1999 LAND ROVER DEFENDER drain bolt

19FUEL SYSTEM
14
REPAIR Refit
19.Clean fuel pump and mating face.
20.Fit new fuel pump sealing ring.
21.Fit fuel pump and secure with locking ring.
22.Fit breather hose and secure clip.
23.Position heat shield and secure with scrivits.
24.With assistance position fuel tank and support
plate.
25.Connect fuel hoses and multiplug to fuel pump.
26.Connect filler neck breather and secure clip.
27.Position vent hose and secure to chassis clips.
28.Raise fuel tank to its fitted position.
29.Fit nuts and bolts securing fuel tank and tighten
to25 Nm (18 lbf.ft).
30.Connect filler hose and secure clip.
Vehicles fitted with tow bar
31.Position support bar and tighten nuts and bolts.
32.Reconnect battery negative lead.
33.Fit battery cover.NECK - FUEL TANK FILLER
Service repair no - 19.55.07
Remove
1.Drain fuel tank.See Adjustment.
2.Loosen clip securing breather hose to fuel filler
neck and release hose.
3.Loosen clip securing fuel filler hose to neck and
release hose.
4.Remove screw and release earth lead from filler
neck.
5.Remove grommet securing filler neck to body.
6.Remove filler neck from body.
Refit
7.Fit filler neck to body.
8.Coat rubber grommet with soap solution.
9.Fit rubber grommet securing filler neck to body.
10.Connect earth lead and tighten screw.
11.Connect filler hose to neck and tighten clip.
12.Fit breather hose to filler neck and secure with
clip.
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COOLING SYSTEM
1
REPAIR COUPLING - COOLING FAN
Service repair no - 26.25.19
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove 3 bolts and remove engine acoustic
cover.
4.Remove cooling fan cowl.
NOTE: Thread is RH.
5.Remove cooling fan usingLRT-12-093and
LRT-12-094.
Refit
6.Position cooling fan and tighten using
LRT-12-093andLRT-12-094.
7.Fit cooling fan cowl.
8.Fit engine acoustic cover.
9.Reconnect battery negative lead.
10.Fit battery cover.THERMOSTAT
Service repair no - 26.45.09
Remove
1.Drain cooling system.See Adjustment.
2.Remove cooling fan.See this Section.
3.Release 3 clips and disconnect coolant hoses
from thermostat.
4.Remove thermostat.
Refit
5.Position thermostat, connect hoses and secure
with clips.
6.Fit cooling fan.See this Section.
7.Fill cooling system.See Adjustment.
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26COOLING SYSTEM
2
REPAIR PUMP - COOLANT
Service repair no - 26.50.01
Remove
1.Drain cooling system.See Adjustment.
2.Remove centrifuge.See ENGINE , Repair.
3.Release clip and hose from coolant pump cover.
4.Remove 5 bolts securing coolant pump cover.
5.Remove cover and coolant pump from housing
and discard’O’rings.Refit
6.Clean coolant pump housing and mating faces.
7.Fit new’O’rings to coolant pump and cover.
8.Fit coolant pump and cover and tighten bolts to9
Nm (7 lbf.ft).
9.Connect hose to pump cover and secure clip.
10.Refit centrifuge.See ENGINE , Repair.
11.Refill cooling system.See Adjustment.
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COOLING SYSTEM
3
REPAIR RADIATOR
Service repair no - 26.40.01
Remove
1.Remove front grille.See CHASSIS AND
BODY, Repair.
2.Drain cooling system.See Adjustment.
3.Remove cooling fan.See this Section.
4.Remove 5 bolts and move bonnet platform
aside.
5.Release clip and disconnect bleed hose from
radiator.
6.Release clip and disconnect top hose from
radiator.
7.Release clip and disconnect fuel cooler hose
from radiator.
8.Release clip and disconnect coolant rail hose
from radiator.
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37MANUAL GEARBOX
8
REPAIR
12.Remove 13 screws securing tunnel cover.
13.Release and remove tunnel cover.
14.Remove cooling fan.See COOLING SYSTEM,
Repair.
15.Remove air filter.See FUEL SYSTEM, Repair.
16.Remove 2 upper bolts securing clutch housing to
engine.
17.Remove bolt securing shim to clutch housing.
18.Release gearbox breather pipes from clips on
heater hose.
19.Remove starter motor.See ELECTRICAL,
Repair.
20.Remove exhaust front pipe.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
21.Drain gearbox oil.See Adjustment.
