Defender (1999-2002). Manual — part 34
ENGINE
27
REPAIR
Refit
9. Clean sump and mating faces.
10. Apply a bead of sealant, Part No. STC 3254 to
joint faces of timing chain cover and crankshaft
rear oil seal.
11. Position new sump gasket.
CAUTION: Gasket must be fitted dry.
12. Position sump, fit bolts ensuring they are in their
correct fitted position, lightly tighten bolts.
13. Fit bolts securing sump to gearbox bell housing
and tighten to 15 Nm (11 lbf.ft) .
14. Using sequence shown, tighten sump bolts to 25
Nm (18 lbf.ft) .
15. Tighten sump to gearbox bell housing bolts to 50
Nm (37 lbf ft) .
16. Fit new gasket to centrifuge drain pipe and
tighten bolts to 10 Nm (7 lbf.ft) .
17. Fit exhaust front pipe. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
18. Refill engine with oil.
19. Reconnect battery negative lead.
20. Refit battery cover.
12
ENGINE
28
REPAIR
SWITCH - OIL PRESSURE
Service repair no - 12.60.50
Remove
1. Remove fixings and remove engine acoustic
cover.
2. Release clip and disconnect breather hose from
camshaft cover.
3. Release clips and disconnect air flow meter from
air filter.
4. Disconnect multiplug from air flow meter.
5. Release clip screw and remove air inlet hose
from turbocharger.
6. Remove 3 bolts and remove exhaust manifold
heat shield.
7. Disconnect multiplug from oil pressure switch.
8. Position container below switch to catch oil
spillage.
9. Remove oil pressure switch.
Refit
10. Clean oil pressure switch threads.
11. Fit oil pressure switch and tighten to 9 Nm (7
lbf.ft).
12. Connect switch multiplug.
13. Position exhaust manifold heat shield and
tighten M6 bolts to 10 Nm (7 lbf.ft) and M8 bolt
to 25 Nm (18 lbf.ft) .
14. Position air inlet hose to turbocharger and
tighten clip screw.
15. Connect air flow meter to air filter and secure
clips.
16. Connect air flow meter multiplug.
17. Connect breather hose and secure clip.
18. Fit and secure engine acoustic cover.
19. Top up engine oil.
ENGINE
29
REPAIR
VALVE - RELIEF - OIL PRESSURE
Service repair no - 12.60.56
Remove
1. Remove sump gasket. See this Section.
2. Remove and discard oil pressure relief valve
plug from oil pump housing.
3. Remove spring and valve.
Refit
4. Clean valve and spring.
5. Clean valve seating inside oil pump housing.
6. Lubricate valve and seating.
7. Fit valve and spring to pump.
8. Apply Loctite 243 sealant to threads of a new
plug.
9. Fit plug and tighten to 23 Nm ( 17 lbf.ft) .
10. Fit sump gasket. See this Section.
11. Check engine oil level, top-up if necessary.
COOLER - ENGINE OIL
Service repair no - 12.60.68
Remove
1. Drain cooling system. See COOLING
SYSTEM, Adjustment.
2. Remove centrifuge assembly. See this
Section.
3. Remove clutch housing bolt and release coolant
pipe from rear of engine.
4. Release clip and coolant hose from oil cooler.
5. Disconnect oil pressure switch multiplug.
6. Remove oil filter element using a suitable strap
wrench.
7. Remove 3 bolts, remove oil filter adaptor and
discard gasket.
8. Remove 7 bolts, remove oil cooler and discard
gasket.
9. Remove oil pressure switch.
12
ENGINE
30
REPAIR
Refit
10. Clean oil cooler and mating faces.
11. Fit oil pressure switch and tighten to 9 Nm (7
lbf.ft) .
12. Position oil cooler using a new gasket and
tighten bolts to 25 Nm (18 lbf.ft) .
13. Position oil filter adaptor, fit new gasket and
tighten bolts to 25 Nm (18 lbf.ft).
14. Position oil filter element hand tight then a
further half turn.
15. Position coolant hose to oil cooler and secure
clip.
16. Position coolant pipe and tighten clutch housing
bolt to 50 Nm (37 lbf.ft) .
17. Connect oil pressure switch multiplug.
18. Fit centrifuge assembly. See this Section.
19. Refill cooling system. See COOLING SYSTEM,
Adjustment.
20. Top up engine oil.
CENTRIFUGE ASSEMBLY
Service repair no - 12.60.90
Remove
1. Remove fixings and remove underbelly panel.
See CHASSIS AND BODY, Repair.
2. Remove 2 bolts securing centrifuge drain pipe to
engine sump and discard gasket.
3. Remove turbocharger. See FUEL SYSTEM,
Repair.
Models with air conditioning only
4. Remove auxiliary drive belt. See
ELECTRICAL, Repair.
5. Remove 4 bolts securing compressor and move
to one side.
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