1999 LAND ROVER DEFENDER fuel pump

01INTRODUCTION
10
INFORMATION CROSS REFERENCE OF EMISSION SYSTEM
TERMINOLOGY
NEW TERM (ACRONYM)
Accelerator pedal (AP).................................................
Air cleaner (ACL)..........................................................
Air conditioning (A/C)...................................................
Battery positive voltage (B+)........................................
Closed loop (CL)..........................................................
Closed throttle position (CTP)......................................
Canister purge valve (CANPV)....................................
Data link connector (DLC)...........................................
Diagnostic trouble code (DTC).....................................
Distributor ignition (DI).................................................
Engine control module (ECM)......................................
Engine coolant level (ECL)...........................................
Engine coolant temperature (ECT)..............................
Engine speed (RPM)....................................................
Evaporative emission system (EVAP)..........................
Engine fuel temperature sensor (EFTS)......................
4th gear, 3rd gear etc. (4GR, 3GR)..............................
Fuel pump (FP)............................................................
Fan control module (FCM)...........................................
Generator (GEN)..........................................................
Ground (GND)..............................................................
Heated oxygen sensor (H02S)....................................
Idle air control (IAC)......................................................
Idle air control valve (IACV).........................................
Ignition control module (ICM).......................................
Intake air temperature (IAT).........................................
Manifold vacuum zone (MVZ)......................................
Mass air flow sensor (MAF).........................................
Open loop (OL)............................................................
Relay module (RM)......................................................
Solid state relay module (SSRM).................................
Three way catalytic converter (TWC)..........................
Throttle body (TB)........................................................
Throttle position sensor (TP)........................................
Transmission range (TR)..............................................
Wide open throttle (WOT)............................................OLD TERM (ACRONYM)
Throttle pedal (-)..........................................................
Air cleaner (-)...............................................................
Air conditioning (AC)....................................................
Battery plus, bat +, bat feed (B+).................................
Closed loop (-).............................................................
Closed throttle, idle position (-)....................................
Charcoal canister purge valve (-).................................
Serial link (-)................................................................
Fault code (-)...............................................................
Electronic ignition (-)....................................................
Electronic control unit (ECU)........................................
Coolant level (-)...........................................................
Coolant temperature (temp).........................................
Coolant temperature thermistor (-)..............................
Engine speed (rev/min)................................................
Evaporative loss system (ELC)...................................
Fuel temperature thermistor (-)....................................
Fourth gear, 3rd gear (-)..............................................
Fuel pump (-)...............................................................
Condenser fan timer (-)................................................
Alternator (-)................................................................
Ground, earth (B-)........................................................
Lambda (02) sensor (-)................................................
Idle speed control (ISC)................................................
Stepper motor (-).........................................................
Ignition module (-)........................................................
Intake temperature/ambient temperature (-)................
Manifold depression, vacuum (-).................................
Air flow meter (-)..........................................................
Fault code display unit (-)............................................
Open loop (-)...............................................................
Relay (-).......................................................................
Control unit (-)..............................................................
Catalyst, catalytic converter (CAT)..............................
Throttle housing (-)......................................................
Transmission gear (-)...................................................
Full throttle, wide open throttle (WOT).........................
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GENERAL SPECIFICATION DATA
3
INFORMATION FUEL SYSTEM - Td5
Type Direct injection from pressure regulated supply with.................................................................................
cooled return flow
Pressure regulator setting 4 bar (58 lbf.in
2) ................................................
Pump Electric two stage submersible................................................................................
Pump output
Low pressure 30 l/h (6.6 gal/h) at 0.5 bar (7.25 lbf.in
2) ..........................................................
High pressure 180 l/h (39.6 gal/h) at 4 bar (58 lbf.in2) ..........................................................
Max consumption 30 l/h (6.6 gal/h).............................................................
Injectors Electronic unit injectors...........................................................................
Injector normal operating pressure 1500 bar (21750 lbf.in
2) ..................................
