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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual
Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual
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19FUEL SYSTEM 2 REPAIR SWITCH - INERTIA - FUEL CUT OFF Service repair no - 19.22.09 Remove 1.Disconnect multiplug from fuel cut off switch. 2.Remove 2 screws securing switch to bulkhead. 3.Remove switch. Refit 4.Position switch to bulkhead. 5.Fit screws securing switch to bulkhead. 6.Connect multiplug. 7.Press top of switch to set switch.SENSOR - MASS AIR FLOW (MAF) Service repair no - 19.22.25 Remove 1.Disconnect multiplug from MAF sensor. 2.Loosen clip screw and release air intake hose from MAF sensor. 3.Release 2 clips and remove sensor from air cleaner. Refit 4.Position sensor to air cleaner and secure clips. 5.Position air intake hose and tighten clip screw. 6.Connect multiplug.
FUEL SYSTEM 3 REPAIR SENSOR - COMBINED MAP AND IAT Service repair no - 19.22.26 Remove 1.Remove 3 bolts and remove engine acoustic cover. 2.Disconnect multiplug from combined MAP and IAT sensor, 3.Remove 2 bolts securing sensor to inlet manifold. 4.Remove sensor and discard’O’ring. Refit 5.Clean sensor and mating face. 6.Fit new’O’ring and position sensor to manifold. 7.Fit and tighten MAF and IAT sensor bolts to9 Nm (7 lbf.ft) 8.Fit engine acoustic cover and secure with bolts.SENSOR - AMBIENT AIR PRESSURE (AAP) Service repair no - 19.22.27 Remove 1.Disconnect multiplug from AAP sensor. 2.Remove 2 screws and remove sensor. 3.Remove and discard’O’ring. Refit 4.Clean sensor and air cleaner cover. 5.Fit new’O’ring, fit sensor and tighten screws. 6.Connect multiplug to AAP sensor.
19FUEL SYSTEM 4 REPAIR ELEMENT - FUEL FILTER Service repair no - 19.25.07 Remove 1.Release fixings and remove battery cover. 2.Disconnect battery negative lead. 3.Raise rear of vehicle. WARNING: Support on safety stands. 4.Release fixing and remove fuel filter cover. 5.Clean area around fuel filter. 6.Disconnect multiplug from filter element. 7.Remove fuel filter element. Refit 8.Clean fuel filter and mating face. 9.Fit new fuel filter element and connect multiplug. 10.Position fuel filter cover and secure with fixing. 11.Remove stand(s) and lower vehicle. 12.Reconnect battery negative lead. 13.Fit and secure battery cover.COOLER - FUEL Service repair no - 19.25.30 Remove 1.Remove 3 bolts and remove engine acoustic cover. 2.Remove battery cover. 3.Disconnect battery negative lead. 4.Drain cooling system.See COOLING SYSTEM, Adjustment. 5.Release 3 clips and disconnect 3 coolant hoses from fuel cooler. 6.Release 2 fuel hoses from fuel cooler. CAUTION: Plug the connections. 7.Release vacuum pipe clip from fuel cooler. 8.Remove 4 bolts securing fuel cooler to inlet manifold and remove cooler. Refit 9.Clean fuel hose connections. 10.Position fuel cooler to inlet manifold. Apply Loctite 242 to bolts and tighten to18 Nm (13 lbf.ft). 11.Connect fuel hoses. 12.Connect coolant hoses, secure with clips. 13.Secure vacuum hose to fuel cooler. 14.Refill cooling system.See COOLING SYSTEM, Adjustment. 15.Fit engine acoustic cover and secure with bolts. 16.Reconnect battery negative lead. 17.Fit battery cover.
