1999 LAND ROVER DEFENDER ECO mode

FUEL SYSTEM
5
DESCRIPTION AND OPERATION FUEL PRESSURE REGULATOR
NOTE: Non EU3 Model illustrated.
1.Gasket
2.Housing
3.Bolt
4.Fuel feed union and pipe
5.Fuel return union and hose
6.Fuel temperature sensor
7.Bonded seal8.’O’ring
9.Circlip
10.Fuel pressure regulator
11.’O’ring
12.’O’ring
13.Gauze filter
The fuel pressure regulator is located in a cast alloy housing which is attached to the rear right hand corner of the
cylinder head with three flanged bolts and sealed with a metal gasket. Two ports in the housing connect with ports
in the cylinder head for fuel pressure feed and return. A gauze filter is located in the pressure feed port in the
cylinder head, and filters the fuel before it reaches the injectors. The filter is a fit for life item but can be changed if
required. An’O’ring is located in a recess in the cylinder head and provides additional sealing for the pressure
feed port between the gauze filter, the cylinder head, and the housing.
A union and pipe is attached to the feed port in the housing and connects with a quick release coupling to the fuel
pressure feed pipe from the fuel pump. A second union and hose is located in the return port and provides the fuel
return connection to the fuel cooler. A third port provides location for the fuel temperature sensor, which is sealed
to the housing with a bonded seal. The fuel temperature sensor is used by the ECM for engine management.
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MANIFOLD AND EXHAUST SYSTEM
5
REPAIR Refit
16.Clean inlet manifold and mating face.
17.Fit new gasket.
18.Fit inlet manifold, and working from the centre
outwards, tighten nuts and bolts to25 Nm (18
lbf.ft).
19.Position harness to sensors and connect
multiplugs.
20.Tighten harness clip bolts to camshaft carrier to
10 Nm (7 lbf.ft).
21.Clean dip stick tube and fit new’O’ring.
22.Fit dip stick tube and tighten bolt to10 Nm (7
lbf.ft).
23.Connect glow plug leads.
24.Fit alternator support bracket and tighten bolts to
45 Nm (33 lbf.ft).
25.Position fuel cooler. Apply Loctite 242 to bolts
and tighten to18 Nm (13 lbf.ft).
26.Fit new gasket, position EGR valve and tighten
bolts to9 Nm (7 lbf.ft).
27.Connect multiplug to MAP sensor.
28.Fit cooling fan cowl.
29.Fit engine acoustic cover.
30.Reconnect battery negative lead.
31.Fit battery cover.GASKET - EXHAUST MANIFOLD
Service repair no - 30.15.12
Remove
1.Remove turbocharger.See FUEL SYSTEM,
Repair.
2. Models with A/C:Remove auxiliary drive belt.
See ELECTRICAL, Repair.
3.Remove 4 bolts securing compressor and move
to one side.
All Models
NOTE: EU3 Model illustrated.
4.Remove and discard 2 Allen screws securing
EGR pipe to exhaust manifold.
5.Remove 10 nuts securing exhaust manifold to
cylinder head.
6.Remove exhaust manifold and gasket.
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FRONT AXLE AND FINAL DRIVE
1
OVERHAUL FRONT DIFFERENTIAL
Service repair no - 54.10.07.
Overhaul
NOTE: The front axle differential, for all
models, is the same as that fitted to the 90
rear axle and can only be serviced as a
complete assemblySee REAR AXLE AND FINAL
DRIVE, Repair. Differential assembly - 90.FRONT HUB
Service repair no - 60.25.14.
Overhaul
1.Remove hub assemblySee FRONT
SUSPENSION, Repair. Front hub bearings.
2.Remove outer bearing.
3.Mark, for reassembly, relationship between hub
and brake disc, if original hub is to be refitted.
4.Remove 5 bolts and separate hub from brake
disc.
5.Drift out grease seal and inner bearing from hub
and discard seal.
6.Drift out inner and outer bearing tracks.
7.Clean hub and drift in inner and outer bearing
tracks.
8.Pack hub inner bearing with recommended
grease and fit to hub.
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PANEL REPAIRS
1
INFORMATION BODY REPAIRS
Body shells are of riveted, bolted and welded
construction and are bolted to the chassis frame.
It is essential that design dimensions and strength are
restored in accident rectification. It is important that
neither structural weakness nor excessive local
stiffness are introduced into the vehicle during body or
chassis repair.
Repairs usually involve a combination of operations
ranging from straightening procedures to renewal of
either individual panels or panel assemblies. The
repairer will determine the repair method and this
decision will take into account a balance of economics
between labour and material costs and the availability
of repair facilities in both equipment and skills. It may
also involve considerations of vehicles down-time,
replacement vehicle availability and repair turn-around
time.
It is expected that a repairer will select the best and
most economic repair method possible, making use of
the facilities available. The instructions given are
intended to assist a skilled body repairer by expanding
approved procedures for panel replacement with the
objective of restoring the vehicle to a safe running
condition and effecting a repair which is visually
acceptable and which, even to the experienced eye,
does not advertise the fact that it has been damaged.
This does not necessarily mean that the repaired
vehicle will be identical in all respects with original
factory build. Repair facilities cannot always duplicate
methods of construction used during production.
The panel repairs shown in this section are all based
on a 110 Station Wagon. Therefore all illustrations
and text relate only to this model. Although certain
areas of the vehicle, such as the front end, are
relevant to all models.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and suspension
geometry checked after completion and if necessary a
road test of the vehicle is carried out, particularly
where safety related items are concerned.Where major units have been disconnected or
removed, it is necessary to ensure that fluid levels are
checked and topped up when necessary. It is also
necessary to ensure that the repaired vehicle is in a
roadworthy condition in respect of tyre pressures,
lights, washer fluid etc.
