Defender 300Tdi (1996+). Manual — part 32
COOLING SYSTEM
5
REPAIR
28. Secure steering pump and bracket to auxiliary
mounting bracket.
29. Fit steering pump pulley.
30. Fit drive belt
See ELECTRICAL, Repair,
Auxiliary drive belt .
31. Fit fan cowl
See Fan cowl .
32. Fit viscous fan unit
See Viscous coupling and
fan .
33. Fit intercooler top hose.
34. Fit radiator top hose.
35. Refill cooling system.
See Adjustment, Drain
and refill cooling system
36. Reconnect battery.
THERMOSTAT
Service repair no - 26.45.01
Remove
1. Partially drain cooling system, until coolant level
is below thermostat housing.
2. Disconnect top hose from outlet elbow.
3. Disconnect electrical connections to water
temperature switch.
4. Unscrew 2 bolts and remove outlet elbow.
5. Withdraw thermostat. Note 88
°
C rating of
thermostat.
6. Place thermostat in a container half full of water.
Heat water and observe temperature at which
thermostat begins to open. Thermostat is
satisfactory if it opens between 85
°
- 89
°
C.
Refit
7. Fit thermostat with jiggle pin/vent hole upwards.
8. Secure outlet elbow to thermostat housing.
Tighten bolts to
25 Nm (18 lbf/ft).
9. Fit water temperature switch connections.
10. Fit top hose to outlet elbow.
11. Refill cooling system.
See Adjustment, Drain
and refill cooling system
26
COOLING SYSTEM
6
REPAIR
RADIATOR
Service repair no - 26.40.01
Remove
1. Disconnect radiator bottom hose and drain
cooling system.
See Adjustment, Drain and
refill cooling system
2. Disconnect radiator top hose.
3. Remove viscous fan unit.
See Viscous
coupling and fan
4. Remove fan cowl.
See Fan cowl
5. Disconnect oil cooler pipes. Plug all connections
to prevent oil spillage and ingress of dirt.
6. Disconnect top and bottom intercooler hoses.
7. Disconnect bleed hose at radiator.
8. Remove 2 bolts from both sides securing
radiator mounting brackets to bonnet platform.
9. Lift and remove radiator/intercooler assembly
from vehicle.
10. Remove 2 bolts from both sides and detach
radiator top cover from side covers.
11. Lift and remove radiator from intercooler and RH
side frame.
12. Check condition of locating grommets in radiator
top cover and lower mounting bushes. Renew if
necessary.
Refit
13. Position radiator between intercooler and RH
side frame.
14. Fit radiator top cover to side covers.
15. Lower radiator/intercooler assembly into
position.
16. Secure radiator mounting brackets to bonnet
platform.
17. Fit radiator bleed hose.
18. Fit top and bottom intercooler hoses.
19. Fit oil cooler pipes.
20. Fit fan cowl
See Fan cowl .
21. Fit viscous fan unit.
See Viscous coupling
and fan
22. Fit radiator top hose.
23. Fit radiator bottom hose and refill cooling
system.
See Adjustment, Drain and refill
cooling system
COOLING SYSTEM
7
REPAIR
EXPANSION TANK
Service repair no - 26.15.01
Remove
1. Position container to collect coolant spillage.
2. Slacken retaining clips and disconnect both
hoses from base of expansion tank.
3. Remove 3 bolts securing expansion tank to
inside wing and mounting bracket.
4. Remove expansion tank.
Refit
5. Fit expansion tank to inside wing and mounting
bracket.
6. Fit both hoses to base of tank.
7. Check and top up cooling system
See
SECTION 10, Maintenance, Under bonnet
maintenance
MANIFOLD AND EXHAUST SYSTEM
1
DESCRIPTION AND OPERATION
MANIFOLDS AND EXHAUST SYSTEM
Description
The exhaust systems fitted on all models with the
300Tdi engine comprise three sections; front pipe
assembly, intermediate silencer assembly, and tail
pipe and silencer assembly. All sections, including
silencers, are manufactured from luminised steel to
give the system a durable working life under all
conditions. Special clamps are provided to ensure
leak proof jointing between the various sections,
which are supported by flexible rubber mountings.
Catalytic convertor
When fitted, the catalytic converter is integral with the
front pipe assembly, which also incorporates a flexible
joint. The catalyst forms part of the engine emission
control that can also include an EGR valve system
See FUEL SYSTEM, Repair, EGR valve
Exhaust system - 90
1. Gasket
2. Front pipe
3. Front pipe with catalytic converter
4. Front mounting bracket
5. Intermediate silencer
6. Intermediate mounting brackets
7. Tail pipe silencer*
8. Tail pipe silencer mounting
9. Tail pipe mounting
* Deleted on later models
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