Land Rover Defender: Fuel Fired Booster Heater

REMOVAL AND INSTALLATION

PART(S)

REMOVAL

CAUTION: Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.

NOTE:

• This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
• This procedure contains illustrations showing certain components removed to provide extra clarity.

The following step(s) applies to: All vehicles

1. Disconnect the startup battery ground cable.

2. Raise and support the vehicle on a suitable 2-post lift.

3. Drain the cooling system.

4. Install the secondary bulkhead center panel.

5. Remove the secondary bulkhead right panel.

6. Remove the front right wheel arch liner.

7.

• Remove the 3 nuts and 1 bolt.
• Remove the Fuel Fired Booster Heater (FFBH) exhaust assembly.
• Remove and discard the gasket.

8.

• Disconnect the electrical connector.
• Release the wiring harness clip.

9.

• Release the FFBH air intake hose from the 2 clips.
• Remove the air intake hose.

10.

CAUTION: Be prepared to collect escaping fuel.

Disconnect the FFBH fuel line.

The following step(s) applies to: Vehicles with 3.0L petrol engine

11.

CAUTION: Be prepared to collect escaping coolant.

Disconnect the 3 coolant hoses.

The following step(s) applies to: Vehicles with 2.0L diesel engine

12.

Disconnect the 3 coolant hoses.

The following step(s) applies to: Vehicles with 2.0L petrol engine

13.

Disconnect the 3 coolant hoses.

The following step(s) applies to: All vehicles

14.

• Remove the 2 bolts.
• Remove the FFBH.

15.

Disconnect the FFBH auxiliary coolant pump electrical connector.

16.

• Release the 2 coolant hoses.
• Remove the bolt.
• Remove the FFBH coolant pump.

17.

• Release the 3 wiring harness clips.
• Disconnect the 3 electrical connectors.
• Remove the wiring harness.

18.

• Remove the 2 bolts.
• Remove the FFBH exhaust pipe.

19.

• Release the FFBH fuel line from the clip.
• Remove the 4 bolts.
• Remove the FFBH.

20.

• Remove the screw.
• Remove the FFBH coolant feed and return hoses.

INSTALLATION

The following step(s) applies to: All vehicles

1.

• Install the Fuel Fired Booster Heater (FFBH) coolant feed and return hoses.
• Install and tighten the screw.

2.

• Install the FFBH.
• Install and tighten the 4 bolts.
• Install the FFBH fuel line to the clip.

3.

• Install the FFBH exhaust pipe.
• Install and tighten the 2 bolts.

4.

• Install the wiring harness.
• Connect the 3 electrical connectors.
• Install the wiring harness at 3 clips.

5.

• Install the FFBH coolant pump.
• Make sure the metal strap bracket sits over the rubber isolator without touching the FFBH coolant pump.
• Install and tighten the bolt.
• Install the 2 coolant hoses.

6. Connect the FFBH auxiliary coolant pump electrical connector.

7.

CAUTION: Make sure that the component is correctly located.

• Install the FFBH assembly.
• Install and tighten the 2 bolts.

  Torque: 10Nm

The following step(s) applies to: Vehicles with 2.0L petrol engine

8.

Connect the 3 coolant hoses.

The following step(s) applies to: Vehicles with 2.0L diesel engine

9.

Connect the 3 coolant hoses.

The following step(s) applies to: Vehicles with 3.0L petrol engine

10.

CAUTION: Be prepared to collect escaping coolant.

Connect the 3 coolant hoses.

The following step(s) applies to: All vehicles

11. Connect the FFBH fuel line.

12.

• Install the air intake hose.
• Install the FFBH air intake hose to the 2 clips.

13.

• Disconnect the electrical connector.
• Install the wiring harness clip.

14.

• Install the fuel fired booster heater (FFBH) exhaust assembly.
• Install a new gasket.

  Renew Part: Fuel fired booster heater seal Quantity: 1.

• Install and tighten the 3 nuts.

  Torque: 10Nm

• Install and tighten the bolt.

  Torque: 10Nm

15. Install the front right wheel arch liner.

16. Install the secondary bulkhead center panel.

17. Install the secondary bulkhead right panel.

18. Fill the coolant system.

19. Connect the startup battery ground cable.

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