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 
inspect and overhaul  throttle lever assembly 
33. Wind  new  spring  onto countershaft  assembly, 
small  hooked  end 
of spring is wound on first. 27. Remove  two retaining  clips  from  spherical 
bush. 
28.  Remove  the countershaft  assembly. 
29. 
If spherical bush is worn,  drill out two securing 
rivets  (4,7 mm,  (3/16 in)  diameter  drill). 
30. Split assembly,  discard worn bush. 
34. Grease  shaft with Admax L3 or Energrease 
LS3, fit countershaft  assembly to spherical 
bearing,  secure with 
two clips. 
35.  Examine  throttle 
stop lever for wear, fit a new 
lever  if necessary. 
16 
REISSUED:  FEB 1993  
						

							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  bore. 
CAUTION:  Ensure that bushes  do not  protrude 
into  bore,  as they 
will interfere  with movement of 
throttle  disc. 
CAUTION:  Take care not to damage  shaft. 
41. Fit throttle shaft and disc,  secure  with two split 
screws. 
Do not  fully  tighten  screws. 
42. Rotate  throttle  shaft 360° once  or twice to 
centralise  disc in bore.  Tighten  split screws. 
43. Rotate  shaft. Use screw  driver to spread  split. 
38.  Remove  shaft and air seal 
from plenum 
chamber. 
REISSUED: FEB 1993 17  
						

							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  throttle levers and bracket 
45.  Fit  stop  lever  to throttle shaft, a new  tab 
washer  and  secure  with throttle  spindle nut. 
46.  Holding  stop  lever  on stop, tighten  throttle 
spindle  nut  securely, bend over tabs to lock 
nut  in position. 
47.  Fit inboard  throttle return spring  noting  that 
small  hooked  end of spring  is nearest plenum. 
48. Locate  hooked  end of inboard  spring  on stop 
lever.  Wind up straight  end one full turn  and 
locate  in appropriate 
slot. 
49.  Fit countershaft to interconnecting  nut of 
throttle  valve  shaft. 
50. Secure  throttle  bracket  assembly to plenum. 
Secure  with three  retaining  bolts. 
51. Ensure hooked  end of outboard  spring  is 
retained  by lever,  wind spring  up one 
full turn 
and  locate 
free end  in appropriate slot. 
highly  grease  throttle  return  and overtravel 
springs  with Admax 
L3 or Energrease LS3. 
52.  Fit overtravel  spring. 
To Refit 
55. Where applicable,  reconnect and adjust  cruise 
control  actuator  link. 
56.  Clean joint  faces 
of plenum  and  ram housing. 
Apply  Hylomar  sealant, refit plenum chamber. 
Tighten bolts 
to 26 Nm. 
57. 
Reverse  remaining instructions. 
NOTE: If new throttle  levers have been fitted, 
minimum  throttle setting of disc  must 
be 
checked  to ensure  it is 90° to bore. 
18 REISSUED: FEB 1993  
						

							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:  Intake manifold  can be removed  from 
securing ram housing  to intake  manifold. cylinder  block without  removing  fuel rail and 
8. Disconnect  electrical leads from 
air
-conditioning  engine coolant  temperature 
sensor. 
9. Disconnect  electrical leads to engine  coolant 
temperature  sensor located  at front  of intake 
manifold. 
10. Remove  injector harnesses  from behind  fuel 
rail,  lay to one  side. 
11.  Release  hose clamps  securing 
two heater 
hoses  behind  water pump. 
12.  Remove  two bolts  securing  rigid heater  pipes 
to  intake  manifold  and ease  pipes  out of 
hoses. 
injectors. 
5. Remove  ram housing  from intake  manifold. 
6. Place  a protective  cover over inlet bores  to 
prevent  ingress of 
dirt. 
To Refit 
13. Lay heater  pipe assembly to one side. 
14. Release  twelve bolts securing  intake manifold. 
16.  Remove 
two gasket  clamps  from cylinder 
block. 
17. Lift  off gasket,  remove  gasket seals. 
18.  Remove  sealing compound  from around  water 
passage  openings  of cylinder  heads. 
7. 
Clean  all mating  faces. 
8. Apply Hylomar  sealant to intake manifold 15, Remove  inlet  manifold. face. 
9. Fit ram  housing.  Tighten bolts, working  from 
two centre bolts, diagonally  towards outer four 
bolts. 
10.  Tighten 
to 26 Nm. 
REMOVING  INTAKE MANIFOLD 
To Remove 
1. Depressurise fuel system. 
2. Disconnect  battery ground  terminal. 
3. Remove  radiator bottom hose, drain coolant 
until  level  is below  thermostat  housing. Refit 
hose,  tighten  clamp. 
4. Remove  plenum chamber. 
5. Remove  ram housing. 
CAUTION:  Place a protective  cover over intake 
manifold  openings  to prevent  ingress of 
dirt. 
REISSUED: FEB 1993 19  
						

