ecu LAND ROVER DEFENDER 1999 Manual PDF
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 1999, Model line: DEFENDER, Model: LAND ROVER DEFENDER 1999Pages: 667, PDF Size: 8.76 MB
Page 216 of 667
EMISSION CONTROL
15
DESCRIPTION AND OPERATION EGR System - Type 2
This system features twin modulators mounted one above the other on a metal plate located on the inner wing at
the RH side of the engine. The modulators are electrically controlled by the engine management system and are
used to modulate a vacuum source to the EGR valve and a supplementary Inlet Throttle (ILT) valve; the two
valves are controlled to operate in tandem. The ILT valve vacuum pot is mounted adjacent to the EGR valve
housing and has a linkage which connects to a butterfly valve mounted in front of the EGR valve at the air intake
manifold.
The modulator operations are electrically controlled by signals from the engine management system which
determines the required volume of exhaust gas needed in response to inputs relating to air flow, engine operating
conditions and ambient parameters such as temperature and altitude. The engine management ECM switches on
the circuit by completing the path to ground, operating the vacuum modulators.
Pre EU3 models:The exhaust gases are routed from the exhaust manifold through a shaped metal pipe which
connects to the underside of the EGR valve. The pipe is held securely in position to the front of the engine cylinder
head using a metal clamp bracket. The EGR pipe is attached to a mating port at the front end of the exhaust
manifold using two Allen screws and at the EGR valve assembly by a metal band clamp. The two Allen screws
fixing the EGR pipe to the exhaust manifold should be replaced every time the EGR pipe is removed.
CAUTION: Extreme care should be exercised when removing and refitting the EGR pipe to avoid
damage.
EU3 models:The exhaust gases are routed from the exhaust manifold through the EGR cooler to the underside
of the EGR valve. The EGR cooler is bolted to the front of the engine cylinder head. An EGR pipe connects the
EGR cooler to the exhaust manifold and is secured by two Allen screws. The two Allen screws fixing the EGR pipe
to the exhaust manifold should be replaced every time the EGR pipe is removed. A second pipe connects the
EGR cooler to the EGR valve; this pipe is secured to the EGR valve by a clip, and to the cooler by two Allen
screws.
CAUTION: Extreme care should be exercised when removing and refitting the EGR pipe to avoid
damage. When refitting the EGR cooler, always tighten the pipe connections BEFORE tightening
the bolts securing the cooler to the cylinder head.
When a vacuum is applied to the EGR suction port, it causes a spindle with sealing disc (EGR valve) to be raised,
opening the port at the EGR pipe to allow the recirculated exhaust gas to pass through into the inlet manifold. The
valve is spring loaded so that when the vacuum is removed from the suction port, the valve returns to its rest
position to tightly close the exhaust gas port.
A vacuum is simultaneously applied to the inlet throttle (ILT) valve suction port which causes the butterfly valve in
the inlet manifold to close by means of a spindle and lever mechanism. Closing the butterfly valve limits the supply
of fresh intercooled air entering the inlet manifold and causes a depression within the inlet manifold to create a
greater suction at the open port to the EGR delivery pipe. In this condition a greater mass of recirculated exhaust
gas is drawn into the inlet manifold for use in the combustion process. When the vacuum is released from the ILT
valve suction port a spring returns the butterfly valve to its fully open position.
By controlling the quantities of recirculated exhaust gas and fresh intake air available in the inlet manifold, the
optimum mix for the prevailing engine operating conditions can be maintained which ensures the intake gas to the
combustion chambers will have burning rate properties which will reduce the NO
2emissions to an acceptable
level. Normally, full recirculation is only applicable when the NO
2emissions are most prevalent.
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Page 218 of 667
EMISSION CONTROL
1
REPAIR VALVE - EGR - NON EU3 MODELS
Service repair no - 17.45.01
Remove
1.Disconnect battery negative lead.
2.Remove 3 bolts and remove engine acoustic
cover.
3.Remove cooling fan.See COOLING SYSTEM,
Repair.
4.Remove battery cover.
5.Disconnect battery negative lead.
6.Disconnect vacuum hose from EGR valve
7.Loosen clip screw and release air intake from
EGR valve.
8.Remove 4 bolts, release EGR valve from inlet
manifold and discard gasket.
9.Remove 2 bolts and release EGR valve clip from
cylinder head.
10.Remove and discard 2 Allen screws securing
EGR valve pipe to exhaust manifold.
11.Remove EGR valve assembly.
12.Remove clip and remove pipe from EGR valve.Refit
13.Clean EGR valve and mating face on pipe.
