ecu LAND ROVER DEFENDER 1999 Owners Manual

19FUEL SYSTEM
14
REPAIR Refit
19.Clean fuel pump and mating face.
20.Fit new fuel pump sealing ring.
21.Fit fuel pump and secure with locking ring.
22.Fit breather hose and secure clip.
23.Position heat shield and secure with scrivits.
24.With assistance position fuel tank and support
plate.
25.Connect fuel hoses and multiplug to fuel pump.
26.Connect filler neck breather and secure clip.
27.Position vent hose and secure to chassis clips.
28.Raise fuel tank to its fitted position.
29.Fit nuts and bolts securing fuel tank and tighten
to25 Nm (18 lbf.ft).
30.Connect filler hose and secure clip.
Vehicles fitted with tow bar
31.Position support bar and tighten nuts and bolts.
32.Reconnect battery negative lead.
33.Fit battery cover.NECK - FUEL TANK FILLER
Service repair no - 19.55.07
Remove
1.Drain fuel tank.See Adjustment.
2.Loosen clip securing breather hose to fuel filler
neck and release hose.
3.Loosen clip securing fuel filler hose to neck and
release hose.
4.Remove screw and release earth lead from filler
neck.
5.Remove grommet securing filler neck to body.
6.Remove filler neck from body.
Refit
7.Fit filler neck to body.
8.Coat rubber grommet with soap solution.
9.Fit rubber grommet securing filler neck to body.
10.Connect earth lead and tighten screw.
11.Connect filler hose to neck and tighten clip.
12.Fit breather hose to filler neck and secure with
clip.
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26COOLING SYSTEM
8
DESCRIPTION AND OPERATION Coolant Pump
1.Drive lugs (hidden)
2.Housing
3.’O’rings4.Cover
5.Feed hose connection
6.Impeller
The coolant pump is attached on the left hand side of the engine, behind the PAS pump. A cast housing, bolted to
the cylinder block provides a common attachment point for both pumps. The housing has galleries which connect
the coolant pump to the cylinder block and the oil cooler housing. The coolant pump comprises a shaft, a housing
and a cover.
The shaft, which passes through the alloy housing, is supported at each end by bearings. Seals at each end of the
shaft protect the bearings from the coolant. The forward end of the shaft has two lugs which engage with the PAS
pump shaft. The opposite end of the shaft is fitted with an impeller which draws coolant from the feed pipe and
circulates it through galleries in the cylinder block. The shaft is driven by the auxiliary drive belt at the same
rotational speed as the crankshaft by a pulley attached to the PAS pump.
The pump is sealed in the cast housing with two’O’rings. An outer cover is positioned over the pump and secured
with six bolts and sealed to the pump with an’O’ring. The cover provides the attachment for the feed pipe
connecting hose.
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COOLING SYSTEM
9
DESCRIPTION AND OPERATION Viscous Fan
1.Idler pulley drive attachment
2.Fan blades3.Bi-metallic coil
4.Body
The viscous fan provides a means of controlling the speed of the fan relative to the operating temperature of the
engine. The fan rotation draws air through the radiator, reducing engine coolant temperatures when the vehicle is
stationary or moving slowly.
The viscous fan is attached to an idler pulley at the front of the engine which is driven at crankshaft speed by the
auxiliary drive belt. The fan is secured to the pulley by a right hand threaded nut. The nut is positively attached to
the fan spindle which is supported on bearings in the fan body. The viscous drive comprises a circular drive plate
attached to the spindle and driven from the idler pulley. The drive plate and body have interlocking annular
grooves with a small clearance which provides the drive when silicone fluid enters the fluid chamber. A bi-metallic
coil is fitted externally on the forward face of the body. The coil is connected to and operates a valve in the body.
The valve operates on a valve plate with ports that connect the reservoir to the fluid chamber. The valve plate also
has return ports which, when the valve is closed, scoop fluid from the fluid chamber and push it into the reservoir
under centrifugal force.
Silicone fluid is retained in a reservoir at the front of the body. When the engine is off and the fan is stationary, the
silicone fluid level stabilises between the reservoir and the fluid chamber. This will result in the fan operating when
the engine is started, but the drive will be removed quickly after the fan starts rotating and the fan will’freewheel’.
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COOLING SYSTEM
1
ADJUSTMENT DRAIN AND REFILL
Service repair no - 26.10.01
WARNING: Hot coolant
Drain
1.Remove engine acoustic cover.
2.Visually check engine and cooling system for
signs of coolant leaks.
3.Examine hoses for signs of cracking, distortion
and security of connections.
4.Position drain tray to collect coolant.
5.Remove expansion tank filler cap.
6.Loosen clip screws securing air inlet hose to
intercooler and inlet manifold, release and
remove hose.
7.Release clip and disconnect bottom hose from
radiator.
8.Allow cooling system to drain.
