fuel LAND ROVER DEFENDER 1999 Service Manual

ENGINE
31
REPAIR All Models
6.Remove 3 bolts securing centrifuge to engine oil
cooler.
7.Remove centrifuge and discard’O’ring.
8.Remove 2 bolts, remove drain pipe from
centrifuge and discard gasket.Refit
9.Clean mating faces of centrifuge, oil cooler and
sump.
10.Position drain pipe to centrifuge using new
gasket and tighten bolts to10 Nm (7 lbf.ft).
11.Position new’O’ring to oil cooler.
12.Position centrifuge and tighten bolts to25 Nm
(18 lbf.ft).
13.Align drain pipe to sump, fit new gasket and
tighten bolts to10 Nm (7 lbf.ft)
Models with air conditioning only
14.Position compressor and tighten bolts to25 Nm
(18 lbf.ft).
15.Fit auxiliary drive belt.See ELECTRICAL,
Repair.
All Models
16.Fit turbocharger.See FUEL SYSTEM, Repair.
17.Fit underbelly panel.See CHASSIS AND
BODY, Repair.
ProCarManuals.com

ENGINE
1
OVERHAUL GASKET - INLET MANIFOLD
Service repair no - 30.15.08.01
Remove
NOTE: The following procedure covers
both EU3 and non EU3 engines
NOTE: EU3 Engine in main illustration, Pre
EU3 condition shown in inset.
1.Remove and discard 2 Allen screws securing
EGR pipe or EGR cooler to exhaust manifold.
2.Remove bolt securing EGR pipe to cylinder
head, (if fitted)
3.Disconnect multiplug from IAT and MAP sensor.
4.Remove 4 bolts securing fuel cooler to inlet
manifold. and remove cooler.
5.Remove bolt securing engine dipstick tube to
camshaft carrier.
6.Release and remove engine dipstick tube.
7.Remove’O’ring from dip stick tube.
8.Disconnect 4 leads from glow plugs.
9.Remove 2 nuts and 8 bolts and remove inlet
manifold.
10.Remove manifold gasket.Refit
1.Clean inlet manifold and mating face, clean
mating faces of EGR pipe, exhaust manifold and
EGR cooler (if fitted).
2.Fit new gasket.
3.Position inlet manifold and working from the
centre outwards, fit inlet manifold nuts and bolts
and tighten to25 Nm (18 lbf.ft).
4.Connect glow plug leads.
5.Clean engine dipstick tube.
6.Fit new’O’ring to dipstick tube.
7.Fit engine dipstick tube to camshaft carrier and
tighten bolt to10 Nm (7 lbf.ft).
8.Position fuel cooler and tighten bolts to25 Nm
(18 lbf.ft).
9.Connect multiplug to IAT and MAP sensor.
10.Position EGR pipe or EGR cooler to exhaust
manifold and using new Allen screws tighten to
10 Nm (7 lbf.ft).
11.Fit EGR pipe clamp to cylinder head, (if fitted)
and tighten bolt to10 Nm (7 lbf.ft).
ProCarManuals.com

12ENGINE
6
OVERHAUL 14.Clean fixed guide Allen screw and apply Loctite
242 to screw threads.
15.Fit fixed timing chain guide Allen screw and
tighten to25 Nm (18 lbf.ft).
16.Clean timing chain tensioner and fit new sealing
washer.
17.Fit timing chain tensioner and tighten to45 Nm
(33 lbf.ft).
18.Tighten camshaft sprocket bolts to36 Nm (27
lbf.ft).
19.Remove toolLRT-12-058from camshaft.
20.Lubricate a new’O’ring with engine oil and fit to
camshaft sprocket access plug.
21.Fit camshaft sprocket access plug.
22.Clean alternator/vacuum pump oil feed hose
union.
23.Lubricate a new’O’ring with engine oil and fit to
alternator/vacuum pump hose union.
24.Fit and tighten alternator/vacuum pump oil hose
union to10 Nm (7 lbf.ft).
25.Fit bolt securing alternator strap bracket to
cylinder head and tighten to25 Nm (18 lbf.ft).
26.Connect multiplugs to ECT sensor and EUIs.
CAUTION: Following cylinder head
overhaul, it will be necessary, before
fitting the camshaft cover, to adjust the
fuel injector rockers using the following
procedures:
27.Rotate engine clockwise until No. 1 EUI lobe is
at full lift.
28.Tighten No.1 rocker adjusting screw until the EUI
plunger is felt to’bottom out’.
29.Loosen rocker adjusting screw 1 complete turn
to give EUI plunger the required bump clearance
and tighten rocker adjusting screw locknut to16
Nm (12 lbf.ft).
CAUTION: Ensure screw does not turn as
locknut is tightened.30.Carry out above procedures for the remaining 4
rocker arms.
31.After completion of rocker adjustment, slowly
rotate engine clockwise 2 complete turns by
hand to ensure that no EUI’s are bottoming out
on their plungers.
32.Clean camshaft cover and mating face.
33.Fit new sealing washers and isolators as
necessary to camshaft cover.
34.Fit new camshaft cover gasket to cover.
CAUTION: Gasket must be fitted dry.
35.Fit camshaft cover to camshaft carrier, fit bolts
and working from the centre outwards, tighten
bolts to10 Nm (7 lbf.ft).
36.Fit inlet manifold gasket.See MANIFOLD AND
EXHAUST SYSTEM, Repair.
37.Fit exhaust manifold gasket.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
38. EGR cooler fitted:-Position EGR pipe to cooler,
fit new Allen screws and tighten to10 Nm (7
lbf.ft).
ProCarManuals.com

