1996 LAND ROVER DEFENDER fuel cap

ENGINE
1
SPECIFICATIONS, TORQUE REV: 05/99 TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Engine block
Bearing cap 133...............................................................................................
Blanking plug, oil gallery, rear 37....................................................................
Oil squirt jet assembly 17................................................................................
Drain plug, cylinder block 25...........................................................................
Oil squirt jet, vacuum pump cam 7.................................................................
Connecting rod to cap 59................................................................................
Oil pick up assembly to bearing cap 9...........................................................
Oil pick up assembly to front cover 25............................................................
Camshaft thrust plate 9..................................................................................
Oil drain pipe to block (internal) 25.................................................................
Oil drain pipe to block (external) 25................................................................
Sump to cylinder block and front cover 25......................................................
Drain plug, oil sump 35...................................................................................
Tappet guide 14..............................................................................................
Breather side cover assembly 25....................................................................
Baffle plate to breather side cover 4..............................................................
Vacuum pump 25............................................................................................
Fuel lift pump 25.............................................................................................
Flywheel housing 45.......................................................................................
Flywheel housing clutch cover stud 10...........................................................
Plug, flywheel housing 12...............................................................................
Rear oil seal assembly 25...............................................................................
Oil filter adaptor 45..........................................................................................
Waxstat adaptor to oil filter adaptor 9............................................................
Oil pressure switch 17.....................................................................................
Oil filter, spin on 13.........................................................................................
Oil cooler unions to filter adaptor 45...............................................................
Oil level tube 25..............................................................................................
Engine mounting foot to cylinder block 85......................................................
Engine mounting foot to flywheel housing 45.................................................
Engine mounting foot rubber to mounting foot (bolt and nut) 85.....................
Flywheel to crankshaft 146..............................................................................
Clutch cover plate to flywheel 34....................................................................
Flex drive plate to crankshaft (auto) 146..........................................................
Flex drive plate to ring gear (auto) 25.............................................................
Flex drive plate to torque converter (auto) 45.................................................

FUEL SYSTEM
1
DESCRIPTION AND OPERATION DESCRIPTION
Fuel system
The fuel system incorporates a supply and spill return
line on all models as illustrated below.
On 90 models, see J6191, the fuel tank is mounted at
the RH side of the vehicle chassis under the front
seat.On standard 110 and 130 models the fuel tank is
located at the rear of the vehicle between the chassis
longitudenal sections, as shown in J6192.
As an option, a twin tank system fitted with a
combined change-over tap and 3 way fuel supply and
return system, can be installed on both 110 and 130
models, see J6193.
The tank/s on all vehicles is vented by a 2 way valve
in the filler cap.
FUEL SYSTEM LAYOUT
1.Fuel tank
2.Fuel sedimentor, if fitted
3.Fuel lift pump
4.Fuel filter5.Fuel injection pump
6.Spill return line
7.Fuel injectors

19FUEL SYSTEM
4
DESCRIPTION AND OPERATION
110/130 TWIN TANK FUEL SYSTEM - 5 DOOR
VEHICLES
1.Fuel filter
2.Supply pipe, lift pump to filter
3.Supply pipe, filter to injection pump
4.Fuel injection pump
5.Fuel lift pump
6.Spill return pipe, injection pump to change-over
tap
7.Supply pipe, fuel tank change-over tap to lift
pump
8.Spill return pipe, change-over tap to side tank
9.Change-over tap, spill return
10.Fuel filler cap
11.Side fuel tank12.Supply pipe, side tank to sedimentor
13.Sedimentor, if fitted, side tank
14.Supply pipe, sedimentor to fuel tank
change-over tap
15.Change-over tap, side and rear tanks
16.Supply pipe, rear sedimentor to fuel tank
change-over tap
17.Spill return pipe, change-over tap to rear tank
18.Rear fuel tank
19.Fuel filler pipe
20.Breather pipe
21.Supply pipe, rear tank to sedimentor
22.Sedimentor, if fitted, rear tank
NOTE: If sedimentors are not fitted, the
fuel supply pipe from the side and rear
tanks connects directly to the fuel tank
change-over tap.

FUEL SYSTEM
1
REPAIR FUEL INJECTION PUMP
Service repair no - 19.30.07
Remove
1.Disconnect battery.
2.Disconnect and remove high pressure fuel
injection pipes, pump to injectors.
3.Viewing valve mechanism through oil filler cap
aperture, turn crankshaft clockwise until No. 1
cylinder is just before TDC.
4.Remove blanking plug from flywheel housing
and fit timing toolLRT-12-044, locating centre
pin on flywheel.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
adjustments or remove and refit procedures are
required, it may be necessary to remove the
undertray and/or integral access panels
See
CHASSIS AND BODY, Repair, Front undertray
or
See CHASSIS AND BODY, Repair, Rear undertray
5.Carefully rotate crankshaft clockwise until centre
pin engages with timing slot in flywheel.
6.Remove injection pump access plate, complete
with gasket, from front cover plate.
7.Fit pin fromLRT-12-045to injection pump gear.
8.Restrain pulley nut to prevent straining timing
belt and remove drive gear to pump hub fixing
bolts and retaining plate.
9.Remove pin from pump gear.
10.Fit gear retaining toolLRT-12-045with an 8 mm
washer, 1,5 - 2 mm thick, under each bolt head
in addition to the existing washer.
11.Remove throttle cable and hand throttle cable, if
fitted.
12.Disconnect lead from fuel cut-off solenoid, and
EGR throttle position sensor multi-plug, if fitted.

