engine LAND ROVER DEFENDER 1999 Workshop Manual

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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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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19FUEL SYSTEM
6
REPAIR Refit
17.Clean turbocharger and oil drain pipe mating
faces.
18.Using a NEW gasket, fit turbocharger drain pipe
and tighten bolts to10 Nm (7 lbf.ft).
19.Using a new gasket fit turbocharger to exhaust
manifold and tighten nuts to30 Nm (22 lbf. ft).
20.Position oil drain pipe to cylinder block and
tighten union.
21.Using new gasket, align exhaust front pipe and
tighten nuts to30 Nm (22 lbf.ft)
22.Fit banjo bolt to oil feed pipe using new sealing
washers and tighten to25 Nm (18 lbf.ft).
23.Position air outlet hose to turbocharger and
tighten clip screw.
24.Position and secure vacuum hose to
turbocharger wastegate.
25.Position exhaust manifold heat shield and
tighten M6 bolts to9 Nm (7 lbf.ft)and M8 bolt to
25 Nm (18 lbf.ft).
26.Position air inlet hose to turbocharger and
tighten clip screw.
27.Connect air flow meter to air filter and secure
clips.
28.Connect air flow meter multiplug.
29.Connect breather hose and secure clip.
30.Fit engine acoustic cover and secure with bolts.
31.Reconnect battery negative lead.
32.Fit battery cover.FILTER ASSEMBLY - AIR
Service repair no - 19.10.01
Remove
1.Loosen clip screw and release intake hose from
air filter.
2.Release 2 clips securing air flow meter.
3.Release air flow meter from air filter cover and
position aside.
4.Disconnect multiplug from AAP sensor.
5.Release air filter from 3 grommets, remove
assembly and discard’O’ring.
6.Remove 2 screws, remove AAP sensor and
discard’O’ring.
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FUEL SYSTEM
7
REPAIR Refit
7.Clean air flow meter faces.
8.Fit new’O’ring to air filter.
9.Clean AAP sensor.
10.Using new’O’ring, fit AAP sensor and tighten
screws.
11.Position air filter assembly and secure in
grommets.
12.Position air flow meter and secure clips.
13.Position intake hose to air filter and tighten clip
screw.INJECTOR - SET
Service repair no - 19.60.12
Remove
1.Remove cooling fan.See COOLING SYSTEM,
Repair.
2.Remove rocker shaft.See ENGINE , Repair.
3.Position container to catch fuel spillage.
4.Disconnect quick release fuel hose connectors
from fuel connector block on cylinder head and
fuel cooler to drain fuel from cylinder head.
5.Disconnect 5 multiplugs from injectors.
6.Remove Torx bolt securing injector unit to
cylinder head.
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19FUEL SYSTEM
8
REPAIR
7.AssembleLRT-12-154/1to injector unit, screw in
slide hammer and remove injector.
8.UsingLRT-12-154/4,remove and discard
sealing washer.9.Remove and discard’O’ring seal.
10.Rotate engine to align camshaft lobes for access
of injector removal tool.
11.Carry out above procedure to remove the
remaining 4 injectors.
12.Rotate engine manually until each cylinder being
worked on is at TDC, and remove excess fuel
from piston bowl using a syringe.
Refit
13.Clean injector unit and mating faces in cylinder
head.
14.PositionLRT-12-154/2to injector units and fit
new’O’rings.
15.Fit new sealing washers to injector nozzles using
LRT-12-154/3.
16.Fit retainers to injectors, carefully fit injectors
ensuring retainer is located on its dowel and
tighten bolt to32 Nm (24 lbf.ft)
17.Connect multiplug to injector.
18.Repeat above operation for remaining injectors.
19.Connect fuel hoses.
20.New injectors must be programmed using
TestBook.
21.Fit rocker shaft.See ENGINE , Repair.
22.Fit cooling fan.See COOLING SYSTEM,
Repair.
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FUEL SYSTEM
9
REPAIR HEATER PLUGS - SET
Service repair no - 19.60.31
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Remove battery cover.
3.Disconnect battery negative lead.
4.Disconnect 4 heater plug leads.
5.Loosen and remove 4 heater plugs.
Refit
6.Throughly clean heater plugs and seating area
in cylinder head.
7.Apply a suitable anti-seize compound to threads
of heater plugs.
8.Fit heater plugs and tighten to16 Nm (12 lbf. ft)
.
9.Connect heater plug leads.
10.Fit engine acoustic cover.
11.Reconnect battery negative lead.
12.Fit battery cover.INTERCOOLER
Service repair no - 19.42.15
Remove
1.Remove radiator.See COOLING SYSTEM,
Repair.
2.Release clip and remove air hose from
intercooler.
Refit
3.Position air hose to intercooler and secure with
clip.
4.Fit radiator.See COOLING SYSTEM, Repair.
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FUEL SYSTEM
11
REPAIR REGULATOR - FUEL PRESSURE
Service repair no - 19.45.06
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove 3 bolts and remove engine acoustic
cover.
4.Release hose from fuel cooler.
5.Release fuel hoses from pressure regulator.
CAUTION: Plug the connections.
6.Disconnect multiplug from fuel temperature
sensor.
7.Remove 3 bolts, remove pressure regulator from
cylinder head and collect gasket and’O’ring.
8.Remove fuel filter from cylinder head.
9.Remove fuel temperature sensor and discard
sealing washer.
10.Remove fuel hose and fuel pipe and discard’O’
rings.
Refit
11.Clean fuel pressure regulator, mating face and
fuel filter.
12.Clean fuel pipe unions.
13.Fit fuel pipe and fuel hose to pressure regulator
using new’O’rings.
14.Fit fuel temperature sensor using new sealing
washer and tighten to14 Nm (11 lbf.ft).
15.Fit fuel filter to cylinder head.
16.Using a new gasket and’O’ring position
pressure regulator and tighten bolts to25 Nm
(18 lbf.ft).
17.Connect fuel temperature sensor.
18.Connect fuel hoses to pressure regulator and
fuel cooler.
19.Fit engine acoustic cover.
20.Reconnect battery negative lead.
21.Fit battery cover.
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COOLING SYSTEM
3
DESCRIPTION AND OPERATION
NOTE: Inset A shows differences for Pre
EU3 models
1.Pressure cap
2.Overflow pipe
3.Heater return hose
4.Heater matrix
5.Heater inlet hose
6.Oil cooler return pipe - EU3 models
7.Connecting hose
8.Oil cooler housing assembly
9.Heater inlet pipe
10.Connecting hose
11.Outlet housing
12.Engine Coolant Temperature (ECT) sensor
13.Bleed screw
14.Radiator top hose
15.Radiator - upper
16.Intercooler
17.Gearbox oil cooler
18.Radiator - lower
19.Viscous fan
20.Drain plug
21.Connecting hose
22.Fuel cooler feed hose
23.Radiator bottom hose
24.Thermostat housing
25.Connecting hose
26.Coolant pump feed pipe
27.Coolant by-pass pipe
28.Radiator bleed pipe
29.Connecting hose
30.Coolant pump
31.Fuel cooler
32.Heater/expansion tank return hose
33.Expansion tank
34.EGR Cooler - EU3 models
35.Connecting hose - EU3 models
36.Connecting hose - EU3 models
37.Hose - EGR Cooler to oil cooler return pipe -
EU3 models
38.Radiator lower feed hose - Pre EU3 models
39.Oil cooler return pipe - Pre EU3 models
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