FUEL SYSTEM 5 REPAIR TURBOCHARGER Service repair no - 19.42.01 Remove 1.Remove battery cover. 2.Disconnect battery negative lead. 3.Remove 3 bolts and remove engine acoustic cover. 4.Release clip and disconnect breather hose from camshaft cover. 5.Release clips and disconnect air flow meter from air filter. 6.Disconnect multiplug from air flow meter. 7.Loosen clip screw and remove air inlet hose from turbocharger. 8.Remove 3 bolts and remove exhaust manifold heat shield. 9.Release clip and disconnect vacuum hose from turbocharger wastegate. 10.Loosen clip screw and release air outlet hose from turbocharger. 11.Remove turbocharger oil feed banjo bolt and discard sealing washers. 12.Remove 3 nuts and release exhaust front pipe from turbocharger and discard gasket. 13.Remove 3 nuts securing turbocharger to exhaust manifold. 14.Loosen and unscrew turbocharger drain pipe union from cylinder block. 15.Remove turbocharger and discard gasket. 16.Remove 2 bolts and remove turbocharger oil drain pipe. Discard gasket.
19FUEL SYSTEM 6 REPAIR Refit 17.Clean turbocharger and oil drain pipe mating faces. 18.Using a NEW gasket, fit turbocharger drain pipe and tighten bolts to10 Nm (7 lbf.ft). 19.Using a new gasket fit turbocharger to exhaust manifold and tighten nuts to30 Nm (22 lbf. ft). 20.Position oil drain pipe to cylinder block and tighten union. 21.Using new gasket, align exhaust front pipe and tighten nuts to30 Nm (22 lbf.ft) 22.Fit banjo bolt to oil feed pipe using new sealing washers and tighten to25 Nm (18 lbf.ft). 23.Position air outlet hose to turbocharger and tighten clip screw. 24.Position and secure vacuum hose to turbocharger wastegate. 25.Position exhaust manifold heat shield and tighten M6 bolts to9 Nm (7 lbf.ft)and M8 bolt to 25 Nm (18 lbf.ft). 26.Position air inlet hose to turbocharger and tighten clip screw. 27.Connect air flow meter to air filter and secure clips. 28.Connect air flow meter multiplug. 29.Connect breather hose and secure clip. 30.Fit engine acoustic cover and secure with bolts. 31.Reconnect battery negative lead. 32.Fit battery cover.FILTER ASSEMBLY - AIR Service repair no - 19.10.01 Remove 1.Loosen clip screw and release intake hose from air filter. 2.Release 2 clips securing air flow meter. 3.Release air flow meter from air filter cover and position aside. 4.Disconnect multiplug from AAP sensor. 5.Release air filter from 3 grommets, remove assembly and discard’O’ring. 6.Remove 2 screws, remove AAP sensor and discard’O’ring.
FUEL SYSTEM 7 REPAIR Refit 7.Clean air flow meter faces. 8.Fit new’O’ring to air filter. 9.Clean AAP sensor. 10.Using new’O’ring, fit AAP sensor and tighten screws. 11.Position air filter assembly and secure in grommets. 12.Position air flow meter and secure clips. 13.Position intake hose to air filter and tighten clip screw.INJECTOR - SET Service repair no - 19.60.12 Remove 1.Remove cooling fan.See COOLING SYSTEM, Repair. 2.Remove rocker shaft.See ENGINE , Repair. 3.Position container to catch fuel spillage. 4.Disconnect quick release fuel hose connectors from fuel connector block on cylinder head and fuel cooler to drain fuel from cylinder head. 5.Disconnect 5 multiplugs from injectors. 6.Remove Torx bolt securing injector unit to cylinder head.
19FUEL SYSTEM 8 REPAIR 7.AssembleLRT-12-154/1to injector unit, screw in slide hammer and remove injector. 8.UsingLRT-12-154/4,remove and discard sealing washer.9.Remove and discard’O’ring seal. 10.Rotate engine to align camshaft lobes for access of injector removal tool. 11.Carry out above procedure to remove the remaining 4 injectors. 12.Rotate engine manually until each cylinder being worked on is at TDC, and remove excess fuel from piston bowl using a syringe. Refit 13.Clean injector unit and mating faces in cylinder head. 14.PositionLRT-12-154/2to injector units and fit new’O’rings. 15.Fit new sealing washers to injector nozzles using LRT-12-154/3. 16.Fit retainers to injectors, carefully fit injectors ensuring retainer is located on its dowel and tighten bolt to32 Nm (24 lbf.ft) 17.Connect multiplug to injector. 18.Repeat above operation for remaining injectors. 19.Connect fuel hoses. 20.New injectors must be programmed using TestBook. 21.Fit rocker shaft.See ENGINE , Repair. 22.Fit cooling fan.See COOLING SYSTEM, Repair.