12ENGINE
8
OVERHAUL CYLINDER HEAD - OVERHAUL
Service repair no - 12.29.19.01
Dismantling
1.Remove cylinder head gasket.See this
Section.
CAUTION: Due to the design of the
cylinder head which incorporates drillings
for the fuel injection system, it is important
that absolute cleanliness is adhered to when
carrying out overhaul procedures.
2.Note the gasket thickness indicator and ensure
the same thickness gasket is used on refitment
of cylinder head.
CAUTION: If new pistons, connecting rods
or crankshaft are fitted, it will be
necessary to determine thickness of
gasket required.See this Section.
3.Remove 4 glow plugs.
4.Disconnect multiplugs from EUI’s and remove
harness from camshaft carrier. Remove and
discard’O’ring from harness multiplug.
5.Loosen lock nuts and fully unscrew rocker
adjusting screws; discard locknuts and screws.
6.Remove and discard 6 bolts securing rocker
shaft, remove shaft.
NOTE: Dowel located.
7.Using sequence shown, progressively loosen 13
bolts securing camshaft carrier to cylinder head
until valve spring pressure is released; remove
bolts.
CAUTION: Do not discard bolts at this
stage.
ProCarManuals.com

12ENGINE
10
OVERHAUL
20.Using toolLRT-12-071, remove and discard
valve stem oil seal.
21.Repeat above operations to remove remaining
valves.
22. Engine Serial No. Prefixes 15P to 19P:-
Disconnect spill return pipe from cylinder head
and fuel connector block, remove and discard’O’
rings.
ProCarManuals.com

ENGINE
11
OVERHAUL
23.Remove 3 bolts and remove fuel connector
block from cylinder head.
24.Remove and discard gasket,’O’ring and fuel
filter.
25.Remove spacer block and gasket (if fitted).Cylinder head and camshaft carrier - cleaning
1.Thoroughly clean cylinder head mating faces,
ensure oil and coolant passages are clear and
bolt holes are clean and dry.
CAUTION: Take care to ensure that EUI
drillings are clear.
2.Using suitable solvent, remove all traces of
sealant and gasket material.
CAUTION: Do not use metal scrapers.
3.Remove all traces of oil from camshaft bearings
and journals.
4.Clean glow plug threads.
Cylinder head - Inspection
1.Check core plugs for signs of leakage and
corrosion, seal replacement plugs with Loctite
243.
2.Check cylinder head for warping across centre
and from corner to corner.
Maximum cylinder head warp =0.1 mm (0.004
in).
CAUTION: Cylinder heads may not be
refaced, replace the head assembly if
warping exceeds the limit given.
ProCarManuals.com

