1995 LAND ROVER DISCOVERY Workshop Manual

19FUEL SYSTEM
14
REPAIR
19.Disconnect hoses and remove plenum chamber.
20.Place cloth over ram pipes to prevent ingress of
foreign matter.
21.Remove 4 bolts securing water jacket to plenum
chamber. Remove water jacket. Remove gasket
and discard.
22.Remove 3 bolts securing throttle linkage bracket
to plenum chamber. Remove bracket. Collect
return spring.
23.Remove 2 Torx bolts securing TP sensor.
Collect clamp plate. Remove TP sensor.
24.Remove 2 bolts securing IAC. Remove motor.
Remove gasket and discard.

SFI
15
REPAIR REV: 09/95 Refit
25.Ensure all mating surfaces are clean.
26.Fit TP sensor. Ensure drive engages correctly
with throttle spindle.
27.Position clamp plate. Secure TP sensor with
bolts. Tighten to
2 Nm.
28.Using a new gasket, fit IAC. Secure with bolts.
Tighten to
2.3 Nm.
29.Ensure mating faces of water jacket and plenum
chamber are clean.
30.Using a new gasket, fit water jacket. Secure with
bolts. Tighten to
13 Nm.
31.Position throttle linkage bracket, fit and engage
return spring.
32.Secure linkage bracket to plenum chamber with
bolts. Tighten to
8 Nm.
33.Remove cloth from ram housing.
34.Ensure mating faces of plenum chamber and
ram pipe housing are clean.
35.Position plenum chamber. Connect coolant
hoses to water jacket. Secure with clips.
36.Remove clamp from coolant pipes. Remove
cloth.
37.Apply a thin, uniform coating of Loctite 577
sealant to sealing face of plenum chamber.
38.Fit plenum chamber.
39.Fit plenum chamber bolts. Tighten to
24 Nm.
40.Connect multiplugs to TP sensor and IAC.
41.Connect breather hose to plenum chamber.
42.Fit kick down cable to abutment bracket and fit
locknut.
43.Connect throttle cable to abutment bracket.
44.Connect vacuum hose to actuator.
45.Align throttle cable to lever. Fit clevis pin. Secure
clevis pin with split pin.
46.Align kick down cable to lever.
47.Fit clevis pin and secure clip.
48.Connect intake hose and secure with clip.
49.Reconnect battery negative lead.
50.Top up cooling system.RELAY MODULE - PRE ADVANCED EVAPS
Service repair no - 18.30.71
Remove
1.Release module from bracket.
2.Disconnect 2 multiplugs.
3.Remove module.
Refit
4.Reverse removal procedure.

19FUEL SYSTEM
16
REPAIRADD: 09/95 RELAY MODULE - ADVANCED EVAPS
Service repair no - 18.30.71
Remove
1.Release module from bracket.
2.Disconnect 2 multiplugs from module.
3.Remove module.
Refit
4.Position module, connect multiplugs and secure
to bracket.FUEL FILTER - ADVANCED EVAPS
Service repair no - 19.25.02
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 1 -
Introduction are strictly adhered to when
carrying out following instructions.
1.Depressurise fuel system.
See fuel system -
depressurise - advanced evaps
2.Raise rear of vehicle.
WARNING: Support on safety stands.
3.Clean area around hose connections to prevent
ingress of foreign matter into fuel system. Clamp
inlet and outlet hoses to prevent fuel spillage
when disconnecting hoses.
4.Loosen 2 fuel line unions and disconnect hoses.
Remove and discard 'O' rings. Plug ends of
hoses to prevent ingress of dirt.
CAUTION: Use two spanners when
loosening or tightening unions.
5.Remove nut and bolt securing fuel filter bracket
to chassis and remove filter from bracket.

SFI
17
REPAIR ADD: 09/95 Refit
6.Fit a NEW filter to bracket.
NOTE: Ensure direction of flow arrow
stamped on canister is correct.
7.Position filter mounting bracket to chassis and
secure with nut and bolt.
8.Remove plugs from fuel hose ends.
9.Lubricate NEW 'O' rings with clean fuel and fit to
fuel hoses.
10.Connect fuel hoses to filter and tighten unions to
18 Nm.
CAUTION: Use two spanners when
loosening or tightening unions.
11.Remove stand(s) and lower vehicle.
12.Run the engine to check for any fuel leaks.FUEL PUMP AND GAUGE SENDER UNIT -
ADVANCED EVAPS
Service repair no - 19.45.03
A plastic fuel tank with a combined fuel pump and
gauge sender unit is fitted. The top flange of the pump
also houses a pressure sensor which is not removable
from the pump. The fuel pump is accessed through a
panel in the load space floor.
WARNING: Ensure that fuel handling
precautions given in 01 - Introduction are
strictly adhered to when carrying out
following instructions.
CAUTION: Before disconnecting any part
of 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.Depressurise fuel system.
See fuel system -
depressurise - advanced evaps
2.Disconnect battery negative lead.
3.Check the amount of fuel in the tank. If the tank
is full, drain 2.4 US gallons (9 litres) minimum.
See fuel tank - draining - advanced evaps
4.Remove 6 screws securing tail door tread strip
and remove tread strip.
5.Remove RH luggage compartment side panel.
See CHASSIS AND BODY, Repair, rear
compartment lower trim panels