Body repairs often involve the removal of mechanical
and electrical units as well as associated wiring.
Where this is necessary use the relevant section in
this manual.
Taking into consideration the differences in body
styles, steering and suspension systems as well as
engine and suspension layouts, the location of the
following components as applicable to a particular
vehicle is critical:
Front suspension upper damper
mountings.
Front suspension or sub frame mountings.
Engine mountings on RH and LH chassis
longitudinals.
Rear suspension upper damper mountings.
Rear suspension mountings or lower
pivots.
Steering rack mountings.
Additional points which can be used to check
alignment and assembly are:
Inner holes in crossmember - side - main
floor.
Holes in valance front assembly.
Body to chassis mounting holes.
Holes in rear floor.
Holes in rear lower panels or extension
rear floor.
Fuel tank mountings.
Apertures for windscreen, backlight, bonnet and doors
can be checked by offering up an undamaged
component as a gauge and also by measuring known
dimensions.See BODY DIMENSIONS section.
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ELECTRICAL
13
DESCRIPTION AND OPERATION Passive Immobilisation
Passive immobilisation occurs when the key is removed from the ignition switch and the drivers door is opened,
after a period of 30 seconds the engine will become immobilised. If the ignition is turned off or the key is removed
from the ignition switch and drivers door is not opened, the engine will become immobilised after 5 minutes.
The passive immobilisation system operates in conjunction with the transponder coil located around the ignition
switch barrel. The transponder coil emits an electro magnetic waveform signal which excites the remote handset
into transmitting a remobilisation signal. When remobilisation is requested, the anti-theft alarm ECU transmits an
appropriate code to the ECM on Td5 models or the engine immobilisation ECU on 300Tdi models.
Active immobilisation
Active immobilisation is only invoked when the vehicle is locked using the remote handset. Active immobilisation
performs the same engine disable functionality as the passive immobilisation previously described, but includes
full CDL and activation of perimetric and volumetric alarm modes.
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86ELECTRICAL
16
DESCRIPTION AND OPERATION CDL Using the Key
The driver and the passenger front doors are fitted with key barrel locks. Using the vehicle key in the passenger
door will only lock or unlock that door. Using the key in the drivers door will operate the CDL system and lock or
unlock all doors.
NOTE: The passenger door key barrel is connected to the door latch and has no electrical input to
the anti-theft alarm ECU. The driver door key barrel is also connected to the door latch and its
operation is monitored by the ECU only via the latch motor and the two wires connected to it.
When the vehicle is locked using the key in the drivers door, only CDL and perimetric protection is invoked.
Volumetric protection and active immobilisation is not initiated.
CDL Using the Remote Handset
The remote handset has two buttons; lock and unlock. A single press on the lock button will lock all doors and
invoke perimetric and volumetric protection and active immobilisation. Remote locking is inhibited if the
transponder coil senses that the key is in the ignition switch.
When the vehicle is locked, a single press of the unlock button will unlock all doors and disable perimetric and
volumetric protection. Immobilisation is only disabled using the transponder coil and the remote handset or the
EKA procedure.
Security LED
In addition to the alarm system status indications, the security LED also displays CDL system status.
The system confirms that the drivers door is open by illuminating the LED for the 10 second confirmation period. If
any other door or the bonnet is open, the LED remains unlit for the 10 second confirmation period. After the 10
second confirmation period the LED reverts to the slow flash deterrent mode if the alarm is armed.
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ELECTRICAL
17
DESCRIPTION AND OPERATION Interior Lamp Functionality
The anti-theft alarm ECU controls the interior lamp functionality. When the lamps are extinguished, they fade out
to the off condition over a 2 second period.
The lamps are turned on by:
Disarming the alarm using the remote handset
Opening any door.
When the lamps are on, they will be extinguished by the following actions:
If all doors are closed, the lamps will be extinguished after a 15 second delay period
If any door is left open, the lamps will be extinguished after an 8 minute delay period
If one of the above delay periods is active and the ignition is switched on or the alarm is armed, the lamps will
be extinguished.
ANTI-THEFT ALARM SYSTEM SELF TEST
The anti-theft alarm ECU has a self test feature which allows all alarm inputs to be tested. To enter self test mode
the following steps must be completed as follows:
1.Ensure that the driver’s door is closed and the driver’s window is open
2.Open the bonnet and with assistance depress and hold the bonnet switch
3.Release the bonnet switch and within 0.5 seconds turn the ignition switch on to position II
4.Quickly open the driver’s door
5.Turn the ignition switch to the off position
6.Turn the ignition switch back to position II
7.If the self test mode has been entered successfully, confirmation will be given by the alarm sounder. If the
ECU has not entered self test mode, repeat the above procedure.
Once in self test mode, the following test inputs will cause the security LED to illuminate and the engine
immobilised warning lamp and the hazard warning lamps to flash. When an input is operated, non illumination of
the security LED, the engine immobilised warning lamp and the hazard warning lamps indicates a fault for that
input.
Perform the following steps to test each input for correct operation:
Close and open the drivers door
Open and close each of the passenger doors and the tail door in turn
Close and open the bonnet (depress switch if bonnet still open)
With drivers door closed, lock and unlock the driver’s door using the vehicle key if spare key available. If spare
key is not available, operate driver’s sill button through open window
Press the unlock button of the remote handset. This enters the volumetric self test mode and all other inputs
will be disabled. Make a movement inside the vehicle. When the volumetric sensor is triggered the security
LED will flash.
To exit the self test mode, turn the ignition switch to the off position.
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