Defender 300Tdi (1996+). Manual — part 31
COOLING SYSTEM
1
REPAIR
VISCOUS COUPLING AND FAN
Service repair no - 26.25.19 - Viscous coupling
Service repair no - 26.25.05 - Fan
Remove
NOTE: The viscous coupling has a LH
thread.
1. Disconnect battery.
2. Using special pulley restraining tool LRT-12-094
and special spanner LRT-12-093 unscrew
viscous coupling from pulley hub adaptor thread.
3. Remove viscous coupling and fan from vehicle.
NOTE: If air conditioning is fitted, the fan
cowl will also need removing,
See Fan
cowl , with the viscous fan unit.
4. If required, remove 4 screws and release
viscous unit from fan blade.
Refit
5. Fit viscous unit to fan blades.
6. If applicable, fit fan cowl.
See Fan cowl
7. Carefully position viscous coupling and fit onto
pulley hub adaptor thread.
8. Using special pulley retaining tool, spanner and
a suitable torque wrench, tighten assembly to
45
Nm (33 lbf/ft).
26
COOLING SYSTEM
2
REPAIR
FAN COWL
Service repair no - 26.25.11
Remove
1. Disconnect battery.
2. Drain coolant.
See Adjustment, Drain and
refill cooling system.
3. Slacken retaining clips and remove radiator top
hose.
4. Slacken retaining clip and remove top hose from
intercooler.
NOTE: On vehicles fitted with EGR system,
remove complete intercooler top hose
assembly.
5. Remove viscous coupling and fan
See Viscous coupling and fan.
6. Remove 2 nuts securing top of fan cowl.
7. Release expansion tank hose from clips at base
of fan cowl.
8. Lift and remove cowl .
NOTE: On vehicles fitted with air
conditioning, it will be necessary to
remove the cowl and viscous fan unit
together to enable clearance of the compressor.
Refit
9. Position fan cowl.
10. Fit viscous fan unit.
See Viscous coupling
and fan
11. Fit expansion tank hose into fan cowl clips.
12. Secure top of fan cowl to radiator top cover.
13. Fit intercooler top hose.
14. Fit radiator top hose.
15. Refill cooling system.
See Adjustment, Drain
and refill cooling system
16. Reconnect battery.
FAN PULLEY
Service repair no - 26.25.04.
Remove
1. Disconnect battery.
2. Remove viscous fan unit.
See Viscous
coupling and fan
3. Remove drive belt.
See ELECTRICAL, Repair,
Auxiliary drive belt
4. Unscrew 4 bolts and remove pulley from adaptor
boss.
Refit
5. Fit fan pulley to adaptor boss. Tighten bolts to
25
Nm (18 lbf/ft).
6. Fit drive belt.
See ELECTRICAL, Repair,
Auxiliary drive belt
7. Fit viscous fan unit.
See Viscous coupling
and fan
8. Reconnect battery.
COOLING SYSTEM
3
REPAIR
WATER PUMP
Service repair no - 26.50.01
Remove
1. Disconnect battery.
2. Drain cooling system.
See Adjustment, Drain
and refill cooling system
3. Remove radiator top hose.
4. Remove intercooler top hose.
5. Slacken water pump and power steering pump
pulley retaining bolts.
6. Remove drive belt.
See ELECTRICAL, Repair,
Auxiliary drive belt
7. Unscrew flange nut and remove belt tensioner.
8. Remove oil filler cap and remove rocker cover
insulation.
9. Slacken retaining clip and disconnect hose at
heater rail.
10. Unscrew 3 bolts and remove water pump pulley.
11. Unscrew 3 bolts and remove power steering
pump pulley.
12. Remove 8 bolts securing water pump, noting
location of 3 through bolts into cylinder block.
13. Withdraw pump and gasket from auxiliary
mounting bracket.
14. Clean all gasket material from mating faces.
Refit
15. Using new gasket, fit water pump to mounting
bracket. Tighten bolts to
25 Nm (18 lbf/ft).
16. Fit power steering pump pulley.
17. Fit water pump pulley. Tighten bolts of both
pulleys to
25 Nm (18 lbf/ft).
18. Fit drive belt.
See ELECTRICAL, Repair,
Auxiliary drive belt
19. Fit hose at heater rail.
20. Fit rocker cover insulation and oil filler cap.
21. Fit drive belt tensioner. Tighten retaining nut to
45 Nm (33 lbf/ft).
22. Fit intercooler top hose.
23. Fit radiator top hose.
24. Refill cooling system.
See Adjustment, Drain
and refill cooling system
25. Reconnect battery.
26
COOLING SYSTEM
4
REPAIR
AUXILIARY MOUNTING BRACKET AND GASKET
Service repair no - 26.50.04
Remove
1. Disconnect battery.
2. Drain cooling system
See Adjustment, Drain
and refill cooling system .
3. Remove radiator top hose.
4. Remove intercooler top hose.
5. Remove viscous fan unit.
See Viscous
coupling and fan
6. Remove fan cowl.
See Fan cowl
7. Slacken power steering pump pulley retaining
bolts.
8. Remove drive belt.
See ELECTRICAL, Repair,
Auxiliary Drive belt
9. Unscrew 3 bolts and remove power steering
pump pulley.
10. Remove 4 bolts securing power steering pump
mounting bracket.
11. Lower pump and bracket. Do not disconnect fluid
pipes.
12. Remove generator.
See ELECTRICAL, Repair,
Generator
13. Unscrew retaining nut and remove drive belt
tensioner.
14. Release hose clip from bracket above water
pump.
15. Disconnect bottom hose/heater return hose at
water pump and heater rail.
16. Disconnect by-pass hose from water pump and
thermostat housing.
17. Remove 5 bolts (one with nut) and single
retaining nut, securing auxiliary mounting
bracket to cylinder block.
18. Withdraw mounting bracket, complete with water
pump.
19. Remove gasket and clean mating faces.
Refit
20. Using 2 slave studs, fit new gasket.
NOTE: All fixing bolts and nuts should be
tightened to
25 Nm (18 lbf/ft) unless
otherwise stated.
21. Locate mounting bracket, complete with water
pump on slave studs and secure with 4 other
fixings.
22. Remove slave studs and fit remaining bolts/nuts.
23. Fit by-pass hose to thermostat housing and
water pump.
24. Fit bottom hose/heater return hose to water
pump and heater rail.
25. Fit heater hose clip to mounting bracket.
26. Fit drive belt tensioner. Tighten nut to
45 Nm (33
lbf/ft).
27. Fit generator.
See ELECTRICAL, Repair,
Generator Do not fit drive belt at this stage.
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