Land Rover Defender Workshop Rover Manual

							FUELSYSTEM
1
REPAIR
FUEL
INJECTION PUMP
Service repairno-19.30.07
Remove 1. Disconnect battery.
2. Disconnect andremove highpressure fuel
injection pipes,pumptoinjectors.
3. Viewing valvemechanism throughoilfiller cap
aperture, turncrankshaft clockwiseuntilNo.1
cylinder isjust before TDC.
4.Remove blankingplugfrom flywheel housing
and fittiming toolLRT-12-044 ,locating centre
pin onflywheel.
NOTE: Achassis undertray maybefitted
on some vehicle derivatives toconform to
legal requirements. Whenunder chassis
adjustments orremove andrefit procedures are
required, itmay benecessary toremove the
undertray and/orintegral accesspanels
See
CHASSIS ANDBODY, Repair, Frontundertray
or
SeeCHASSIS ANDBODY, Repair, Rearundertray
5.Carefully rotatecrankshaft clockwiseuntilcentre
pin engages withtiming slotinflywheel.
6. Remove injectionpumpaccess plate,complete
with gasket, fromfrontcover plate.
7. Fitpin from LRT-12-045 toinjection pumpgear.
8.Restrain pulleynuttoprevent straining timing
belt and remove drivegeartopump hubfixing
bolts andretaining plate.
9. Remove pinfrom pump gear.
10.Fitgear retaining toolLRT-12-045 withan8m m
washer, 1,5-2 mm thick, under eachbolthead
in addition tothe existing washer.
11. Remove throttlecableandhand throttle cable,if
fitted.
12. Disconnect leadfrom fuelcut-off solenoid, and
EGR throttle position sensormulti-plug, iffitted.     
						

							19FUEL
SYSTEM
2 REPAIR
13.
Remove banjoboltssecuring spillreturn, main
fuel and boost signal pipes, refitbanjo boltsafter
disconnecting pipes.
14. Remove 2bolts securing rearofpump to
mounting bracket.
15. Remove 3pump securing nutsatflange and
withdraw pumpandgasket.
16. Fitsuitable capstopipe connections toprevent
ingress ofdirt.
Refit 17. Clean mating facesofpump andfront cover and
fit new gasket intoposition overpump mounting
studs.
18. Remove pumpblanking plugs.
19. Slacken the3bolts, securing injectionpump
mounting brackettocylinder block,sufficiently
enough toallow bracket tomove.
20. Fitpump tocover andsecure with3nuts.
Tighten to
25Nm (18lbf/ft).
21. Loosely attachpumptomounting bracketwith
nuts andbolts, thentighten boltssecuring
bracket tocylinder blockandbolts securing
pump tobracket, fingertightonly.
22. Toensure correctfittingandalignment of
injection pump,firsttighten the2bolts securing
pump tomounting bracketto
25Nm (18lbf/ft).
Then tighten the3bolts securing mounting
bracket tocylinder block,alsoto
25Nm (18
lbf/ft).
23. Connect spillreturn andmain fuelpipes and
secure withbanjo bolts.Tighten to
25Nm (18
lbf/ft).
24. Connect boostsignal pipeandsecure withbanjo
bolt. Tighten to
10Nm (7lbf/ft).
25. Connect fuelcut-off solenoid leadandthrottle
position sensormulti-plug, iffitted.
26. Connect throttlecableandwhere applicable,
hand throttle cable.
27. Remove pumpgearretaining toolLRT-12-045 .
28. Carefully turnthepump hubnutinaclockwise
direction, sufficiently enoughtoenable timing
tool pintobe inserted intoinjection pump.
29. Fitgear retaining plateandsecure with3bolts.
Tighten to
25Nm (18lbf/ft).
30. Remove timingpin.
31. Ensure flywheel timingpinisdisengaged from
slot inflywheel.
32. Turn crankshaft twocomplete revolutions, check
timing pinfrom RT-12-045 canbefully and
easily inserted intothepump. Atthe same time
check flywheel timingpinLRT-12-044 canalso
be inserted inthe flywheel slot.
33. If,with theflywheel timingpinlocated, thetiming
pin cannot beinserted cleanlyintotheinjection
pump, carryoutthefollowing:
a. Ensure flywheel timingpinisdisengaged from
slot inflywheel.
b. Slacken the3pump gearretaining bolts.
c. Turn thepump hubnutinaclockwise
direction, sufficiently toenable timingtoolpinto
be easily inserted intotheinjection pump.
d. Keeping thetension onthe hub nut,check
that flywheel timingpinlocates withslotin
flywheel. e. Tighten the3pump gearretaining boltsto
25
Nm (18lbf/ft).
f.Remove timingpinsfrom pump andflywheel
housing.
34. Using asuitable anti-seize compound, fitthe
blanking plugtoflywheel housing. Tightento
12
Nm (9lbf/ft).
35. Fitaccess platewithgasket tofront cover plate.
Tighten boltsto
25Nm (18lbf/ft).
36. Refit injector pipes.
37. Reconnect battery.  
						