ENGINE
19
OVERHAUL 16.Lubricate finger followers with engine oil.
17.Fit finger followers ensuring they are in their
original fitted order.
18.Lubricate cams and bearing journals on
camshaft, cylinder head and camshaft carrier
with engine oil.
19.Position camshaft in cylinder head with the
timing pin hole in the vertical position.
20.Apply an even film of sealant, Part No. STC
4600 to camshaft carrier face and spread to an
even film using a roller.
CAUTION: Ensure sealant does not block
oilways (arrowed) or contaminate
camshaft bearings. Assembly and bolt
tightening must be completed within 20 minutes
of applying sealant.
21.Fit camshaft carrier ensuring it is correctly
located on dowels.
22.Fit and lightly tighten new camshaft carrier bolts.
23.Using sequence shown, progressively tighten
bolts to25 Nm (18 lbf.ft).
24.Lubricate a new camshaft rear oil seal with
engine oil, fit seal using a suitable mandrel.
25.Position rocker shaft on camshaft carrier,
ensuring rocker shaft is located on dowel.
26.Fit new rocker shaft retaining bolts and working
from the centre outwards, tighten bolts
progressively to32 Nm (24 lbf.ft).27.Lubricate a new’O’ring with engine oil and fit to
injector harness multiplug.
28.Fit injector harness and connect multiplugs.
29.Clean fuel connector block and mating face.
30.Lubricate a new fuel filter’O’ring with engine oil.
31.Fit new fuel filter,’O’ring and gasket.
CAUTION: Gasket must be fitted dry.
32.Fit fuel connector block spacer and gasket (if
fitted).
33.Fit fuel connector block, fit bolts and tighten to
25 Nm (18 lbf.ft).
34.Clean glow plugs.
35.Fit glow plugs to cylinder head and tighten to16
Nm (12 lbf.ft).
36. Engine Serial No. Prefixes 15P to 19P:-
Lubricate new’O’rings with engine oil and fit to
spill return pipe; fit pipe and tighten connectors
to20 Nm (15 lbf.ft).
37.Fit new cylinder head gasket.See this Section.
CAUTION: Ensure that the fuel injector
rockers are adjusted following the
procedures given in Gasket - Cylinder
head - Refit.
ProCarManuals.com

EMISSION CONTROL
7
DESCRIPTION AND OPERATION CRANKCASE EMISSION CONTROL
All internal combustion engines generate oil vapour and smoke in the crankcase as a result of high crankcase
temperatures and piston ring and valve stem blow-by. A closed crankcase ventilation system is used to vent
crankcase gases back to the air induction system and so reduce the emission of hydrocarbons.
Gases from the crankcase are drawn into the inlet manifold to be burnt in the combustion chambers with the fresh
air/fuel mixture. The system provides effective emission control under all engine operating conditions.
Crankcase gases are drawn through the breather port in the top of the camshaft cover and routed through the
breather hose and breather valve on the flexible air intake duct to be drawn into the turbocharger intake for
delivery to the air inlet manifold via the intercooler.
An oil separator plate is included in the camshaft cover which removes the heavy particles of oil before the
crankcase gas leaves via the camshaft cover port. The rocker cover features circular chambers which promote
swirl in the oil mist emanating from the cylinder head and camshaft carrier. As the mist passes through the series
of chambers between the rocker cover and oil separator plate, oil particles are thrown against the separator walls
where they condense and fall back into the cylinder head via two air inlet holes located at each end of the rocker
cover.
The breather valve is a pressure depression limiting valve which progressively closes as engine speed increases,
thereby limiting the depression in the crankcase. The valve is of moulded plastic construction and has a port on
the underside which plugs into a port in the flexible air duct. A port on the side of the breather valve connects to
the camshaft cover port by means of a breather hose which is constructed from a heavy duty braided rubber hose
which is held in place by hose clips. A corrugated plastic sleeve is used to give further protection to the breather
hose. The breather valve is orientation sensitive, and’TOP’is marked on the upper surface to ensure it is
mounted correctly.
It is important that the system is air tight. Hose connections to ports should be checked and the condition of the
breather hose should be periodically inspected to ensure it is in good condition.
ProCarManuals.com

17EMISSION CONTROL
8
DESCRIPTION AND OPERATION EXHAUST GAS RECIRCULATION
The exhaust gas recirculation (EGR) valve permits a controlled amount of exhaust gas to combine with the fresh
air entering the engine. The exhaust gas reduces the combustion temperature by delaying the fuel burning rate,
which assists in reducing the quantity of oxides of nitrogen.
On EU3 models, an EGR cooler is employed to further reduce the combustion temperature. By passing the
exhaust gas through a bundle of pipes flooded by coolant, the density of the exhaust gas going into the engine is
increased. This process further reduces the amount of NO
2in the exhaust.
Recirculation of too much exhaust gas can result in higher emissions of soot, HC and CO due to insufficient air.
The recirculated exhaust gas must be limited so that there is sufficient oxygen available for combustion of the
injected fuel in the combustion chamber. To do this the ECM is used to control the precise quantity of exhaust gas
to be recirculated in accordance with the prevailing operating conditions. Influencing factors include:
The mass of air flow detected by the MAF sensor.
The ambient air temperature detected by the AAP sensor. This is used to initiate adjustments to reduce the
amount of smoke produced at high altitudes.
The mass of air flow detected by the MAF sensor.
The ambient air temperature detected by the AAP sensor. This is used to initiate adjustments to reduce the
amount of smoke produced at high altitudes.
Other factors which are taken into consideration by the engine management system for determining the optimum
operating condition include:
Manifold inlet air temperature
Coolant temperature
Engine speed
Fuel delivered
The main components of the EGR system are as follows.
ProCarManuals.com

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................................
ProCarManuals.com