alternator LAND ROVER DEFENDER 1999 User Guide

EMISSION CONTROL
5
DESCRIPTION AND OPERATION
CAUTION: Inset A shows the Pre-EU3 condition for the EGR pipe. Inset B shows the Pre-EU3
condition filter and venting.
1.ILT valve modulator
2.ILT modulator vacuum hose (brown)
3.EGR valve modulator
4.EGR modulator vacuum hose (brown)
5.Vent hose - EGR modulator to in-line filter (green)
6.Vacuum hose to ILT valve suction port (blue)
7.Vacuum hose to EGR valve suction port (blue)
8.’T’-piece (4-way)
9.Vacuum hose to brake servo
10.Non-return valve
11.Brake servo
12.Inlet manifold
13.Exhaust manifold
14.ILT valve
15.EGR cooler - EU-3 models
16.Vacuum pump/alternator assembly
17.Air intake hose from intercooler
18.EGR valve (incorporating ILT valve) assembly
19.Vacuum hose to vacuum pump
20.Vent hose - ILT valve modulator to in-line filter (green)
21.3-way connector
22.Vent hose to air cleaner
23.ILT modulator harness connector (green)
24.EGR modulator harness connector (black)
25.To atmosphere - Pre-EU3 models
26.In-line filter - Pre-EU3 models
27.EGR pipe - Pre-EU3 models
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17EMISSION CONTROL
10
DESCRIPTION AND OPERATION INLET THROTTLE (ILT) MODULATOR
1.Port to vacuum source (white band)
2.Port to ILT valve (blue band)
3.Port to atmosphere via in-line filter (green band)
4.Harness connector (green)
The ILT modulator is located on a plate fixed to the inner wing on the RH side of the engine below the EGR
modulator. The modulator is attached to the plate by two through-studs, each with two nuts which secure the
modulator assembly to a rubber mounting which helps to reduce noise. The modulator must be mounted in the
vertical orientation with the two vacuum ports uppermost.
The modulator operation is controlled by a signal from the ECM which determines the required ratio of exhaust
gas to fresh inlet air needed in response to inputs relating to air flow and engine operating and ambient conditions.
The modulator has a green two-pin connector at its base to connect it to the ECM through the engine harness.
The ILT valve modulator features three ports:
The top port is identified by a white band and connects to a’T’-piece in the vacuum line via a small-bore brown
plastic hose where it is connected in parallel with the vacuum source line to the EGR valve modulator. The two
other ports on the’T’-piece connect vacuum line hoses of black vinyl tubing between the vacuum pump
attached to the alternator and the brake-servo assembly attached to the bulkhead.
The middle port is identified by a blue band and connects to the suction port on the ILT valve through a
small-bore blue plastic hose.
The lower port is identified by a green band and connects to atmosphere through an in-line filter via a green
plastic hose and a three-way connector positioned in-line between the modulators and the filter. The ILT
modulator hose is connected opposite to the two parallel ports at the three-way connector which connect the
vent lines to the EGR valve modulator and the in-line filter. The other port of the in-line filter vents directly to
atmosphere.
The blue and brown vacuum hoses are protected by corrugated plastic sheaths. The ends of the hoses are fitted
with rubber boots to ensure vacuum tight seals at the component ports.
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30MANIFOLD AND EXHAUST SYSTEM
4
REPAIR
7.Remove 4 bolts securing fuel cooler to inlet
manifold.
8.Remove 2 bolts and remove alternator support
bracket and disconnect fuel injector harness
multiplug.
9.Remove bolt securing engine dip stick tube to
camshaft carrier.
10.Remove dip stick tube and discard’O’ring.
11.Remove 2 nuts and 8 bolts securing inlet
manifold to cylinder head.
12.Disconnect multiplugs from turbocharger boost
control soleniod, ECT sensor, ambient air
pressure sensor, MAF sensor, and A/C
compressor.
NOTE: EU3 Model illustrated.
13.Remove 2 bolts securing harness to camshaft
carrier.
14.Release harness from engine and inlet manifold.
15.Remove inlet manifold and gasket.
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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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PANEL REPAIRS
9
REPAIR REAR LAMP PANEL
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect alternator.
3.Remove rear bench seat.
4. RH side:Remove tail door.See CHASSIS
AND BODY, Repair.
5.Remove rear lights and reflector.
6. LH side:Remove number plate and tail door
striker.
Refit
7.Prepare and clean panel joint faces.
8.Reverse removal procedure.REAR CROSSMEMBER PANEL
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove both rear lamp panels.See this
Section.
Refit
3.Prepare and clean panel joint faces.
4.Reverse removal procedure.