							FUELSYSTEM
3
REPAIR
FUEL
INJECTORS
Service repairno-19.60.10
Remove
NOTE: Whenafuel injector isconsidered
to be the cause ofirregular runningand
loss ofpower itwill benecessary tofita
donor setofinjectors todetermine whichinjector
is at fault. DONOT attempt todismantle orcarry
out spray testsonthe fuel injectors. Thiswork
can only carried outbyauthorised Boschdealers.
1.Remove oilfiller capand release sound
insulation coverfromtopofengine.
2. Disconnect highpressure fuelsupply pipesfrom
injectors andinjection pump.Remove inpairs.
3. Disconnect spillreturn hose(s) frominjectors.
4. Plug pipes andinjector connections toprevent
the ingress ofdirt and foriegn matter. 5.
Remove retaining nutand release eachinjector
clamp platefromcylinder head.
6. Remove injectoranddiscard copperwasher.
Refit 7. Ensure injectors andseating incylinder headare
clean.
8. Lightly grease anew copper sealing washer and
position oneach injector.
9. Fitinjectors incylinder headwithspillreturn
outlets facingoutward.
10. Secure injector withclamp plateandnut.Tighten
nut to
25Nm (18lbf/ft).
NOTE: Theclamp platesareslightly
curved andshould befitted withthe
convex sideuppermost.
11. Fitthe spill return pipewithasingle copper
washer underthehead ofthe banjo boltand 2
copper washers fittedbetween theinjector and
the banjo. Tighten banjoboltto
10Nm (7lbf/ft).
12. Fithigh pressure pipestoinjectors andinjection
pump. Tighten unionnutsto
28Nm (21lbf/ft).
13. Fitsound insulation coverandoilfiller cap.    
						

							19FUEL
SYSTEM
4 REPAIR
FUEL
LIFTPUMP
Service repairno-19.45.09
Remove
NOTE: Blankoffpipe ends and
connections toprevent ingressofdirt.
1. Disconnect battery.
2. Remove highpressure fuelpipes, injection pump
to injectors.
3. Disconnect fuelinlet andoutlet pipesfromlift
pump.
4. Remove 2bolts andwithdraw liftpump and
gasket fromcylinder block.
Refit 5. Clean mating facesofpump andcylinder block.
6. Fitliftpump tocylinder blockwithanew gasket,
ensure correctlocation ofoperating leverwith
camshaft.
7. Secure withbolts. Tighten to
25Nm (18lbf/ft).
8.Connect inletandoutlet pipesusingnewnuts
and olives.
9. Refit injector pipes.Tighten unionnutsto
28Nm
(21 lbf/ft).
FUEL SEDIMENTOR
Service repairno-19.25.01
Remove 1. Disconnect battery.
2.Disconnect inletandoutlet fuelpipes from
sedimentor.
3. Slacken draintapand allow sedimentor to
completely drain.
4. Remove 2bolts, washers andnuts anddetach
sedimentor fromchassis mounting bracket.
Refit 5. Secure sedimentor tochassis mounting with
fixing bolts.
6. Reconnect inletandoutlet fuelpipes to
sedimentor.
7. Slacken drainpluguntildiesel freefrom air
flows, thenretighten plug.
8. Prime vehicle fuelsystem.
See Adjustment,
Priming thefuel system
9.Reconnect battery.   
						

