1996 LAND ROVER DEFENDER service

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

COOLING SYSTEM
1
ADJUSTMENT DRAIN AND REFILL COOLING SYSTEM
Service repair no - 26.10.01
Draining
WARNING: DO NOT remove caps or plugs
when the engine is hot. The cooling
system is pressurised and personal
scalding could result.
1.Remove expansion tank filler cap.
2.Position a clean container under radiator if
coolant is to be reused.
3.Disconnect radiator bottom hose and allow
coolant to drain.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
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
orSee CHASSIS AND
BODY, Repair, Rear undertray
4.When expansion tank has emptied remove
thermostat housing plug to assist drainage.
5.Similarly when coolant is below top of radiator,
remove radiator plug.
6.Fit radiator bottom hose and fully tighten hose
clip.Refill
CAUTION: It is important that the correct
procedure is followed when refilling or
topping up the cooling system to avoid
trapping air in the system.
7.Fill cooling system with 50% - 50% of
water/anti-freeze mixture
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids
8.Fill through expansion tank until radiator is full,
with level in expansion tank the same as
radiator.
NOTE: Care should be taken to avoid
excess coolant spillage.
9.Fit plastic plug in radiator.
10.Add a further 1 litre (1.76 pints) of coolant into
expansion tank and allow to settle.
11.Refit expansion tank cap and thermostat
housing plug.
12.Run engine at idle speed for 5 minutes.
13.Switch off engine and allow to cool.
14.Check that coolant in expansion tank is level
with top of indicator post. Top up if necessary.