22.Drain transfer gearbox oil.See
MAINTENANCE ,
23.Remove 3 nuts securing intermediate silencer to
tail pipe.
24.Release silencer from mounting rubbers, remove
silencer and discard gasket.
25.Mark front and rear propeller shaft to transfer
gearbox flanges for reassembly purposes.
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TRANSFER GEARBOX
1
REPAIR BOTTOM COVER - TRANSFER GEARBOX -
RESEAL
Service repair no - 41.20.06
1.Raise vehicle on ramp.
2.Remove 6 bolts securing rear underbelly panel
and remove panel.
3.Drain transfer gearbox oil.
4.Remove 10 bolts securing bottom cover to
transfer gearbox and remove cover.
Refit
5.Clean bottom cover and mating face on transfer
gearbox.
6.Clean bolt threads.
7.Apply Loctite 290 to bolt threads.
8.Apply Hylosil RTV sealant to bottom cover
sealing face.
9.Position bottom cover, fit bolts and tighten to25
Nm (18 lbf.ft).
10.Fill transfer gearbox with oil.
11.Fit rear underbelly panel and tighten bolts.
12.Lower vehicle on ramp.TRANSFER GEARBOX
Service repair no - 41.20.25.99
Remove
1.Position vehicle on a’4 post’ramp
2.Remove battery cover.
3.Disconnect battery negative lead.
4.Select low range gear and leave vehicle in
neutral.
5.Remove gear lever knobs.
6.Remove gearbox tunnel carpet.
7.Remove gear lever cover.
8.Release and remove insulation pad.
9.Remove cubby box.See CHASSIS AND
BODY, Repair.
10.Remove 4 screws securing access panel,
diagnostic plug mounting bracket and place
aside.
11.Remove trim stud and lift up handbrake gaiter for
access to clevis pin.
12.Remove split pin, washer, clevis pin and
disconnect cable from handbrake lever.
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41TRANSFER GEARBOX
2
REPAIR
13.Release handbrake outer cable from heelboard.
14.Remove breather pipe banjo bolt from transfer
gearbox high/low cross shaft housing and
discard sealing washers.
15.Remove retaining clip and disconnect high/low
operating rod from lever.
16.Remove cooling fan.See COOLING SYSTEM,
Repair.
17.Remove front exhaust pipe.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
18.Drain transfer gearbox oil.
19.Remove 3 nuts securing intermediate silencer to
tail pipe.
20.Release intermediate silencer from rubber
mountings and remove silencer from tail pipe,
discard gasket.
21.Using a centre punch, mark relationship between
front propeller shaft and transfer gearbox drive
flanges and rear propeller shaft and brake drum
drive flanges.
22.Remove 4 nuts securing front propeller shaft to
transfer gearbox drive flange and remove
propeller shaft.
23.Remove 4 nuts securing rear propeller shaft to
brake drum flange.
24.Release propeller shaft and tie aside.
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41TRANSFER GEARBOX
12
REPAIR
10.Fit new seal usingLRT-41-012.
NOTE: Use end of tool marked’REAR’to
fit seal.
11.Position drive flange, fit new felt and steel
washers.
12.PositionLRT-51-003fit and tighten new drive
flange nut to148 Nm (109 lbf.ft).
13.Position brake drum and tighten screw.
14.Tighten adjuster bolt to25 Nm (18 lbf.ft)then
back off 1 1/2 turns.
15.Check that brake drum is free to rotate.
16.Fit propeller shaft.See PROPELLER SHAFTS,
Repair.
17.Top-up transfer gearbox oil.GASKET - REAR OUTPUT SHAFT HOUSING
Service repair no - 41.20.55
Remove
1.Drain transfer gearbox oil.See
MAINTENANCE ,
2.Remove rear output shaft seal.See this
Section.
3.Mark output shaft housing to main casing for
assembly purposes.
4.Note position of shoulder bolt, remove 6 bolts
securing housing to main casing.
Refit
5.Clean output shaft housing, mating face on main
casing and sealant from bolt threads.
6.Apply Hylosil RTV 102 to mating flange on
output shaft housing.
7.Fit output shaft housing to main casing ensuring
that splines of output shaft are engaged in
differential.
8.Apply Loctite 290 to bolt threads.
9.Fit bolts and tighten by diagonal selection to45
Nm (33 lbf.ft).
10.Fit rear output shaft seal.See this Section.
11.Fill transfer gearbox with oil.See
MAINTENANCE ,
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