Land Rover Defender Workshop 1993 Rover Manual

FUEL SYSTEM 
RR2406E 
KEY 
1. Spherical bush/housing 
2. Retaining  clips (2) 
3. Countershaft  assembly 
4. Overtravel spring 
5. Throttle spindle nut 
6. Throttle  return spring (2) 
7. Tab washer 
8. Throttle  stop lever 
9. Throttle  bracket assembly 
10. Pop rivets (2) 
REISSUED: FEB 1993 15  

FUEL SYSTEM 
25. Remove three bolts securing  throttle bracket 31. Grease  new bush  with Admax L3 or 
to  plenum  chamber,  withdraw bracket  Energrease LS3. Assemble bush into  housing. 
assembly 
. Assemble  to  throttle  bracket  using two 4.7 mm 
(3/16 in)  diameter  domed head rivets. 
from  throttle  shaft.  32. Examine  bearing  surface  of countershaft 
assembly. 
If worn  fit new  assembly,  otherwise 
wind  throttle  return spring 
off levers. 
26.  Remove  tab 
washer and throttle  stop lever...

FUEL SYSTEM 
Inspect and overhaul  throttle disc 39. Using  suitable  drift, drive  out bushes. 
36.  Examine  throttle shaft 
for excessive  wear CAUTION:  Take care not to damage  plenum 
between bushes in plenum  chamber  and chamber bores 
shaft. A small  amount  of clearance  is 
permissible. 
If excessive  wear is evident fit 
new  shaft  and bushes  as follows. 
37.  Remove 
two split screws  securing  throttle disc 
and  withdraw  disc. 
40. Press in new bushes  until flush  with throttle 
disc...

FUEL SYSTEM 
44. Grease  new  air  seal  with  Admax L3 or 53. Using a depth vernier  or depth  micrometer, 
check  dimension  from  mouth 
of bore to top 
and  bottom 
of valve  disc.  Dimension  must be 
within 
0.5 mm  (0.019  in) total  indicator  reading 
across  diameter  of disc. 
54. 
If dimension  is out  of limits,  adjust  small  set 
screw  below stop  lever. 
Energrease 
LS3. Push  seal down  shaft,  into 
counterbore  until seal  is 6.0  mm  (0.236  in) 
below  face of plenum. Assemble...

FUEL SYSTEM 
6. Disconnect electrical multi-plugs to engine  fuel 
REMOVING  RAM HOUSING temperature  sensor and injectors. 
7. Remove  two nuts  and bolts  securing  fuel 
To Remove pressure  regulator to fuel rail,  ease  fuel 
pressure  regulator out of rail.  Seal  end of fuel 
1. Disconnect  battery ground  terminal.  rail 
with  plastic  plugs to prevent  ingress of 
2.  Remove  plenum chamber.  dirt. 
3. Release hoses from ram housing. 
4. Remove  six through  bolts (with plain  washers) NOTE:...

FUEL SYSTEM 
To Refit 26. Tighten  gasket clamps to 18 Nm. 
27. Reverse  remaining  removal instructions. 
29.  Start  engine, check 
for coolant and fuel leaks. 
19.  Locate 
NEW seals 
in position  with ends  28.  Replenish cooling  system. 
engaged  in notches  formed  between  cylinder 
heads  and  block. 
REMOVING FUEL FILTER 
To Remove 
WARNING:  Spilling of fuel  is  unavoidable  during 
this  operation.  Ensure  all  necessary  precautions 
are  taken  to prevent  fire and  explosion. 
WARNING:...

FUEL SYSTEM 
REMOVING FUEL TANK  AND FUEL  PUMP 13. Finally  remove  the  tank from the vehicle 
DEFENDER  110 together with the fuel pump and rear section 
of the  fuel  feed pipe. Place  tank in a safe 
Remove area. 
WARNING: Ensure  fuel handling  precautions NOTE: A fuel vapour  warning  label  must  be 
given 
in section 01 - introduction  regarding fuel 
handling  are strictly  adhered 
to when carrying 14. Disconnect  the rear section of the fuel feed 
out  following  instructions.  pipe 
from...

FUEL SYSTEM 
18. Offer up tank  to chassis  ana connect  the 
electrical  leads; black to ground 
(-) and  white to positive (+). Remove 
19. Locate  front of tank on the two captive  bolts 
and  secure  with the mounting  rubber, 
flat and WARNING: During the following  operations 
spring  washers  and nut.  ensure 
that the fuel  handling  precautions  and 
warnings 
in Section 1 of this  manual  are being 
adhered  to. 
FUEL 
TANK  DEFENDER 
90 
1. Disconnect  battery. 
2.  Raise  vehicle  onto axle...

FUEL SYSTEM 
Refitting REMOVING ACCELERATOR  CABLE 
15. Position protection  plate and fuel tank  under 
rear 
of vehicle. Remove 
16.  Raise  plate and tank  sufficient to connect 1 Remove  clevis pin securing  accelerator  cable 
multi
-plug. to lever. 
17. Complete  raising and secure  plate with bolts. 2. Carefully  pry accelerator  cable adjustment  nut 
18.  Connect  all fuel  and  breather  pipes at their 
various  locations/  3. Remove  accelerator  cable from mounting 
19. Refit spare  wheel...

FUEL SYSTEM 
REMOVING ACCELERATOR  PEDAL 
Remove 
1. Remove toe board  from drivers  footwell. 
2. Remove  clevis pin securing  throttle cable to 
accelerator  pedal. 
3. Release tension from pedal return  spring. 
4. Remove  circlip from pedal  pivot pin. 
5. Withdraw  pivot pin. 
6. Remove  accelerator  pedal. 
Refit 
7. Lightly grease  pivot and clevis  pins. 
8. Fit clevis  pin using a new  split pin. 
9. Reverse  remaining  removal instructions. 
24 ADDITION: OCT 1993