fuse box LAND ROVER DEFENDER 1999 Workshop Manual

ENGINE MANAGEMENT SYSTEM
21
DESCRIPTION AND OPERATION RELAY - FUEL PUMP
The fuel pump relay is located in the engine compartment fuse box. It switches on the fuel pump to draw fuel from
the tank to the electronic unit injectors (EUI).
Input / Output
The fuel pump relay is a 4 pin normally open relay. The fuel pump relay (C0730-4) is provided with a feed by the
main relay (C0063-78) via header 291 on a brown/orange wire. An earth path is provided for the fuel pump relay
(C0730-6) via the ECM (C658-5) on a blue/purple wire. This energises the fuel pump relay and allows a feed to be
provided to the fuel pump. When the ECM interrupts the earth, the relay is de-energised and the fuel pump stops
operating.
The fuel pump relay can fail in one or more of the following ways:
Relay open circuit.
Short circuit to vehicle supply.
Short circuit to vehicle earth.
Broken relay return spring.
In the event of a fuel pump relay failure any of the following symptoms may be observed:
Engine will crank but not start.
If the engine is running, it will stop.
RELAY - MAIN
The main relay is located in the engine compartment fuse box and supplies battery voltage to the following:
The ECM.
The MAF sensor.
Fuel pump relay.
Input / Output
The main relay is a 4 pin normally open relay, which must be energised to provide a voltage to the ECM. The main
relay (C0063-86) is provided with an earth path via a transistor within the ECM (C0658-21) on a blue/red wire.
When the earth path is completed, the relay is energised and supplies the ECM (C0658-3, C0658-22 & C0658-27)
with a feed on brown/orange wires via header 291.
The main relay can fail in the following ways:
Relay open circuit.
Short circuit to vehicle supply.
Short circuit to vehicle earth.
Broken relay return spring.
In the event of a main relay failure any of the following symptoms may be observed:
Engine will crank but not start.
If the engine is running, it will stop.
For the ECM start up to take place the ignition feed when the switch is in position’II’must be greater than 6.0
volts.
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37MANUAL GEARBOX
4
REPAIR MECHANISM AND HOUSING - GEAR SELECTOR
Service repair no - 37.16.37
Remove
1.Remove gear lever knobs.
2.Remove gearbox tunnel carpet.
3.Remove gear lever gaiter(s)
4.Release and remove insulation pad from around
gear levers.
5.Remove 2 screws securing relay/fuse panel and
collect 2 spacers.
6.Release bulkhead carpet from LH side of tunnel
and move aside.
7.Remove 13 screws securing tunnel cover.
8.Release and remove tunnel cover.
9.Remove 4 bolts securing gear change housing,
remove housing, remove and discard gasket.
10.Using a suitable piece of tubing located over
ends of bias spring, release both ends of bias
spring from ball pins.
11.Loosen locknuts and remove bias spring
adjusting screws.
12.Drift out roll pin, remove bias spring.
13.Remove nut and extension from lower gear
lever.
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MANUAL GEARBOX
5
REPAIR
14.Remove bolt and special washer securing lower
gear lever in housing.
15.Carefully withdraw lower gear lever from the
housing ensuring that the spring loaded nylon
pad is retained during removal.
WARNING: Personal injury may result if
nylon pad is not retained.
16.Release nylon pad, recover spring.
Refit
17.Clean components, gear change housing and
mating face on remote housing.
18.Apply multi - purpose grease to ball pin and fit
spring and nylon pad.
19.Depress nylon pad against spring pressure,
position lower gear lever in housing with the
nylon pad facing away from bias spring location.
20.Fit lower gear lever retaining bolt and special
washer and tighten bolt to10 Nm (7 lbf.ft).
21.Fit upper gear lever to lower gear lever and
tighten nut to25 Nm (18 lbf.ft).
22.Drift new roll pin into housing.
23.Fit bias spring adjusting screws and locknuts.
24.Using a suitable piece of tubing, locate both
ends of bias spring over ball pins.
25.Fit new gasket to remote housing, position gear
change housing to remote housing and tighten
bolts to25 Nm (18 lbf.ft).26.Adjust bias springs.See Adjustment.
27.Fit and align tunnel cover, fit and tighten screws.
28.Secure bulkhead carpet to LH side of tunnel.
29.Position relay/fuse panel, fit spacers and tighten
screws.
30.Fit insulation pad around gear levers.
31.Fit gear lever gaiter(s).
32.Fit gearbox tunnel carpet.
33.Fit gear lever knobs.
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37MANUAL GEARBOX
6
REPAIR MECHANISM AND HOUSING - GEAR SELECTOR -
RESEAL
Service repair no - 37.16.37.01
Remove
1.Remove gear lever knobs.
2.Remove gearbox tunnel carpet.
3.Remove gear lever gaiter(s).
4.Release and remove insulation pad from around
gear levers.
5.Remove 2 screws securing relay/fuse panel and
collect 2 spacers.
6.Release bulkhead carpet from LH side of tunnel
and move aside.
7.Remove 13 screws securing tunnel cover.
8.Release and remove tunnel cover.
9.Remove 4 bolts securing gear change housing,
remove housing, remove and discard gasket.
Refit
10.Clean gear change housing and mating face on
remote housing.
11.Fit new gasket to remote housing, position gear
change housing to remote housing; fit bolts and
tighten to25 Nm (18 lbf.ft).
12.Fit and align tunnel cover, fit and tighten screws.
13.Secure bulkhead carpet to LH side of tunnel.
14.Position relay/fuse panel, fit spacers and tighten
screws.
15.Fit insulation pad around gear levers.
16.Fit gear lever gaiter(s).
17.Fit gearbox tunnel carpet.
18.Fit gear lever knobs.
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37MANUAL GEARBOX
12
REPAIR SWITCH - REVERSE LIGHT
Service repair no - 37.27.01
Remove
1.Remove gear lever knobs.
2.Remove gearbox tunnel carpet.
3.Remove gear lever (s) gaiter.
4.Release and remove insulation pad from around
gear levers.
5.Remove 2 screws securing relay/fuse panel and
collect 2 spacers.
6.Release bulkhead carpet from LH side of tunnel
and move aside.
7.Remove 13 screws securing tunnel cover.
8.Release and remove tunnel cover.
9.Disconnect reverse light switch multiplug.
10.Remove switch and discard sealing washer.
Refit
11.Clean switch and mating face on gearbox.
12.Fit new sealing washer and fit switch to gearbox.
13.Connect reverse light switch multiplug.
14.Fit and align tunnel cover, fit and tighten screws.
15.Secure bulkhead carpet to LH side of tunnel.
16.Position relay/fuse panel, fit spacers and tighten
screws.
17.Fit insulation pad around gear levers.
18.Fit gear lever (s) gaiter.
19.Fit gearbox tunnel carpet.
20.Fit gear lever knobs.
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TRANSFER GEARBOX
1
ADJUSTMENT DIFFERENTIAL LOCK WARNING LAMP SWITCH
Service repair no - 41.20.36
Adjust
NOTE: This procedure is only necessary
for switches fitted with a locknut in place
of the threaded spacer.
1.Move differential lock selector fork to differential
locked position.
2.Connect a 12V test lamp and battery to
differential lock warning lamp switch.
3.Screw switch in until test lamp is illuminated then
screw switch in a further 1/2 turn; tighten locknut.
4.Disengage differential lock, check that test lamp
is extinguished.
5.Remove test lamp.HIGH/LOW SELECTOR LINKAGE
Service repair no - 41.20.46
Adjust
1.Disconnect battery negative lead.
2.Remove gear lever knobs.
3.Remove gearbox tunnel carpet.
4.Remove gear lever (s) gaiter.
5.Release and remove insulation pad from around
gear levers.
6.Remove 2 screws securing relay/fuse panel and
collect 2 spacers.
7.Release bulkhead carpet from LH side of tunnel
and move aside.
8.Remove 2 bolts securing hand-brake lever to
body and move aside.
9.Remove 13 screws securing tunnel cover.
10.Release and remove tunnel cover.
11.Loosen linkage locknut.
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41TRANSFER GEARBOX
2
ADJUSTMENT
12.Remove clevis pin clip and clevis pin securing
high-low selector linkage to lever.
13.Select neutral in transfer gearbox.
14.Move gear lever to neutral position.
