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Defender 300Tdi (1996+). Manual - part 26

FUEL SYSTEM

REPAIR

FUEL LIFT PUMP

Service repair no - 19.45.09

Remove

NOTE: Blank off pipe ends and
connections to prevent ingress of dirt.

1. Disconnect battery.
2. Remove high pressure fuel pipes, injection pump

to injectors.

3. Disconnect fuel inlet and outlet pipes from lift

pump.

4. Remove 2 bolts and withdraw lift pump and

gasket from cylinder block.

Refit

5. Clean mating faces of pump and cylinder block.
6. Fit lift pump to cylinder block with a new gasket,

ensure correct location of operating lever with
camshaft.

7. Secure with bolts. Tighten to

25 Nm (18 lbf/ft).

8. Connect inlet and outlet pipes using new nuts

and olives.

9. Refit injector pipes. Tighten union nuts to

28 Nm

(21 lbf/ft).

FUEL SEDIMENTOR

Service repair no - 19.25.01

Remove

1. Disconnect battery.

2. Disconnect inlet and outlet fuel pipes from

sedimentor.

3. Slacken drain tap and allow sedimentor to

completely drain.

4. Remove 2 bolts, washers and nuts and detach

sedimentor from chassis mounting bracket.

Refit

5. Secure sedimentor to chassis mounting with

fixing bolts.

6. Reconnect inlet and outlet fuel pipes to

sedimentor.

7. Slacken drain plug until diesel free from air

flows, then retighten plug.

8. Prime vehicle fuel system.

See Adjustment,

Priming the fuel system

9. Reconnect battery.

FUEL SYSTEM

REPAIR

FUEL FILTER ASSEMBLY

Service repair no - 19.25.02

Remove

1. Disconnect battery.

2. Place a suitable container under filter element

and slacken filter bleed screw.

3. Slacken drain tap and allow fuel to drain from

filter element.

4. Slacken fuel inlet and outlet banjo connections.
5. Remove 2 bolts and nuts securing filter head to

inner wing.

6. Remove fuel inlet and outlet banjo bolts and

detach fuel pipes.

7. Remove filter assembly from vehicle. Unscrew

filter element, if necessary.

8. Plug fuel pipe ends to prevent ingress of dirt.

Refit

9. Position filter assembly and fit fuel inlet and

outlet pipes using new copper sealing washers
both sides of the banjo connections.

10. Secure filter head to inner wing.
11. Fully tighten banjo connections.
12. Prime fuel system to remove any air trapped in

filter

See Adjustment, Priming the fuel

system

13. Reconnect battery.

FUEL FILTER ELEMENT

Service repair no - 19.25.07

For remove and refit procedure.

See Fuel filter

element

FUEL SYSTEM

REPAIR

SIDE MOUNTED FUEL TANK

Service repair no - 19.55.05

NOTE: This fuel tank is standard on 90
models and an option on 110/130 2 door
vehicles fitted with twin tanks.

Remove

WARNING: Before any attempt is made to
start the removal procedure it is vital that
the FUEL HANDLING PRECAUTIONS are

carefully studied and implemented in the interests
of safety.

See INTRODUCTION, Information, Fuel

Handling Precautions

1. Disconnect battery.
2. Remove fuel filler cap.

3. Remove fuel tank drain plug, allow fuel to drain

into a clean container and refit plug.

4. Remove RH seat cushion.
5. Release retaining catch and remove seat base

cover to gain access to fuel tank.

6. Disconnect electrical plug from fuel gauge unit.
7. Disconnect fuel supply pipe from tank.
8. Disconnect spill return pipe from fuel tank.
9. Disconnect breather pipe from fuel filler tube.

10. Slacken hose clip and remove filler hose from

filler tube.

11. From rear of tank, remove 2 nuts and washers

securing tank mounting to captive-headed bolts.

12. Support rear of fuel tank and remove captive

bolts.

FUEL SYSTEM

REPAIR

13. Remove single bolt fixing assembly securing

front of tank to chassis mounted bracket.

14. Remove 3 bolts securing tank mounting bracket

to chassis and release bracket.

15. Lower front of tank while turning anti-clockwise

and remove from vehicle.

16. If required, remove tank gauge unit.

See

INSTRUMENTS, Repair, Fuel gauge tank unit
- side fuel tank or See INSTRUMENTS,
Repair, Fuel gauge tank unit - rear fuel tank,
110/130

Refit

17. Fit filler hose and clip to tank but do not fully

tighten. Position clip screw so that it is
accessible when tank is fitted.

18. Fit breather hose and secure with clip.
19. Position fuel tank in vehicle and loosely secure

front mounting bracket to tank with special bolt
and rubber bushes.

20. Secure mounting bracket to chassis with 3 bolts

and fully tighten to

20 Nm (15 lbf/ft).

21. Secure rear of tank to chassis mounting and

tighten captive bolt plate fixings to

20 Nm (15

lbf/ft).

22. Fully tighten front fixing bolt assembly to

20 Nm

(15 lbf/ft).

23. Fit spill return and fuel supply pipes and secure

union connections.

24. Fit fuel level unit electrical plug.
25. Fit hose to filler tube and tighten upper and lower

clips.

26. Check that drain plug is secure and fill fuel tank.
27. Reconnect battery.
28. Prime fuel system

See Adjustment, Priming

the fuel system and start engine.

29. Check system for leaks and operation of fuel

gauge.

30. Fit seat base cover and seat cushion.

SIDE MOUNTED FUEL TANK - 5 DOOR VEHICLES

Service repair no - 19.55.01

NOTE: This fuel tank is used on 110/130 5
door vehicles fitted with a twin tank
option.

WARNING: Before any attempt is made to
start the removal procedure it is vital that
the FUEL HANDLING PRECAUTIONS,

See

INTRODUCTION, Information, Fuel handling
precautions are carefully studied and
implemented in the interests of safety.

Remove

1. Disconnect battery.
2. Remove tank drain plug, allow fuel to drain into a

clean container, and refit plug.

3. Remove RH seat cushion.
4. Remove retaining catch and remove seat base

cover to gain access to fuel tank.

5. Disconnect electrical plug from fuel gauge unit.
6. Disconnect fuel supply pipe from tank.
7. Disconnect spill return pipe from tank.
8. Remove 3 bolts securing tank to front mounting

bracket.

9. Support front of tank and remove single fixing

assembly securing tank to rear mounting
bracket.

10. Remove tank from vehicle.
11. If required, remove fuel gauge unit.

See

INSTRUMENTS, Repair, Fuel gauge tank unit
- side fuel tank or See INSTRUMENTS,
Repair, Fuel gauge tank unit - rear fuel tank,
110/130

Refit

12. Position fuel tank in vehicle and loosely secure

to rear mounting bracket with special bolt and
rubber bushes.

13. Secure tank to front mounting bracket and

tighten fixings to

20 Nm (15 lbf/ft).

14. Fully tighten rear fixing bolt assembly to

20 Nm

(15 lbf/ft).

15. Fit spill return and fuel supply pipes to fuel tank

and securely tighten union connectios.

16. Fit electrical plug to fuel gauge unit.
17. Check that drain plug is secure and fill fuel tank.
18. Reconnect battery.
19. Prime fuel system.

See Adjustment, Priming

the fuel system and start engine.

20. Check system for leaks and operation of fuel

gauge.

21. Fit seat base cover and seat cushion.

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