1996 LAND ROVER DEFENDER fuel cap

19FUEL SYSTEM
8
REPAIR REAR MOUNTED FUEL TANK - 110/130
Service repair no - 19.55.26
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 fuel filler cap.
3.Remove tank drain plug, allow fuel to drain into a
clean container, and refit plug.
4.Slacken retaining clips and disconnect fuel filler
hose from rear tank.5.Disconnect breather hose from filler tube.
6.Disconnect electrical plug and fuel supply pipe
from outlet pipe union on fuel gauge unit.
7.If the vehicle is fitted with a tow ball drop-plate
with support bars, the bars must be removed.
8.Remove anti-roll bar chassis mountings.
See
REAR SUSPENSION, Repair, Anti-roll bar
and push roll bar down to provide access to the
tank.
9.Remove LH lashing eye to assist access to tank.
10.Position a support under the tank, preferably one
that can be progressively lowered.

MANIFOLD AND EXHAUST SYSTEM
1
REPAIR INDUCTION MANIFOLD
Service repair no - 30.15.02
Remove
1.Disconnect battery.
2.Remove oil filler cap and remove rocker cover
insulation.
3.Remove hose intercooler to induction manifold. If
fitted, remove EGR valve.
See FUEL SYSTEM,
Repair, EGR valve
4.Remove 2 screws and release heat shield from
induction manifold.
5.Slacken induction manifold lower securing nuts,
located below exhaust manifold.
6.Remove induction manifold upper securing bolts.
7.Remove induction manifold. Plug apertures in
cylinder head with clean rag to prevent any items
falling into engine.
8.Check gasket is satisfactory for further use.
Refit
9.Clean induction manifold mating face.
10.Position induction manifold and secure with
upper and lower fixings.
11.Tighten securing nuts and bolts to
25 Nm (18
lbf/ft).
12.Fit manifold heat shield.
13.Fit hose intercooler to induction manifold.
14.Fit rocker cover insulation.
15.Reconnect battery.INDUCTION/EXHAUST MANIFOLD GASKET
Service repair no - 30.15.15
Remove
1.Remove induction manifold
See Induction
manifold
.
2.Remove turbocharger outlet hose.
3.Raise vehicle and slacken exhaust front pipe to
intermediate silencer flange nuts. Ensure pipe is
free to turn.
NOTE: If removing exhaust manifold and
turbocharger assembly from vehicle,
remove manifold to exhaust front pipe
nuts while working under vehicle.
4.Remove exhaust manifold securing nuts,
removing centre lower nut first.
5.Move heater rail clear of exhaust manifold.
6.With exhaust manifold and turbocharger still
attached to exhaust front pipe, withdraw from
head by turning front pipe until sufficient access
is gained to remove gasket.
7.Suitably support exhaust manifold and
turbocharger assembly to prevent damage.
8.Remove induction manifold lower nuts.
9.Remove gasket.
10.Clean mating faces.

ELECTRICAL
25
REPAIR DIGITAL DIESEL SHUT-OFF VALVE (DDS)
Service repair no - 86.77.00
Remove
1.Remove fuel injection pump
See FUEL
SYSTEM, Repair, Fuel injection pump.
2.Drill out 2 shear bolts securing DDS valve and
clamp, using a 3.2 mm drill, to a depth of
approximately 5 mm.
CAUTION: Use a drill bushing to guide the
drill.
3.Using an extractor, remove the 2 DDS valve
retaining bolts and discard.
4.Release DDS valve from fuel shut-off solenoid.
5.Remove protective cap from shut-off solenoid.
6.Unscrew terminal nut, release terminal lead
eyelet and remove DDS valve.7.Remove protective cap retainer and release
DDS valve clamp from behind fuel shut-off
solenoid.
Refit
8.Position DDS valve clamp behind fuel shut-off
solenoid and fit protective cap retainer.
9.Fit DDS terminal lead to fuel shut-off solenoid.
Tighten nut to
2 Nm (1.5 lbf/ft).
10.Fit protective cap to fuel shut-off solenoid,
ensuring terminal lead is correcly routed on RH
side of cap.
11.Secure DDS valve to fuel cut-off solenoid and
clamp. Tighten new shear bolts progressively
until heads shear.
12.Fit fuel injection pump
See FUEL SYSTEM,
Repair, Fuel injection pump.

88INSTRUMENTS
4
REPAIR PRINTED CIRCUIT - WARNING LIGHT PANEL
Service repair no - 88.20.20
Remove
1.Remove warning light panel
See Warning light
panel
.
2.Remove 13 illumination bulb holders from light
panel.
3.Release printed circuit from locating pins and
remove from panel seatings.
Refit
4.Fit new printed circuit over panel seatings and
position on locating pins.
5.Fit illumination bulbs to secure circuit.
6.Fit warning light panel
See Warning light
panel
.FUEL GAUGE TANK UNIT - REAR FUEL TANK,
110/130
Service repair no - 88.25.30
WARNING: Ensure that fuel handling
precautions given in Section 01 -
Introduction are strictly adhered to when
carrying out the following instructions.
Remove
1.Disconnect battery.
2.Remove fuel filler cap.
3.Remove tank drain plug, allow fuel to drain into a
clean container, and refit plug.
4.On LH side of tank, disconnect fuel supply pipe
from outlet pipe on fuel gauge unit.
5.Disconnect electrical plug from fuel gauge unit.
6.Release locking ring and withdraw fuel gauge
unit from tank, complete with sealing ring.
Refit
7.Insert gauge unit into tank with float positioned to
base of tank. Fit new sealing washer, if
necessary.
8.Secure gauge unit with locking ring.
9.Fit electrical plug and reconnect fuel supply pipe.
10.Refill fuel tank.
11.Reconnect battery.