LAND ROVER DEFENDER 1996 Workshop Manual

FUEL SYSTEM
9
REPAIR REV: 05/99
11.Remove 2 nuts that secure front fixing assembly
of the tank to chassis mounting bracket.
12.Remove tank rear mounting nuts.
13.With care, lower tank sufficiently to enable nut
and olive of spill return to be disconnected from
elbow in centre of tank.
14.Continue to lower tank until it can be removed
from vehicle.
NOTE: On later vehicles a separate stone
guard is fitted and is attached to the tank
with the existing front and rear fixings.
15.If required, remove tank gauge unit.
See
INSTRUMENTS, Repair, Fuel gauge tank unit
- side fuel tank
orSee INSTRUMENTS,
Repair, Fuel gauge tank unit - rear fuel tank,
110/130
Refit
16.If applicable, locate stone guard under tank.
17.Raise rear tank into position and connect spill
return pipe to the elbow with the nut and olive.
18.Continue to raise tank so that front and rear
mounting bolts locate in respective tank flange
holes.
19.Fit and tighten fixings to
20 Nm (15 lbf/ft).
20.Connect fuel suppnly pipe to the tank unit.
21.Fit fuel filler hose and breather pipe to filler tube
and secure with retaining clips.
22.Fit LH lashing eye to chassis.23.Fit anti-roll bar chassis mountings.
See REAR
SUSPENSION, Repair, Anti-roll bar
24.Check that drain plug is secure and fill fuel tank.
25.Reconnect battery.
26.Prime fuel system.
See Adjustment, Priming
the fuel system
and start engine.
27.Check system for leaks and operation of fuel
gauge.

19FUEL SYSTEM
10
REPAIR TWIN TANK CHANGE-OVER TAP ASSEMBLY
Service repair no - 19.43.50 - Fuel supply tap
Service repair no - 19.43.51 - Spill return tap
Service repair no - 19.43.52 - Fuel tank
change-over lever
Remove
1.Disconnect battery.
2.Remove RH front seat cushion.
3.Release retaining clip and remove access cover
from seat base.
4.Disconnect leads from fuel tank change-over
switch.
5.Unscrew retaining nut and withdraw change-over
lever and washers from pivot pin at heelboard.
6.Disconnect spill return pipes at spill change-over
tap.
7.Remove 4 bolts, washers and nuts securing tap
support bracket assembly to heel board.
8.Lift up support bracket assembly and disconnect
control rod from spill tap lever.
9.Remove support bracket assembly from vehicle.
10.Disconnect fuel supply pipes at fuel change-over
tap.
11.Remove 2 screws and release fuel tap from
chassis mounted support bracket.12.Remove fuel tap, complete with operating rod
and lever.
13.Plug all connections to prevent ingress of dirt.
14.Dismantle spill return and fuel tap components
as necessary.
Refit
15.Fit fuel change-over tap, complete with operating
rod and lever, to chassis mounted support
bracket and fully tighten fixing screws.
16.Connect fuel supply pipes at fuel tap, ensuring
they are fitted to correct ports.
17.Position support bracket assembly behind
heelboard and connect operating rod to spill
change-over tap lever.
18.With pivot pin bush correctly seated, secure
support bracket assembly to heel board and
tighten fixings to
8 Nm (6 lbf/ft).
19.Connect spill return pipes to change-over tap,
ensuring they are fitted to correct ports.
20.Secure change-over lever to pivot pin.
21.Fit leads to fuel tank change-over switch.
22.Reconnect battery.
23.Prime vehicle fuel system,
See Adjustment,
Priming the fuel system
if necessary and
check for leaks.
24.Fit access cover to seat base and seat cushion.

FUEL SYSTEM
11
REPAIR HEATER PLUGS
Service repair no - 19.60.31
Remove
1.Disconnect battery.
No.1 heater plug - air conditioning models:
2.Release drive belt from compressor pulley.See
AIR CONDITIONING, Repair, Compressor
drive belt
3.Remove 4 bolts securing compressor to front
cover, move compressor aside.
No.3 heater plug:
4.Remove retaining bolt and withdraw breather
valve from rocker cover. Remove and discard 'O'
ring.
All heater plugs:
5.Remove terminal nut and disconnect wire from
heater plug terminal.
6.Unscrew heater plug.
Refit
7.Clean heater plug and seating.
8.Coat threads of heater plug with suitable
anti-seize compound operational to a
temperature of 1000°C.
9.Fit heater plug, tighten to
23 Nm (17 lbf/ft).
10.Connect wire to heater plug terminal and secure
with nut.
NOTE: Feed wire must be connected to
No. 4 heater plug terminal.
No. 3 heater plug:
11.Lubricate new 'O' ring with engine oil and fit to
breather valve.
12.Fit valve to rocker cover, tighten to bolt to
15 Nm
(11 lbf/ft).
No. 1 heater plug - air conditioning models
13.Position compressor to front cover, fit bolts and
tighten to
25 Nm (18 lbf/ft).
14.Fit drive belt to compressor pulley and adjust
tension.
See AIR CONDITIONING, Repair,
Compressor drive belt
All models:
15.Reconnect battery.

