Land Rover Defender: Fuel Fired Booster Heater Fuel Pump

REMOVAL AND INSTALLATION

GENERAL EQUIPMENT

REMOVAL

CAUTIONS:

• Be prepared to collect escaping fluids.
• Protect the surrounding paintwork to avoid damage.
• Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.
• Make sure the Fuel Fired Booster Heater (FFBH) operates correctly after pump replacement by conducting an Activation Test through SDD.
• When installation of the FFBH has been completed and the coolant system fully degassed, the FFBH MUST be run continually for a minimum of 15 minutes to make sure all traces of residual fuel, coolant or oil on the FFBH and exhaust resulting from the installation process are removed. Failure to do this may result in the FFBH creating excessive smoke/odours which may be detected by the customer.
• When done, the FFBH must be run continually for a minimum of 5 minutes to make sure the fuel system is primed, fully degassed and that the FFBH operates without issue.

NOTES:

• This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
• This procedure contains illustrations showing certain components removed to provide extra clarity.
• All vehicles.

1. Always follow the fuel system health and safety precautions when doing any repairs to the fuel system.

NOTE: Vehicles with 7 seats.

2. Remove the second row right seat.

3. Disconnect the startup battery ground cable.

4.

Reposition the carpet for access.

NOTE: Vehicles with 5 seats.

5. Disconnect the startup battery ground cable.

6.

Fold up the second row seat 2 cushions.

7.

• Remove the 4 bolts.
• Remove the Noise, Vibration and Harshness (NVH) material.

8.

• Remove the 5 clips.
• Remove the 16 bolts.
• Reposition the carpet.
• Remove the second row seat cushion plate.

9.

• Cut the NVH material as illustrated.
• Reposition the NVH material.

NOTE: All vehicles.

10.

• Release the wiring harness cover at the 4 clips.
• Release the wiring harness from the 2 clips.

11.

• Remove the 5 nuts.
• Release the fuel pump module access cover.
• Reposition the access cover to get access to the FFBH fuel pump.

12.

Disconnect the breather pipe.

13.

• Disconnect the electrical connector from the fuel pump of the FFBH.
• Disconnect the 2 fuel line connectors from the FFBH fuel pump.
• Remove the bolt.
• Remove the FFBH fuel pump.

INSTALLATION

NOTE: All vehicles.

1.

• Install the fuel pump of the Fuel Fired Booster Heater (FFBH).
• Install and tighten the bolt.

  Torque: 9Nm

• Connect the 2 fuel line connectors to the FFBH fuel pump.
• Connect the electrical connector to the FFBH fuel pump.

2. Connect the breather pipe.

3.

• Position the fuel pump module access cover.
• Install and tighten the 5 nuts.

  Torque: 6Nm

• Install the wiring harness to the 2 clips.
• Install the wiring harness cover to the 4 clips.

NOTE: Vehicles with 7 seats.

4. Position the carpet.

5. Connect the startup battery ground cable.

6. Install the second row right seat.

NOTE: Vehicles with 5 seats.

7. Position the Noise, Vibration and Harshness (NVH) material.

8.

• Install the second row seat cushion plate.
• Install and tighten the 16 bolts.

  Torque: 10Nm

• Install the 5 clips.
• Position the carpet.

9.

• Install the NVH material.
• Install and tighten the 4 bolts.

  Torque: 10Nm

10. Fold down the second row seat 2 cushions to the original position.

11. Connect the startup battery ground cable.

NOTE: All vehicles.

12. Use the Jaguar Land Rover (JLR) approved diagnostic equipment perform the HVAC Control Module routine 9010 FFBH activation test. This will activate the FFBH in full, half and idle mode. As a result the engine coolant temperature will be raised to a level set by the HVAC.

General Equipment: Jaguar Land Rover approved diagnostic equipment

READ NEXT: