Defender (1993+). Manual — part 35

FUEL SYSTEM

REMOVING FUEL TANK AND FUEL PUMP

13.

Finally remove the tank

from

the

vehicle

DEFENDER 110

together with the fuel

pump

and

rear section

of the fuel feed

pipe.

Place tank

in

a

safe

Remove

area.

WARNING: Ensure fuel handling precautions

NOTE:

A

fuel vapour warning label must be

given

in

section

01

-

introduction regarding fuel

handling are strictly adhered

to

when carrying

14.

Disconnect the

rear

section

of

the

fuel

feed

out following instructions.

pipe from the pump.

15.

Remove the

five

retaining

screws

and

CAUTION: Before disconnecting any part

of

fuel

withdraw the fuel

pump

and sealing ring from

system it is imperative that all dust, dirt and

the tank.

debris is removed from around components to

16.

Cover the pump aperture in the tank

to

prevent ingress of foreign matter into fuel

prevent the ingress of foreign matter and

system.

escape

of

fuel vapours.

To

renew the pump, it

is

necessary

to

remove the

fuel tank from the vehicle.

attached to vehicle.

Refit

17.

Fit the pump into the tank with a

new

sealing

1.

Move the vehicle

to

a well ventilated area and

ring

so that the outlet pipe is directed towards

disconnect the battery. Clean the area around

the

front

of the vehicle and the electrical

the pump.

connections to the rear.

2.

Remove the fuel tank drain plug and allow the

fuel to drain into a suitable receptacle that can
be sealed afterwards

ENSURE TANK IS DRAINED COMPLETELY,
Refit drain plug

-

refer

to WARNING

concerning fuel handling at start

of

procedure.

3.

Working from the right hand side of the

vehicle, disconnect the fuel feed pipe and the
spill return at the rubber connections.

4.

Disconnect the fuel filler hose and breather
hose from the tank.

5. Whilst noting the cable colours, disconnect the

electrical leads from the fuel gauge unit at

the

left hand side

of

the vehicle.

6.

Disconnect pipes to expansion tank.

7.

Remove the eight nuts and bolts securing

the

anti-roll bar

to the chassis and push the

anti-roll bar down

to

provide access to the

tank.

8.

Remove the left hand lashing eye to facilitate
removal of the fuel tank.

9.

Place a support under the fuel tank. preferably
one which will enable

the

fuel tank

lo

be

progressively lowered.

10.

Remove the

two nuts retaining

the

forward

end

of the tank.

11

.

Remove the

two

nuts retaining the rear end of

the tank.

12.

Carefully lower the tank sufficiently to enable
the electrical leads to the fuel pump to be
disconnected.

RE-ISSUED: FEB

1993

21

FUEL SYSTEM

18.

Offer up tank to chassis ana connect the
electrical leads; black to ground

(-)

and white

to

positive

(+).

Remove

19.

Locate front

of

tank on the two captive bolts

and secure with the mounting rubber,

flat

and

WARNING: During the following operations

spring washers and nut.

ensure that the fuel handling precautions and
warnings

in

Section

1

of

this manual are being

adhered to.

FUEL TANK DEFENDER

90

1. Disconnect battery.

2. Raise vehicle onto axle stands.
3. Remove rear step.
4. Remove spare wheel.
5. Remove spare wheel carrier.
6. Drain fuel tank.
7. Disconnect fuel filler pipe at tank.
8. Disconnect breather pipe at filler neck.
9. Disconnect

main

fuel

lines

at

union

connections forward of tank.

20. Secure the rear

of the tankwith the

two

captive bolts, plain washer and Nyloc nut.

10.

Disconnect pipe to expansion tank using

11.

Loosen protection plate/fuel tank securing

special

tool LRT-19-002 on green connector.

bolts.

21

Connect the fuel teed and expansion tank

pipes.

22. Connect the spill return pipe.
23. Connect the fuel filler hose and breather pipe

to me tank.

24. Fit the left hand lashing eye.

12. Support tank and plate, remove securing

25. Fit the anti roll bar.

13. Lower tank sufficient to gain access and

26. Fit the drop plate support bars - if fitted.

27. Connect the fuel gage unit leads

disconnect multi-plug

28. Reconnect battery and check operation of

14

Complete lowering of tank and withdraw with

pump and changeover solenoid - if fitted.

29. Run engine check all connection for leaks.

bolts.

protection plate.

22

REVISED:

OCT

1993

FUEL SYSTEM

Refitting

REMOVING ACCELERATOR CABLE

15.

Position protection plate and fuel tank under
rear

of

vehicle.

Remove

16. Raise plate and tank sufficient

to

connect

1

Remove clevis pin securing accelerator cable

multi-plug.

to

lever.

17.

Complete raising and secure plate with bolts.

2.

Carefully pry accelerator cable adjustment nut

18. Connect all fuel and breather pipes at their

various locations/

3. Remove accelerator cable from mounting

19.

Refit spare wheel carrier.

bracket.

20. Refit spare wheel.
21. Refit rear step.
22. Remove vehicle from axle stands.
23. Replenish fuel tank.

24.

Reconnect battery.

25. Run engine for short period.
26. Check all disturbed connections for leaks.

out of mounting bracket.

FUEL PUMP/SENDER UNIT

Special tool

LRT-19-001 Fuel pump remover

Removal

WARNING:. During the following operations
ensure that the fuel handling precautions and
warnings in Section

1

of this manual are being

adhered to.

4.

Release outer cable from retaining clips in
engine compartment.

5. Remove

toe

board from drivers footwell.

6.

Disconnect cable from accelerator pedal and
release cable locknut.

7. Feed cable through bulkhead grommet into

engine compartment.

1. Disconnect battery.

2. Remove fuel tank.
3. Disconnect fuel and breather pipes from

pump/sender unit.

Refit

8. Feed new accelerator cable

from

engine

compartment through bulkhead grommet.

9. Connect cable

to

accelerator pedal.

10.

Connect cable

to accelerator linkage, using

a

new split pin.

11.

Clip outer cable adjustment nut into mounting

4.

Using special

tool

LRT-19-001 remove fuel

bracket.

12.

Adjust outer cable

to

give

1

57

mm

(0 062

in)

5.

Withdraw pump/sender unit from tank.

free play in inner cable Check

accelerator

operation.

pump retaining ring.

Refitting

6.

Refit in reverse order

to

removal.

REVISED: OCT

1993

23

FUEL

SYSTEM

REMOVING ACCELERATOR PEDAL

Remove

1.

Remove toe board from driver's footwell.

2.

Remove clevis pin securing throttle cable

to

accelerator pedal.

3.

Release tension

from

pedal return spring.

4.

Remove circlip from pedal pivot pin.

5.

Withdraw pivot pin.

6.

Remove accelerator pedal.

Refit

7.

Lightly grease pivot and clevis pins.

8.

Fit clevis pin using

a

new split pin.

9.

Reverse remaining removal instructions.

24

ADDITION:

OCT

1993