Filter In-line canister filter/water separator with water.................................................................................
detection
COOLING SYSTEM - Td5
Type Pressurised spill return partial flow, thermostatically.................................................................................
controlled
Cooling fans 11 blade axial flow on viscous coupling and 11 blade.....................................................................
axial flow electric
Electric cooling fan switching points
On Vehicle speeds of 50 mph (80 km/h) and below while...........................................................................
ambient temperature is 28°C (82°F) or above
Off Vehicle speeds of 62.5 mph (100 km/h) and above or...........................................................................
ambient temperatures of 25°C (77°F) and below
Coolant pump Centrifugal impeller, belt driven from crankshaft...................................................................
Thermostat Waxstat with pressure relief valve.......................................................................
Thermostat opening temperature
Initial opening 82°C (179°F) ..........................................................
Fully open 96°C (204°F) ...............................................................
Expansion tank cap relief valve operating pressure 1.4 bar (20.3 lbf.in
2) .........
CLUTCH - Td5
Type Diaphragm spring, hydraulically operated with.................................................................................
self-centering pre-loaded release bearing
Drive plate diameter 267 mm.........................................................
Pressure plate diameter 270 mm...................................................
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GENERAL SPECIFICATION DATA
5
INFORMATION STEERING
Power steering box
Make/type Adwest Varamatic - worm and roller box........................................................................
Ratio Variable: straight ahead 19.3:1 on lock 14.3:1.................................................................................
Steering wheel turns, lock-to-lock 3.375....................................
Steering pump
Make/type Hobourn-Eaton series 500........................................................................
Steering geometry
Steering wheel diameter 412 mm (16.22 in)..................................................
Toe-out measurement 0 to 2 mm toe out......................................................
Toe-out included angle 0°to 0°20’ .....................................................
Camber angle 0°* ..................................................................
Castor angle 3°* .....................................................................
Swivel pin inclination static 7°* ...............................................
* Check with vehicle on level ground, in unladen
condition and five gallons of fuel. Rock the front of the
vehicle up and down to allow it to take up a normal
static position.
Turning circle between kerbs
90 models:
265/75 x 16 tyres 12,65 m (41.5 ft)..............................................................
All other tyres 11,70 m (38.4 ft)...................................................................
110 models:
750 x 16 tyres 13,41 m (44 ft)..................................................................
130 models:
750 x 16 tyres 15,24 m (50 ft)..................................................................
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ENGINE
25
DESCRIPTION AND OPERATION CYLINDER HEAD COMPONENTS
The cylinder head components are described below:
Cylinder head
The cylinder head is of aluminium construction. It is not possible to reface the cylinder head if it becomes worn or
damaged. An alloy camshaft carrier is bolted directly to the upper surface of the cylinder head. Two dowels are
included in the cylinder head upper face for correct location of the camshaft carrier.
The EU3 cylinder head has a single internal fuel rail for delivering fuel to the injectors and an external fuel pipe for
returning spill fuel back to the fuel connector block. Therefore, pre EU3 and EU3 cylinder heads are not
interchangeable.
CAUTION: The cylinder head incorporates drillings for the fuel injection system, any
contamination which enters these drillings could cause engine running problems or injector
failure. It is therefore, essential that absolute cleanliness is maintained when carrying out work on
the cylinder head.
The camshaft carrier and cylinder head assembly is attached to the cylinder block by twelve cylinder head
retaining bolts which pass through the camshaft carrier and the cylinder head to secure the assembly to the
cylinder block.
CAUTION: The valve heads, tips of the injectors and glow plugs protrude below the face of the
cylinder head and will be damaged if the cylinder head is stored face down.
The camshaft is located between the cylinder head and the camshaft carrier, and the bearing journals are line
bored between the two components to form a matched pair.
CAUTION: Always fit plugs to open connections to prevent contamination.
The valve guides and valve seat inserts are sintered components which are an interference fit to the cylinder
head. The cylinder head machining also provide the locations for the electronic unit injectors, glow plugs, hydraulic
lash adjusters, finger followers and low pressure fuel rail.
Cooling to the cylinder head is provided by coolant flow through a water jacket machined into the cylinder head.
Drillings through the block provide lubrication channels for pressurised oil supply to cylinder head components
such as the lash adjusters, finger followers, rocker arms and camshaft bearings.
A coolant outlet elbow is fitted to the front LH side of the cylinder head to allow flow of coolant from the cylinder
head back to the radiator. A metal gasket is used to seal the joint between the water outlet elbow and the cylinder
head. A coolant temperature sensor is located in a port in the side of the water outlet elbow for monitoring coolant
temperature.