19FUEL SYSTEM
2
REPAIR
13.Remove banjo bolts securing spill return, main
fuel and boost signal pipes, refit banjo bolts after
disconnecting pipes.
14.Remove 2 bolts securing rear of pump to
mounting bracket.
15.Remove 3 pump securing nuts at flange and
withdraw pump and gasket.
16.Fit suitable caps to pipe connections to prevent
ingress of dirt.
Refit
17.Clean mating faces of pump and front cover and
fit new gasket into position over pump mounting
studs.
18.Remove pump blanking plugs.
19.Slacken the 3 bolts, securing injection pump
mounting bracket to cylinder block, sufficiently
enough to allow bracket to move.
20.Fit pump to cover and secure with 3 nuts.
Tighten to
25 Nm (18 lbf/ft).
21.Loosely attach pump to mounting bracket with
nuts and bolts, then tighten bolts securing
bracket to cylinder block and bolts securing
pump to bracket, finger tight only.
22.To ensure correct fitting and alignment of
injection pump, first tighten the 2 bolts securing
pump to mounting bracket to
25 Nm (18 lbf/ft).
Then tighten the 3 bolts securing mounting
bracket to cylinder block, also to
25 Nm (18
lbf/ft).
23.Connect spill return and main fuel pipes and
secure with banjo bolts. Tighten to
25 Nm (18
lbf/ft).
24.Connect boost signal pipe and secure with banjo
bolt. Tighten to
10 Nm (7 lbf/ft).
25.Connect fuel cut-off solenoid lead and throttle
position sensor multi-plug, if fitted.
26.Connect throttle cable and where applicable,
hand throttle cable.
27.Remove pump gear retaining toolLRT-12-045.
28.Carefully turn the pump hub nut in a clockwise
direction, sufficiently enough to enable timing
tool pin to be inserted into injection pump.
29.Fit gear retaining plate and secure with 3 bolts.
Tighten to
25 Nm (18 lbf/ft).
30.Remove timing pin.
31.Ensure flywheel timing pin is disengaged from
slot in flywheel.
32.Turn crankshaft two complete revolutions, check
timing pin fromRT-12-045can be fully and
easily inserted into the pump. At the same time
check flywheel timing pinLRT-12-044can also
be inserted in the flywheel slot.
33.If, with the flywheel timing pin located, the timing
pin cannot be inserted cleanly into the injection
pump, carry out the following:
a.Ensure flywheel timing pin is disengaged from
slot in flywheel.
b.Slacken the 3 pump gear retaining bolts.
c.Turn the pump hub nut in a clockwise
direction, sufficiently to enable timing tool pin to
be easily inserted into the injection pump.
d.Keeping the tension on the hub nut, check
that flywheel timing pin locates with slot in
flywheel.
e.Tighten the 3 pump gear retaining bolts to
25
Nm (18 lbf/ft).
f.Remove timing pins from pump and flywheel
housing.
34.Using a suitable anti-seize compound, fit the
blanking plug to flywheel housing. Tighten to
12
Nm (9 lbf/ft).
35.Fit access plate with gasket to front cover plate.
Tighten bolts to
25 Nm (18 lbf/ft).
36.Refit injector pipes.
37.Reconnect battery.

FUEL SYSTEM
3
REPAIR FUEL INJECTORS
Service repair no - 19.60.10
Remove
NOTE: When a fuel injector is considered
to be the cause of irregular running and
loss of power it will be necessary to fit a
donor set of injectors to determine which injector
is at fault. DO NOT attempt to dismantle or carry
out spray tests on the fuel injectors. This work
can only carried out by authorised Bosch dealers.
1.Remove oil filler cap and release sound
insulation cover from top of engine.
2.Disconnect high pressure fuel supply pipes from
injectors and injection pump. Remove in pairs.
3.Disconnect spill return hose(s) from injectors.
4.Plug pipes and injector connections to prevent
the ingress of dirt and foriegn matter.5.Remove retaining nut and release each injector
clamp plate from cylinder head.
6.Remove injector and discard copper washer.
Refit
7.Ensure injectors and seating in cylinder head are
clean.
8.Lightly grease a new copper sealing washer and
position on each injector.
9.Fit injectors in cylinder head with spill return
outlets facing outward.
10.Secure injector with clamp plate and nut. Tighten
nut to
25 Nm (18 lbf/ft).
NOTE: The clamp plates are slightly
curved and should be fitted with the
convex side uppermost.
11.Fit the spill return pipe with a single copper
washer under the head of the banjo bolt and 2
copper washers fitted between the injector and
the banjo. Tighten banjo bolt to
10 Nm (7 lbf/ft).
12.Fit high pressure pipes to injectors and injection
pump. Tighten union nuts to
28 Nm (21 lbf/ft).
13.Fit sound insulation cover and oil filler cap.

19FUEL SYSTEM
6
REPAIR SIDE MOUNTED FUEL TANK
Service repair no - 19.55.05
NOTE: This fuel tank is standard on 90
models and an option on 110/130 2 door
vehicles fitted with twin tanks.
Remove
WARNING: Before any attempt is made to
start the removal procedure it is vital that
the FUEL HANDLING PRECAUTIONS are
carefully studied and implemented in the interests
of safety.
See INTRODUCTION, Information, Fuel
Handling Precautions
1.Disconnect battery.
2.Remove fuel filler cap.3.Remove fuel tank drain plug, allow fuel to drain
into a clean container and refit plug.
4.Remove RH seat cushion.
5.Release retaining catch and remove seat base
cover to gain access to fuel tank.
6.Disconnect electrical plug from fuel gauge unit.
7.Disconnect fuel supply pipe from tank.
8.Disconnect spill return pipe from fuel tank.
9.Disconnect breather pipe from fuel filler tube.
10.Slacken hose clip and remove filler hose from
filler tube.
11.From rear of tank, remove 2 nuts and washers
securing tank mounting to captive-headed bolts.
12.Support rear of fuel tank and remove captive
bolts.

FUEL SYSTEM
7
REPAIR REV: 05/99
13.Remove single bolt fixing assembly securing
front of tank to chassis mounted bracket.
14.Remove 3 bolts securing tank mounting bracket
to chassis and release bracket.
15.Lower front of tank while turning anti-clockwise
and remove from vehicle.
16.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
17.Fit filler hose and clip to tank but do not fully
tighten. Position clip screw so that it is
accessible when tank is fitted.
18.Fit breather hose and secure with clip.
19.Position fuel tank in vehicle and loosely secure
front mounting bracket to tank with special bolt
and rubber bushes.
20.Secure mounting bracket to chassis with 3 bolts
and fully tighten to
20 Nm (15 lbf/ft).
21.Secure rear of tank to chassis mounting and
tighten captive bolt plate fixings to
20 Nm (15
lbf/ft).
22.Fully tighten front fixing bolt assembly to20 Nm
(15 lbf/ft).
23.Fit spill return and fuel supply pipes and secure
union connections.
24.Fit fuel level unit electrical plug.
25.Fit hose to filler tube and tighten upper and lower
clips.
26.Check that drain plug is secure and fill fuel tank.
27.Reconnect battery.
28.Prime fuel system
See Adjustment, Priming
the fuel system
and start engine.
29.Check system for leaks and operation of fuel
gauge.
30.Fit seat base cover and seat cushion.SIDE MOUNTED FUEL TANK - 5 DOOR VEHICLES
Service repair no - 19.55.01
NOTE: This fuel tank is used on 110/130 5
door vehicles fitted with a twin tank
option.
WARNING: Before any attempt is made to
start the removal procedure it is vital that
the FUEL HANDLING PRECAUTIONS,
See
INTRODUCTION, Information, Fuel handling
precautions
are carefully studied and
implemented in the interests of safety.
Remove
1.Disconnect battery.
2.Remove tank drain plug, allow fuel to drain into a
clean container, and refit plug.
3.Remove RH seat cushion.
4.Remove retaining catch and remove seat base
cover to gain access to fuel tank.
5.Disconnect electrical plug from fuel gauge unit.
6.Disconnect fuel supply pipe from tank.
7.Disconnect spill return pipe from tank.
8.Remove 3 bolts securing tank to front mounting
bracket.
9.Support front of tank and remove single fixing
assembly securing tank to rear mounting
bracket.
10.Remove tank from vehicle.
11.If required, remove fuel 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
12.Position fuel tank in vehicle and loosely secure
to rear mounting bracket with special bolt and
rubber bushes.
13.Secure tank to front mounting bracket and
tighten fixings to
20 Nm (15 lbf/ft).
14.Fully tighten rear fixing bolt assembly to20 Nm
(15 lbf/ft).
15.Fit spill return and fuel supply pipes to fuel tank
and securely tighten union connectios.
16.Fit electrical plug to fuel gauge unit.
17.Check that drain plug is secure and fill fuel tank.
18.Reconnect battery.
19.Prime fuel system.
See Adjustment, Priming
the fuel system
and start engine.
20.Check system for leaks and operation of fuel
gauge.
21.Fit seat base cover and seat cushion.