alternator LAND ROVER DEFENDER 1999 Workshop Manual

01INTRODUCTION
10
INFORMATION CROSS REFERENCE OF EMISSION SYSTEM
TERMINOLOGY
NEW TERM (ACRONYM)
Accelerator pedal (AP).................................................
Air cleaner (ACL)..........................................................
Air conditioning (A/C)...................................................
Battery positive voltage (B+)........................................
Closed loop (CL)..........................................................
Closed throttle position (CTP)......................................
Canister purge valve (CANPV)....................................
Data link connector (DLC)...........................................
Diagnostic trouble code (DTC).....................................
Distributor ignition (DI).................................................
Engine control module (ECM)......................................
Engine coolant level (ECL)...........................................
Engine coolant temperature (ECT)..............................
Engine speed (RPM)....................................................
Evaporative emission system (EVAP)..........................
Engine fuel temperature sensor (EFTS)......................
4th gear, 3rd gear etc. (4GR, 3GR)..............................
Fuel pump (FP)............................................................
Fan control module (FCM)...........................................
Generator (GEN)..........................................................
Ground (GND)..............................................................
Heated oxygen sensor (H02S)....................................
Idle air control (IAC)......................................................
Idle air control valve (IACV).........................................
Ignition control module (ICM).......................................
Intake air temperature (IAT).........................................
Manifold vacuum zone (MVZ)......................................
Mass air flow sensor (MAF).........................................
Open loop (OL)............................................................
Relay module (RM)......................................................
Solid state relay module (SSRM).................................
Three way catalytic converter (TWC)..........................
Throttle body (TB)........................................................
Throttle position sensor (TP)........................................
Transmission range (TR)..............................................
Wide open throttle (WOT)............................................OLD TERM (ACRONYM)
Throttle pedal (-)..........................................................
Air cleaner (-)...............................................................
Air conditioning (AC)....................................................
Battery plus, bat +, bat feed (B+).................................
Closed loop (-).............................................................
Closed throttle, idle position (-)....................................
Charcoal canister purge valve (-).................................
Serial link (-)................................................................
Fault code (-)...............................................................
Electronic ignition (-)....................................................
Electronic control unit (ECU)........................................
Coolant level (-)...........................................................
Coolant temperature (temp).........................................
Coolant temperature thermistor (-)..............................
Engine speed (rev/min)................................................
Evaporative loss system (ELC)...................................
Fuel temperature thermistor (-)....................................
Fourth gear, 3rd gear (-)..............................................
Fuel pump (-)...............................................................
Condenser fan timer (-)................................................
Alternator (-)................................................................
Ground, earth (B-)........................................................
Lambda (02) sensor (-)................................................
Idle speed control (ISC)................................................
Stepper motor (-).........................................................
Ignition module (-)........................................................
Intake temperature/ambient temperature (-)................
Manifold depression, vacuum (-).................................
Air flow meter (-)..........................................................
Fault code display unit (-)............................................
Open loop (-)...............................................................
Relay (-).......................................................................
Control unit (-)..............................................................
Catalyst, catalytic converter (CAT)..............................
Throttle housing (-)......................................................
Transmission gear (-)...................................................
Full throttle, wide open throttle (WOT).........................
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04GENERAL SPECIFICATION DATA
8
INFORMATION AIR CONDITIONING
System CFC free, expansion valve system.............................................................................
Compressor Nippon Denso.....................................................................
Refrigerant R134a CFC free.......................................................................
Charge quantity 750 g±50 g ................................................................
Refrigerant oil ND-OIL 8...................................................................
WIPER MOTORS
Tailgate wiper motor
Make/type IMOS (non-serviceable)........................................................................
Running current, wet screen at 20°C ambient 1.0 to 2.8 amps.................
Wiper speed, wet screen at 20°C ambient 37 to 43 cycles per minute.......................
Windscreen wiper motor
Make/type Lucas 14W uprated two speed........................................................................
Armature end float 0,1 to 0,2 mm............................................................
Brush length, minimum 4,8 mm....................................................
Brush spring tension 140 to 200 g........................................................
Resistance of armature winding
at 16˚C (69˚F) measured between adjacent
commutatator segments 0.23 to 0.35 ohms...................................................
Light running, rack disconnected: current at 13.5 V 2.0 amps.........
Wiper speed, wet screen, 60 seconds from cold Low speed - 45±3 rev/min, High speed - 65±5 ..............
rev/min
ELECTRICAL
System 12 volt, negative ground.............................................................................
Battery
Make/type Delphi GP31........................................................................
Alternator
Type Nippon Denso.................................................................................
Fuses
Type Autofuse (blade type) blow ratings to suit individual.................................................................................
circuits
Horns
Make/type Mixo TR99........................................................................
Starter motor
Make and type Bosch 12v.................................................................
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12ENGINE
8
REPAIR
NOTE: Non EU3 model illustrated.
