Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							19FUEL SYSTEM
12
REPAIR MASS AIR FLOW (MAF) SENSOR
Service repair no - 19.22.25
Remove
1.Loosen clip securing air intake hose to MAF
sensor and disconnect.
2.Disconnect multiplug from sensor.
3.Release 2 clips securing sensor to air cleaner.
4.Remove sensor, collect and discard O ring.
Refit
5.Clean sensor and mating faces.
6.Fit NEW O ring to sensor.
7.Fit sensor to air cleaner and secure clips.
8.Connect multiplug.
9.Connect air intake hose to sensor and tighten
clip.PLENUM CHAMBER
Service repair no - 19.22.46
Remove
1.Disconnect battery negative lead.
2.Loosen clip securing air intake hose to plenum
chamber.
3.Disconnect air intake hose.
4.Remove split pin from throttle cable clevis pin.
5.Remove clevis pin.
6.Release and remove kick down cable clevis pin.
7.Release throttle cable from abutment bracket.
8.Remove front locknut from kick down cable.
9.Release cable from bracket. 
						

							SFI
13
REPAIR
10.Disconnect purge hose from plenum chamber.
11.Disconnect breather hose from plenum chamber.
12.Depress spring clip and disconnect TP sensor
multiplug.
13.Disconnect multiplug from IACV.
14.Remove 6 bolts securing plenum chamber to
inlet manifold.
15.Release plenum chamber from inlet manifold.
16.Fit hose clamp to water jacket coolant hoses.
17.Tighten clamp.
18.Position cloth to absorb coolant spillage.
19.Loosen clips securing coolant hoses to plenum
chamber.
20.Release hoses from plenum chamber.
21.Remove plenum chamber.
22.Place cloth over ram housing.
Do not carry out further dismantling if component
is removed for access only.
23.Remove 4 bolts securing water jacket to plenum
chamber.
24.Remove water jacket from plenum chamber.
25.Remove gasket from water jacket.
26.Move throttle linkage aside to gain access to
mounting bolts.
27.Remove 3 bolts securing throttle linkage to
plenum chamber.
28.Remove throttle linkage and collect spring.
29.Remove 2 screws securing TP sensor to plenum
chamber.
30.Remove TP sensor and collect clamping plate.
31.Remove 2 bolts securing IACV to plenum
chamber.
32.Remove IACV and collect gasket. 
						

							19FUEL SYSTEM
14
REPAIR Refit
33.Position throttle linkage and spring to plenum
chamber.
34.Fit spring to linkage.
35.Hold throttle open to gain access to mounting
bolts.
36.Fit and tighten mounting bolts to
8 Nm, 6 lbf ft.
37.Clean mating faces of TP sensor and plenum
chamber.
38.Fit TP sensor and engage spindle.
39.Fit clamping plate and tighten bolts to
2 Nm, 1.5
lbf ft.
40.Clean mating faces of IACV and plenum
chamber.
41.Fit gasket to IACV.
42.Fit IACV to plenum chamber and tighten bolts to
2 Nm, 1.5 lbf ft.
43.Clean mating faces of water jacket and plenum
chamber.
44.Position gasket to plenum chamber.
45.Fit water jacket to plenum chamber and tighten
bolts to
13 Nm, 10 lbf ft.
46.Remove cloth from ram housing.
47.Clean plenum and inlet manifold mating faces.
48.Position plenum chamber.
49.Connect coolant hoses to plenum chamber.
50.Tighten hose clips.
51.Loosen and remove hose clamp.
52.Remove cloth.
53.Apply a thin, uniform coating of Loctite 577
sealant to sealing face of plenum chamber.
54.Fit plenum chamber and tighten bolts to
24 Nm,
18 lbf ft.
55.Connect multiplug to TP sensor.
56.Connect multiplug to IACV.
57.Connect breather hose to plenum chamber.
58.Connect purge hose to plenum chamber.
59.Fit kick down cable to abutment bracket, fit
locknut and adust cable.
See AUTOMATIC
GEARBOX, Adjustment, Kickdown cable
adjustment
60.Connect throttle cable to abutment bracket.
61.Align throttle cable to lever, fit clevis pin and
secure with new split pin.
62.Align kick down cable to lever.
63.Fit and secure clevis pin.
64.Connect air intake hose and secure with clip.
65.Reconnect battery negative lead.
66.Top up cooling system.THROTTLE POSITION (TP) SENSOR
Service repair no - 19.22.49
Remove
1.Disconnect multiplug from TP sensor.
2.Remove 2 screws securing TP sensor and
collect clamp plate.
3.Remove TP sensor.
Remove
4.Clean TP sensor and mating face.
5.Fit sensor ensuring drive engages with throttle
spindle.
6.Position clamp plate, fit screws and tighten to
2
Nm, 1.5 lbf ft.
7.Connect multiplug. 
						

