1999 LAND ROVER DEFENDER fuel filter

12ENGINE
14
REPAIR
9. Not EU3 model:-Apply two 3 mm diameter
beads of sealant, Part No.STC 5433 to areas’A’
shown on illustration.
CAUTION: Excessive use of sealant could
result in blockage of oil drain hole,
arrowed’B’in illustration.
10.Fit new gasket to camshaft cover. fit cover and
tighten bolts to10 Nm (7 lbf.ft).
11.Position breather hose and secure clip.
12.Fit engine acoustic cover.
13.Reconnect battery negative lead.
14.Fit battery cover.ENGINE AND ANCILLARIES
Service repair no - 12.41.01.99
Remove
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Drain engine oil.
3.Remove radiator.See COOLING SYSTEM,
Repair.
4.Remove turbocharger.See FUEL SYSTEM,
Repair.
5.Remove starter motor.See ELECTRICAL,
Repair.
6.Remove air filter.See FUEL SYSTEM, Repair.
7.Loosen clip screw and release air intake hose
from intake elbow.
8.Release clips and disconnect coolant hoses
from fuel cooler and coolant rail.
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ENGINE
19
REPAIR 70.Connect coolant hoses to fuel cooler and coolant
rail and secure clips.
71.Fit air intake hose to intake elbow and tighten
clip screw.
72.Fit starter motor.See ELECTRICAL, Repair.
73.Fit turbocharger.See FUEL SYSTEM, Repair.
74.Fit radiator.See COOLING SYSTEM, Repair.
75.Fit air filter.See FUEL SYSTEM, Repair.
76.Fill engine with oil.
77.Fit underbelly panel.See CHASSIS AND
BODY, Repair.MOUNTING - FRONT - LH
Service repair no - 12.45.01
Remove
1.Remove centrifuge assembly.See this
Section.
2.Remove 3 bolts, remove oil filter adaptor
housing and discard gasket.
3.Fit suitable lifting chains to support engine.
4.Remove 2 nuts securing engine mounting to
chassis.
5.Remove 4 bolts securing engine mounting
bracket to cylinder block.
6.Remove nut securing mounting to mounting
bracket.
7.Remove mounting and mounting bracket.
8.Remove mounting shield.
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12ENGINE
20
REPAIR Refit
9.Fit shield to mounting ensuring cut-away portion
is correctly aligned.
10.Fit mounting and mounting bracket.
11.Fit mounting bracket to cylinder block bolts and
tighten to48 Nm (35 lbf.ft).
12.Fit nuts securing mounting to chassis and tighten
to85 Nm (63 lbf.ft).
13.Fit mounting to mounting bracket nut and tighten
to85 Nm (63 lbf.ft).
14.Remove engine support chains.
15.Clean oil filter adaptor housing and mating face.
16.Fit oil filter adaptor housing using a new gasket
and tighten bolts to25 Nm (18 lbf.ft).
17.Fit centrifuge assembly.See this Section.MOUNTING - FRONT - RH
Service repair no - 12.45.03
Remove
1.Remove engine acoustic cover.See this
Section.
2.Remove fixings, remove battery cover.
3.Disconnect battery negative lead.
4.Raise front of vehicle.
WARNING: Support on safety stands.
5.Remove 4 bolts, move fuel cooler to one side.
6.Fit suitable lifting chains to support engine.
7.Remove 2 nuts securing engine mounting to
chassis.
8.Remove 4 bolts securing engine mounting
bracket to cylinder block.
9.Remove nut securing mounting to mounting
bracket.
10.Remove mounting and mounting bracket.
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12ENGINE
30
REPAIR Refit
10.Clean oil cooler and mating faces.
11.Fit oil pressure switch and tighten to9Nm(7
lbf.ft).
12.Position oil cooler using a new gasket and
tighten bolts to25 Nm (18 lbf.ft).
13.Position oil filter adaptor, fit new gasket and
tighten bolts to25 Nm (18 lbf.ft).
14.Position oil filter element hand tight then a
further half turn.
15.Position coolant hose to oil cooler and secure
clip.
16.Position coolant pipe and tighten clutch housing
bolt to50 Nm (37 lbf.ft).
17.Connect oil pressure switch multiplug.
18.Fit centrifuge assembly.See this Section.
19.Refill cooling system.See COOLING SYSTEM,
Adjustment.
20.Top up engine oil.CENTRIFUGE ASSEMBLY
Service repair no - 12.60.90
Remove
1.Remove fixings and remove underbelly panel.
See CHASSIS AND BODY, Repair.
2.Remove 2 bolts securing centrifuge drain pipe to
engine sump and discard gasket.
3.Remove turbocharger.See FUEL SYSTEM,
Repair.
Models with air conditioning only
4.Remove auxiliary drive belt.See
ELECTRICAL, Repair.
5.Remove 4 bolts securing compressor and move
to one side.
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ENGINE
11
OVERHAUL
23.Remove 3 bolts and remove fuel connector
block from cylinder head.
24.Remove and discard gasket,’O’ring and fuel
filter.
25.Remove spacer block and gasket (if fitted).Cylinder head and camshaft carrier - cleaning
1.Thoroughly clean cylinder head mating faces,
ensure oil and coolant passages are clear and
bolt holes are clean and dry.