9.Disconnect bottom hose from radiator.Refill
1.Flush system with water under low pressure.
2.Do not use water under high pressure as it could
damage the radiator.
3.Connect bottom hose to radiator and secure
hose with clip.
4.Prepare coolant to required concentration.
5.Position heater temperature control to maximum
hot position.
6.Remove bleed screw from top hose.
7.Fill system slowly through coolant expansion
tank until a steady flow of coolant is emitted from
the bleed hole in top hose.
8.Fit bleed screw to top hose.
9.Continue filling system until coolant level
reaches’MAX’mark on expansion tank.
10.Fit expansion tank filler cap.
11.Position air intake hose and tighten clip screws.
12.Start and run engine until normal running
temperature is reached.
13.If fitted, DO NOT operate air conditioning.
14.Switch off engine and allow to cool.
15.Check for leaks and top-up coolant to’MAX’
mark on expansion tank.
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COOLING SYSTEM
1
REPAIR COUPLING - COOLING FAN
Service repair no - 26.25.19
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove 3 bolts and remove engine acoustic
cover.
4.Remove cooling fan cowl.
NOTE: Thread is RH.
5.Remove cooling fan usingLRT-12-093and
LRT-12-094.
Refit
6.Position cooling fan and tighten using
LRT-12-093andLRT-12-094.
7.Fit cooling fan cowl.
8.Fit engine acoustic cover.
9.Reconnect battery negative lead.
10.Fit battery cover.THERMOSTAT
Service repair no - 26.45.09
Remove
1.Drain cooling system.See Adjustment.
2.Remove cooling fan.See this Section.
3.Release 3 clips and disconnect coolant hoses
from thermostat.
4.Remove thermostat.
Refit
5.Position thermostat, connect hoses and secure
with clips.
6.Fit cooling fan.See this Section.
7.Fill cooling system.See Adjustment.
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26COOLING SYSTEM
2
REPAIR PUMP - COOLANT
Service repair no - 26.50.01
Remove
1.Drain cooling system.See Adjustment.
2.Remove centrifuge.See ENGINE , Repair.
3.Release clip and hose from coolant pump cover.
4.Remove 5 bolts securing coolant pump cover.
5.Remove cover and coolant pump from housing
and discard’O’rings.Refit
6.Clean coolant pump housing and mating faces.
7.Fit new’O’rings to coolant pump and cover.
8.Fit coolant pump and cover and tighten bolts to9
Nm (7 lbf.ft).
9.Connect hose to pump cover and secure clip.
10.Refit centrifuge.See ENGINE , Repair.
11.Refill cooling system.See Adjustment.
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26COOLING SYSTEM
4
REPAIR
9.Remove 4 bolts securing RH and LH radiator
mounting brackets to body and remove brackets.
10.Release clip and release air hose from
turbocharger inlet pipe.11.Release bottom hose from bracket on lower
cooling fan cowl.
12.Remove radiator assembly and collect lower
mounting spacers.
13.Remove 2 bolts and remove intercooler from
radiator. Collect 2 nuts from radiator side
brackets.
14.Remove 2 rubber mountings from intercooler.
15.Remove 2 screws and remove lower cooling fan
cowl from radiator.
16.Remove 2 rubber mountings from bottom of
radiator.
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COOLING SYSTEM
5
REPAIR Refit
17.Fit rubber mountings to bottom of radiator.
18.Fit lower cooling fan cowl to radiator and secure
with screws.
19.Fit nuts to radiator side brackets.
20.Position intercooler to radiator and tighten bolts.
21.Fit rubber mountings to intercooler.
22.Position mounting spacers and fit radiator.
23.Fit bottom hose into bracket on lower cooling fan
cowl.
24.Position air hose to turbocharger pipe and
secure with clip.
25.Position LH and RH radiator mounting brackets
to body and radiator and tighten bolts.
26.Position coolant rail hose to radiator and secure
with clip.
27.Position fuel cooler hose to radiator and secure
with clip.
28.Position top hose to radiator and secure with
clip.
29.Position bleed hose to radiator and secure with
clip.
30.Position bonnet platform and tighten bolts.
31.Fit cooling fan.See this Section.
32.Fit front grille.See CHASSIS AND BODY,
Repair.
33.Fill cooling system.See Adjustment.
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30MANIFOLD AND EXHAUST SYSTEM
2
DESCRIPTION AND OPERATION DESCRIPTION
General
The diesel engine has the inlet manifold attached to the right hand side of the engine and the exhaust manifold
attached to the left hand side of the engine. The inlet manifold directs cooled compressed air from the
turbocharger and intercooler into the cylinders, where it is mixed with fuel from the injectors. Exhaust gases from
the exhaust manifold can also be directed into the inlet manifold via a pipe from the exhaust manifold and an
Exhaust Gas Recirculation (EGR) valve on the inlet manifold. The exhaust manifold allows combustion gases from
the cylinders to leave the engine where they are directed into the exhaust system and turbocharger.
