Defender 300Tdi (1996+). Manual — part 28
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19
FUEL SYSTEM
12
REPAIR
HEATER PLUG CONTROL UNIT
Service repair no - 19.60.33
Remove
1. Disconnect battery.
2. Remove screw securing control unit to bulkhead.
3. Disconnect multi-plug and release control unit.
Refit
4. Fit harness multi-plug to control unit.
5. Secure control unit to bulkhead.
6. Reconnect battery.
AIR CLEANER
Service repair no - 19.10.01
Remove
1. Slacken hose clip and detach outlet hose.
2. Release clips and open air cleaner retaining
straps.
3. Lift up air cleaner, slacken hose clip and detach
inlet hose.
4. Remove air cleaner.
Refit
5. Position air cleaner and connect inlet hose.
6. Close air cleaner retaining straps and secure
lock clips.
7. Connect outlet hose.
NOTE: If an EGR fuel system is fitted,
ensure the modulator valve vacuum spill
pipe is secure in the outlet hose.
AIR CLEANER ELEMENT
Service repair no - 19.10.10
For remove and refit procedure.
See SECTION 10,
Maintenance, Under bonnet maintenance
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FUEL SYSTEM
13
REPAIR
THROTTLE CABLE
Service repair no - 19.20.06
Remove
1. Disconnect battery.
2. Remove split pin and clevis pin securing throttle
cable to injector pump throttle lever .
3. Depress ferrule retaining tags, release ferrule
from abutment bracket and withdraw throttle
cable.
4. Release throttle cable from clip on bulkhead.
5. Remove pin and clevis pin securing throttle
cable to pedal lever.
6. Release grommet from bulkhead.
7. Withdraw throttle cable from engine
compartment.
Refit
8. Feed throttle cable through bulkhead from
engine compartment and fit grommet.
9. Secure throttle cable to pedal lever. Use new
split pin to secure clevis.
10. Secure throttle cable in bulkhead clip.
11. Guide throttle cable through abutment bracket
and fit ferrule.
12. Secure cable to injection pump throttle lever.
Use new split pin to secure clevis.
13. Adjust throttle cable.
See Adjustment,
Throttle cable
THROTTLE PEDAL
Service repair no - 19.20.01
Remove
1. Remove throttle cable from pedal.
See Throttle
cable
2. Remove 6 bolts securing throttle pedal assembly
to engine bulkhead.
3. Remove pedal assembly from footwell, complete
with trim retainer.
4. Release return spring from pedal lever.
5. Remove roll pin securing pivot shaft to pedal
assembly.
6. Withdraw pivot shaft and remove pedal from
mounting bracket.
7. Remove return spring from pedal boss.
Refit
8. Fit return spring to pedal boss.
9. Fit pedal to mounting bracket and locate return
spring.
10. Fit pivot shaft to pedal assembly and secure with
roll pin.
11. Locate return spring on pedal lever.
12. Secure throttle pedal assembly and trim retainer
to bulkhead. Tighten bolts to
9 Nm (7 lbf/ft).
13. Fit throttle cable to pedal.
See Throttle cable
14. Adjust pedal, if necessary.
See Adjustment,
Throttle pedal adjustment
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19
FUEL SYSTEM
14
REPAIR
TURBOCHARGER INLET HOSE
Service repair no - 19.42.11
Remove
1. Disconnect battery.
2. Slacken retaining clip and disconnect intake
hose from turbocharger.
3. Slacken retaining clip and disconnect hose from
air cleaner.
4. If fitted, disconnect EGR modulator valve
vacuum spill pipe from inlet hose.
5. Slacken retaining clip and disconnect breather
valve hose from inlet hose.
6. Remove inlet hose.
Refit
7. Fit inlet hose to air cleaner.
8. Fit cyclone breather hose to inlet hose.
9. If applicable, fit vacuum spill pipe to inlet hose.
10. Fit inlet hose to turbocharger.
11. Reconnect battery.
TURBOCHARGER OIL FEED PIPE
Service repair no - 19.42.14
Remove
1. Disconnect battery.
2. Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
front pipe
3. Remove banjo bolt securing oil feed pipe to
turbocharger and discard 2 joint sealing
washers.
4. Unscrew union and remove feed pipe from
cylinder block.
5. Plug connections to prevent ingress of dirt.
Refit
6. Using new joint washer, fit oil feed pipe to
cylinder block. Tighten union connector to
25
Nm (18 lbf/ft).
7. Fit a new joint washer to both sides of banjo and
secure feed pipe to turbocharger. Tighten banjo
bolt to
20 Nm (15 lbf/ft).
8. Fit exhaust front pipe.
See MANIFOLD AND
EXHAUST SYSTEM, Repair, Exhaust front
pipe
9. Check/top-up engine oil level.
See SECTION
10, Maintenance, Under bonnet maintenance
10. Reconnect battery.
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FUEL SYSTEM
15
REPAIR
TURBOCHARGER OIL DRAIN PIPE
Service repair no - 19.42.12
Remove
1. Disconnect battery.
2. Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
front pipe
3. Unscrew union and disconnect oil drain pipe
from cylinder block.
4. Remove 2 bolts securing oil drain pipe to
turbocharger.
5. Remove drain pipe and discard gasket.
6. Plug connections to prevent ingress of dirt.
Refit
7. Ensure mating surfaces of oil pipe, turbocharger
and engine block are clean.
8. Using new gasket, fit oil drain pipe to
turbocharger. Tighten bolts to
25 Nm (18 lbf/ft).
9. Fit drain pipe to cylinder block and tighten union
connector to
38 Nm (28 lbf/ft).
10. Fit exhaust front pipe.
See MANIFOLD AND
EXHAUST SYSTEM, Repair, Exhaust front
pipe
11. Check/top-up engine oil level.
See SECTION
10, Maintenance, Under bonnet maintenance
12. Reconnect battery.
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