21.Loosen vacuum pipe union from cylinder head
and discard’O’ring.
22.Loosen 2 bolts and release alternator support
bracket from cylinder head.
23. Pre EU3 model:-Remove bolt securing EGR
valve pipe to cylinder head.
24. EU3 model:-Release the clips and disconnect
the coolant hoses from the EGR cooler.
25.Release clips and disconnect top hose, heater
hose and heater feed hose.
26.Remove the nut and bolt securing the cuylinder
head to the timing chain cover.
27.Rotate engine clockwise to align mark on
camshaft sprocket between coloured links on
timing chain.
28.PositionLRT-12-058through camshaft carrier to
lock camshaft.
29.PositionLRT-12-158through gearbox bell
housing to lock crankshaft.
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12ENGINE
10
REPAIR Refit
39.Clean mating faces of cylinder head and cylinder
block.
40.Check cylinder head for warping, across centre
and from corner to corner:
Maximum warp = 0.10 mm (0.004 in)
CAUTION: Cylinder heads may not be
refaced, replace cylinder head assembly if
warping exceeds figure given.
41.Ensure coolant and oil passages are clean.
42.Clean dowel holes and fit new dowels.
43.Fit new cylinder head gasket of the correct
thickness with the word’TOP’uppermost.
44.Using assistance, fit cylinder head and locate on
to dowels.
45.Carefully enter new cylinder head bolts together
with their captive washers,DO NOT DROP.
Lightly tighten bolts.
46.Using sequence shown, tighten cylinder head
bolts to:-
Stage 1 -30 Nm (23 lbf.ft)
Stage 2 -65 Nm (48 lbf.ft)
Stage 3 -90°
Stage 4 -Further 180°
Stage 5 -Further 45°
CAUTION: Ensure correct tightening
sequence is followed for all 5 tightening
stages. Do not tighten bolts 315°in one
operation.
47.Fit nut and bolt securing cylinder head to timing
chain cover and tighten to25 Nm (18 lbf.ft).
48.Clean camshaft sprocket and mating face on
camshaft.
49.Ensure engine is set to TDC No. 1 cylinder and
mark on camshaft sprocket is positioned
between the 2 coloured links.
50.Position camshaft sprocket to camshaft, fit and
lightly tighten new bolts then loosen bolts half a
turn.
51.Clean fixed guide retaining pin and apply Loctite
242 to threads.
52.Fit and tighten fixed guide retaining pin to25 Nm
(18 lbf.ft).
53.Clean timing chain tensioner and fit new sealing
washer.
54.Fit timing chain tensioner and tighten to45 Nm
(33 lbf.ft).
55.Tighten camshaft sprocket retaining bolts to36
Nm (27 lbf.ft).
56.RemoveLRT-12-058from camshaft.
57.RemoveLRT-12-158from gearbox bell housing.
58.Clean access plug recess in cylinder head and
fit new’O’ring. Fit access plug.
59.Clean vacuum pump union.
60.Tighten vacuum pipe union to10 Nm (7lbf.ft).
61.Fit bolts securing alternator bracket to cylinder
head and tighten to25 Nm (18 lbf.ft).
62.Connect top hose, heater hoses and secure with
clips.
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12ENGINE
16
REPAIR
NOTE: Non EU3 model illustrated.
17.Disconnect multiplug from fuel temperature
sensor.
18.Disconnect multiplug from CKP sensor. Remove
bolt securing CKP sensor, remove sensor and
discard’O’ring.
CAUTION: If fitted:- Retain CKP sensor
spacer.
19.Disconnect 4 glow plug leads.
20.Remove nut securing alternator lead and
disconnect multiplug.
NOTE: Non EU3 model illustrated.
21.Remove 2 bolts securing engine harness to
camshaft carrier.
22.Disconnect A/C compressor and ECT sensor
multiplugs.
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12ENGINE
18
REPAIR
35.Remove 2 bolts and remove acoustic cover from
rear of cylinder head.
36.FitLRT-12-138to suitable lifting chains and
connect to lifting eyes on engine.
37.Remove 2 nuts from RH and LH front engine
mountings.
38.Fit trolley jack to support gearbox.
39.With assistance raise chains and remove engine
from vehicle.Refit
40.With assistance, raise engine from bench and
position in vehicle.
41.With assistance, align engine to gearbox input
shaft.
42.Position 2 upper bolts securing gearbox housing
to engine and tighten to50 Nm (37 lbf.ft).
43.Lower engine onto mountings and tighten nuts to
85 Nm (63 lbf.ft).
44.RemoveLRT-12-138from engine.
45.Fit and tighten bolt securing engine closing panel
to gearbox.
46.Raise vehicle on ramp.
47.Fit bolts securing gearbox housing to engine and
tighten to50 Nm (37 lbf.ft).
48.Lower ramp.
49.Fit acoustic cover to rear of cylinder head and
tighten bolts.
