ABS LAND ROVER DEFENDER 1999 User Guide

ENGINE
9
OVERHAUL
8.Gently tap camshaft carrier upwards to break
sealant bond, remove carrier.
NOTE: Dowel located.
9.Remove camshaft.
10.Remove and discard camshaft rear oil seal.
11.Remove finger followers and lash adjusters.
CAUTION: Store lash adjusters and finger
followers in their fitted order and store
lash adjusters upright. Maintain absolute
cleanliness when handling components.
12.Remove and discard 5 bolts securing EUI
retainers.
13.Using toolLRT-12-154/1remove EUI units from
cylinder head and collect retainers. Remove
reaction posts and keep in their fitted order.
14.Using toolLRT-12-154/4, remove and discard
sealing washer and’O’ring from each EUI unit.
15.Support cylinder head clear of valves, use a
hollow drift and tap each valve spring cap to free
collets.
16.Using toolLRT-12-034, compress valve spring.
17.Remove 2 collets from valve stem using a stick
magnet.
18.Remove toolLRT-12-034.
19.Remove valve spring cap, valve spring and
valve.
CAUTION: Keep components in their fitted
order.
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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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ENGINE MANAGEMENT SYSTEM
3
DESCRIPTION AND OPERATION 1.Mass Air Flow (MAF) sensor.
2.Engine Coolant Temperature (ECT) sensor.
3.Glow plugs.
4.Manifold Absolute Pressure (MAP) / Inlet Air Temperature (IAT) sensor.
5.Fuel pump relay.
6.Engine Control Module (ECM).
7.Air Conditioning (A/C) and cooling fan relay.
8.Fuel Temperature (FT) sensor.
9.Crankshaft Speed and Position (CKP) sensor.
10.Electronic Unit Injectors (EUI).
11.Ambient Air Pressure (AAP) sensor.
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ENGINE MANAGEMENT SYSTEM
5
DESCRIPTION AND OPERATION DESCRIPTION
General
An engine control module (ECM) controls the five cylinder direct injection diesel engine, and works on the drive by
wire principal. This means there is no throttle cable, the ECM controls the drivers needs via a signal from the
Throttle Position (TP) sensor on the throttle pedal.
The ECM is a full authoritative diesel specific microprocessor that also incorporates features for air conditioning. In
addition, the ECM supplies output control for the Exhaust Gas Recirculation (EGR) and turbocharger boost
pressure. The ECM has a self diagnostic function, which is able to provide backup strategies for most sensor
failures.
The ECM processes information from the following input sources:
Mass Air Flow (MAF) sensor.
Ambient Air Pressure (AAP) sensor.
Manifold Absolute Pressure (MAP) / Inlet Air Temperature (IAT) sensor.
Engine Coolant Temperature (ECT) sensor.
Crankshaft Speed and Position (CKP) sensor.
Throttle Position (TP) sensor.
Fuel Temperature (FT) sensor.
Air conditioning request.
Air conditioning fan request.
Brake pedal switch.
Clutch pedal switch.
The input from the sensors constantly updates the ECM with the current operating condition of the engine. Once
the ECM has compared current information with stored information within its memory, it can make any adjustment
it requires to the operation of the engine via the following:
Air conditioning clutch relay.
Air conditioning cooling fan relay.
Electronic vacuum regulator solenoid.
Fuel pump relay.
Glow plug warning lamp.
Glow plugs.
Fuel injectors.
Main relay.
Turbocharger wastegate modulator.
Temperature gauge.
The ECM interfaces with the following:
Serial communication link.
Instrument pack.
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ENGINE MANAGEMENT SYSTEM
9
DESCRIPTION AND OPERATION SENSOR - MANIFOLD ABSOLUTE PRESSURE
(MAP) / INLET AIR TEMPERATURE (IAT)
The MAP/IAT sensors are combined in one unit located in the inlet manifold. It provides pressure and temperature
information about the air in the inlet manifold to the ECM. The ECM compares the voltage signal to stored values
and compensates fuel delivery as necessary. The ECM uses the signal from the MAP/IAT sensor for the following
functions:
To calculate the delivered fuel limits.
