Land Rover Defender 90 110 Workshop Book 2 Rover

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: *:+ .* ; LAND ROVER 90 BASIC FUEL SYSTEM *- 
I. In-tank fuel pump. 
2. Fuel tank gauge unit. 
3. Fuel supply pipc to filter. 
4. Fuel  filter. 
5. Fuel  supply  pipe filter  to vapour  separator 
6. Vapour  separator. 
7. Vapour separator,  outlet to carburctter. 
8. Spill return pipc  to fuel  tank  via restrictor. 
9. Fuel  filler. 
10. Breather  hose. 
11. Restrictor. 
12. Fuel tank drain  plug.  

El PETROL FUEL SYSTEM 
REMOVE REAR TANK FUEL PUMP 
To renew  the pump it is first  necessary  to remove  the 
fuel  tank  from  the vehicle.  Before  commencing the 
following  instructions  it is  essential  that the 
WARNINGS  and safety  precautions  concerning  fuel 
tank  draining  and removal  are studied  and observed. 
These  precautions  are included 
in the introduction  to 
this  and  each 
of the five  books  comprising  the 
workshop  manual for the  Ninety and One
-Ten  vehicles. 
1. Move...

PETROL FUEL SYSTEM 1191 
,.. 20. Secure the  rear  of the tank with  the  two  captive I . >,.. Y;:. :* .I a. bolts,  plain washer  and nyloc  nut. 
21.  Connect  the fuel  feed pipe. 
22.  Connect  the spill  return  pipe. 
23.  Connect  the fuel  filter  hose and breather  pipe to 
24. Fit the  left-hand  lashing eye. 
25. 
Fit the  anti-roll  bar. 
26. Fit the drop  plate  support  bars- if fitted. 
27. Connect  the fuel gauge  unit leads. 
28. Reconnect  battery,  and  check operation  of pump 
the...

El DIESEL FUEL SYSTEM 
FUEL INJECTORS 
CHECKING NOZZLE ASSEMBLIES 
WARNING: Do not allow  the fuel  spray  to contact  the 
person  otherwise  injury may result 
from skin 
penetration. 
When  an injection  nozzle is considcrcd  to be the cause 
of irregular  running  and loss of  power,  a quick  check 
may  be 
made by loosening  the fuel  feed  pipe union  nut 
on  each  nozzle  in turn,  whilst  the engine  is idling  at 
approximately 
1,000 rev/min. 
If  the  injection  nozzle assembly  being...

DIESEL FUEL SYSTEM 1191 
.rcs,~ 
..... f ~::.; L:::!  1. Do not attempt  to start  the engine  hoping  to draw , , . . . . . . . ... ~.~,, the  fuel  through in this way,  othcrwisc the full 
priming  procedure  will be necessary. 
2. Slacken  the bleed  pipe banjo  bolt on the top of the 
main  fuel filter. 
C... 
- .. ,. .. , .... .. .. .., :  ,. . .I. ... .. 
3. Operate  the hand  priming  lever on the mechanical 
pump,  until fuel free  from  bubbles  emerges. 
Always  ensure that fuel pump  lever is...

DIESEL FUEL SYSTEM 
OVERHAUL 
Service  tools: 
271483  or 
18G109 or  12. 
Clean 
the three oil feed  passages  in the  nozzle body 0 ,,: 5, with  a wire  or drill of 1,5 mm (0.062 in)  diameter. -- 
13. Remove  the  carbon  from the  annular  recess with 
the tool illustrated. 
FUEL  INJECTORS 
Injector  nozzle testing  and setting  kit 
Adaptor  Pintaux Injector 
Diesel 
tune 
111 
278182  or 
18G109B or 
Diesel  tune 
102 
Injector  nozzle flushing  tool 
Injector  nozzle cleaning  kit 
278181 or...

DIESEL FUEL SYSTEM El 
- I. :-; : ..\..* 16. Carbon may be removed  from the nozzle  valve 
cone  by inserting the  valve into the  tool illustrated 
and  then  rotating 
it alternately  in a clockwise  then 
anti
-clockwise  manner whilst pressing the valve 
inward. 
If the  nozzle  is blued  or the  seating  has a 
dull circumferential  ring indicating pitting  or wear, 
the  nozzle  body  and  valve should  be returned  to a 
CAV  Service  Agent and  replacement  parts fitted. 
Do not attempt to lap...

DIESEL FUEL SYSTEM 
25. The efficient  operation of the injection  nozzle 
assembly  is dependent 
on four  main  conditions, as 
follows: 
The  nozzle  valve  must open  at 
135 Ats. 
The  rate of back  leakage  must  be within 
150 to 
100 Ats. 
Seat  tightness  must be sufficient  to prevent 
leakage. 
Spray  form 
must compare  favourably  with the 
illustrations. 
26.  Pressure  setting, back leakage  and seat  tightness 
tests  may be made  by coupling  the injection  nozzle 
and  holder  assembly...

DIESEL FUEL SYSTEM 
.. . I. :.:T 39. The adaptor  differs mainly  in the  cap  nut and 
nozzle  valve  from the ordinary  type of injection 
nozzle  and holder  assembly as  fitted  to the engine; 
the  nozzle valve  has 
no pintle. 
40. The cap nut is extended,  bored  and  threaded to 
receive nozzles  for testing. 
41, Connect the  adaptor assembly  to the  pressure pipe. 
42. Remove  the end  cap and  adjust  the opening 
pressure 
of the  nozzle  valve to 220 atmospheres. 
43. Screw  the injection...

1191 DIESEL FUEL SYSTEM 
3. Lightly grease the copper  washer into position on 
each  injector  before fitting to the  cylinder  head. 
4. Fit the  injector  and evenly  tighten  the retaining 
nuts 
to the correct torque 6 to 8 Nm (4 to 6 Ibs  ft). 
Uneven 
or overtightening of the injector nuts  could 
distort  the nozzle  and cause  misfiring when  normal 
running  temperature  is reached. 
5. Reconnect  the injector  pipes  but  do not 
overtighten 
thc union  nuts. 
THROTTLE  PEDAL ADJUSTMENT -...