							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:  Ensure fuel handling  precautions 
given  in  section 
01 - Introduction  regarding  fuel 
handling  are  strictly adhered  to when  carrying 
out  following  instructions. 
1. Depressurise fuel  system. 
2. Fuel filter  is located  on chassis  side member 
below front  passengers door. 
3. Clean  area  around  hose  connections to 
prevent ingress of foreign matter into fuel 
system.  Clamp inlet and outlet  hoses 
to 
20. Lightly apply  Hylomar  sealant  around  outside  prevent fuel spillage  when disconnecting 
of  water  passage  openings  on cylinder  heads,  hoses. 
manifold gasket  and intake  manifold. 
4. Loosen two fuel line unions  and  remove 
hoses.  Plug  ends 
of hoses to prevent  ingress 
of  dirt. 
5. Release  securing  bolt and  bracket  and 
remove  fuel filter  from  chassis  side  member. 
21. Fit manifold  gasket with word FRONT to To Refit 
front and  open  bolt hole to front  right hand 
side. 
6. Fit  a new  fuel  filter observing  direction of flow 
22. Fit gasket  clamps,  DO NOT  fully tighten  bolts.  arrows stamped  on canister. 
23. Locate intake manifold  onto cylinder  heads, 7. Tighten securing  nut and  bolt. 
clean  threads  of manifold  securing  bolts. 
8. Fit inlet  and outlet  hoses.  Tighten unions to a 
24. Fit  manifold  bolts. Evenly  tighten  a  little at a  of 30Nm. 
time,  alternating  sides,  working  from  centre  9. Refit  fuel  pump  relay module,  reconnect 
outwards.  battery. 
25. Tighten  to 38 Nm. 10. Start  engine  and inspect  for fuel  leaks  around 
hose  connections. 
20 REISSUED: FEB 1993  
						

							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  the  pump. 
15. Remove  the five retaining screws and 
CAUTION: Before disconnecting  any part of fuel  withdraw the fuel pump and  sealing  ring from 
system  it is  imperative  that  all dust,  dirt and  the tank. 
debris  is removed  from  around  components 
to 16. Cover the pump  aperture  in the  tank to 
prevent  ingress  of  foreign  matter  into fuel  prevent the ingress of foreign  matter and 
system.  escape 
of fuel  vapours. 
To renew the pump,  it is necessary to remove  the 
fuel  tank  from  the  vehicle.  attached 
to vehicle. Refit 
17. Fit  the  pump  into the tank  with a new sealing 
1. Move  the  vehicle to a well  ventilated area  and ring so that the outlet  pipe is directed  towards 
disconnect  the  battery.  Clean the  area around  the 
front of the vehicle  and the electrical 
the  pump.  connections 
to  the rear. 
2. Remove  the fuel  tank  drain  plug and allow  the 
fuel  to drain  into a suitable  receptacle  that  can 
be  sealed  afterwards 
ENSURE  TANK IS DRAINED  COMPLETELY, 
Refit  drain  plug - refer to WARNING 
concerning fuel  handling  at start of procedure. 
3. Working  from the right  hand  side of the 
vehicle,  disconnect  the fuel  feed pipe  and  the 
spill  return  at the  rubber  connections. 
4. Disconnect  the fuel  filler  hose  and breather 
hose  from the tank. 
5. Whilst  noting the  cable  colours, disconnect  the 
electrical  leads from the  fuel  gauge unit at 
the 
left hand  side of the  vehicle. 
6. Disconnect  pipes to expansion  tank. 
7. Remove the  eight  nuts  and  bolts securing the 
anti-roll bar to the  chassis  and push  the 
anti
-roll  bar  down to provide  access to the 
tank. 
8. Remove  the left hand  lashing  eye to facilitate 
removal  of the fuel  tank. 
9. Place a support  under  the  fuel tank.  preferably 
one  which  will enable 
the fuel  tank lo be 
progressively  lowered. 
10. Remove the two nuts retaining the forward 
end 
of the  tank. 
11 . Remove  the two nuts retaining  the  rear  end  of 
the  tank. 
12. Carefully  lower  the tank  sufficiently  to enable 
the  electrical  leads to the  fuel  pump  to be 
disconnected. 
RE-ISSUED:  FEB 1993 21  
						