							SFI
15
REPAIR IDLE AIR CONTROL VALVE (IACV)
Service repair no - 19.22.54
Remove
1.Disconnect battery negative lead.
2.Disconnect multiplug from IACV.
3.Remove 2 bolts securing IACV to plenum
chamber.
4.Remove IACV.
5.Remove gasket and discard.
Refit
6.Clean mating faces of IACV and plenum
chamber.
7.Clean plunger on IACV and plunger seat on
plenum chamber.
8.Using a new gasket, fit IACV to plenum
chamber.
9.Fit and tighten bolts securing IACV to plenum
chamber to
2 Nm, 1.5 lbf ft.
10.Connect multiplug to IACV.
11.Reconnect battery negative lead.FUEL FILTER
Service repair no - 19.25.02
WARNING: Spilling of fuel is unavoidable
during this operation. Ensure all
necessary precautions are taken to
prevent fire and explosion.
WARNING: Ensure fuel handling
precautions given in Section 01 -
Introduction are strictly adhered to when
carrying out the following instructions.
Remove
1.Depressurise fuel system.
See Adjustment,
fuel system depressurise
2.Clean area around hose connections to prevent
ingress of dirt into fuel system.
3.Clamp inlet and outlet hoses to reduce fuel
spillage when disconnecting.
4.Loosen 2 unions and disconnect hoses from fuel
filter.
CAUTION: Plug the connections.
5.Loosen bolt securing fuel filter to chassis
member.
6.Remove fuel filter.
Refit
7.Position NEW filter to chassis member,
observing direction of flow arrow stamped on
side.
8.Tighten bolt securing filter to chassis member.
9.Remove plugs.
10.Connect hoses to fuel filter and tighten unions to
30 Nm, 22 lbf ft.
11.Remove clamps from hoses.
12.Start engine and inspect for fuel leaks. 
						

							19FUEL SYSTEM
16
REPAIR FUEL PRESSURE REGULATOR
Service repair no - 19.45.06
Remove
1.Disconnect battery negative lead.
2.Depressurise fuel system.
See Adjustment,
fuel system depressurise
3.Release clip and disconnect fuel return hose
from fuel pipe.
CAUTION: Plug the connections.
4.Disconnect vacuum hose from pressure
regulator.
5.Remove 4 nuts securing coil mounting bracket to
inlet manifold.
6.Release coil mounting bracket from studs and
move aside.
7.Release regulator connecting pipe from clip.
8.Remove 2 bolts securing pressure regulator to
fuel rail.
9.Remove regulator from fuel rail.
10.Remove and discard O ring.
11.Release clip and remove fuel hose from
regulator.
CAUTION: Plug the connections.Refit
12.Clean mating faces of pressure regulator and
fuel rail.
13.Remove plugs from pressure regulator and fuel
rail.
14.Fit fuel hose to regulator and secure with clip.
15.Lubricate new pressure regulator O ring.
16.Fit regulator to fuel rail.
17.Connect fuel hose to pipe and secure with clip.
18.Fit bolts securing regulator to fuel rail and tighten
to
10 Nm, 7 lbf ft.
19.Position ignition coil mounting bracket to studs.
20.Fit nuts and tighten to
8 Nm, 6 lbf ft.
21.Remove plugs.
22.Connect fuel return hose and secure with clip.
23.Connect vacuum hose.
24.Remove cloth.
25.Reconnect battery negative lead. 
						

							SFI
17
REPAIR FUEL PUMP
Service repair no - 19.45.08
Remove
1.Disconnect battery negative lead.
2.Remove fuel tank.
See fuel tank
3.Loosen clip and disconnect breather hose from
fuel pump.
4.Remove fuel feed and return hoses from fuel
pump.5.Using toolLRT-19-001remove locking ring
securing pump. Withdraw fuel pump from fuel
tank.
WARNING: A quantity of fuel will be
retained in body of pump. Care must be
taken to prevent spillage during above
operation.
6.Remove and discard sealing ring.
Refit
7.Fit new sealing ring to pump and fit pump.
8.Fit locking ring and using toolLRT-19-001,
tighten to
48 Nm, 35 lbf ft.
9.Fit feed and return hoses to pump.
10.Fit breather hose and tighten clip.
11.Fit fuel tank.
See fuel tank; Refit 
						

							19FUEL SYSTEM
18
REPAIR FUEL TANK
Service repair no - 19.55.26
WARNING: Ensure that fuel handling
precautions given in Section 01 -
Introduction are strictly adhered to when
carrying out following instructions.
CAUTION: Before disconnecting any part
of the fuel system, it is imperative that all
dust, dirt and debris is removed from
around components to prevent ingress of foreign
matter into fuel system.
Remove
1.Position vehicle on ramp [hoist].
2.Disconnect battery negative lead.
3.Depressurise fuel system.
See Adjustment,
fuel system depressurise
4.Drain fuel tank.See Adjustment, fuel tank
drain
5.Loosen clip securing filler hose to fuel tank and
disconnect hose.
6.Loosen clip securing breather hose to filler neck
and disconnect hose.
7.Using toolLRT-19-002disconnect vapour
separator pipe at green end of speedfit
connector.
8.Position cloth to absorb fuel spillage. 
						