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86 - ELECTRICAL
CONTENTS
Page
DESCRIPTION AND OPERATION
SECURITY AND CENTRAL DOOR LOCKING 1....................................................
SECURITY AND CENTRAL DOOR LOCKING 2....................................................
ANTI-THEFT ALARM - FROM 02MY 3...................................................................
IMMOBILISATION SYSTEM - FROM 02MY 12......................................................
CENTRAL DOOR LOCKING (CDL) - FROM 02MY 15...........................................
ANTI-THEFT ALARM SYSTEM SELF TEST 17.....................................................
FASCIA CONSOLE 18............................................................................................
HEATED FRONT SCREEN - FROM 02MY 20.......................................................
HEATED FRONT SEATS - FROM 02MY 22..........................................................
ELECTRIC FRONT WINDOWS - FROM 02MY 24.................................................
PASSENGER COMPARTMENT FUSE BOX 26.....................................................
UNDER SEAT FUSE BOX 27.................................................................................
ADJUSTMENT
HEADLAMPS - ALIGN BEAM 1..............................................................................
SOLENOID/MOTOR - FRONT DOOR - ADJUST 1................................................
REPAIR
BELT - AUXILLARY DRIVE 1.................................................................................
HARNESS - INJECTORS 1....................................................................................
STARTER MOTOR 2..............................................................................................
CENTRE HIGH MOUNTED STOP LIGHT (CHMSL) - UP TO 02MY 2...................
ALTERNATOR 3.....................................................................................................
HORN - LH 4...........................................................................................................
HEADLAMP 5.........................................................................................................
LAMP - TAIL 6.........................................................................................................
RADIO6 ..................................................................................................................
SPEAKER - FRONT 7.............................................................................................
SWITCH - TRANSMISSION BRAKE 7...................................................................
LAMP - FRONT FLASHER 8..................................................................................
BATTERY - DISCONNECT - FROM 02MY 8..........................................................
MOTOR & REGULATOR - FRONT DOOR - FROM 02MY 9..................................
SWITCH - FASCIA - FROM 02MY 10.....................................................................
HARNESS - FRONT DOOR - FROM 02MY 10.......................................................
SOLENOID/MOTOR - TAIL DOOR - FROM 02MY 11............................................
SOLENOID/MOTOR - FRONT DOOR - FROM 02MY 12.......................................
SOLENOID/MOTOR - REAR DOOR - FROM 02MY 13.........................................
HARNESS - REAR DOOR - FROM 02MY 14.........................................................
REVERSE AND FOG GUARD LAMP - BULB 15....................................................
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ELECTRICAL
3
REPAIR ALTERNATOR
Service repair no - 86.10.02
Remove
1.Remove auxilliary drive belt.See this Section.
2.Release cover and remove nut securing lead to
alternator.
3.Disconnect alternator multiplug.
4.Remove bolt (LH thread) and remove auxiliary
drive belt tensioner.
5.Remove bolt securing support stay to alternator.
6.Release clip securing lubrication drain hose to
vacuum pump.
7.Loosen vacuum pump lubrication pipe from
cylinder head and discard’O’ring.
8.Remove bolt securing alternator and release
from mounting bracket.
9.Disconnect hose from vacuum pump.
10.Remove alternator taking care not to damage
radiator cooling fins.
11.Remove 4 bolts, and remove vacuum pump from
alternator.
CAUTION: Plug the connections.
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86ELECTRICAL
4
REPAIR Refit
12.Clean mating face of alternator and vacuum
pump.
13.Fit vacuum pump to alternator and tighten bolts
to10 Nm (7 lbf.ft).
14.Position alternator and connect multiplug.
15.Connect vacuum hose and oil drain hose to
vacuum pump and secure clip.
16.With assistance align alternator to mounting
bracket and fit but do not tighten bolt.
17.Fit bolt securing support stay to alternator and
tighten to25 Nm (18 lbf.ft).
18.Tighten alternator to mounting bracket bolt to45
Nm (33 lbf.ft).
19.Using new’O’ring, fit and tighten lubrication pipe
union to10 Nm (8 lbf.ft).
20.Connect lead to alternator and tighten nut to6
Nm (4.4 lbf.ft).
21.Fit auxilliary drive belt tensioner and tighten bolt
to50 Nm (37 lbf.ft).
22.Fit auxilliary drive belt.See this Section.HORN - LH
Service repair no - 86.30.10
Remove
1.Remove LH headlamp.See this Section.
2.Disconnect horn multiplug.
3.Remove nut and remove horn from mounting
bracket.
Refit
4.Position horn, tighten securing and connect
multiplug.
5.Fit LH headlamp.See this Section.
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