19FUEL SYSTEM
12
REPAIR HEATER PLUG CONTROL UNIT
Service repair no - 19.60.33
Remove
1.Disconnect battery.
2.Remove screw securing control unit to bulkhead.
3.Disconnect multi-plug and release control unit.
Refit
4.Fit harness multi-plug to control unit.
5.Secure control unit to bulkhead.
6.Reconnect battery.AIR CLEANER
Service repair no - 19.10.01
Remove
1.Slacken hose clip and detach outlet hose.
2.Release clips and open air cleaner retaining
straps.
3.Lift up air cleaner, slacken hose clip and detach
inlet hose.
4.Remove air cleaner.
Refit
5.Position air cleaner and connect inlet hose.
6.Close air cleaner retaining straps and secure
lock clips.
7.Connect outlet hose.
NOTE: If an EGR fuel system is fitted,
ensure the modulator valve vacuum spill
pipe is secure in the outlet hose.
AIR CLEANER ELEMENT
Service repair no - 19.10.10
For remove and refit procedure.
See SECTION 10,
Maintenance, Under bonnet maintenance

FUEL SYSTEM
13
REPAIR THROTTLE CABLE
Service repair no - 19.20.06
Remove
1.Disconnect battery.
2.Remove split pin and clevis pin securing throttle
cable to injector pump throttle lever .
3.Depress ferrule retaining tags, release ferrule
from abutment bracket and withdraw throttle
cable.
4.Release throttle cable from clip on bulkhead.
5.Remove pin and clevis pin securing throttle
cable to pedal lever.
6.Release grommet from bulkhead.
7.Withdraw throttle cable from engine
compartment.Refit
8.Feed throttle cable through bulkhead from
engine compartment and fit grommet.
9.Secure throttle cable to pedal lever. Use new
split pin to secure clevis.
10.Secure throttle cable in bulkhead clip.
11.Guide throttle cable through abutment bracket
and fit ferrule.
12.Secure cable to injection pump throttle lever.
Use new split pin to secure clevis.
13.Adjust throttle cable.
See Adjustment,
Throttle cable
THROTTLE PEDAL
Service repair no - 19.20.01
Remove
1.Remove throttle cable from pedal.
See Throttle
cable
2.Remove 6 bolts securing throttle pedal assembly
to engine bulkhead.
3.Remove pedal assembly from footwell, complete
with trim retainer.
4.Release return spring from pedal lever.
5.Remove roll pin securing pivot shaft to pedal
assembly.
6.Withdraw pivot shaft and remove pedal from
mounting bracket.
7.Remove return spring from pedal boss.
Refit
8.Fit return spring to pedal boss.
9.Fit pedal to mounting bracket and locate return
spring.
10.Fit pivot shaft to pedal assembly and secure with
roll pin.
11.Locate return spring on pedal lever.
12.Secure throttle pedal assembly and trim retainer
to bulkhead. Tighten bolts to
9 Nm (7 lbf/ft).
13.Fit throttle cable to pedal.See Throttle cable
14.Adjust pedal, if necessary.See Adjustment,
Throttle pedal adjustment

19FUEL SYSTEM
14
REPAIR TURBOCHARGER INLET HOSE
Service repair no - 19.42.11
Remove
1.Disconnect battery.
2.Slacken retaining clip and disconnect intake
hose from turbocharger.
3.Slacken retaining clip and disconnect hose from
air cleaner.
4.If fitted, disconnect EGR modulator valve
vacuum spill pipe from inlet hose.
5.Slacken retaining clip and disconnect breather
valve hose from inlet hose.
6.Remove inlet hose.
Refit
7.Fit inlet hose to air cleaner.
8.Fit cyclone breather hose to inlet hose.
9.If applicable, fit vacuum spill pipe to inlet hose.
10.Fit inlet hose to turbocharger.
11.Reconnect battery.TURBOCHARGER OIL FEED PIPE
Service repair no - 19.42.14
Remove
1.Disconnect battery.
2.Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
front pipe
3.Remove banjo bolt securing oil feed pipe to
turbocharger and discard 2 joint sealing
washers.
4.Unscrew union and remove feed pipe from
cylinder block.
5.Plug connections to prevent ingress of dirt.
Refit
6.Using new joint washer, fit oil feed pipe to
cylinder block. Tighten union connector to
25
Nm (18 lbf/ft).
7.Fit a new joint washer to both sides of banjo and
secure feed pipe to turbocharger. Tighten banjo
bolt to
20 Nm (15 lbf/ft).
8.Fit exhaust front pipe.See MANIFOLD AND
EXHAUST SYSTEM, Repair, Exhaust front
pipe
9.Check/top-up engine oil level.See SECTION
10, Maintenance, Under bonnet maintenance
10.Reconnect battery.

FUEL SYSTEM
15
REPAIR TURBOCHARGER OIL DRAIN PIPE
Service repair no - 19.42.12
Remove
1.Disconnect battery.
2.Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
front pipe
3.Unscrew union and disconnect oil drain pipe
from cylinder block.
4.Remove 2 bolts securing oil drain pipe to
turbocharger.
5.Remove drain pipe and discard gasket.
6.Plug connections to prevent ingress of dirt.
Refit
7.Ensure mating surfaces of oil pipe, turbocharger
and engine block are clean.
8.Using new gasket, fit oil drain pipe to
turbocharger. Tighten bolts to
25 Nm (18 lbf/ft).
9.Fit drain pipe to cylinder block and tighten union
connector to
38 Nm (28 lbf/ft).
10.Fit exhaust front pipe.See MANIFOLD AND
EXHAUST SYSTEM, Repair, Exhaust front
pipe
11.Check/top-up engine oil level.See SECTION
10, Maintenance, Under bonnet maintenance
12.Reconnect battery.

19FUEL SYSTEM
16
REPAIR INTERCOOLER
Service repair no - 19.42.15
Remove
1.Disconnect battery.
2.Remove 2 nuts securing fan cowl to radiator top
cover.
3.Remove 4 bolts securing radiator top cover to
side covers.
4.Remove 2 bolts from both sides, securing
radiator top cover mounting brackets to bonnet
platform.
5.Detach radiator top cover, complete with
mounting brackets.
6.Slacken retaining clip and disconnect top hose
from intercooler.
7.Slacken 2 clips and disconnect bottom hose
from intercooler.
8.Manoeuvre intercooler upwards and remove
from vehicle.
9.Check condition of foam pads fitted to top and
bottom of intercooler and renew if necessary.
10.Check condition of intercooler locating grommets
in radiator top cover and renew if necessary.
Refit
11.Manoeuvre intercooler into position at LH side of
radiator.
12.Carefully lower intercooler and locate bottom
lugs into radiator bottom support frame.
13.Fit bottom and top hoses to intercooler.
14.Fit radiator top cover and secure mounting
brackets to bonnet platform.
15.Secure radiator top cover to side covers.
16.Fit fan cowl to top cover.
17.Reconnect battery.

FUEL SYSTEM
17
REPAIR EGR VALVE
Service repair no - 17.45.01
Remove
1.Disconnect multi-plug from EGR valve.
2.Disconnect vacuum pipe from EGR valve.
3.Remove 2 Allen screws securing EGR valve to
exhaust manifold.
4.Remove 2 bolts securing air inlet delivery tube to
EGR valve.
5.Remove EGR valve and discard gaskets.
Refit
6.Clean mating faces of EGR valve and exhaust
manifold.
7.Position new gaskets and fit EGR valve to
delivery tube and exhaust manifold. Tighten
bolts to
25 Nm (18 lbf/ft).
8.Fit vacuum pipe and multi-plug to EGR valve.EGR VALVE MODULATOR
Service repair no - 17.45.04
Remove
1.Disconnect multi-plug from modulator.
2.Disconnect spill pipe (green), modulator to air
cleaner hose.
3.Disconnect vacuum pipe (blue), modulator to
EGR valve.
4.Disconnect vacuum pipe (white), modulator to
brake servo pipe.
5.Unscrew 2 nuts securing modulator to flexible
mountings.
6.Remove modulator.
Refit
7.Fit modulator to flexible mountings and tighten
nuts to
8 Nm (6 lbf/ft).
8.Fit modulator pipes, ensuring they are connected
to correct ports.
9.Connect modulator multi-plug.

19FUEL SYSTEM
18
REPAIR EGR THROTTLE POSITION SENSOR
Service repair no - 17.45.08
Remove
1.Remove 2 screws securing throttle position
sensor mounting plate to injection pump.
2.Disconnect sensor multi-plug.
3.Remove sensor assembly.
Refit
4.Position sensor assembly on injection pump and
secure with screws.
5.Connect multi-plug.
6.Adjust sensor
See Adjustment, EGR throttle
sensor
EGR CONTROL UNIT
Service repair no - 17.45.07
Remove
1.Raise centre seat, or cubby box
See CHASSIS
AND BODY, Repair, Cubby box
to gain access
to EGR control unit harness.
2.Disconnect control unit multi-plug and remove
centre seat or cubby box.
3.Remove 4 screws and detach control unit from
seat or cubby box base.
Refit
4.Secure EGR control unit to base of centre seat
or cubby box.
5.Position centre seat or cubby box and connect
control unit multi-plug.
6.Fit centre seat, or cubby box.
See CHASSIS
AND BODY, Repair, Cubby box