1999 LAND ROVER DEFENDER service

18ENGINE MANAGEMENT SYSTEM
2
REPAIR SENSOR - CRANKSHAFT SPEED AND POSITION
(CKP)
Service repair no - 18.30.12
Remove
1.Disconnect CKP sensor multiplug.
2.Remove bolt, remove CKP sensor from gearbox
housing and discard’O’ring.
3.If fitted, collect spacer.
Refit
4.Clean gearbox housing and CKP sensor.
5.If fitted, refit spacer.
6.Fit new’O’ring, position CKP sensor to gearbox
housing and tighten bolt to10 Nm (7 lbf.ft).
7.Connect sensor multiplug.
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FUEL SYSTEM
1
ADJUSTMENT HEATER PLUG TEST
Service repair no - 19.90.20.01
Check
1. Test out of engine
2.Remove heater plug.See Repair.
3.UsingLRT-12-511,connect RED lead to battery
’+’positive and the BLACK lead to battery’-’
negative.
4.Position heater plug into tester and retain with
spring loaded bar.
5.Connect YELLOW lead to heater plug terminal.
6.Press red button on tester and note ammeter
reading. Keep button depressed, heater plug tip
should start to glow after 5 seconds
CAUTION: The heater plug tip must glow
first, if it fails to do so, replace heater plug.
7.The ammeter reading should show an initial
current draw of 25 amps, which should fall to 12
amps after 20 seconds.
8.Refit heater plug.See Repair.FUEL SYSTEM - BLEED
Service repair no - 19.50.07
Fuel Purging Procedure
1.If the vehicle runs out of fuel, or the fuel level is
so low that the fuel system draws air into the fuel
rail, the fuel rail will need to be purged before the
engine will start. This can be achieved by
following a set procedure. The process does not
require the use of any specialist equipment and
can be performed by the driver of the vehicle.
The process is as follows:
2.Switch off ignition and wait 15 seconds.
3.Turn ignition key to position 2 and wait 3
minutes, (this ensures that the fuel system
purges all the air from the fuel rail within the
cylinder head).
4.Depress the throttle pedal to more than 90% of
its total travel, (to the throttle stop).
5.Crank the engine keeping the throttle pedal
depressed.
NOTE: This operation is controlled by the
ECM and it is important that the purging
operation is not carried out on a vehicle
that has not run out of fuel. If it is carried out
unnecessarily it can lead to the engine flooding
and failing to start.
This operation will be cancelled:
6.As soon as engine speed exceeds 600 rev/min.
7.The driver allows the throttle pedal to close to a
position less than 90% of its travel.
8.The ignition key is released from the start
position.
NOTE: The engine must not be cranked for
more than 30 seconds in any one period.
9.Repeat the above procedure if the engine fails to
start.
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19FUEL SYSTEM
2
ADJUSTMENT FUEL TANK - DRAIN
Service repair no - 19.55.02
1.Remove battery cover.
2.Disconnect both leads from battery, earth lead
first.
WARNING: Fuel vapour is highly
flammable and in contained spaces is also
explosive and toxic. Always have a fire
extinguisher containing FOAM, CO2, GAS OR
POWDER close at hand when handling or draining
fuel.
3.Using a fuel recovery appliance, drain the fuel
from the tank into a sealed container. Follow the
manufacturers instructions for the connection
and safe use of the appliance.
4.Remove filler cap and insert hose into filler neck.
5.Connect bowser earth line. Drain fuel.
6.Connect battery leads.
7.Fit battery cover.
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FUEL SYSTEM
1
REPAIR ELEMENT - AIR FILTER
Service repair no - 19.10.10
Remove
1.Release 2 clips and disconnect air flow meter
from air filter cover.
2.Disconnect multiplug from AAP sensor.
3.Release 2 clips and remove cover from air filter.
4.Remove air filter element.
Refit
5.Clean air filter body and cover.
6.Fit new air filter element.
7.Position air cleaner cover and secure clips.
8.Position air flow meter and secure clips.
9.Connect AAP sensor multiplug.SENSOR - FUEL TEMPERATURE
Service repair no - 19.22.08
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Release fixings and remove battery cover.
3.Disconnect battery negative lead.
4.Disconnect multiplug from fuel temperature
sensor.
5.Thoroughly clean area around fuel temperature
sensor before removal.
6.Remove fuel temperature sensor and discard
sealing washer.
Refit
7.Clean fuel temperature sensor mating faces.
8.Fit new sealing washer and tighten fuel
temperature sensor to13 Nm (9 lbf. ft).
9.Connect multiplug to fuel temperature sensor.
10.Reconnect battery negative lead.
