Defender 300Tdi (1996+). Manual — part 29
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19
FUEL SYSTEM
16
REPAIR
INTERCOOLER
Service repair no - 19.42.15
Remove
1. Disconnect battery.
2. Remove 2 nuts securing fan cowl to radiator top
cover.
3. Remove 4 bolts securing radiator top cover to
side covers.
4. Remove 2 bolts from both sides, securing
radiator top cover mounting brackets to bonnet
platform.
5. Detach radiator top cover, complete with
mounting brackets.
6. Slacken retaining clip and disconnect top hose
from intercooler.
7. Slacken 2 clips and disconnect bottom hose
from intercooler.
8. Manoeuvre intercooler upwards and remove
from vehicle.
9. Check condition of foam pads fitted to top and
bottom of intercooler and renew if necessary.
10. Check condition of intercooler locating grommets
in radiator top cover and renew if necessary.
Refit
11. Manoeuvre intercooler into position at LH side of
radiator.
12. Carefully lower intercooler and locate bottom
lugs into radiator bottom support frame.
13. Fit bottom and top hoses to intercooler.
14. Fit radiator top cover and secure mounting
brackets to bonnet platform.
15. Secure radiator top cover to side covers.
16. Fit fan cowl to top cover.
17. Reconnect battery.
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FUEL SYSTEM
17
REPAIR
EGR VALVE
Service repair no - 17.45.01
Remove
1. Disconnect multi-plug from EGR valve.
2. Disconnect vacuum pipe from EGR valve.
3. Remove 2 Allen screws securing EGR valve to
exhaust manifold.
4. Remove 2 bolts securing air inlet delivery tube to
EGR valve.
5. Remove EGR valve and discard gaskets.
Refit
6. Clean mating faces of EGR valve and exhaust
manifold.
7. Position new gaskets and fit EGR valve to
delivery tube and exhaust manifold. Tighten
bolts to
25 Nm (18 lbf/ft).
8. Fit vacuum pipe and multi-plug to EGR valve.
EGR VALVE MODULATOR
Service repair no - 17.45.04
Remove
1. Disconnect multi-plug from modulator.
2. Disconnect spill pipe (green), modulator to air
cleaner hose.
3. Disconnect vacuum pipe (blue), modulator to
EGR valve.
4. Disconnect vacuum pipe (white), modulator to
brake servo pipe.
5. Unscrew 2 nuts securing modulator to flexible
mountings.
6. Remove modulator.
Refit
7. Fit modulator to flexible mountings and tighten
nuts to
8 Nm (6 lbf/ft).
8. Fit modulator pipes, ensuring they are connected
to correct ports.
9. Connect modulator multi-plug.
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19
FUEL SYSTEM
18
REPAIR
EGR THROTTLE POSITION SENSOR
Service repair no - 17.45.08
Remove
1. Remove 2 screws securing throttle position
sensor mounting plate to injection pump.
2. Disconnect sensor multi-plug.
3. Remove sensor assembly.
Refit
4. Position sensor assembly on injection pump and
secure with screws.
5. Connect multi-plug.
6. Adjust sensor
See Adjustment, EGR throttle
sensor
EGR CONTROL UNIT
Service repair no - 17.45.07
Remove
1. Raise centre seat, or cubby box
See CHASSIS
AND BODY, Repair, Cubby box to gain access
to EGR control unit harness.
2. Disconnect control unit multi-plug and remove
centre seat or cubby box.
3. Remove 4 screws and detach control unit from
seat or cubby box base.
Refit
4. Secure EGR control unit to base of centre seat
or cubby box.
5. Position centre seat or cubby box and connect
control unit multi-plug.
6. Fit centre seat, or cubby box.
See CHASSIS
AND BODY, Repair, Cubby box
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COOLING SYSTEM
1
DESCRIPTION AND OPERATION
ENGINE COOLING SYSTEM
Description
The complete cooling system of the 300Tdi engine
incorporates three independent functions:- Engine
(coolant) cooling; Turbo (charge air) intercooling;
Engine oil cooling.
The intercooler is a separate aluminium unit, located
on the LH side of the engine compartment adjacent to
the radiator, sharing the same upper and lower
mountings. For details of turbo intercooling
See
FUEL SYSTEM, Description and operation,
Operation . The oil cooler matrix is an integral part of
the radiator. Pre-formed pipes/hoses are used to link
the components within the separate systems as
shown below.
Engine cooling system
1. Radiator
2. Thermostat housing
3. Radiator bottom hose
4. Viscous fan
5. Water pump
6. Radiator top hose
7. Heater return hose
8. Coolant supply hose
9. By-pass hose
10. Radiator bleed (purge) hose
11. Bleed (purge) hose, thermostat housing
12. ’Y’ piece ejector
13. Expansion tank
14. Heater rail
15. Heater unit
16. Heater feed hose
17. Intercooler
18. Air cleaner
19. Air feed hose
20. Turbocharger
21. Charge air supply pipe/hose
22. Cooled charge air supply hose
23. Exhaust manifold
24. Engine oil cooler
25. Feed pipe, engine oil cooler
26. Return pipe, engine oil cooler
27. Oil filter
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