19FUEL SYSTEM
18
REPAIRADD: 09/95
6.Fold back loadspace carpet and sound
insulation to reveal access panel.
7.Remove 6 screws securing fuel pump access
panel.
8.Remove access panel.
9.Disconnect multiplugs from fuel pump and
pressure sensor.
10.Release vent hose from pressure sensor body.
11.Noting their fitted positions, disconnect both fuel
connections by pressing the black release
latches on each connector and pushing the
connector back down the line. Care must be
taken to catch any excess fuel which may spill
from the fuel lines once removed.

SFI
19
REPAIR ADD: 09/95
12.Using service tool LRT-19-009 loosen and
remove the metal locking ring.
13.Prise the pump from the tank opening using a
blunt instrument under the edge of the pump
flange. Once clear of the seal, tip the pump to
the right to allow fuel contained in the body of
the pump to drain into the tank.
CAUTION: Do not lift the pump from the
tank using the feed and return stubs.
14.Remove and discard seal.Refit
15.Fit NEW pump seal to tank opening.
16.Carefully lower pump into tank opening, pressing
firmly on the pump top flange to allow correct
positioning.
NOTE: Ensure location tag on pump top
flange is engaged correctly to tank
opening lip.
17.Fit locking ring and tighten to
35 Nmusing
service tool LRT-19-009.
18.Connect both fuel lines to the pump by pushing
the connectors down each line square to the
pump connection until the connectors positively
latch.
19.Connect vent hose to pressure sensor body.
20.Connect multiplugs to fuel pump and pressure
sensor.
21.Reconnect battery negative lead.
22.Refill tank with drained fuel.
23.Run the engine to check for any fuel leaks.
24.Fit access panel and secure with screws.
25.Reposition loadspace sound insulation and
carpet.
26.Fit RH luggage compartment side panel.
See
CHASSIS AND BODY, Repair, rear
compartment lower trim panels
27.Fit tail door tread strip and secure with screws.

19FUEL SYSTEM
20
REPAIRADD: 09/95 FUEL SYSTEM - DEPRESSURISE - ADVANCED
EVAPS
Service repair no - 19.50.02
WARNING: Fuel pressure of up to 2.5 bar
will be present in the system, even if the
engine has not been run for some time.
Always depressurise the system before
disconnecting any components in the fuel feed
line (between fuel pump and pressure regulator).
The spilling of fuel is unavoidable during this
operation. Ensure that all necessary precautions
are taken to prevent fire and explosion.
NOTE: Fuel pressure can be relieved at
fuel filter unions.
1.Position cloth around relevant union to protect
against fuel spray.
2.Carefully loosen union.
CAUTION: Use two spanners when
loosening or tightening unions.
3.Tighten union once fuel pressure is relieved.
4.Remove cloth.FUEL TANK - ADVANCED EVAPS
Service repair no - 19.55.01
WARNING: Ensure fuel handling
precautions given in section 01
Introduction are strictly adhered to when
carrying out following instructions.
CAUTION: Before disconnecting any part
of fuel system, it imperative that all dust,
dirt and debris is removed from around
components to prevent ingress of foreign matter
into fuel system.
Remove
1.Disconnect battery negative lead.
2.Drain fuel tank completely.
See fuel tank -
draining - advanced evaps
3.Remove 6 screws securing tail door tread strip
and remove tread strip.
4.Remove RH luggage compartment side panel.
See CHASSIS AND BODY, Repair, rear
compartment lower trim panels

SFI
21
REPAIR ADD: 09/95
5.Fold back loadspace carpet and sound
insulation to reveal access panel.
6.Remove 6 screws securing fuel pump access
panel.
7.Remove access panel.8.Disconnect multiplugs from fuel pump and
pressure sensor
9.Noting their fitted positions, disconnect both fuel
connections by pressing the black release
latches on each connector and pushing the
connector back down the line.
10.Care must be taken to catch any excess fuel
which may spill from the fuel lines once
removed.
11.Raise rear of vehicle.
WARNING: Support on safety stands.