Fuel relief valve — removal and installation (Defender 2007+)

Removal

Warnings:

• Some fuel will inevitably spill during this operation. Make sure that all necessary precautions are taken to prevent fire and explosion.
• Do not carry or use a cell phone while working with or in the immediate vicinity of any fuel related components. There is a risk of ignition of flammable vapors. Failure to follow these instructions may result in injury.
• Do not smoke or carry a lighted cigarette or open flame of any type when working on or near fuel-related components. There is a risk of ignition of flammable vapors. Failure to follow these instructions may result in injury.
• If fuel gets into your eyes, rinse them with cold water or a special eye wash solution and seek medical attention immediately.
• Wash your hands thoroughly after handling fuel, as prolonged contact with the skin may cause irritation. If irritation occurs, seek medical attention.
• Do not perform any repairs to the fuel system while the engine is running. Fuel pressure in the system can reach 2000 bar. Failure to follow this instruction may result in injury.

CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very small clearances. Therefore, absolute cleanliness is required when working on these components. Be sure to insert new plugs into all open ports and lines. Failure to do so may result in dirt entering the fuel injection system.

1. Disconnect the ground wire from the battery.

For more information, refer to the chapter: Disconnecting and connecting the battery (414-01 Battery, Battery Mounting and Cables, General Procedures).



2. Using a vacuum cleaner, remove foreign material from the high-pressure fuel supply lines, fuel rails and high-pressure fuel pump.

For more information, refer to the chapter: Cleaning the fuel injection system components (303-04A Fuel Delivery and Controls - ID4 2.4L Diesel Engine, General Procedures).

3. Remove the coupling sleeve.



4. Remove and discard the fuel relief valve.



5.

CAUTION: Ensure that the mating surfaces of the fuel rail are not damaged. Failure to follow this instruction may result in component damage.

Remove the gasket and dispose of it.

Installation

1.

CAUTION: Ensure that the mating surfaces of the fuel rail are not damaged. Failure to follow this instruction may result in component damage.

Install a new gasket. Clean the contact surfaces of the parts.



2. Install a new fuel rail pressure relief valve. Tighten (tightening torque 30 Nm).



3. Draw a line on the corner of the fuel relief valve (1) and on the side of the fuel manifold (2).



4. Draw line (3) 3 mm from line (2)





5. Tighten the fuel relief valve and make sure line 1 is aligned with line 3. Tighten (tightening torque 172 Nm).



6. If line (1) does not align with line (3), remove the fuel relief valve and inspect it for contamination and damage to the threads for connection to the fuel manifold. Reassemble starting with step 2.

7.

NOTE: Remove and discard plugs.

Install the connecting fitting.

• Clean the contact surfaces of the parts.
• Tighten it up (tightening torque 20 Nm).

8. Connect the ground wire to the battery.



For more information, refer to the chapter: Connecting the Battery (414-01 Battery, Battery Mounting and Cables, General Procedures).

9. Check the fuel system for leaks using a Land Rover approved diagnostic system.