Defender 300Tdi (1996+). Manual — part 15
ENGINE
3
REPAIR
ENGINE
Service repair no - 12.41.01
Remove
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray and/or
integral access panels.
See CHASSIS AND BODY, Repair, Front
undertray or See CHASSIS AND BODY, Repair,
Rear undertray
CAUTION: Seal all exposed pipe ends
against ingress of dirt after disconnection.
1. Ensure vehicle is level and apply park brake.
2. Disconnect battery.
NOTE: The vehicle may be fitted with an
alarm and immobilisation system using a
battery backed-up alarm sounder.
See ELECTRICAL, Repair, battery
3. Remove bonnet.
4. Remove cable ties securing gearbox harness to
breather pipes.
5. Disconnect harness from diff lock and reverse
light switches.
6. Manouvre harness into engine bay.
7. Remove air cleaner.
See FUEL SYSTEM,
Repair, Air cleaner
8. Remove radiator assembly.
See COOLING
SYSTEM, Repair, Radiator
If air conditioning is fitted the condenser will
have to be removed, compressor pipes and
heater matrix hoses disconnected.
See AIR CONDITIONING, Repair, Condenser
9. Remove rocker cover insulation.
10. Remove feed pipe/hose from turbo-charger and
intercooler.
11. Disconnect heater hoses from cylinder head and
heater rails.
12. Disconnect electrical feed plug at rear of cylinder
head.
13. Disconnect heater plug feed wire.
12
ENGINE
4
REPAIR
14. Disconnect engine harness multi-plug.
15. Remove single bolt securing transmission
breather pipe clip to cylinder head and move
breather pipes aside.
16. Disconnect multi-plug and vacuum pipe from
EGR valve, if fitted.
17. Remove starter motor cover and disconnect
battery and fuse box leads.
18. Remove 3 retaining nuts and disconnect exhaust
down pipe.
19. Disconnect inlet and outlet hoses from power
steering pump.
20. Disconnect bleed hose from thermostat housing.
21. Release bleed hose from retaining clips on front
timing cover plate.
22. Remove split pin securing inner throttle cable to
injector pump lever.
23. Depress tags on outer cable adjusting nut,
remove cable from mounting bracket and move
aside.
24. If fitted, release hand throttle cable from
mounting bracket and injector pump lever and
move aside.
25. Disconnect feed pipe and spill return pipe from
injector pump.
ENGINE
5
REPAIR
26. Disconnect both pipes from fuel lift pump.
27. Release fuel feed pipe from retaining clip on air
cleaner bracket.
28. Disconnect vacuum hose from brake servo.
29. Remove oil pipes from oil filter adaptor.
30. Using suitable hoist, fit chains to lifting brackets
and support engine.
31. Remove nuts and plain washers securing front
engine mountings to chassis.
32. Support gearbox.
33. Remove engine to bell housing fixings, leaving
starter motor attached to engine.
34. Carefully raise engine to release from gearbox.
35. Ensure all relevant connections to engine have
been removed.
36. Remove engine.
Refit
37. Clean bell housing.
38. Apply Hylomar sealant to mating faces of bell
housing and flywheel housing.
39. Lubricate splines of gearbox primary pinion with
Rocol MV 3.
40. Carefully lower engine into position and locate
primary pinion into clutch and engage bell
housing dowels.
41. Fit engine to bell housing fixings. Tighten to
40
Nm (30 lbf/ft).
12
ENGINE
6
REPAIR
42. Raise engine, and locate front engine mountings
to chassis.
43. Remove gearbox support and lower engine.
44. Tighten front engine mounting to chassis fixings
to
45 Nm (33 lbf/ft).
45. Release chains from engine lifting brackets and
remove hoist.
46. Connect oil cooler pipes to oil filter adaptor.
47. Fit vacuum hose to brake servo adaptor.
48. Secure fuel feed pipe in retaining clip on air
cleaner bracket.
49. Fit fuel lift pump pipes.
50. Connect feed and spill return pipes to injector
pump.
51. If fitted, reconnect hand throttle cable to
mounting bracket and injector pump.
52. Fit outer cable adjusting nut into injector pump
mounting bracket.
53. Fit inner throttle cable to injector pump and
secure with clevis and split pin.
54. Secure bleed hose in retaining clips on front
timing cover.
55. Fit bleed hose to thermostat housing.
56. Connect inlet and outlet hoses to power steering
pump.
57. Fit down pipe to exhaust manifold and secure
with 3 nuts.
58. Connect starter motor battery and fuse box
leads.
59. If fitted, connect EGR valve multi-plug and
vacuum pipe.
60. Secure breather pipe clip to cylinder head.
61. Connect engine harness multi-plug.
62. Fit heater plug feed wire.
63. Connect electrical feed plug at rear of cylinder
head.
64. Fit heater hoses to cylinder head and heater
rails.
65. Fit feed pipe/hose to turbo-charger and
intercooler.
66. Fit rocker cover insulation.
67. Fit radiator assembly.
See COOLING SYSTEM,
Repair, Radiator If applicable, fit air
conditioning condenser, compressor pipes and
heater matrix hoses.
See AIR CONDITIONING,
Repair, Condenser
68. Fit bonnet.
69. Reconnect battery.
CRANKSHAFT PULLEY
Service repair no - 12.21.01
Remove
1. Disconnect battery.
2. Drain coolant.
See COOLING SYSTEM,
Repair, Drain and refill cooling system
3. Remove top hose from radiator.
4. Remove intercooler to induction manifold hose.
5. Remove viscous coupling and fan.
See
COOLING SYSTEM, Repair, Viscous
coupling and fan
6. Remove fan cowl.
See COOLING SYSTEM,
Repair, Fan cowl
7. Remove drive belt.
See ELECTRICAL, Repair,
Auxiliary drive belt
8. Fit crankshaft pulley retainer LRT-12-080 and
secure with 4 bolts.
9. Remove crankshaft pulley retaining bolt
anti-clockwise using socket and suitable long
bar.
10. Remove pulley retainer.
11. Remove pulley, if necessary using extractor
LRT-12-049 with thrust pad from LRT-12-031.
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