1999 LAND ROVER DEFENDER coolant

ENGINE
7
REPAIR
14.Disconnect MAP sensor multiplug from inlet
manifold.
15.Position engine harness clear of inlet manifold.
16.Disconnect vacuum hose from EGR valve.
17.Loosen clip screw and disconnect air intake
hose from EGR valve.
18.Release 3 clips and disconnect coolant hoses
from fuel cooler.
19.Disconnect fuel hoses, tank to fuel cooler and
connector block on cylinder head.
CAUTION: Plug the connections.
20.Disconnect fuel hose from fuel cooler and secure
to connector block on cylinder head. This is to
prevent contamination of the fuel injection
system.
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12ENGINE
8
REPAIR
NOTE: Non EU3 model illustrated.
21.Loosen vacuum pipe union from cylinder head
and discard’O’ring.
22.Loosen 2 bolts and release alternator support
bracket from cylinder head.
23. Pre EU3 model:-Remove bolt securing EGR
valve pipe to cylinder head.
24. EU3 model:-Release the clips and disconnect
the coolant hoses from the EGR cooler.
25.Release clips and disconnect top hose, heater
hose and heater feed hose.
26.Remove the nut and bolt securing the cuylinder
head to the timing chain cover.
27.Rotate engine clockwise to align mark on
camshaft sprocket between coloured links on
timing chain.
28.PositionLRT-12-058through camshaft carrier to
lock camshaft.
29.PositionLRT-12-158through gearbox bell
housing to lock crankshaft.
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12ENGINE
10
REPAIR Refit
39.Clean mating faces of cylinder head and cylinder
block.
40.Check cylinder head for warping, across centre
and from corner to corner:
Maximum warp = 0.10 mm (0.004 in)
CAUTION: Cylinder heads may not be
refaced, replace cylinder head assembly if
warping exceeds figure given.
41.Ensure coolant and oil passages are clean.
42.Clean dowel holes and fit new dowels.
43.Fit new cylinder head gasket of the correct
thickness with the word’TOP’uppermost.
44.Using assistance, fit cylinder head and locate on
to dowels.
45.Carefully enter new cylinder head bolts together
with their captive washers,DO NOT DROP.
Lightly tighten bolts.
46.Using sequence shown, tighten cylinder head
bolts to:-
Stage 1 -30 Nm (23 lbf.ft)
Stage 2 -65 Nm (48 lbf.ft)
Stage 3 -90°
Stage 4 -Further 180°
Stage 5 -Further 45°
CAUTION: Ensure correct tightening
sequence is followed for all 5 tightening
stages. Do not tighten bolts 315°in one
operation.
47.Fit nut and bolt securing cylinder head to timing
chain cover and tighten to25 Nm (18 lbf.ft).
48.Clean camshaft sprocket and mating face on
camshaft.
49.Ensure engine is set to TDC No. 1 cylinder and
mark on camshaft sprocket is positioned
between the 2 coloured links.
50.Position camshaft sprocket to camshaft, fit and
lightly tighten new bolts then loosen bolts half a
turn.
51.Clean fixed guide retaining pin and apply Loctite
242 to threads.
52.Fit and tighten fixed guide retaining pin to25 Nm
(18 lbf.ft).
53.Clean timing chain tensioner and fit new sealing
washer.
54.Fit timing chain tensioner and tighten to45 Nm
(33 lbf.ft).
55.Tighten camshaft sprocket retaining bolts to36
Nm (27 lbf.ft).
56.RemoveLRT-12-058from camshaft.
57.RemoveLRT-12-158from gearbox bell housing.
58.Clean access plug recess in cylinder head and
fit new’O’ring. Fit access plug.
59.Clean vacuum pump union.
60.Tighten vacuum pipe union to10 Nm (7lbf.ft).
61.Fit bolts securing alternator bracket to cylinder
head and tighten to25 Nm (18 lbf.ft).
62.Connect top hose, heater hoses and secure with
clips.
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ENGINE
11
REPAIR 63. Pre EU3 model:-Fit bolt, EGR valve pipe to
cylinder head and tighten to25 Nm (18 lbf.ft).
64. EU3 model:-Connect coolant hoses to EGR
cooler and secure with clips.
65.Position air intake hose to EGR valve and
tighten clip screw.
66.Disconnect fuel hose from connector block and
connect to fuel cooler.
67.Connect fuel hoses to fuel cooler and connector
block on cylinder head.
68.Connect coolant hoses to fuel cooler and secure
clips.
69.Connect vacuum hose to EGR valve.
70.Position engine harness and connect multiplugs
and heater plug connectors.
71.Fit and tighten bolts, engine harness to camshaft
carrier.
72.Clean exhaust manifold and mating face.
73.Fit new gasket to exhaust manifold, position
turbocharger and tighten nuts to30 Nm (22 lbf.
ft).
74.Clean turbocharger feed hose bolt.
75.Position feed hose using new sealing washers,
tighten bolt to25 Nm (18 lbf.ft).
76.Position exhaust manifold heat shield, and
tighten M6 bolts to10 Nm (7 lbf.ft)and M8 bolt
to25 Nm (18 lbf.ft).
77.Position air inlet hose to turbocharger and
tighten clip screw.
78.Connect air flow meter to air filter and secure
clips.
79.Connect air flow meter multiplug.
80.Fit cooling fan.See COOLING SYSTEM,
Repair.
81.Fit camshaft cover gasket.See this Section.
82.Refill cooling system.See COOLING SYSTEM,
Adjustment.
83.Fit underbelly panel.See CHASSIS AND
BODY, Repair.ROCKER SHAFT ASSEMBLY
Service repair no - 12.29.29
Remove
1.Remove cooling fan.See COOLING SYSTEM,
Repair.
2.Remove camshaft cover gasket.See this
Section.
3.Loosen lock nuts and fully retract rocker
adjusting screws to prevent damage on
reassembly.
4.Rotate engine clockwise, until camshaft gear
and timing chain marks are aligned and fit
LRT-12-058through camshaft carrier to lock
camshaft.
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12ENGINE
14
REPAIR
9. Not EU3 model:-Apply two 3 mm diameter
beads of sealant, Part No.STC 5433 to areas’A’
shown on illustration.
CAUTION: Excessive use of sealant could
result in blockage of oil drain hole,
arrowed’B’in illustration.
10.Fit new gasket to camshaft cover. fit cover and
tighten bolts to10 Nm (7 lbf.ft).
11.Position breather hose and secure clip.
12.Fit engine acoustic cover.
13.Reconnect battery negative lead.
14.Fit battery cover.ENGINE AND ANCILLARIES
Service repair no - 12.41.01.99
Remove
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Drain engine oil.
3.Remove radiator.See COOLING SYSTEM,
Repair.
4.Remove turbocharger.See FUEL SYSTEM,
Repair.
5.Remove starter motor.See ELECTRICAL,
Repair.
6.Remove air filter.See FUEL SYSTEM, Repair.
7.Loosen clip screw and release air intake hose
from intake elbow.
8.Release clips and disconnect coolant hoses
from fuel cooler and coolant rail.
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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.
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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.
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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.
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