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