							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 stands. 
3.  Remove  rear step. 
4.  Remove  spare wheel. 
5.  Remove  spare wheel  carrier. 
6.  Drain  fuel tank. 
7.  Disconnect  fuel filler  pipe  at tank. 
8.  Disconnect  breather pipe at filler  neck. 
9.  Disconnect  main fuel lines  at union 
connections  forward of tank. 
20. Secure  the rear of the tankwith  the two 
captive bolts, plain washer  and Nyloc  nut. 
10. Disconnect pipe to expansion  tank using 
11. Loosen  protection  plate/fuel tank securing 
special 
tool LRT-19-002 
on green  connector. 
bolts. 
21 Connect  the fuel  teed  and expansion  tank 
pipes. 
22.  Connect  the spill  return  pipe. 
23.  Connect  the fuel  filler  hose  and breather  pipe 
to  me  tank. 
24.  Fit the  left hand  lashing  eye.  12. Support  tank and plate,  remove  securing 
25.  Fit the  anti  roll bar. 
13. Lower  tank sufficient  to gain  access  and 
26. 
Fit the  drop  plate  support  bars - if  fitted. 
27.  Connect  the fuel  gage  unit leads  disconnect multi
-plug 
28.  Reconnect  battery and check  operation  of 14 Complete  lowering of tank  and withdraw  with 
pump  and  changeover  solenoid 
- if fitted. 
29.  Run engine  check all connection  for leaks.  bolts. 
protection 
plate. 
22 REVISED: OCT 1993  
						

							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  carrier.  bracket. 
20.  Refit spare  wheel. 
21.  Refit rear step. 
22.  Remove  vehicle from axle stands. 
23.  Replenish  fuel tank. 
24. Reconnect  battery. 
25.  Run engine  for short  period. 
26.  Check  all disturbed  connections  for leaks.  out 
of mounting  bracket. 
FUEL PUMP/SENDER  UNIT 
Special tool 
LRT-19-001  Fuel  pump  remover 
Removal 
WARNING:.  During the following  operations 
ensure  that the fuel  handling  precautions  and 
warnings  in  Section 
1 of  this  manual  are being 
adhered  to. 
4. Release outer cable  from retaining  clips in 
engine  compartment. 
5. Remove toe board from drivers  footwell. 
6. Disconnect  cable from accelerator  pedal and 
release  cable locknut. 
7. Feed  cable  through  bulkhead  grommet into 
engine  compartment. 
1.  Disconnect  battery. 
2.  Remove  fuel tank. 
3.  Disconnect  fuel and  breather  pipes from 
pump/sender  unit. 
Refit 
8. Feed new accelerator  cable from engine 
compartment  through bulkhead  grommet. 
9. Connect cable to accelerator  pedal. 
10. Connect cable to accelerator  linkage, using a 
new split pin. 
11. Clip  outer  cable  adjustment  nut into  mounting 
4. Using  special tool LRT-19-001 remove  fuel  bracket. 
12. Adjust outer cable to give 1 57 mm (0 062 in) 
5. Withdraw  pump/sender  unit from  tank. free play  in inner  cable  Check accelerator 
operation. 
pump 
retaining  ring. 
Refitting 
6. Refit in reverse  order to removal. 
REVISED: OCT 1993 23  
						

							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