The exhaust system is attached to the turbocharger and is directed along the underside of the vehicle to emit
exhaust gases from a tail pipe at the rear of the vehicle. A silencer is installed midway along the system and a
second tail silencer is located at the rear of the vehicle.
Inlet manifold
The inlet manifold is a one piece aluminium casting. The manifold is secured to the cylinder head with two studs
and flanged nuts and eight flanged bolts. A one piece laminated gasket seals the manifold to the cylinder head.
Four threaded bosses on the manifold provide for the attachment of the fuel cooler. The fuel cooler is secured to
the manifold with four bolts. A boss with two threaded holes allows for the attachment of the combined intake air
temperature/pressure sensor. The sensor is secured to the manifold with two screws and sealed with a gasket.
At the forward end of the manifold, a machined face and four threaded holes provide for the attachment of the
EGR valve. The valve is sealed to the manifold with a gasket.
Exhaust manifold
The exhaust manifold is made from cast iron. The manifold has five ports, one from each cylinder, which merge
into one flanged outlet connection positioned centrally on the manifold.
The manifold is attached to the cylinder head with ten studs and flanged nuts. A laminated metal gasket seals the
manifold to the cylinder head. The flanged outlet on the manifold provides the attachment for the turbocharger,
which is attached with three studs and flanged nuts and sealed with a metal laminated gasket.
A second flanged outlet, located at the forward end of the manifold, provides attachment for the EGR pipe. The
EGR pipe is secured to the manifold with two cap screws and connected to the EGR valve mounted on the inlet
manifold. There is no gasket used between the pipe and the exhaust manifold.
Exhaust system
The exhaust system comprises a front pipe, an intermediate pipe which incorporates a silencer and a tail pipe
assembly which also has a silencer. The exhaust system is constructed mainly of 63 mm (2.48 in) diameter
extruded pipe with a 1.5 mm (0.06 in) wall thickness. All pipes are aluminized to resist corrosion and the silencers
are fabricated from stainless steel sheet.
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MANIFOLD AND EXHAUST SYSTEM
3
DESCRIPTION AND OPERATION Front pipe assembly
The front pipe is of welded and fabricated tubular construction. The front pipe is connected to a flange on the
turbocharger and secured with three flanged nuts and sealed with a metal laminated gasket. The front pipe
incorporates a flexible pipe near the connection with the turbocharger and terminates in a flanged connection with
the intermediate pipe.
The flexible pipe is formed into a concertina shape with woven metal strands around its outer diameter. The
flexible pipe allows for ease of exhaust system alignment and also absorbs engine vibration. The woven metal
strands also increase the longevity of the flexible pipe.
The front pipe is attached via a bracket and a mounting rubber to the chassis. The mounting rubber allows ease of
alignment and vibration absorption.
Intermediate pipe and silencer
The intermediate pipe is of welded and fabricated tubular construction. It connects at its forward end to the front
pipe flange. Two captive studs on the intermediate pipe flange allow for attachment to the front pipe with locknuts.
The rear section of intermediate pipe connects to the tail pipe assembly via a flanged joint, sealed with a metal
gasket and secured with locknuts and studs.
The forward and rear sections are joined by a silencer. The silencer is fabricated from stainless steel sheet to form
the body of the silencer. An end plate closes each end of the silencer and is attached to the body with seam joints.
Perforated baffle tubes, inside the silencer, are connected to the inlet and outlet pipes on each end plate. Internal
baffle plates support the baffle tubes and, together with a stainless steel fibre packing, absorb combustion noise
as the exhaust gases pass through the silencer.
The intermediate pipe is attached by two brackets, positioned at each end of the silencer, and two mounting
rubbers to the chassis. The mounting rubber allows for ease of alignment and vibration absorption.
Tail pipe assembly
The tail pipe is of welded and fabricated construction. The tail pipe connects to the intermediate pipe with a
flanged joint secured with locknuts and sealed with a metal gasket. The pipe is shaped to locate above the rear
axle allowing clearance for axle articulation. The pipe is also curved to clear the left hand side of the fuel tank
which has a reflective shield to protect the tank from heat generated from the pipe.
A fabricated silencer is located at the rear of the tail pipe. The silencer is circular in section and is constructed from
stainless steel sheet. A baffle tube is located inside the silencer and the space around the baffle tube is packed
with a stainless steel fibre. The holes in the baffle tube allow the packing to further reduce combustion noise from
the engine. The tail pipe from the silencer is curved downwards at the rear of the vehicle and directs exhaust
gases towards the ground. The curved pipe allows the exhaust gases to be dissipated by the airflow under the
vehicle and prevents the gases from being drawn behind the vehicle.
The tail pipe is attached by a bracket, positioned forward of the silencer, and a mounting rubber to the chassis.
The mounting rubber allows ease of alignment and vibration absorption.
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