CAUTION: Take care to ensure that EUI
drillings are clear.
2.Using suitable solvent, remove all traces of
sealant and gasket material.
CAUTION: Do not use metal scrapers.
3.Remove all traces of oil from camshaft bearings
and journals.
4.Clean glow plug threads.
Cylinder head - Inspection
1.Check core plugs for signs of leakage and
corrosion, seal replacement plugs with Loctite
243.
2.Check cylinder head for warping across centre
and from corner to corner.
Maximum cylinder head warp =0.1 mm (0.004
in).
CAUTION: Cylinder heads may not be
refaced, replace the head assembly if
warping exceeds the limit given.
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ENGINE
19
OVERHAUL 16.Lubricate finger followers with engine oil.
17.Fit finger followers ensuring they are in their
original fitted order.
18.Lubricate cams and bearing journals on
camshaft, cylinder head and camshaft carrier
with engine oil.
19.Position camshaft in cylinder head with the
timing pin hole in the vertical position.
20.Apply an even film of sealant, Part No. STC
4600 to camshaft carrier face and spread to an
even film using a roller.
CAUTION: Ensure sealant does not block
oilways (arrowed) or contaminate
camshaft bearings. Assembly and bolt
tightening must be completed within 20 minutes
of applying sealant.
21.Fit camshaft carrier ensuring it is correctly
located on dowels.
22.Fit and lightly tighten new camshaft carrier bolts.
23.Using sequence shown, progressively tighten
bolts to25 Nm (18 lbf.ft).
24.Lubricate a new camshaft rear oil seal with
engine oil, fit seal using a suitable mandrel.
25.Position rocker shaft on camshaft carrier,
ensuring rocker shaft is located on dowel.
26.Fit new rocker shaft retaining bolts and working
from the centre outwards, tighten bolts
progressively to32 Nm (24 lbf.ft).27.Lubricate a new’O’ring with engine oil and fit to
injector harness multiplug.
28.Fit injector harness and connect multiplugs.
29.Clean fuel connector block and mating face.
30.Lubricate a new fuel filter’O’ring with engine oil.
31.Fit new fuel filter,’O’ring and gasket.
CAUTION: Gasket must be fitted dry.
32.Fit fuel connector block spacer and gasket (if
fitted).
33.Fit fuel connector block, fit bolts and tighten to
25 Nm (18 lbf.ft).
34.Clean glow plugs.
35.Fit glow plugs to cylinder head and tighten to16
Nm (12 lbf.ft).
36. Engine Serial No. Prefixes 15P to 19P:-
Lubricate new’O’rings with engine oil and fit to
spill return pipe; fit pipe and tighten connectors
to20 Nm (15 lbf.ft).
37.Fit new cylinder head gasket.See this Section.
CAUTION: Ensure that the fuel injector
rockers are adjusted following the
procedures given in Gasket - Cylinder
head - Refit.
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19 - FUEL SYSTEM
CONTENTS
Page
DESCRIPTION AND OPERATION
COMPONENT LOCATION 1...................................................................................
DESCRIPTION 2.....................................................................................................
FUEL PUMP AND FUEL GAUGE SENDER 3........................................................
FUEL PRESSURE REGULATOR 5........................................................................
INJECTORS 7.........................................................................................................
FUEL FILTER 9.......................................................................................................
WATER SENSOR 10..............................................................................................
OPERATION 11......................................................................................................
ADJUSTMENT
HEATER PLUG TEST 1..........................................................................................
FUEL SYSTEM - BLEED 1.....................................................................................
FUEL TANK - DRAIN 2...........................................................................................
REPAIR
ELEMENT - AIR FILTER 1......................................................................................
SENSOR - FUEL TEMPERATURE 1......................................................................
SWITCH - INERTIA - FUEL CUT OFF 2.................................................................
SENSOR - MASS AIR FLOW (MAF) 2....................................................................
SENSOR - COMBINED MAP AND IAT 3................................................................
SENSOR - AMBIENT AIR PRESSURE (AAP) 3.....................................................
ELEMENT - FUEL FILTER 4...................................................................................
COOLER - FUEL 4..................................................................................................
TURBOCHARGER 5...............................................................................................
FILTER ASSEMBLY - AIR 6...................................................................................
INJECTOR - SET 7.................................................................................................
HEATER PLUGS - SET 9.......................................................................................
INTERCOOLER 9...................................................................................................
POTENTIOMETER - THROTTLE 10......................................................................
PUMP - FUEL 10.....................................................................................................
REGULATOR - FUEL PRESSURE 11....................................................................
FUEL TANK 12.......................................................................................................
NECK - FUEL TANK FILLER 14.............................................................................
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FUEL SYSTEM
1
DESCRIPTION AND OPERATION COMPONENT LOCATION
1.HP stage
2.LP stage
3.Filters
4.Jet pump
5.Fuel pump and fuel gauge sender unit
6.LP return connection
7.LP feed connection8.HP feed connection
9.Air bleed connection
10.Fuel filter
11.Water sensor
12.Fuel cooler
13.Fuel pressure regulator
14.Electronic Unit Injectors
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