							FUELSYSTEM
5
REPAIR
FUEL
FILTER ASSEMBLY
Service repairno-19.25.02
Remove 1. Disconnect battery.
2.Place asuitable container underfilterelement
and slacken filterbleed screw.
3. Slacken draintapand allow fueltodrain from
filter element.
4. Slacken fuelinlet andoutlet banjo connections.
5. Remove 2bolts andnuts securing filterhead to
inner wing.
6. Remove fuelinlet andoutlet banjo boltsand
detach fuelpipes.
7. Remove filterassembly fromvehicle. Unscrew
filter element, ifnecessary.
8. Plug fuelpipe ends toprevent ingressofdirt. Refit
9. Position filterassembly andfitfuel inlet and
outlet pipesusingnewcopper sealing washers
both sides ofthe banjo connections.
10. Secure filterhead toinner wing.
11. Fully tighten banjoconnections.
12. Prime fuelsystem toremove anyairtrapped in
filter
See Adjustment, Primingthefuel
system
13. Reconnect battery.
FUEL FILTER ELEMENT
Service repairno-19.25.07
For remove andrefitprocedure.
See Fuelfilter
element   
						

							19FUEL
SYSTEM
6 REPAIR
SIDE
MOUNTED FUELTANK
Service repairno-19.55.05
NOTE: Thisfueltank isstandard on90
models andanoption on110/130 2door
vehicles fittedwithtwintanks.
Remove
WARNING: Beforeanyattempt ismade to
start theremoval procedure itis vital that
the FUEL HANDLING PRECAUTIONS are
carefully studiedandimplemented inthe interests
of safety.
See INTRODUCTION, Information,Fuel
Handling Precautions
1.Disconnect battery.
2. Remove fuelfiller cap. 3.
Remove fueltank drain plug,allow fueltodrain
into aclean container andrefitplug.
4. Remove RHseat cushion.
5. Release retaining catchandremove seatbase
cover togain access tofuel tank.
6. Disconnect electricalplugfrom fuelgauge unit.
7. Disconnect fuelsupply pipefrom tank.
8. Disconnect spillreturn pipefrom fueltank.
9. Disconnect breatherpipefrom fuelfiller tube.
10. Slacken hoseclipand remove fillerhose from
filler tube.
11. From rearoftank, remove 2nuts andwashers
securing tankmounting tocaptive-headed bolts.
12. Support rearoffuel tank andremove captive
bolts.  
						