A stub pipe is connected at the front RH side of the cylinder block above the timing cover which connects a pipe to
supply oil to the vacuum pump. The timing chain tensioner adjuster is screwed in a thread in the cylinder head at a
location on the front RH side of the engine below the oil feed port for the vacuum pump.
An access hole for the camshaft gear is included at the front of the cylinder head which is sealed with a plastic
plug and rubber’O’ring. A press-fit core plug for the chain chest is located on the front face of the cylinder head.
A press-fit core plug for the cylinder head water jacket is located at the rear of the cylinder head and a threaded
brass plug for the water jacket is located on the LH side of the cylinder head beneath the exhaust manifold
assembly.
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ENGINE
15
REPAIR
NOTE: Non EU3 model illustrated.
9.Disconnect fuel hoses, tank to fuel cooler and
connector block on cylinder head.
CAUTION: Plug the connections.
10.Disconnect fuel hose from fuel cooler and secure
to connector block on cylinder head. This to
prevent contamination of the fuel system.
11.Release servo vacuum pipe, remove 4 bolts and
remove fuel cooler.
12.Release servo vacuum pipe from engine rear
cover clips and vacuum pump.
NOTE: Non EU3 model illustrated.
13.Disconnect vacuum hose from EGR valve.
14.Release EGR vacuum hose from vacuum pipe.
15.Disconnect multiplug from condensor cooling
fan.
NOTE: Non EU3 model illustrated.
16.Disconnect multiplugs from EGR solenoid, inlet
manifold sensor and injector harness.
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12ENGINE
18
REPAIR
35.Remove 2 bolts and remove acoustic cover from
rear of cylinder head.
36.FitLRT-12-138to suitable lifting chains and
connect to lifting eyes on engine.
37.Remove 2 nuts from RH and LH front engine
mountings.
38.Fit trolley jack to support gearbox.
39.With assistance raise chains and remove engine
from vehicle.Refit
40.With assistance, raise engine from bench and
position in vehicle.
41.With assistance, align engine to gearbox input
shaft.
42.Position 2 upper bolts securing gearbox housing
to engine and tighten to50 Nm (37 lbf.ft).
43.Lower engine onto mountings and tighten nuts to
85 Nm (63 lbf.ft).
44.RemoveLRT-12-138from engine.
45.Fit and tighten bolt securing engine closing panel
to gearbox.
46.Raise vehicle on ramp.
47.Fit bolts securing gearbox housing to engine and
tighten to50 Nm (37 lbf.ft).
48.Lower ramp.
49.Fit acoustic cover to rear of cylinder head and
tighten bolts.
50.Position coolant hose to engine oil cooler and
secure clip.
51.Position PAS pump and tighten bolts to25 Nm
(18 lbf.ft).
52.Position PAS pulley and tighten bolts to25 Nm
(18 lbf.ft).
53.Position A/C compressor and tighten bolts to25
Nm (18 lbf.ft).
54.Route engine harness beneath inlet manifold
and connect multiplugs to oil pressure switch,
A/C compressor, and ECT sensor.
55.Fit and tighten bolts securing engine harness to
camshaft carrier.
56.Connect multiplug to alternator.
57.Connect battery lead to alternator and tighten
nut.
58.Clean CKP sensor and mating face.
CAUTION: If originally fitted:- Fit spacer to
CKP sensor.
59.Using a new’O’ring, fit CKP sensor, tighten bolt
to10 Nm (7 lbf.ft).
60.Connect CKP sensor multiplug.
61.Connect multiplugs to EGR solenoid, inlet
manifold sensor, injector harness, fuel
temperature sensor and CKP sensor.
62.Connect glow plug leads.
63.Connect multiplug to condensor cooling fan.
64.Connect vacuum hose to EGR valve.
65.Connect EGR vacuum hose to vacuum pipe.
66.Position pipe to vacuum pump and secure pipe
to acoustic cover clips.
67.Position fuel cooler. Apply Loctite 242 to bolts
and tighten to18 Nm (13 lbf.ft).
68.Disconnect fuel hose from connector block and
connect to fuel cooler.
69.Connect fuel hoses to fuel cooler and connector
block on cylinder head.
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12ENGINE
6
OVERHAUL 14.Clean fixed guide Allen screw and apply Loctite
242 to screw threads.
