change time LAND ROVER DEFENDER 1999 Workshop Manual

01INTRODUCTION
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INFORMATION ACCESSORIES AND CONVERSIONS
DO NOT FITunapproved accessories or conversions,
as they could affect the safety of the vehicle.
Land Rover will not accept liability for death, personal
injury, or damage to property which may occur as a
direct result of the fitting of non-approved conversions
to the vehicle.
WHEELS AND TYRES
WARNING: DO NOT replace the road
wheels with any type other than genuine
Land Rover wheels which are designed for
multi-purpose on and off road use and have very
important relationships with the proper operation
of the suspension system and vehicle handling.
Replacement tyres must be of the make and sizes
recommended for the vehicle, and all tyres must
be the same make, ply rating and tread pattern.
STEAM CLEANING
To prevent consequential rusting, any steam cleaning
within the engine bayMUSTbe followed by careful
re-waxing of the metallic components affected.
Particular attention must be given to the steering
column, engine coolant pipes and hose clips.
SPECIFICATION
The specification details and instructions set out in
this Supplement apply only to a range of vehicles and
not to any one. For the specification of a particular
vehicle purchasers should consult their Dealer.
The Manufacturer reserves the right to vary
specifications with or without notice, and at such times
and in such manner as it thinks fit. Major as well as
minor changes may be involved in accordance with
the Manufacturer’s policy of constant product
improvement.
Whilst every effort is made to ensure the accuracy of
the particulars contained in this Supplement, neither
the Manufacturer or Dealer, by whom this Supplement
is supplied, shall in any circumstances be held liable
for any inaccuracy or the consequences thereof.SPECIAL SERVICE TOOLS
The use of approved special service tools is
important. They are essential if service operations are
to be carried out efficiently, and safely. Where special
tools are specified,only these tools should be used
to avoid the posibility of personal injury or
damage to the components.Also, the amount of time
which they can save can be considerable.
Special tools bulletins will be issued periodically giving
details of new tools as they are introduced.
All orders and enquiries from the United Kingdom
should be sent direct to Cartool (UK) Ltd. Overseas
orders should be placed with the local Cartool
distributor, where one exists. Countries where there is
no distributor may order direct from:
Cartool (UK) Ltd.
Unit 3,
Sterling Business Park,
Brackmills,
Northampton,
England, NN4 7EX.
The tools recommended in this Workshop Manual are
listed in an illustrated catalogue, obtainable from:
Land Rover Publications,
Character Mailing,
Heysham Road,
Bootle,
Merseyside, L70 1JL
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ENGINE
17
DESCRIPTION AND OPERATION The engine oil cooler assembly is located on the left hand side of the engine block behind the oil centrifuge and oil
filter. The housing is bolted to the engine block by seven bolts. A matrix is included in the oil cooler housing which
acts as a heat exchanger. Coolant flow circulates through the oil cooler housing under pressure from the coolant
pump and distributes the flow evenly around the matrix fins and then along the block into three core holes for
cylinder cooling. Coolant enters the oil cooler through a pipe with a rubber hose extension at the rear side of the
engine. The coolant hose is attached to the stub pipe of the oil cooler by a spring clip.
Oil, drawn from the sump by the oil pump, passes through the oil cooler via the cylinder block. The flow of coolant
around the exterior surface of the oil cooler matrix cools a proportion of the engine oil flow as it passes through the
oil cooler.
The oil cooler is sealed to the cylinder block by a gasket which must be replaced every time the oil cooler housing
is removed.
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EMISSION CONTROL
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DESCRIPTION AND OPERATION EGR VALVE
1.EGR valve vacuum port
2.EGR valve assembly
3.Gasket - EGR valve to inlet manifold
4.EGR pipe connection5.Exhaust gas intake
6.Intake air
7.EGR valve open (vacuum applied to EGR valve)
8.EGR valve closed (no vacuum applied to EGR
valve)
The EGR valve is a cast and machined assembly which locates on the front end of the inlet manifold assembly.
The machined faces of the EGR assembly and the inlet manifold are attached attached together using four bolts
passing through the four corners of a flange in the EGR assembly to tappings in the front face of the inlet manifold.
A gasket is used to seal the interface between the EGR valve and the front face of the inlet manifold. The gasket
should be changed every time the EGR valve assembly is removed from the air intake manifold.
The intake side of the EGR valve allows the passage of fresh intercooled air through to the inlet manifold via a
rubber hose which is attached to the front face of the EGR valve assembly by a metal band clamp. The bottom
port of the EGR valve is connected to the EGR pipe using a metal band clamp.
A vacuum port on top of the EGR valve connects the EGR solenoid through a blue, small bore suction hose.
When a vacuum is applied to the EGR valve suction port it causes a spindle with sealing disc (EGR valve) to be
raised, thereby opening the port at the EGR pipe to allow the recirculated exhaust gas to pass through into the
inlet manifold. When the vacuum is removed from the suction port the EGR valve returns to its rest position under
the influence of a spring to tightly close the exhaust gas port. Thus, controlled opening of the EGR valve
determines the mass of recirculated gas allowed to flow through to the inlet manifold.
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18ENGINE MANAGEMENT SYSTEM
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DESCRIPTION AND OPERATION OPERATION
Engine Management
The ECM controls the operation of the engine using stored information within its memory. This guarantees
optimum performance from the engine in terms of torque delivery, fuel consumption and exhaust emissions in all
operating conditions, while still giving optimum driveability.
