Defender (1999-2002). Manual — part 32
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ENGINE
19
REPAIR
70. Connect coolant hoses to fuel cooler and coolant
rail and secure clips.
71. Fit air intake hose to intake elbow and tighten
clip screw.
72. Fit starter motor. See ELECTRICAL, Repair.
73. Fit turbocharger. See FUEL SYSTEM, Repair.
74. Fit radiator. See COOLING SYSTEM, Repair.
75. Fit air filter. See FUEL SYSTEM, Repair.
76. Fill engine with oil.
77. Fit underbelly panel. See CHASSIS AND
BODY, Repair.
MOUNTING - FRONT - LH
Service repair no - 12.45.01
Remove
1. Remove centrifuge assembly. See this
Section.
2. Remove 3 bolts, remove oil filter adaptor
housing and discard gasket.
3. Fit suitable lifting chains to support engine.
4. Remove 2 nuts securing engine mounting to
chassis.
5. Remove 4 bolts securing engine mounting
bracket to cylinder block.
6. Remove nut securing mounting to mounting
bracket.
7. Remove mounting and mounting bracket.
8. Remove mounting shield.
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12
ENGINE
20
REPAIR
Refit
9. Fit shield to mounting ensuring cut-away portion
is correctly aligned.
10. Fit mounting and mounting bracket.
11. Fit mounting bracket to cylinder block bolts and
tighten to 48 Nm (35 lbf.ft) .
12. Fit nuts securing mounting to chassis and tighten
to 85 Nm (63 lbf.ft) .
13. Fit mounting to mounting bracket nut and tighten
to 85 Nm (63 lbf.ft) .
14. Remove engine support chains.
15. Clean oil filter adaptor housing and mating face.
16. Fit oil filter adaptor housing using a new gasket
and tighten bolts to 25 Nm (18 lbf.ft) .
17. Fit centrifuge assembly. See this Section.
MOUNTING - FRONT - RH
Service repair no - 12.45.03
Remove
1. Remove engine acoustic cover. See this
Section.
2. Remove fixings, remove battery cover.
3. Disconnect battery negative lead.
4. Raise front of vehicle.
WARNING: Support on safety stands.
5. Remove 4 bolts, move fuel cooler to one side.
6. Fit suitable lifting chains to support engine.
7. Remove 2 nuts securing engine mounting to
chassis.
8. Remove 4 bolts securing engine mounting
bracket to cylinder block.
9. Remove nut securing mounting to mounting
bracket.
10. Remove mounting and mounting bracket.
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ENGINE
21
REPAIR
Refit
11. Fit mounting and mounting bracket.
12. Fit mounting bracket to cylinder block bolts and
tighten to 48 Nm (35 lbf.ft) .
13. Fit nuts securing mounting to chassis and tighten
to 85 Nm (63 lbf. ft).
14. Fit mounting to mounting bracket nut and tighten
to 85 Nm (63 lbf.ft) .
15. Remove engine support chains.
16. Position fuel cooler. Apply Loctite 242 to bolts
and tighten to 18 Nm (13 lbf.ft).
17. Remove stand(s) and lower vehicle.
18. Reconnect battery negative lead.
19. Fit engine acoustic cover. See this Section.
MOUNTING - GEARBOX - REAR - LH
Service repair no - 12.45.07
Remove
1. Raise vehicle on ramp.
2. Position jack to support gearbox.
3. Remove 4 bolts securing mounting bracket to
transfer gearbox.
4. Remove 2 nuts, remove mounting and mounting
bracket.
5. Remove heat shield from mounting.
Refit
6. Clean mounting and mating faces.
7. Position heat shield to mounting.
8. Position mounting and mounting bracket and
tighten nuts to 48 Nm (35 lbf.ft) and bolts to 85
Nm (63 lbf. ft).
9. Lower support jack.
10. Lower vehicle.
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12
ENGINE
22
REPAIR
MOUNTING - GEARBOX - REAR - RH
Service repair no - 12.45.09
Remove
1. Remove LH rear gearbox mounting. See this
Section.
2. Remove 4 bolts securing mounting bracket to
transfer gearbox.
3. Remove 2 nuts, remove mounting and mounting
bracket.
Refit
4. Clean mounting and mating faces.
5. Position mounting and mounting bracket and
tighten nuts to 48 Nm (35 lbf.ft) and bolts to 85
Nm (63 lbf.ft).
6. Fit LH rear gearbox mounting. See this
Section.
FLYWHEEL
Service repair no - 12.53.07
Remove
1. Remove clutch assembly. See CLUTCH,
Repair.
2. Remove and discard 8 bolts securing flywheel to
crankshaft and remove flywheel.
NOTE: Dowel located.
Refit
3. Clean flywheel and crankshaft mating face.
4. Position flywheel to crankshaft.
5. Fit new flywheel retaining bolts and tighten by
diagonal selection to:
Stage 1 - 40 Nm (30 lbf.ft)
Stage 2 - Further 90
°
CAUTION: Do not carry out stages 1 and 2
in one operation.
6. Fit clutch assembly. See CLUTCH, Repair.
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