Range Rover Classic. Manual — part 46
19
FUEL SYSTEM
14
REPAIR
RAM HOUSING
Service repair no - 19.70.04
Remove
1. Disconnect battery negative lead.
2. Remove plenum chamber.
See Plenum
Chamber
3. Release hoses from ram housing.
4. Remove six through bolts (with plain washers)
securing ram housing to intake manifold.
5. Remove ram housing from intake manifold.
6. Place a protective cover over inlet bores to
prevent ingress of dirt.
Refit
7. Clean all mating faces.
8. Apply ’Hylomar’ sealant to intake manifold face.
9. Fit ram housing. Tighten bolts, working from two
centre bolts, diagonally towards outer four bolts.
10. Tighten to
26 Nm.
INTAKE MANIFOLD
Service repair no - 30.15.08
Remove
1. Depressurise fuel system.
See Depressurising
Fuel System
2. Disconnect battery negative lead.
3. Drain cooling system.
See COOLING SYSTEM,
Repair, Radiator
4. Remove plenum chamber.
See Plenum
chamber
5. Remove ram housing.
See Ram Housing
CAUTION: Place a protective cover over
intake manifold openings to prevent the
ingress of dirt.
6. Disconnect the fuel temperature sensor and
injector multiplugs.
7. Remove fuel pressure regulator.
See Fuel
Pressure Regulator
8. Disconnect multiplug from coolant temperature
sensor.
9. Disconnect instrument pack temperature
thermistor.
10. Disconnect coolant sensor multiplug.
MFI
15
REPAIR
11. Loosen clip and disconnect top hose from
thermostat housing.
12. Disconnect multiplug from distributor amplifier
module.
13. Loosen clip and disconnect hose from heater
valve.
14. Remove injector harnesses from behind fuel rail
and lay to one side.
15. Loosen union and disconnect fuel return hose
from fuel rail.
NOTE: The intake manifold can be
removed from the cylinder block without
removing the fuel rail and injectors.
16. Using the sequence shown, remove 12 bolts
securing the intake manifold to cylinder block.
17. Remove the intake manifold.
18. Noting their fitted position, remove bolts and
clamps securing intake manifold gasket to
cylinder block.
19. Remove and discard gasket.
20. Remove and discard gasket seals.
Do not carry out further dismantling if component
is removed for access only.
21. Remove 5 nuts securing fuel rail support
brackets to intake manifold.
22. Remove fuel rail and injectors.
23. Remove 2 bolts securing thermostat housing to
intake manifold.
24. Remove thermostat housing.
25. Remove bolt securing coolant pipe to intake
manifold. Loosen union and remove coolant
pipe. Remove and discard ’O’ ring.
26. Fit new ’O’ ring to coolant pipe. Position coolant
pipe to intake manifold. Fit bolt securing coolant
pipe support bracket to intake manifold and
tighten pipe union.
27. Clean mating faces of thermostat housing and
intake manifold.
28. Fit thermostat housing to intake manifold using a
new gasket, fit and tighten bolts.
29. Position fuel rail to intake manifold, fit and
tighten retaining bolts.
19
FUEL SYSTEM
16
REPAIR
Refit
1. Clean mating faces of cylinder heads, cylinder
block and intake manifold.
2. Locate NEW seals in position with ends
engaged in notches formed between the cylinder
heads and block.
3. Apply RTV sealant between ends of seals,
cylinder head and block.
4. Fit intake manifold gasket with the word
’FRONT’ to the front and open bolts hole to the
front RH side.
5. Fit gasket clamps and tighten bolts finger tight.
6. Locate intake manifold onto cylinder heads,
clean threads of manifold securing bolts.
7. Allow 10 minutes for RTV sealant to cure.
8. Fit manifold bolts finger tight. Working in the
sequence shown tighten the bolts to
38 Nm.
9. Tighten the gasket clamp bolts to
18 Nm.
10. Reverse removal procedure.
11. Fill cooling system.
See COOLING SYSTEM,
Repair, Radiator
12. Start engine check for water and fuel leaks.
MFI
17
REPAIR
FUEL FILTER
Service repair no - 19.25.02
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 are strictly adhered to when
carrying out following instructions.
1. Depressurise fuel system.
See Depressurising
Fuel System
2. Access to filter is gained through right hand rear
wheel arch.
3. Clean area around hose connections to prevent
ingress of foreign matter into fuel system. Clamp
inlet and outlet hoses to prevent fuel spillage
when disconnecting hoses.
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
filter from chassis side member.
Refit
6. Fit a new filter observing direction of flow arrows
stamped on canister.
7. Tighten securing nut and bolt.
8. Fit inlet and outlet hoses. Tighten to
30Nm.
9. Refit fuel pump relay module, reconnect battery.
10. Start engine and inspect for fuel leaks around
hose connections.
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