							FUELSYSTEM
7
REPAIR
13.
Remove singleboltfixing assembly securing
front oftank tochassis mounted bracket.
14. Remove 3bolts securing tankmounting bracket
to chassis andrelease bracket.
15. Lower frontoftank while turning anti-clockwise
and remove fromvehicle.
16. Ifrequired, removetankgauge unit.
See
INSTRUMENTS, Repair,Fuelgauge tankunit
- side fueltank
orSee INSTRUMENTS,
Repair, Fuelgauge tankunit-rear fueltank,
110/130
Refit
17. Fitfiller hose andcliptotank butdonot fully
tighten. Position clipscrew sothat itis
accessible whentankisfitted.
18. Fitbreather hoseandsecure withclip.
19. Position fueltank invehicle andloosely secure
front mounting brackettotank withspecial bolt
and rubber bushes.
20. Secure mounting brackettochassis with3bolts
and fully tighten to
20Nm (15lbf/ft).
21. Secure rearoftank tochassis mounting and
tighten captive boltplate fixings to
20Nm (15
lbf/ft).
22. Fully tighten frontfixing boltassembly to20Nm
(15 lbf/ft).
23. Fitspill return andfuelsupply pipesandsecure
union connections.
24. Fitfuel level unitelectrical plug.
25. Fithose tofiller tube andtighten upperandlower
clips.
26. Check thatdrain plugissecure andfillfuel tank.
27. Reconnect battery.
28. Prime fuelsystem
See Adjustment, Priming
the fuel system
andstart engine.
29. Check system forleaks andoperation offuel
gauge.
30. Fitseat base cover andseat cushion. SIDE
MOUNTED FUELTANK -5 DOOR VEHICLES
Service repairno-19.55.01
NOTE: Thisfueltank isused on110/130 5
door vehicles fittedwithatwin tank
option.
WARNING: Beforeanyattempt ismade to
start theremoval procedure itis vital that
the FUEL HANDLING PRECAUTIONS,
See
INTRODUCTION, Information,Fuelhandling
precautions
are carefully studiedand
implemented inthe interests ofsafety.
Remove 1. Disconnect battery.
2. Remove tankdrain plug,allow fueltodrain intoa
clean container, andrefitplug.
3. Remove RHseat cushion.
4. Remove retaining catchandremove seatbase
cover togain access tofuel tank.
5. Disconnect electricalplugfrom fuelgauge unit.
6. Disconnect fuelsupply pipefrom tank.
7. Disconnect spillreturn pipefrom tank.
8. Remove 3bolts securing tanktofront mounting
bracket.
9. Support frontoftank andremove singlefixing
assembly securingtanktorear mounting
bracket.
10. Remove tankfrom vehicle.
11. Ifrequired, removefuelgauge unit.
See
INSTRUMENTS, Repair,Fuelgauge tankunit
- side fueltank
orSee INSTRUMENTS,
Repair, Fuelgauge tankunit-rear fueltank,
110/130
Refit
12. Position fueltank invehicle andloosely secure
to rear mounting bracketwithspecial boltand
rubber bushes.
13. Secure tanktofront mounting bracketand
tighten fixingsto
20Nm (15lbf/ft).
14. Fully tighten rearfixing boltassembly to20Nm
(15 lbf/ft).
15. Fitspill return andfuelsupply pipestofuel tank
and securely tightenunionconnectios.
16. Fitelectrical plugtofuel gauge unit.
17. Check thatdrain plugissecure andfillfuel tank.
18. Reconnect battery.
19. Prime fuelsystem.
See Adjustment, Priming
the fuel system
andstart engine.
20. Check system forleaks andoperation offuel
gauge.
21. Fitseat base cover andseat cushion.   
						

							19FUEL
SYSTEM
8 REPAIR
REAR
MOUNTED FUELTANK -110/130
Service repairno-19.55.26
WARNING: Beforeanyattempt ismade to
start theremoval procedure itis vital that
the FUEL HANDLING PRECAUTIONS
See
INTRODUCTION, Information,FUELHANDLING
PRECAUTIONS
are carefully studiedand
implemented inthe interests ofsafety.
Remove 1. Disconnect battery.
2. Remove fuelfiller cap.
3. Remove tankdrain plug,allow fueltodrain intoa
clean container, andrefitplug.
4. Slacken retaining clipsanddisconnect fuelfiller
hose fromreartank. 5.
Disconnect breatherhosefromfillertube.
6. Disconnect electricalplugandfuelsupply pipe
from outlet pipeunion onfuel gauge unit.
7. Ifthe vehicle isfitted withatow balldrop-plate
with support bars,thebars must beremoved.
8. Remove anti-rollbarchassis mountings.
See
REAR SUSPENSION, Repair,Anti-roll bar
andpush rollbar down toprovide accesstothe
tank.
9. Remove LHlashing eyetoassist access totank.
10. Position asupport underthetank, preferably one
that canbeprogressively lowered.  
						