To calculate the air mass in the cylinder.
To calculate the air speed density.
To calculate the air temperature.
The MAP sensor works on the piezo crystal principal. Piezo crystals are pressure sensitive and will oscillate in
accordance to changes in air pressure. The MAP sensor produces a voltage between 0 and 5 volts proportional to
the pressure level of the air in the inlet manifold. A reading of 0 volts indicates a low pressure, a reading of 5 volts
a high pressure.
The IAT portion of the sensor works as a Negative Temperature Co-efficient (NTC) sensor. As air temperature
rises, the resistance in the sensor decreases. As temperature decreases the resistance in the sensor increases.
The ECM compares the voltage signal to stored values and compensates fuel delivery as necessary.
Inputs / Outputs
The MAP/IAT sensor (C0567-3) is provided a 5 volt supply by the ECM (C0158-8) on a pink/purple wire. The
MAP/IAT sensor provides the ECM with 2 outputs. The MAP sensor output (C0567-4) is connected to the ECM
(C0158-6) by a white/yellow wire. The IAT sensor output (C0567-2) is connected to the ECM (C0158-34) on a
green/black wire. The MAP/IAT sensor is earthed (C0567-1) via the ECM (C0158-17) on a pink/black wire.
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ENGINE MANAGEMENT SYSTEM
1
REPAIR ENGINE CONTROL MODULE (ECM)
Service repair no - 18.30.03
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery negative lead.
3.Remove RH seat cushion, release clip and
remove ECM access panel.
4.Remove 3 bolts, release ECM and disconnect 2
multiplugs. Remove ECM.
Refit
5.Position new ECM and connect multiplugs.
6.Fit ECM and tighten bolts.
7.Fit access panel and RH seat cushion.
8.Reconnect battery negative lead.
9.Fit battery cover and secure with fixings.SENSOR - ENGINE COOLANT TEMPERATURE
(ECT)
Service repair no - 18.30.10
Remove
1.Disconnect battery negative lead.
2.Remove spring clip and disconnect ECT sensor
multiplug.
3.Position cloth around ECT sensor to absorb
coolant spillage.
4.Remove ECT sensor.
5.Remove sealing washer and discard.
Refit
6.Clean sealing washer, sensor threads and
sensor location.
7.Coat sensor threads with Loctite 577 and fit new
sealing washer.
8.Fit ECT sensor and tighten to20 Nm (14 lbf.ft).
9.Fit spring clip to multiplug and connect multiplug
to ECT sensor.
10.Top up cooling system.
11.Run engine to normal operating temperature.
Check for leaks around ECT sensor.
12.Reconnect battery negative lead.
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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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33CLUTCH
6
DESCRIPTION AND OPERATION DESCRIPTION
General
The clutch system is a diaphragm type clutch operated by a hydraulic cylinder. The drive plate is of the rigid centre
type with no integral damping springs. The flywheel is of the dual mass type with damping springs integral with the
flywheel. The clutch requires no adjustment to compensate for wear.
Hydraulic Clutch
The hydraulic clutch comprises a master cylinder, slave cylinder and a hydraulic reservoir. The master and slave
cylinders are connected to each other hydraulically by plastic and metal pipes. The plastic section of the pipe
allows ease of pipe routing and also absorbs engine movements and vibrations.
The master cylinder comprises a body with a central bore. Two ports in the body connect the bore to the hydraulic
feed pipe to the slave cylinder and the fluid reservoir. The bore is also connected to a damper which prevents
engine pulses being transferred hydraulically to the clutch pedal. A piston is fitted in the bore and has an external
rod which is attached to the clutch pedal with a pin. Two coil springs on the clutch pedal reduce the effort required
to depress the pedal.