50.Position coolant hose to engine oil cooler and
secure clip.
51.Position PAS pump and tighten bolts to25 Nm
(18 lbf.ft).
52.Position PAS pulley and tighten bolts to25 Nm
(18 lbf.ft).
53.Position A/C compressor and tighten bolts to25
Nm (18 lbf.ft).
54.Route engine harness beneath inlet manifold
and connect multiplugs to oil pressure switch,
A/C compressor, and ECT sensor.
55.Fit and tighten bolts securing engine harness to
camshaft carrier.
56.Connect multiplug to alternator.
57.Connect battery lead to alternator and tighten
nut.
58.Clean CKP sensor and mating face.
CAUTION: If originally fitted:- Fit spacer to
CKP sensor.
59.Using a new’O’ring, fit CKP sensor, tighten bolt
to10 Nm (7 lbf.ft).
60.Connect CKP sensor multiplug.
61.Connect multiplugs to EGR solenoid, inlet
manifold sensor, injector harness, fuel
temperature sensor and CKP sensor.
62.Connect glow plug leads.
63.Connect multiplug to condensor cooling fan.
64.Connect vacuum hose to EGR valve.
65.Connect EGR vacuum hose to vacuum pipe.
66.Position pipe to vacuum pump and secure pipe
to acoustic cover clips.
67.Position fuel cooler. Apply Loctite 242 to bolts
and tighten to18 Nm (13 lbf.ft).
68.Disconnect fuel hose from connector block and
connect to fuel cooler.
69.Connect fuel hoses to fuel cooler and connector
block on cylinder head.
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ENGINE
3
OVERHAUL GASKET - CYLINDER HEAD
Service repair no - 12.29.02.01
Remove
CAUTION: The following procedures
should only be carried out when cylinder
head is to be overhauled; for replacement
of cylinder head gasket only, see Repairs section -
Gasket - Cylinder head.
NOTE: The following procedure covers
both EU3 and non EU3 engines
1.Remove exhaust manifold gasket.See
MANIFOLD AND EXHAUST SYSTEM, Repair.
2.Remove inlet manifold gasket.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
3. Models with EGR cooler:Remove and discard
2 Allen screws securing EGR pipe to cooler.
4.Progressively loosen then remove 13 bolts
securing camshaft cover, remove cover; remove
and discard gasket.
5.Remove isolators and sealing washers from
cover.
6.Disconnect injector multiplug from camshaft
carrier.
7.Disconnect multiplug from ECT sensor.
8.Remove bolt securing alternator strap bracket to
cylinder head.
9.Set engine to TDC firing - No. 1 cylinder -
coloured links on timing chain are aligned with
timing mark on camshaft sprocket.
10.Fit timing pinLRT-12-058into slot in camshaft.
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12ENGINE
4
OVERHAUL
11.Disconnect alternator/vacuum pump oil feed pipe
union from cylinder head, remove and discard
’O’ring.
12.Remove camshaft sprocket access plug from
front of cylinder head, remove and discard’O’
ring.
13.Remove timing chain fixed guide Allen screw.
14.Remove timing chain tensioner, remove and
discard sealing washer.
15.Remove and discard 3 bolts securing camshaft
sprocket to camshaft; release sprocket from
camshaft.
16.Remove bolt and nut securing front of cylinder
head to timing chain cover.
17.Using sequence shown, progressively loosen
then remove 12 cylinder head bolts; discard
bolts together with their captive washers.
18.Using assistance, remove cylinder head and
place on 2 wooden blocks.
CAUTION: Cylinder head is dowel located,
do not tap it sideways to free it from
cylinder block. Support both ends of
cylinder head on blocks of wood. With the
camshaft carrier bolted down, the injector nozzles
and some of the valves will protrude from the face
of the cylinder head.
19.Remove the cylinder head gasket.
20.Note the gasket thickness indicator and ensure
the same thickness gasket is used on refitment
of the cylinder head.
CAUTION: If new pistons, connecting rods
or crankshaft are fitted, it will be
necessary to measure piston stand proud
in order to determine thickness of gasket
required.See this Section.
21.Remove and discard 2 plastic locating dowels
from cylinder block.
22.Carry out cylinder head overhaul procedures.
See this Section.
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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).
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EMISSION CONTROL
3
DESCRIPTION AND OPERATION 1.EGR Solenoid
2.Vacuum hose (light brown)
3.T-piece
4.Vacuum hose to brake servo
5.Non-return valve
6.Brake servo
7.Inlet manifold
8.Exhaust manifold
9.EGR pipe
10.Vacuum pump/alternator assembly
11.Air intake hose from intercooler
12.EGR valve assembly
13.Vacuum hose to vacuum pump
14.Vacuum hose to EGR valve suction port (blue)
15.To atmosphere
16.In-line filter
17.Vent hose - EGR solenoid to in-line filter (green)
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