							FUELSYSTEM
9
REPAIR
11.
Remove 2nuts thatsecure frontfixing assembly
of the tank tochassis mounting bracket.
12. Remove tankrearmounting nuts.
13. With care, lower tanksufficiently toenable nut
and olive ofspill return tobe disconnected from
elbow incentre oftank.
14. Continue tolower tankuntilitcan beremoved
from vehicle.
NOTE: Onlater vehicles aseparate stone
guard isfitted andisattached tothe tank
with theexisting frontandrear fixings.
15. Ifrequired, removetankgauge unit.
See
INSTRUMENTS, Repair,Fuelgauge tankunit
- side fueltank
orSee INSTRUMENTS,
Repair, Fuelgauge tankunit-rear fueltank,
110/130
Refit
16. Ifapplicable, locatestoneguard undertank.
17. Raise reartank intoposition andconnect spill
return pipetothe elbow withthenutand olive.
18. Continue toraise tanksothat front andrear
mounting boltslocate inrespective tankflange
holes.
19. Fitand tighten fixingsto
20Nm (15lbf/ft).
20. Connect fuelsuppnly pipetothe tank unit.
21. Fitfuel filler hose andbreather pipetofiller tube
and secure withretaining clips.
22. FitLH lashing eyetochassis. 23.
Fitanti-roll barchassis mountings.
SeeREAR
SUSPENSION, Repair,Anti-roll bar
24.Check thatdrain plugissecure andfillfuel tank.
25. Reconnect battery.
26. Prime fuelsystem.
See Adjustment, Priming
the fuel system
andstart engine.
27. Check system forleaks andoperation offuel
gauge.   
						

							19FUEL
SYSTEM
10 REPAIR
TWIN
TANK CHANGE-OVER TAPASSEMBLY
Service repairno-19.43.50 -Fuel supply tap
Service repairno-19.43.51 -Spill return tap
Service repairno-19.43.52 -Fuel tank
change-over lever
Remove 1. Disconnect battery.
2. Remove RHfront seatcushion.
3. Release retaining clipand remove accesscover
from seatbase.
4.Disconnect leadsfromfueltank change-over
switch.
5. Unscrew retainingnutand withdraw change-over
lever andwashers frompivot pinatheelboard.
6. Disconnect spillreturn pipesatspill change-over
tap.
7. Remove 4bolts, washers andnuts securing tap
support bracketassembly toheel board.
8. Lift upsupport bracketassembly anddisconnect
control rodfrom spilltaplever.
9. Remove supportbracketassembly fromvehicle.
10. Disconnect fuelsupply pipesatfuel change-over
tap.
11. Remove 2screws andrelease fueltapfrom
chassis mounted supportbracket. 12.
Remove fueltap, complete withoperating rod
and lever.
13. Plug allconnections toprevent ingressofdirt.
14. Dismantle spillreturn andfueltapcomponents
as necessary.
Refit 15. Fitfuel change-over tap,complete withoperating
rod and lever, tochassis mounted support
bracket andfully tighten fixingscrews.
16. Connect fuelsupply pipesatfuel tap, ensuring
they arefitted tocorrect ports.
17. Position supportbracketassembly behind
heelboard andconnect operating rodtospill
change-over taplever.
18. With pivot pinbush correctly seated,secure
support bracketassembly toheel board and
tighten fixingsto
8Nm (6 lbf/ft).
19. Connect spillreturn pipestochange-over tap,
ensuring theyarefitted tocorrect ports.
20. Secure change-over levertopivot pin.
21. Fitleads tofuel tank change-over switch.
22. Reconnect battery.
23. Prime vehicle fuelsystem,
See Adjustment,
Priming thefuel system
ifnecessary and
check forleaks.
24. Fitaccess covertoseat base andseat cushion.