300Tdi Discovery
19
FUEL SYSTEM
6
REPAIR
15. Disconnect hose, plug return hose and rail.
Remove cloth.
16. Remove 6 nuts securing fuel rail and ignition coil
bracket to inlet manifold.
17. Release ignition coil bracket from inlet manifold
studs. Place aside.
18. Release fuel rail and injectors from inlet
manifold.
Do not carry out further dismantling if component
is removed for access only.
19. Remove fuel rail and injectors.
20. Remove 2 bolts securing fuel pressure regulator
to fuel rail.
21. Remove pressure regulator assembly.
22. Remove ’O’ ring from fuel pressure regulator and
discard.
23. Remove 8 clips securing injectors to fuel rail.
24. Remove injectors from fuel rail.
25. Remove 2 ’O’ rings from each injector and
discard.
Refit
26. Ensure mating surfaces between inlet manifold
and ram pipe housing are clean.
27. Ensure all locations in fuel rail and inlet manifold
are clean.
28. Lubricate and fit new ’O’ rings to injectors and
fuel pressure regulator.
29. Fit fuel pressure regulator to fuel rail. Secure
with bolts. Tighten to
10 Nm.
30. Fit injectors to fuel rail. Secure with clips.
31. Position fuel rail to inlet manifold. Engage
injectors, one bank at a time.
32. Position ignition coil bracket on inlet manifold
studs.
33. Secure ignition coil bracket and fuel rail to inlet
manifold with nuts. Tighten to
8 Nm.
34. Remove plugs from fuel feed and return pipes
and rail.
35. Connect hose and tighten clip.
36. Clean feed pipe union and connect fuel feed
pipe to fuel rail. Tighten union to
16 Nm.
37. Connect multiplugs to fuel injectors and fuel
temperature sensor.
38. Remove cloth from inlet manifold.
39. Apply a thin, uniform coating of Loctite 577
sealant to mating face of inlet manifold.
40. Fit ram housing to inlet manifold. Secure with
bolts. Tighten to
24 Nm.
41. Connect purge hose, crankcase breather hose,
servo and pressure regulator vacuum hoses to
ram housing.
42. Fit plenum chamber.
See Plenum Chamber
43. Reconnect battery negative lead.
44. Start engine. Check for leaks around fuel rail and
injectors.