14.Position pipe to EGR valve, fit retaining clip and
finger tighten bolt.
15.Clean inlet manifold face.
16.Position EGR valve to inlet manifold using new
gasket and tighten bolts to10 Nm (7lbf.ft).
17.Position air intake hose and tighten clip screw.
18.Position EGR pipe bracket, fit bolts and finger
tighten.
19.Position EGR valve pipe to exhaust manifold and
finger tighten allen screws
20.Tighten EGR valve clip to5 Nm (3 lbf.ft).
21.Tighten EGR pipe bracket bolts to10 Nm (7
lbf.ft).
22.Tighten 2 Allen screws to10 Nm (7 lbf.ft).
23.Connect vacuum hose to EGR valve.
24.Fit cooling fan.See COOLING SYSTEM,
Repair.
25.Fit engine acoustic cover.
26.Reconnect battery negative lead.
27.Fit battery cover.
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Page 219 of 667
17EMISSION CONTROL
2
REPAIR VALVE - EGR - EU3 MODELS
Service repair no - 17.45.01
Remove
1.Release turnbuckles and remove battery cover.
2.Disconnect battery earth lead.
3.Remove 3 bolts and remove engine acoustic
cover.
4.Remove cooling fan coupling.See COOLING
SYSTEM, Repair.
5.Disconnect vacuum hose(s) from EGR valve.
6.Loosen screw and disconnect air intake hose
from EGR valve.
7.Remove screw and remove clamp securing EGR
pipe to EGR valve.
8.Remove 4 bolts securing EGR valve, remove
valve and discard gasket.
9.Discard EGR pipe gasket.Refit
10.Clean EGR valve and mating faces.
11.Fit new gasket to EGR pipe.
12.Using new gasket, position EGR valve to inlet
manifold fit bolts and tighten to10 Nm (7 lbf.ft).
13.Fit EGR pipe clamp and tighten screw to6Nm
(4.4 lbf.ft).
14.Connect air intake hose to EGR valve and
tighten clip.
15.Connect vacuum hoses to EGR valve.
16.Fit cooling fan coupling.See COOLING
SYSTEM, Repair.
17.Fit engine acoustic cover and tighten bolts to10
Nm (7 lbf.ft).
18.Connect battery earth lead.
19.Fit battery cover and secure the fixings.
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Page 220 of 667
EMISSION CONTROL
3
REPAIR INLET THROTTLE (ILT) MODULATOR
Service repair no - 17.45.03
Remove
1.Identify the fitted positions of the 3 vacuum
pipes, then disconnect from the ILT modulator
valve.
2.Disconnect multiplug from ILT modulator.
3.Remove 2 nuts securing modulator and remove
ILT modulator from its moutings.
Refit
4.Fit ILT modulator to its mountings, fit the nuts
and tighten to10 Nm (7 lbf.ft).
5.Connect vacuum pipes to the positions identified
during removal.
6.Connect multiplug to ILT modulator.SOLENOID - VALVE - EGR
Service repair no - 17.45.04
Remove
1.Disconnect vacuum pipes and multiplug from
EGR solenoid.
2.Remove 2 nuts and remove EGR solenoid.
Refit
3.Position EGR solenoid and tighten securing
nuts.
4.Connect vacuum hoses and multiplug.
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Page 248 of 667
ENGINE MANAGEMENT SYSTEM
25
DESCRIPTION AND OPERATION Input / Output
The glow plugs receive a feed from the glow plug relay (C0215-3) on a yellow/black then individual black wires.
The ECM provides the earth path for the glow plug relay (C0151-6), working in tandem with the Alarm ECU. The
supply voltage heats the coils to approximately 1000°C (1832°F). The glow plug circuit is wired in parallel, the
body of each glow plug is screwed directly into the engine block which provides each glow plug with an earth path.
The glow plugs can fail in one or more of the following ways:
Heater coil open circuit.
Control coil open circuit.
Poor earth quality.
Short circuit to vehicle supply.
Short circuit to vehicle earth.
Harness fault.
Relay windings open circuit.
Incorrect relay fitted.
In the event of a glow plug failure, any of the following symptoms may be observed:
Difficult starting.
Excessive smoke emissions after engine start.
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Page 252 of 667
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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Page 257 of 667
19FUEL SYSTEM
2
DESCRIPTION AND OPERATION DESCRIPTION
General
The fuel delivery system comprises a fuel tank, fuel pump, fuel pressure regulator, five injectors and a fuel filter.
The system is controlled by the ECM, which energises the fuel pump relay and controls the operation and timing
of each injector solenoid.
