Defender (1993+). Instruction - page 34

FUEL SYSTEM

Inspect and overhaul throttle disc

39. Using suitable drift, drive out bushes.

36. Examine throttle shaft

for excessive wear

CAUTION: Take care not to damage plenum

between bushes in plenum chamber and

chamber bores

shaft. A small amount of clearance is
permissible.

If

excessive wear is evident

fit

new shaft and bushes as follows.

37. Remove two split screws securing throttle disc

and withdraw disc.

40.

Press

in new bushes until flush with throttle

disc bore.

CAUTION: Ensure that bushes do not protrude
into bore, as they

will interfere with movement

of

throttle disc.

CAUTION: Take care not to damage shaft.

41.

Fit

throttle shaft and disc, secure with

two

split

screws.

Do not fully tighten screws.

42.

Rotate throttle shaft 360° once or twice

to

centralise disc in bore. Tighten split screws.

43.

Rotate shaft. Use screw driver

to

spread split.

38. Remove shaft and air seal

from plenum

chamber.

REISSUED:

FEB

1993

17

FUEL

SYSTEM

44. Grease new air seal with Admax

L3

or

53.

Using

a

depth vernier or depth micrometer,

check dimension from mouth

of

bore

to

top

and bottom

of

valve disc. Dimension must be

within

0.5

mm (0.019 in) total indicator reading

across diameter of disc.

54. If dimension is out of limits, adjust small set

screw below stop lever.

Energrease LS3. Push seal down shaft, into

counterbore until seal is 6.0 mm (0.236 in)
below face of plenum.

Assemble throttle levers and bracket

45. Fit stop lever to throttle shaft, a new tab

washer and secure with throttle spindle nut.

46. Holding stop lever on stop, tighten throttle

spindle nut securely, bend over tabs to lock
nut in position.

47. Fit inboard throttle return spring noting that

small hooked end of spring is nearest plenum.

48.

Locate hooked end of inboard spring on stop
lever. Wind up straight end one full turn and
locate in appropriate slot.

49. Fit countershaft

to

interconnecting nut of

throttle valve shaft.

50.

Secure throttle bracket assembly

to

plenum.

Secure with three retaining bolts.

51.

Ensure hooked end of outboard spring is

retained by lever, wind spring up one

full

turn

and locate

free end in appropriate

slot.

highly grease throttle return and overtravel

springs with Admax

L3 or Energrease

LS3.

52. Fit overtravel spring.

To

Refit

55. Where applicable, reconnect and adjust cruise

control actuator link.

56. Clean joint faces

of plenum and ram housing.

Apply 'Hylomar' sealant, refit plenum chamber.
Tighten bolts

to 26 Nm.

57. Reverse remaining instructions.

NOTE: If new throttle levers have been fitted,
minimum throttle setting of disc must

be

checked to ensure it

is

90°

to

bore.

18

REISSUED:

FEB

1993

FUEL SYSTEM

6.

Disconnect electrical multi-plugs to engine fuel

REMOVING RAM HOUSING

temperature sensor and injectors.

7. Remove two nuts and bolts securing fuel

To Remove

pressure regulator

to

fuel rail, ease fuel

pressure regulator out of rail. Seal end of fuel

1.

Disconnect battery ground terminal.

rail with plastic plugs

to

prevent ingress of

2. Remove plenum chamber.

dirt.

3.

Release hoses from ram housing.

4.

Remove six through bolts (with plain washers)

NOTE: Intake manifold can be removed from

securing ram housing to intake manifold.

cylinder block without removing fuel

rail and

8. Disconnect

electrical

leads

from

air-conditioning engine coolant temperature
sensor.

9.

Disconnect electrical leads to engine coolant

temperature sensor located at front of intake

manifold.

10.

Remove injector harnesses from behind fuel
rail, lay to one side.

11. Release hose clamps securing

two

heater

hoses behind water pump.

12. Remove two bolts securing rigid heater pipes

to intake manifold and ease pipes out of

hoses.

injectors.

5. Remove ram housing from intake manifold.
6. Place a protective cover over inlet bores to

prevent ingress of dirt.

To Refit

13. Lay heater pipe assembly

to

one side.

14.

Release twelve bolts securing intake manifold.

16. Remove

two

gasket clamps from cylinder

block.

17.

Lift off gasket, remove gasket seals.

18. Remove sealing compound from around water

passage openings of cylinder heads.

7. Clean all mating faces.
8. Apply 'Hylomar' sealant

to intake manifold

15, Remove inlet manifold.

face.

9.

Fit ram housing. Tighten bolts, working from

two

centre bolts, diagonally towards outer four

bolts.

10. Tighten to 26 Nm.

REMOVING INTAKE MANIFOLD

To Remove

1.

Depressurise

fuel

system.

2.

Disconnect battery ground terminal.

3.

Remove radiator bottom hose, drain coolant
until level is below thermostat housing. Refit
hose, tighten clamp.

4.

Remove plenum chamber.

5. Remove ram housing.

CAUTION: Place a protective cover over intake
manifold openings to prevent ingress of

dirt.

REISSUED: FEB 1993

19

FUEL

SYSTEM

To

Refit

26. Tighten gasket clamps

to

18 Nm.

27.

Reverse remaining removal instructions.

29. Start engine, check

for coolant and fuel leaks.

19. Locate

NEW seals in position with ends

28. Replenish cooling system.

engaged in notches formed between cylinder
heads and block.

REMOVING

FUEL

FILTER

To Remove

WARNING: Spilling of fuel is unavoidable during
this operation. Ensure all necessary precautions
are taken to prevent fire and explosion.

WARNING: Ensure fuel handling precautions
given in section

01 -

Introduction regarding fuel

handling are strictly adhered to when carrying
out following instructions.

1.

Depressurise fuel system.

2. Fuel filter is located on chassis side member

below front passenger's door.

3.

Clean area around hose connections

to

prevent ingress of foreign matter into fuel
system. Clamp inlet and outlet hoses

to

20.

Lightly apply 'Hylomar' sealant around outside

prevent fuel spillage when disconnecting

of water passage openings on cylinder heads,

hoses.

manifold gasket and intake manifold.

4.

Loosen

two fuel line unions and remove

hoses. Plug ends

of

hoses to prevent ingress

of dirt.

5.

Release securing bolt and bracket and
remove fuel filter from chassis side member.

21.

Fit manifold gasket with word

'FRONT'

to

To Refit

front and open bolt hole

to

front right hand

side.

6.

Fit a new fuel filter observing direction of flow

22.

Fit gasket clamps, DO NOT fully tighten bolts.

arrows stamped on canister.

23.

Locate intake manifold onto cylinder heads,

7.

Tighten securing nut and bolt.

clean threads of manifold securing bolts.

8.

Fit inlet and outlet hoses. Tighten unions

to

a

24.

Fit manifold bolts. Evenly tighten a little at a

of 30Nm.

time, alternating sides, working from centre

9. Refit fuel pump relay module, reconnect

outwards.

battery.

25.

Tighten to 38

Nm.

10.

Start engine and inspect for fuel leaks around

hose connections.

20

REISSUED: FEB

1993

Рассказать друзьям