FUEL SYSTEM 9 REPAIR HEATER PLUGS - SET Service repair no - 19.60.31 Remove 1.Remove 3 bolts and remove engine acoustic cover. 2.Remove battery cover. 3.Disconnect battery negative lead. 4.Disconnect 4 heater plug leads. 5.Loosen and remove 4 heater plugs. Refit 6.Throughly clean heater plugs and seating area in cylinder head. 7.Apply a suitable anti-seize compound to threads of heater plugs. 8.Fit heater plugs and tighten to16 Nm (12 lbf. ft) . 9.Connect heater plug leads. 10.Fit engine acoustic cover. 11.Reconnect battery negative lead. 12.Fit battery cover.INTERCOOLER Service repair no - 19.42.15 Remove 1.Remove radiator.See COOLING SYSTEM, Repair. 2.Release clip and remove air hose from intercooler. Refit 3.Position air hose to intercooler and secure with clip. 4.Fit radiator.See COOLING SYSTEM, Repair.
19FUEL SYSTEM 10 REPAIR POTENTIOMETER - THROTTLE Service repair no - 19.30.14 Remove NOTE: The throttle potentiometer is an integral part of the throttle pedal assembly and must not be dismantled. 1.With assistance remove 2 nuts and bolts securing throttle pedal to body. 2.Disconnect multiplug from throttle potentiometer and remove throttle pedal. Refit NOTE: From Vin 607225 a three track throttle potentiometer was fitted in place of a two track potentiometer. Three track potentiometers cannot be fitted to vehicles previously fitted with two track potentiometers. Two track potentiometers can be fitted to vehicles previously fitted with three track potentiometers, but TestBook must be used to configure the ECM. 3.Connect multiplug to throttle potentiometer. 4.Position throttle pedal assembly, tighten nuts and bolts to25 Nm (18 lbf.ft).PUMP - FUEL Service repair no - 19.45.08 Remove 1.Remove fuel tank.See this Section. 2.UsingLRT-19-009remove locking ring from fuel pump housing. 3.Remove fuel pump from tank and discard sealing ring. Refit 4.Clean pump housing and mating face on fuel tank. 5.Fit seal to pump housing. 6.Fit pump to fuel tank and secure with locking ring. 7.Fit fuel tank.See this Section.
FUEL SYSTEM 11 REPAIR REGULATOR - FUEL PRESSURE Service repair no - 19.45.06 Remove 1.Remove battery cover. 2.Disconnect battery negative lead. 3.Remove 3 bolts and remove engine acoustic cover. 4.Release hose from fuel cooler. 5.Release fuel hoses from pressure regulator. CAUTION: Plug the connections. 6.Disconnect multiplug from fuel temperature sensor. 7.Remove 3 bolts, remove pressure regulator from cylinder head and collect gasket and’O’ring. 8.Remove fuel filter from cylinder head. 9.Remove fuel temperature sensor and discard sealing washer. 10.Remove fuel hose and fuel pipe and discard’O’ rings. Refit 11.Clean fuel pressure regulator, mating face and fuel filter. 12.Clean fuel pipe unions. 13.Fit fuel pipe and fuel hose to pressure regulator using new’O’rings. 14.Fit fuel temperature sensor using new sealing washer and tighten to14 Nm (11 lbf.ft). 15.Fit fuel filter to cylinder head. 16.Using a new gasket and’O’ring position pressure regulator and tighten bolts to25 Nm (18 lbf.ft). 17.Connect fuel temperature sensor. 18.Connect fuel hoses to pressure regulator and fuel cooler. 19.Fit engine acoustic cover. 20.Reconnect battery negative lead. 21.Fit battery cover.