1999 LAND ROVER DEFENDER service

19FUEL SYSTEM
6
REPAIR Refit
17.Clean turbocharger and oil drain pipe mating
faces.
18.Using a NEW gasket, fit turbocharger drain pipe
and tighten bolts to10 Nm (7 lbf.ft).
19.Using a new gasket fit turbocharger to exhaust
manifold and tighten nuts to30 Nm (22 lbf. ft).
20.Position oil drain pipe to cylinder block and
tighten union.
21.Using new gasket, align exhaust front pipe and
tighten nuts to30 Nm (22 lbf.ft)
22.Fit banjo bolt to oil feed pipe using new sealing
washers and tighten to25 Nm (18 lbf.ft).
23.Position air outlet hose to turbocharger and
tighten clip screw.
24.Position and secure vacuum hose to
turbocharger wastegate.
25.Position exhaust manifold heat shield and
tighten M6 bolts to9 Nm (7 lbf.ft)and M8 bolt to
25 Nm (18 lbf.ft).
26.Position air inlet hose to turbocharger and
tighten clip screw.
27.Connect air flow meter to air filter and secure
clips.
28.Connect air flow meter multiplug.
29.Connect breather hose and secure clip.
30.Fit engine acoustic cover and secure with bolts.
31.Reconnect battery negative lead.
32.Fit battery cover.FILTER ASSEMBLY - AIR
Service repair no - 19.10.01
Remove
1.Loosen clip screw and release intake hose from
air filter.
2.Release 2 clips securing air flow meter.
3.Release air flow meter from air filter cover and
position aside.
4.Disconnect multiplug from AAP sensor.
5.Release air filter from 3 grommets, remove
assembly and discard’O’ring.
6.Remove 2 screws, remove AAP sensor and
discard’O’ring.
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FUEL SYSTEM
7
REPAIR Refit
7.Clean air flow meter faces.
8.Fit new’O’ring to air filter.
9.Clean AAP sensor.
10.Using new’O’ring, fit AAP sensor and tighten
screws.
11.Position air filter assembly and secure in
grommets.
12.Position air flow meter and secure clips.
13.Position intake hose to air filter and tighten clip
screw.INJECTOR - SET
Service repair no - 19.60.12
Remove
1.Remove cooling fan.See COOLING SYSTEM,
Repair.
2.Remove rocker shaft.See ENGINE , Repair.
3.Position container to catch fuel spillage.
4.Disconnect quick release fuel hose connectors
from fuel connector block on cylinder head and
fuel cooler to drain fuel from cylinder head.
5.Disconnect 5 multiplugs from injectors.
6.Remove Torx bolt securing injector unit to
cylinder head.
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FUEL SYSTEM
9
REPAIR HEATER PLUGS - SET
Service repair no - 19.60.31
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Remove battery cover.
3.Disconnect battery negative lead.
4.Disconnect 4 heater plug leads.
5.Loosen and remove 4 heater plugs.
Refit
6.Throughly clean heater plugs and seating area
in cylinder head.
7.Apply a suitable anti-seize compound to threads
of heater plugs.
8.Fit heater plugs and tighten to16 Nm (12 lbf. ft)
.
9.Connect heater plug leads.
10.Fit engine acoustic cover.
11.Reconnect battery negative lead.
12.Fit battery cover.INTERCOOLER
Service repair no - 19.42.15
Remove
1.Remove radiator.See COOLING SYSTEM,
Repair.
2.Release clip and remove air hose from
intercooler.
Refit
3.Position air hose to intercooler and secure with
clip.
4.Fit radiator.See COOLING SYSTEM, Repair.
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19FUEL SYSTEM
10
REPAIR POTENTIOMETER - THROTTLE
Service repair no - 19.30.14
Remove
NOTE: The throttle potentiometer is an
integral part of the throttle pedal assembly
and must not be dismantled.
1.With assistance remove 2 nuts and bolts
securing throttle pedal to body.
2.Disconnect multiplug from throttle potentiometer
and remove throttle pedal.
Refit
NOTE: From Vin 607225 a three track
throttle potentiometer was fitted in place
of a two track potentiometer. Three track
potentiometers cannot be fitted to vehicles
previously fitted with two track potentiometers.
Two track potentiometers can be fitted to vehicles
previously fitted with three track potentiometers,
but TestBook must be used to configure the ECM.
3.Connect multiplug to throttle potentiometer.
4.Position throttle pedal assembly, tighten nuts
and bolts to25 Nm (18 lbf.ft).PUMP - FUEL
Service repair no - 19.45.08
Remove
1.Remove fuel tank.See this Section.
2.UsingLRT-19-009remove locking ring from fuel
pump housing.
3.Remove fuel pump from tank and discard
sealing ring.
Refit
4.Clean pump housing and mating face on fuel
tank.
5.Fit seal to pump housing.
6.Fit pump to fuel tank and secure with locking
ring.
7.Fit fuel tank.See this Section.
