1999 LAND ROVER DEFENDER ECU

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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12ENGINE
20
REPAIR Refit
9.Fit shield to mounting ensuring cut-away portion
is correctly aligned.
10.Fit mounting and mounting bracket.
11.Fit mounting bracket to cylinder block bolts and
tighten to48 Nm (35 lbf.ft).
12.Fit nuts securing mounting to chassis and tighten
to85 Nm (63 lbf.ft).
13.Fit mounting to mounting bracket nut and tighten
to85 Nm (63 lbf.ft).
14.Remove engine support chains.
15.Clean oil filter adaptor housing and mating face.
16.Fit oil filter adaptor housing using a new gasket
and tighten bolts to25 Nm (18 lbf.ft).
17.Fit centrifuge assembly.See this Section.MOUNTING - FRONT - RH
Service repair no - 12.45.03
Remove
1.Remove engine acoustic cover.See this
Section.
2.Remove fixings, remove battery cover.
3.Disconnect battery negative lead.
4.Raise front of vehicle.
WARNING: Support on safety stands.
5.Remove 4 bolts, move fuel cooler to one side.
6.Fit suitable lifting chains to support engine.
7.Remove 2 nuts securing engine mounting to
chassis.
8.Remove 4 bolts securing engine mounting
bracket to cylinder block.
9.Remove nut securing mounting to mounting
bracket.
10.Remove mounting and mounting bracket.
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ENGINE
21
REPAIR Refit
11.Fit mounting and mounting bracket.
12.Fit mounting bracket to cylinder block bolts and
tighten to48 Nm (35 lbf.ft).
13.Fit nuts securing mounting to chassis and tighten
to85 Nm (63 lbf. ft).
14.Fit mounting to mounting bracket nut and tighten
to85 Nm (63 lbf.ft).
15.Remove engine support chains.
16.Position fuel cooler. Apply Loctite 242 to bolts
and tighten to18 Nm (13 lbf.ft).
17.Remove stand(s) and lower vehicle.
18.Reconnect battery negative lead.
19.Fit engine acoustic cover.See this Section.MOUNTING - GEARBOX - REAR - LH
Service repair no - 12.45.07
Remove
1.Raise vehicle on ramp.
2.Position jack to support gearbox.
3.Remove 4 bolts securing mounting bracket to
transfer gearbox.
4.Remove 2 nuts, remove mounting and mounting
bracket.
5.Remove heat shield from mounting.
Refit
6.Clean mounting and mating faces.
7.Position heat shield to mounting.
8.Position mounting and mounting bracket and
tighten nuts to48 Nm (35 lbf.ft)and bolts to85
Nm (63 lbf. ft).
9.Lower support jack.
10.Lower vehicle.
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12ENGINE
22
REPAIR MOUNTING - GEARBOX - REAR - RH
Service repair no - 12.45.09
Remove
1.Remove LH rear gearbox mounting.See this
Section.
2.Remove 4 bolts securing mounting bracket to
transfer gearbox.
3.Remove 2 nuts, remove mounting and mounting
bracket.
Refit
4.Clean mounting and mating faces.
5.Position mounting and mounting bracket and
tighten nuts to48 Nm (35 lbf.ft)and bolts to85
Nm (63 lbf.ft).
6.Fit LH rear gearbox mounting.See this
Section.FLYWHEEL
Service repair no - 12.53.07
Remove
1.Remove clutch assembly.See CLUTCH,
Repair.
2.Remove and discard 8 bolts securing flywheel to
crankshaft and remove flywheel.
NOTE: Dowel located.
Refit
3.Clean flywheel and crankshaft mating face.
4.Position flywheel to crankshaft.
5.Fit new flywheel retaining bolts and tighten by
diagonal selection to:
Stage 1 -40 Nm (30 lbf.ft)
Stage 2 -Further 90°
CAUTION: Do not carry out stages 1 and 2
in one operation.