The ECM will receive information from its sensors under all operating conditions, especially during:
Cold starting.
Hot starting.
Idle.
Wide open throttle.
Acceleration.
Adaptive strategy.
Backup strategy for sensor failures.
The ECM receives information from various sensors to determine the current operating state of the engine. The
ECM then refers this information to stored values in its memory and makes any necessary changes to optimise
air/fuel mixture and fuel injection timing. The ECM controls the air/fuel mixture and fuel injection timing via the
Electronic Unit Injectors (EUI), by the length of time the EUI’s are to inject fuel into the cylinder. This is a rolling
process and is called adaptive strategy. By using this adaptive strategy the ECM is able to control the engine to
give optimum driveability under all operating conditions.
During cold start conditions the ECM uses ECT information to allow more fuel to be injected into the cylinders.
This, combined with the glow plug timing strategy supplied by the ECM, facilitates good cold starting.
During hot start conditions, the ECM uses ECT and FT information to implement the optimum fuelling strategy to
facilitate good hot starting.
During idle and wide open throttle conditions, the ECM uses mapped information within its memory to respond to
input information from the TP sensor to implement the optimum fuelling strategy to facilitate idle and wide open
throttle.
To achieve an adaptive strategy for acceleration, the ECM uses input information from the CKP sensor, the TP
sensor, the ECT sensor, the MAP/IAT sensor, and the FT sensor. This is compared to mapped information within
its memory to implement the optimum fuelling strategy to facilitate acceleration.
Fuel Delivery / Injection Control
The fuel delivery/injection control delivers a precise amount of finely atomised fuel to mix with the air in the
combustion chamber to create a controlled explosion. To precisely control fuel delivery and control fuel injection,
the following input conditions must be met:
CKP information.
Injection timing map information.
FT information.
ECT information.
The ECM monitors the conditions required for optimum combustion of fuel in the cylinder from the various sensors
around the engine and then compares it against stored information. From this calculation, the ECM can adjust the
quantity and timing of the fuel being delivered into the cylinder. The ECM uses CKP information as follows:
To calculate engine speed.
To determine engine crankshaft position.
Engine speed and crankshaft position allows the ECM to determine fuel injection timing.
The ECM also uses ECT and FT information to allow optimum fuel delivery and injection control for all engine
coolant and fuel temperatures.
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MANUAL GEARBOX
1
ADJUSTMENT SPRINGS - GEAR LEVER BIAS
Service repair no - 37.16.26
Check
NOTE: The purpose of this adjustment is
to set both bolts so that the bias spring
legs apply equal pressure on both ends of
the gear lever cross pin when 3rd or 4th gear is
engaged. This will ensure that when the gear lever
is in neutral, the gear change mechanism is
automatically aligned for 3rd or 4th gears.
1.Remove gear lever knobs.
2.Release and remove gear lever gaiter.
3.Select 3rd or 4th gear.
4.Adjust the two adjusting screws until both legs of
the spring are approximately 0.5 mm (0.02 in)
clear of cross pin in the gear lever.
5.Apply a light load to the gear lever in a RH
direction and adjust the LH adjusting screw
downwards until the LH spring leg just makes
contact with the cross pin.
6.Repeat the same procedure for the RH adjusting
screw.
7.Lower both adjusting screws equal amounts until
the radial play is just eliminated. Tighten lock
nuts.
8.Return gear lever to neutral position and move
gear lever across the gate several times. The
gear lever should return to the 3rd and 4th gate.
9.Fit gear lever gaiter.
10.Fit gear lever knobs.
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86ELECTRICAL
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DESCRIPTION AND OPERATION Remote Handset
The remote handset is a separate unit from the vehicle key and is used to arm and disarm the alarm system. The
handset comprises two buttons; lock and unlock. The handset contains a battery (CR3032) and a printed circuit
board containing the circuitry to generate the RF signals.
NOTE: In selected markets, the vehicle key, when used in the drivers door key barrel switch, will
not disarm the alarm system.
The remote handset RF code consists of two parts. One part is a fixed code that is unique to the handset and the
second part is a rolling code which changes in accordance with a predetermined pattern. The anti-theft alarm ECU
can store the codes of up to four different remote handsets at any one time.
If the remote handset battery falls below a predetermined level, the handset will transmit an additional RF signal
code to the anti-theft alarm ECU when either button is depressed. The security LED will display this as two rapid
flashes every 0.5 seconds to visually display the low handset battery condition. This will continue for the 10
second confirmation period or until the ignition is switched on.
Resynchronisation of Remote Handset
If either the remote handset battery or the vehicle battery is removed or disconnected, the rolling part the handset
code is lost and the handset(s) need to be resynchronised to the anti-theft alarm ECU. The resynchronisation
procedure is as follows:
Disconnect the vehicle battery.
Wait for 30 seconds for residual current to dissipate.
Reconnect the vehicle battery.
Carefully prise the remote handset apart and remove the battery. Avoid unnecessary handling of the battery.
With the battery removed, press either the lock or unlock button several times to remove residual current from
the circuitry.
Check the handset battery with a voltmeter. If the battery voltage is less than 2.7 volts, replace the battery.
Ensure that the battery contact surfaces are clean and replace the battery in the handset clip with the + symbol
uppermost. Put the two halves of the handset case back together.
DO NOT press any buttons.
With the handset within range of the vehicle, press the lock button four times in quick succession. The
anti-theft alarm ECU will respond by locking the vehicle.
Press the unlock button once to complete the resynchronisation procedure.
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