Defender 300Tdi (1996+). Manual - part 15

ENGINE

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.

ENGINE

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

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

Nm (30 lbf/ft).

ENGINE

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

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.

Content .. 13 14 15 16 ..