6.Fit clutch assembly.See CLUTCH, Repair.
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ENGINE
23
REPAIR FILTER - OIL
Service repair no - 12.60.04
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Release clip and disconnect breather hose from
camshaft cover.
3.Release clips and disconnect air flow meter from
air filter.
4.Disconnect multiplug from air flow meter.
5.Loosen clip screw and remove air inlet hose
from turbocharger.
6.Remove 3 bolts and remove manifold heat
shield.
7.Clean area around filter head and place a
container beneath engine.
8.Using a strap wrench, unscrew and discard filter.
Refit
9.Clean mating face of filter head.
10.Lubricate sealing ring of new filter with clean
engine oil.
11.Fit filter and tighten by hand until it seats then
tighten a further half turn.
12.Start and run engine to check for leaks.
13.Stop engine, wait a few minutes, then check oil
level.
14.Top up engine oil.
15.Position exhaust manifold heat shield and
tighten 3 bolts.
16.Position air inlet hose to turbocharger and
tighten clip screw.
17.Connect air flow meter to air filter and secure
clips.
18.Connect air flow meter multiplug.
19.Connect breather hose and secure with clip.
20.Position engine acoustic cover.
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12ENGINE
24
REPAIR STRAINER - OIL PICK-UP
Service repair no - 12.60.20
Remove
1.Remove sump gasket.See this Section.
2.Remove 3 Torx screws securing oil pick-up
strainer.
3.Remove and discard’O’ring.
Refit
4.Clean oil pick-up strainer faces.
5.Fit new’O’ring to oil pick-up strainer.
6.Fit oil pick-up strainer, apply Loctite 242 to
threads of Torx screws; fit screws and tighten to
10 Nm (7 lbf.ft).
7.Fit new sump gasket.See this Section.PUMP - OIL
Service repair no - 12.60.26
Remove
1.Remove sump gasket.See this Section.
2.Remove bolt securing oil pump sprocket to oil
pump drive spindle.
3.Remove sprocket from oil pump.
4.Remove 3 Torx screws securing oil pick-up
strainer; remove strainer.
5.Remove and discard’O’ring.
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ENGINE
25
REPAIR
6.Using sequence shown, remove and discard 22
bolts securing oil pump and stiffener assembly.
7.Remove oil pump and stiffener assembly.
NOTE: Dowel located.
8.Remove and discard’O’ring.Refit
9.Clean mating faces of oil pump and stiffener
assembly to main bearing caps and cylinder
block.
10.Fit new’O’ring to oil pump housing.
11.Position oil pump and stiffener assembly on to
cylinder block ensuring 2 dowels are correctly
located.
12.Fit new bolts and using sequence shown, tighten
to13 Nm (10 lbf.ft).
13.Lubricate a new’O’ring with engine oil and fit to
oil pick-up strainer.
14.Fit oil pick-up strainer, apply Loctite 242 to
threads of Torx screws; fit screws and tighten to
10 Nm (7 lbf.ft).
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12ENGINE
26
REPAIR
15.Position oil pump drive sprocket and chain on to
oil pump ensuring that the’D’shape on the drive
sprocket is located on flat on the oil pump drive
shaft.
16.Clean oil pump drive sprocket retaining bolt and
apply Loctite 242 to bolt threads.
17.Fit oil pump drive sprocket retaining bolt and
tighten to25 Nm (18 lbf.ft).
18.Fit new sump gasket.See this Section.GASKET - ENGINE TO SUMP
Service repair no - 12.60.38
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove exhaust front pipe.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
4.Drain engine oil.
5.Loosen 4 bolts securing sump to gearbox bell
housing.
6.Remove 2 bolts securing centrifuge drain pipe to
sump and discard gasket.
7.Using sequence shown and noting their fitted
position, remove 20 bolts securing sump.
8.Remove sump, remove and discard gasket.
CAUTION: Do not lever between sump and
cylinder block.
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