if
component is removed for access only.6.Release pin securing rear wash wipe knob to
switch and remove knob.
7.Remove locknut securing rear wash wipe switch
to panel.
8.Remove rear wash wipe switch.
9.Remove knob from headlamp levelling switch.
10.Remove locknut securing headlamp switch to
panel.
11.Remove headlamp levelling switch.
12.Remove element from cigar lighter.
13.Release bulb holder from cigar lighter.
14.Release cigar lighter from tags and remove from
panel.
15.Fit cigar lighter to panel and locate tags.
16.Fit bulb holder to cigar lighter.
17.Fit element to cigar lighter.
18.Fit headlamp levelling switch to panel and
secure with locknut.
19.Fit knob to headlamp levelling switch.
20.Fit rear wash wipe switch to panel and secure
with locknut.
21.Fit knob to rear wash wipe switch, ensuring pin
is correctly located.
Refit
22.Position auxilliary switch panel to fascia and
connect 4 Lucars to rear wash wipe switch.
23.Connect multiplug and Lucar to cigar lighter.
24.Connect multiplug to headlamp levelling switch.
25.Fit auxilliary switch panel to fascia and secure
with screws.
ProCarManuals.com

76CHASSIS AND BODY
20
REPAIR
14.Carefully prise Land Rover decal from grab
handle.
15.Remove 2 screws securing grab handle to crash
pad and lower fascia panel.
16.Remove grab handle.
17.Remove 4 screws securing demister vents to
crash pad.
18.Remove both demister vents.
19.Remove 3 screws securing crash pad to
bulkhead.
20.Remove crash pad.
21.Release radio from fascia.
22.Disconnect 2 multiplugs and aerial from radio.23.Remove radio.
24.Remove 2 trim studs securing radio housing to
fascia.
25.Remove radio housing.
26.Remove auxilliary switch panel.See this
Section.
27.Remove auxilliary switch panel cover.
28.Remove interior fuse box cover.
ProCarManuals.com

76CHASSIS AND BODY
22
REPAIR
35.Remove 7 trim clips securing trim upper fascia
trim casing to bulkhead.
36.Carefully fold back trim casing over fresh air vent
operating levers and remove.
37.Release demist hose from parcel shelf.
38.Remove 18 screws securing parcel shelf to
lower fascia panel.
39.Remove parcel shelf.
40.Remove 7 screws securing bottom edge of lower
fascia panel to bulkhead.
41.Remove both retaining plates and lower footwell
covers.
42.Remove 2 bolts securing top of lower fascia to
bulkhead.
43.With assistance, remove lower fascia.Refit
44.With assistance, fit lower fascia.
45.Fit 2 bolts securing top of lower fascia to
bulkhead.
46.Fit both retaining plates and footwell covers to
lower fascia.
47.Fit 7 screws securing bottom edge of lower
fascia to bulkhead.
48.Fit parcel shelf to lower fascia and secure with
screws.
49.Fit demist hose to parcel shelf.
50.Carefully manoeuvre upper fascia trim casing
over fresh air vents and fit to fascia.
51.Fit trim clips securing trim casing to bulkhead.
52.Fit finisher rail to lower fascia and secure with
screws.
53.Fit wiper motor cover and secure with screws.
54.Fit both door check strap covers and secure with
screws.
55.Fit both footwell vents to lower fascia and secure
with screws.
56.Fit interior fuse box cover.
57.Fit auxilliary switch panel cover.
58.Fit auxilliary switch panel.See this Section.
ProCarManuals.com