11.Fit battery cover and secure fixings.
12.Fit engine acoustic cover and secure with bolts.
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19FUEL SYSTEM
2
REPAIR SWITCH - INERTIA - FUEL CUT OFF
Service repair no - 19.22.09
Remove
1.Disconnect multiplug from fuel cut off switch.
2.Remove 2 screws securing switch to bulkhead.
3.Remove switch.
Refit
4.Position switch to bulkhead.
5.Fit screws securing switch to bulkhead.
6.Connect multiplug.
7.Press top of switch to set switch.SENSOR - MASS AIR FLOW (MAF)
Service repair no - 19.22.25
Remove
1.Disconnect multiplug from MAF sensor.
2.Loosen clip screw and release air intake hose
from MAF sensor.
3.Release 2 clips and remove sensor from air
cleaner.
Refit
4.Position sensor to air cleaner and secure clips.
5.Position air intake hose and tighten clip screw.
6.Connect multiplug.
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FUEL SYSTEM
3
REPAIR SENSOR - COMBINED MAP AND IAT
Service repair no - 19.22.26
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Disconnect multiplug from combined MAP and
IAT sensor,
3.Remove 2 bolts securing sensor to inlet
manifold.
4.Remove sensor and discard’O’ring.
Refit
5.Clean sensor and mating face.
6.Fit new’O’ring and position sensor to manifold.
7.Fit and tighten MAF and IAT sensor bolts to9
Nm (7 lbf.ft)
8.Fit engine acoustic cover and secure with bolts.SENSOR - AMBIENT AIR PRESSURE (AAP)
Service repair no - 19.22.27
Remove
1.Disconnect multiplug from AAP sensor.
2.Remove 2 screws and remove sensor.
3.Remove and discard’O’ring.
Refit
4.Clean sensor and air cleaner cover.
5.Fit new’O’ring, fit sensor and tighten screws.
6.Connect multiplug to AAP sensor.
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19FUEL SYSTEM
4
REPAIR ELEMENT - FUEL FILTER
Service repair no - 19.25.07
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery negative lead.
3.Raise rear of vehicle.
WARNING: Support on safety stands.
4.Release fixing and remove fuel filter cover.
5.Clean area around fuel filter.
6.Disconnect multiplug from filter element.
7.Remove fuel filter element.
Refit
8.Clean fuel filter and mating face.
9.Fit new fuel filter element and connect multiplug.
10.Position fuel filter cover and secure with fixing.
11.Remove stand(s) and lower vehicle.
12.Reconnect battery negative lead.
13.Fit and secure battery cover.COOLER - FUEL
Service repair no - 19.25.30
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Remove battery cover.
3.Disconnect battery negative lead.
4.Drain cooling system.See COOLING
SYSTEM, Adjustment.
5.Release 3 clips and disconnect 3 coolant hoses
from fuel cooler.
6.Release 2 fuel hoses from fuel cooler.
CAUTION: Plug the connections.
7.Release vacuum pipe clip from fuel cooler.
8.Remove 4 bolts securing fuel cooler to inlet
manifold and remove cooler.
Refit
9.Clean fuel hose connections.
10.Position fuel cooler to inlet manifold. Apply
Loctite 242 to bolts and tighten to18 Nm (13
lbf.ft).
11.Connect fuel hoses.
12.Connect coolant hoses, secure with clips.
13.Secure vacuum hose to fuel cooler.
14.Refill cooling system.See COOLING SYSTEM,
Adjustment.
15.Fit engine acoustic cover and secure with bolts.
16.Reconnect battery negative lead.
17.Fit battery cover.
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FUEL SYSTEM
5
REPAIR TURBOCHARGER
Service repair no - 19.42.01
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove 3 bolts and remove engine acoustic
cover.
4.Release clip and disconnect breather hose from
camshaft cover.
5.Release clips and disconnect air flow meter from
air filter.
6.Disconnect multiplug from air flow meter.
7.Loosen clip screw and remove air inlet hose
from turbocharger.
8.Remove 3 bolts and remove exhaust manifold
heat shield.
9.Release clip and disconnect vacuum hose from
turbocharger wastegate.
10.Loosen clip screw and release air outlet hose
from turbocharger.
11.Remove turbocharger oil feed banjo bolt and
discard sealing washers.
12.Remove 3 nuts and release exhaust front pipe
from turbocharger and discard gasket.
13.Remove 3 nuts securing turbocharger to exhaust
manifold.
14.Loosen and unscrew turbocharger drain pipe
union from cylinder block.
15.Remove turbocharger and discard gasket.
16.Remove 2 bolts and remove turbocharger oil
drain pipe. Discard gasket.
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