The master cylinder is mounted on the bulkhead and secured with two bolts. The cylinder is connected to the
shared brake/clutch reservoir on the brake servo by a braided connecting hose.
The slave cylinder is located on the left hand side of the gearbox housing and secured with two bolts. A heat
shield is fitted to protect the underside of the slave cylinder from heat generated from the exhaust system. The
slave cylinder comprises a cylinder with a piston and a rod. A port in the cylinder body provides the attachment for
the hydraulic feed pipe from the master cylinder. A second port is fitted witha bleed nipple used for removing air
from the hydraulic system after servicing. The piston rod locates on a clutch release lever located in the gearbox
housing. The rod is positively retained on the release lever with a clip.
Clutch Mechanism
The clutch mechanism comprises a flywheel, drive plate, pressure plate, release lever and a release bearing. The
clutch mechanism is fully enclosed at the rear of the engine by the gearbox housing.
A clutch release bearing sleeve is attached in the gearbox housing with two bolts and located on two dowels. A
spigot with a ball end is formed on the release bearing sleeve and provides a mounting and pivot point for the
clutch release lever. A dished pivot washer is located on the ball of the spigot. When the release lever is located
on the ball, the pivot washer seats against the rear face of the release lever. A spring clip is located on the lever
and the pivot washer and secures the lever on the spigot. A small bolt retains the spring clip in position.
The release lever is forked at its inner end and locates on the clutch release bearing carrier. The outer end of the
release lever has a nylon seat which locates the slave cylinder piston rod. A second nylon seat, positioned
centrally on the release lever, locates on the ball spigot of the release bearing sleeve and allows the release lever
to pivot freely around the ball.
The clutch release bearing locates on the clutch release lever and release bearing sleeve. The bearing is retained
on a carrier which has two flats to prevent the carrier rotating on the release lever. A clip retains the release lever
on the carrier. The bearing and carrier are not serviceable individually.
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REAR AXLE AND FINAL DRIVE
1
REPAIR REAR AXLE
Service repair no - 51.25.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
the axle when lowering or repositioning
axle.
1.Drain brake system.
2.Support chassis rear.
3.Remove road wheels.
4.Support axle weight with hydraulic jack.
5.Disconnect shock absorbers.
6.Disconnect flexible brake hose at RH chassis
side member and breather hose at banjo
connection on axle casing.
7.Disconnect lower links at axle.8.Mark differential and propeller shaft flanges with
identification marks for assembly.
9.Remove 4 nuts and bolts, lower propeller shaft
and tie to one side.
10.Disconnect pivot bracket ball joint at axle
bracket.
11.Release bolts and remove coil spring retaining
plates.
12.Lower axle and remove road springs.
13.If applicable, remove anti-roll bar links at axle
See REAR SUSPENSION, Repair. anti-roll
bar.
14.Remove axle assembly.
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51REAR AXLE AND FINAL DRIVE
2
REPAIR Refit
15.Position axle and fit lower links. Tighten fixings
to176 Nm (130 lbf/ft).
16.If applicable, fit anti-roll bar links to axleSee
REAR SUSPENSION, Repair. Anti-roll bar
links.
17.Raise axle and locate road springs.
18.Fit coil spring retaining plates and secure with
fixing bolts.
19.Secure pivot bracket ball joint to axle bracket.
Tighten fixing to176 Nm (130 lbf/ft).
20.Align propeller shaft to differential drive flange
and tighten fixings to47 Nm (35 lbf/ft).
21.Reconnect flexible brake hose and axle breather
hose.
22.Refit shock absorbers.
23.Fit road wheels and tighten to correct torque:
Alloy wheels -130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy Duty wheels -170 Nm (125 lbf/ft)
24.Remove rear chassis support.
25.Bleed brake systemSee BRAKES, Repair.
brake system bleed.
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