Unlike other Diesel engines, the Td5 has no injection pump. The diesel direct injection system receives fuel at
pressure from a two stage fuel pump located in the fuel tank. The system incorporates a fuel return to the fuel
pump, via a fuel cooler attached to the inlet manifold, and a fuel filter. A fuel pressure regulator is located in a
housing on the rear of the cylinder head. The regulator maintains the fuel delivered to the injectors at a constant
pressure and returns excess fuel back to the fuel filter and pump via the fuel cooler.
A fuel filter is positioned on the chassis longitudinal, below the RH rear wheel arch. The fuel feed and return to and
from the engine passes through the filter. The filter also incorporates a water sensor, which illuminates a warning
lamp in the instrument pack.
A moulded fuel tank is located at the rear underside of the vehicle between the chassis longitudinals. The tank
provides the attachment for the fuel pump and the fuel gauge sender unit, which is located inside the tank.
Fuel Tank and Breather
The fuel tank and breather system is a major part of the fuel delivery system. The fuel tank and breathers are
located at the rear of the vehicle between the chassis longitudinals.
Fuel Tank
The moulded fuel tank is made from High Molecular Weight (HMW) High Density Polyethylene (HDPE), and is
manufactured using a proportion of recycled plastic.
The tank is held in position by a metal cradle which is secured to the chassis cross members by four bolts, two
holding the front of the cradle in position, two holding the rear. The fuel tank has a useable capacity of 75 litres
(16.5 gallons).
An aperture in the top surface of the tank allows for the fitment of the fuel pump and fuel gauge sender unit, which
is retained with a locking ring. A reflective metallic covering is attached to the tank with three scrivets to shield the
tank from heat generated by the exhaust system.
Fuel Tank Breather System
The fuel tank filler tube incorporates a tank vent which allows air and fuel vapour displaced from the tank when
filling to vent to atmosphere via the filler neck.
A breather spout within the tank controls the tank’Full’height. When fuel covers the spout it prevents fuel vapour
and air from escaping from the tank. This causes the fuel to’back-up’in the filler tube and shuts off the filler gun.
The position of the spout ensures that when the filler gun shuts off, a vapour space of approximately 10% of the
tanks total capacity remains. The vapour space ensures that the Roll Over Value (ROV) is always above the fuel
level and vapour can escape and allow the tank to breathe.
The ROV is welded to the top surface of the tank. It is connected by a tube to the filler tube, which in turn is
connected to the atmospheric vent pipe. The ROV allows fuel vapour to pass through it during normal vehicle
operation. In the event of the vehicle being overturned the valve shuts off, sealing the tank and preventing fuel
from spilling from the atmospheric vent pipe.
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Page 261 of 667
19FUEL SYSTEM
6
DESCRIPTION AND OPERATION The fuel pressure regulator is located in a machined port in the lower part of the housing. The regulator is sealed
in the housing with two’O’rings and secured with an internal clip.
The regulator maintains the fuel pump delivery pressure at 4 bar (58 lbf.in
2). When the fuel pressure exceeds 4
bar (58 lbf.in2), the regulator opens and allows fuel to return to the fuel tank via the fuel cooler. The fuel returned
from the regulator is directed back into the fuel filter before being drawn by the high pressure stage of the fuel
pump and directed back to the injectors. A special tool can be attached to the regulator housing fuel feed port and
allows for the fitment of a suitable gauge to measure fuel pump delivery pressure.
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Page 262 of 667
FUEL SYSTEM
7
DESCRIPTION AND OPERATION INJECTORS
1.Solenoid housing
2.Electrical connector
3.Push rod socket
4.Push rod return spring
5.Housing
6.Fuel delivery port7.Fuel return port
8.Nozzle cap nut
9.Copper washer
10.Nozzle
11.’O’ring
12.Cap screw
The five injectors are located in the cylinder head adjacent the camshaft, with the nozzle of each injector
protruding directly into the cylinder. Each injector is sealed into the cylinder head with a’O’ring and copper
washer and secured with a clamp and bolt.
Each injector is operated mechanically by an overhead camshaft and rocker, and electrically by a solenoid
controlled by the ECM. Each injector is supplied with pressurised fuel from the pump via the regulator housing and
internal drillings in the cylinder head.
The solenoid housing is secured to the injector body with two cap screws and is a sealed unit. It has a two pin
electrical connector on its top face.
The injector body is machined from a forging. The body has a machined central bore which locates the push rod.
A thread on the outer diameter provides the attachment for the nozzle cap nut. The body also provides attachment
for the solenoid housing.
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Page 270 of 667
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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