							SFI
19
REPAIR
9.Disconnect fuel feed hose union.
10.Disconnect fuel return hose union.
CAUTION: Plug the connections.
11.Loosen 2 anti-roll [sway] bar link bolts.
12.Mark location of anti-roll [sway] bar straps.
13.Remove 4 bolts securing anti-roll [sway] bar
straps and swing bar down clear of fuel tank.
14.Position transmission jack under fuel tank cradle
to support fuel tank.
CAUTION: Use a block of wood or hard
rubber pad to protect fuel tank.
15.Remove 6 bolts securing fuel tank cradle.
16.Lower fuel tank sufficiently to gain access to fuel
pump multiplug.
17.Disconnect multiplug and remove clip securing
harness to fuel hoses.
18.With assistance, lower jack, remove fuel tank
cradle and fuel tank.
Do not carry out further dismantling if component
is removed for access only.
19.Remove 3 screws securing heat shield. Remove
heat shield.
20.Release 2 fuel cut-off valves and remove valve
and pipe assembly. Remove and discard 2
rubber seals.
21.Loosen clip and remove breather hose from fuel
pump.
22.Remove fuel feed and return hoses from fuel
pump. 
						

							19FUEL SYSTEM
20
REPAIR
23.Using toolLRT-19-001remove locking ring
securing pump. Withdraw fuel pump from tank.
WARNING: A quantity of fuel will be
retained in body of pump. Care must be
taken to prevent fuel spillage during above
operation.
24.Remove and discard sealing ring.
25.Fit new sealing ring to pump and fit pump.
26.Fit locking ring and using toolLRT-19-001,
tighten to
48 Nm, 35 lbf ft.
27.Fit fuel feed and return hoses to pump.
28.Fit breather hose and tighten clip.
29.Fit new fuel cut-off valve seals.
30.Fit valve and pipe assembly.
31.Fit heat shield.Refit
32.With assistance, locate fuel tank and position
cradle.
33.Position jack to support tank.
34.Connect fuel pump multiplug.
35.Raise jack, align cradle and fit and tighten bolts.
36.Raise anti-roll [sway] bar, align straps and fit and
tighten bolts.
37.Tighten anti-roll [sway] bar link bolts
38.Clean fuel pipes, connect pipes and tighten
unions.
39.Secure harness to fuel pipes with clip.
40.Connect vapour separator pipe.
41.Connect breather hose to filler neck and tighten
hose clip.
42.Connect filler hose to fuel tank and tighten hose
clip.
43.Reconnect battery negative lead.
44.Run engine and check for leaks. 
						

							SFI
21
REPAIR FUEL RAIL
Service repair no - 19.60.04
Remove
1.Disconnect battery negative lead.
2.Depressurise fuel system.
See Adjustment,
fuel system depressurise
3.Remove ram housing.See ram housing
4.Disconnect 8 injector multiplugs.
5.Disconnect fuel temperature sensor multiplug.
6.Position cloth around fuel feed pipe union to
absorb any fuel spillage.
7.Disconnect fuel feed pipe from fuel rail.
8.Plug fuel pipe and rail.
9.Loosen clip securing fuel return hose to fuel rail
and disconnect hose.
10.Plug hose and rail.
11.Remove cloth.
12.Remove 6 nuts securing fuel rail and ignition coil
mounting bracket to inlet manifold.
13.Release ignition coil mounting bracket from inlet
manifold studs and move aside.
14.Release fuel rail and injectors from inlet
manifold.
15.Remove fuel rail and injectors.
Do not carry out further dismantling if component
is removed for access only.
16.Remove 2 bolts securing regulator to fuel rail.
17.Remove regulator.
18.Remove and discard O ring.
19.Remove 8 clips securing injectors to fuel rail.
20.Remove injectors from fuel rail.
21.Remove and discard O rings from injectors.
22.Clean lower mating faces on ram housing and
manifold.
23.Lubricate new O rings.
24.Fit NEW O rings to injectors. Lightly coat O
rings with silicone grease.
25.Fit injectors to fuel rail.
26.Fit clips securing injectors to fuel rail.
CAUTION: Care must be taken when
refitting the fuel rail and injectors to inlet
manifold to prevent damage to O rings.
27.Lubricate NEW O ring of fuel regulator with
silicone grease.
28.Fit O ring.
29.Fit regulator to fuel rail and tighten bolts to
10
Nm, 7 lbf ft.
Refit
30.Position fuel rail.
31.Secure fuel rail.
32.Position coil bracket.
33.Fit nuts securing coil bracket and fuel rail and
tighten to
8 Nm, 6 lbf ft..
34.Remove plugs from fuel feed and return pipes
and fuel rail.
35.Connect return hose and secure with clip.
36.Clean feed pipe union.
37.Connect fuel feed pipe and tighten union to
16
Nm, 11 lbf ft.
38.Connect injector and fuel temperature sensor
multiplugs.
39.Fit ram housing.
See ram housing; Refit
40.Reconnect battery negative lead.