15.Fit fixed timing chain guide Allen screw and
tighten to25 Nm (18 lbf.ft).
16.Clean timing chain tensioner and fit new sealing
washer.
17.Fit timing chain tensioner and tighten to45 Nm
(33 lbf.ft).
18.Tighten camshaft sprocket bolts to36 Nm (27
lbf.ft).
19.Remove toolLRT-12-058from camshaft.
20.Lubricate a new’O’ring with engine oil and fit to
camshaft sprocket access plug.
21.Fit camshaft sprocket access plug.
22.Clean alternator/vacuum pump oil feed hose
union.
23.Lubricate a new’O’ring with engine oil and fit to
alternator/vacuum pump hose union.
24.Fit and tighten alternator/vacuum pump oil hose
union to10 Nm (7 lbf.ft).
25.Fit bolt securing alternator strap bracket to
cylinder head and tighten to25 Nm (18 lbf.ft).
26.Connect multiplugs to ECT sensor and EUIs.
CAUTION: Following cylinder head
overhaul, it will be necessary, before
fitting the camshaft cover, to adjust the
fuel injector rockers using the following
procedures:
27.Rotate engine clockwise until No. 1 EUI lobe is
at full lift.
28.Tighten No.1 rocker adjusting screw until the EUI
plunger is felt to’bottom out’.
29.Loosen rocker adjusting screw 1 complete turn
to give EUI plunger the required bump clearance
and tighten rocker adjusting screw locknut to16
Nm (12 lbf.ft).
CAUTION: Ensure screw does not turn as
locknut is tightened.30.Carry out above procedures for the remaining 4
rocker arms.
31.After completion of rocker adjustment, slowly
rotate engine clockwise 2 complete turns by
hand to ensure that no EUI’s are bottoming out
on their plungers.
32.Clean camshaft cover and mating face.
33.Fit new sealing washers and isolators as
necessary to camshaft cover.
34.Fit new camshaft cover gasket to cover.
CAUTION: Gasket must be fitted dry.
35.Fit camshaft cover to camshaft carrier, fit bolts
and working from the centre outwards, tighten
bolts to10 Nm (7 lbf.ft).
36.Fit inlet manifold gasket.See MANIFOLD AND
EXHAUST SYSTEM, Repair.
37.Fit exhaust manifold gasket.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
38. EGR cooler fitted:-Position EGR pipe to cooler,
fit new Allen screws and tighten to10 Nm (7
lbf.ft).
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18 - ENGINE MANAGEMENT SYSTEM
CONTENTS
Page
DESCRIPTION AND OPERATION
COMPONENT LOCATION 2...................................................................................
DESCRIPTION 5.....................................................................................................
ENGINE CONTROL MODULE (ECM) 6.................................................................
SENSOR - MASS AIR FLOW (MAF) 7....................................................................
SENSOR - AMBIENT AIR PRESSURE AND 8.......................................................
SENSOR - MANIFOLD ABSOLUTE PRESSURE 9................................................
SENSOR - ENGINE COOLANT TEMPERATURE 11.............................................
SENSOR - CRANKSHAFT SPEED AND 12...........................................................
SENSOR - THROTTLE POSITION (TP) 14............................................................
SENSOR - THROTTLE POSITION (TP) 15............................................................
ELECTRONIC UNIT INJECTOR (EUI) 18...............................................................
SENSOR - FUEL TEMPERATURE (FT) 20............................................................
RELAY - FUEL PUMP 21........................................................................................
RELAY - MAIN 21...................................................................................................
SWITCH - BRAKE PEDAL 22.................................................................................
SWITCH - CLUTCH PEDAL 22...............................................................................
MODULATOR - EXHAUST GAS REGULATOR (EGR) 23.....................................
WARNING LAMP - GLOW PLUG 23......................................................................
GLOW PLUGS 24...................................................................................................
TURBOCHARGER 26.............................................................................................
INTERCOOLER 27.................................................................................................
OPERATION 28......................................................................................................
REPAIR
ENGINE CONTROL MODULE (ECM) 1.................................................................
SENSOR - ENGINE COOLANT TEMPERATURE (ECT) 1....................................
SENSOR - CRANKSHAFT SPEED AND POSITION (CKP) 2................................
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