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FUEL SYSTEM
11
REPAIR REGULATOR - FUEL PRESSURE
Service repair no - 19.45.06
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove 3 bolts and remove engine acoustic
cover.
4.Release hose from fuel cooler.
5.Release fuel hoses from pressure regulator.
CAUTION: Plug the connections.
6.Disconnect multiplug from fuel temperature
sensor.
7.Remove 3 bolts, remove pressure regulator from
cylinder head and collect gasket and’O’ring.
8.Remove fuel filter from cylinder head.
9.Remove fuel temperature sensor and discard
sealing washer.
10.Remove fuel hose and fuel pipe and discard’O’
rings.
Refit
11.Clean fuel pressure regulator, mating face and
fuel filter.
12.Clean fuel pipe unions.
13.Fit fuel pipe and fuel hose to pressure regulator
using new’O’rings.
14.Fit fuel temperature sensor using new sealing
washer and tighten to14 Nm (11 lbf.ft).
15.Fit fuel filter to cylinder head.
16.Using a new gasket and’O’ring position
pressure regulator and tighten bolts to25 Nm
(18 lbf.ft).
17.Connect fuel temperature sensor.
18.Connect fuel hoses to pressure regulator and
fuel cooler.
19.Fit engine acoustic cover.
20.Reconnect battery negative lead.
21.Fit battery cover.
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19FUEL SYSTEM
12
REPAIR FUEL TANK
Service repair no - 19.55.01
Remove
1.Drain fuel tank.See Adjustment.
2.Raise rear of vehicle.
WARNING: Support on safety stands.
Vehicles fitted with tow bar
3.Remove 2 bolts securing support bars to drop
plate.
4.Loosen 2 nuts securing support bars to chassis.All Vehicles
5.Remove 2 nuts securing fuel tank support to rear
chassis member.
6.Remove 2 bolts securing fuel tank support plate
to chassis member.
7.Release clip securing filler hose and release
hose from filler neck.
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19FUEL SYSTEM
14
REPAIR Refit
19.Clean fuel pump and mating face.
20.Fit new fuel pump sealing ring.
21.Fit fuel pump and secure with locking ring.
22.Fit breather hose and secure clip.
23.Position heat shield and secure with scrivits.
24.With assistance position fuel tank and support
plate.
25.Connect fuel hoses and multiplug to fuel pump.
26.Connect filler neck breather and secure clip.
27.Position vent hose and secure to chassis clips.
28.Raise fuel tank to its fitted position.
29.Fit nuts and bolts securing fuel tank and tighten
to25 Nm (18 lbf.ft).
30.Connect filler hose and secure clip.
Vehicles fitted with tow bar
31.Position support bar and tighten nuts and bolts.
32.Reconnect battery negative lead.
33.Fit battery cover.NECK - FUEL TANK FILLER
Service repair no - 19.55.07
Remove
1.Drain fuel tank.See Adjustment.
2.Loosen clip securing breather hose to fuel filler
neck and release hose.
3.Loosen clip securing fuel filler hose to neck and
release hose.
4.Remove screw and release earth lead from filler
neck.
5.Remove grommet securing filler neck to body.
6.Remove filler neck from body.
Refit
7.Fit filler neck to body.
8.Coat rubber grommet with soap solution.
9.Fit rubber grommet securing filler neck to body.
10.Connect earth lead and tighten screw.
11.Connect filler hose to neck and tighten clip.
12.Fit breather hose to filler neck and secure with
clip.
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COOLING SYSTEM
1
ADJUSTMENT DRAIN AND REFILL
Service repair no - 26.10.01
WARNING: Hot coolant
Drain
1.Remove engine acoustic cover.
2.Visually check engine and cooling system for
signs of coolant leaks.
3.Examine hoses for signs of cracking, distortion
and security of connections.
4.Position drain tray to collect coolant.
5.Remove expansion tank filler cap.
6.Loosen clip screws securing air inlet hose to
intercooler and inlet manifold, release and
remove hose.
7.Release clip and disconnect bottom hose from
radiator.
8.Allow cooling system to drain.
9.Disconnect bottom hose from radiator.Refill
1.Flush system with water under low pressure.
2.Do not use water under high pressure as it could
damage the radiator.
3.Connect bottom hose to radiator and secure
hose with clip.
4.Prepare coolant to required concentration.
5.Position heater temperature control to maximum
hot position.
6.Remove bleed screw from top hose.
7.Fill system slowly through coolant expansion
tank until a steady flow of coolant is emitted from
the bleed hole in top hose.
8.Fit bleed screw to top hose.
9.Continue filling system until coolant level
reaches’MAX’mark on expansion tank.
10.Fit expansion tank filler cap.
11.Position air intake hose and tighten clip screws.
12.Start and run engine until normal running
temperature is reached.
13.If fitted, DO NOT operate air conditioning.
14.Switch off engine and allow to cool.
15.Check for leaks and top-up coolant to’MAX’
mark on expansion tank.
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