15.Align linkage and check that clevis pin passes
through linkage without binding.
16.If binding occurs, adjust linkage until clevis pin
passes through without binding.
17.Fit clevis pin and clevis pin clip.
18.Tighten locknut.
19.Fit and align tunnel cover and secure with
screws.
20.Position hand-brake lever and tighten bolts to25
Nm (18 lbf.ft).
21.Secure bulkhead carpet to LH side of tunnel.
22.Position relay/fuse panel, fit spacers and tighten
screws.
23.Position insulation pad around gear levers.
24.Fit gear lever gaiter.
25.Fit gearbox tunnel carpet.
26.Fit gear lever knobs.
27.Reconnect battery negative lead.
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TRANSFER GEARBOX
7
REPAIR SWITCH - DIFFERENTIAL LOCK WARNING LAMP
Service repair no - 41.20.34
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove gear lever knobs.
4.Remove gearbox tunnel carpet.
5.Remove gear lever (s) gaiter.
6.Release and remove insulation pad from around
gear levers.
7.Remove 2 screws securing relay/fuse panel and
collect 2 spacers.
8.Release bulkhead carpet from LH side of tunnel
and move aside.
9.Remove 2 bolts securing hand-brake lever to
body and move aside.
10.Remove 13 screws securing tunnel cover.
11.Release and remove tunnel cover.
12.Disconnect Lucars from differential lock warning
lamp switch.
13.Loosen and remove switch.
NOTE: Locknut fitted in place of spacer on
early transfer boxes.
14.Remove locknut/spacer from switch.
Refit
15.Clean switch, locknut/spacer and mating face on
gearbox.
16.Fit locknutnut/spacer to switch with counterbore
on spacer positioned towards switch head.
NOTE: To ensure that the switch setting is
correct, make sure the spacer is fully
tightened to switch head, (no gap).
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41TRANSFER GEARBOX
8
REPAIR 17.Apply Hylomar PL32 sealant to switch threads.
18.Position switch into gearbox housing until
locknut/spacer bottoms out on housing.
19. Switches fitted with spacer:Tighten spacer
securing differential lock switch to11 Nm (8
lbf.ft).
20.Connect Lucars to switch.
21. Switches fitted with locknut:Adjust switch.
See Adjustment.
22.Fit and align tunnel cover, fit and tighten screws.
23.Fit hand-brake lever and tighten bolts to25 Nm
(18 lbf.ft).
24.Secure bulkhead carpet to LH side of tunnel.
25.Position relay/fuse panel, fit spacers and tighten
screws.
26.Fit insulation pad around gear levers.
27.Fit gear lever (s) gaiter.
28.Fit gearbox tunnel carpet.
29.Fit gear lever knobs.
30.Reconnect battery negative lead.
31.Fit battery cover.SEAL - INPUT SHAFT
Service repair no - 41.20.50
Remove
1.Remove transfer gearbox.See this Section.
2.Remove and discard input shaft oil seal from
transfer gearbox.
Refit
3.Clean oil seal recess in transfer gearbox.
4.Lubricate new oil seal with transfer gearbox oil.
5.UsingLRT-37-014, fit input shaft seal to transfer
gearbox.
6.Fit transfer gearbox.See this Section.
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TRANSFER GEARBOX
13
REPAIR SWITCH - LOW DETECT
Service repair no - 41.30.05
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove gear lever knobs.
4.Remove gearbox tunnel carpet.
5.Remove gear lever(s) gaiter.
6.Release and remove insulation pad from around
gear levers.
7.Remove 2 screws securing relay/fuse panel and
collect 2 spacers.
8.Release bulkhead carpet from LH side of tunnel
and move aside.
9.Remove 2 bolts securing hand-brake lever to
body and move lever aside.
10.Remove 13 screws securing tunnel cover.
11.Release and remove tunnel cover.12.Release switch multiplug from bracket on
transfer gearbox, disconnect from harness.
13.Remove switch.
Refit
14.Clean switch and mating face on transfer
gearbox.
15.Fit nut/spacer to switch with counterbore
positioned towards switch head.
16.Apply Hylomar PL32 sealant to switch threads.
17.Fit switch and tighten to24 Nm (19 lbf.ft).
18.Connect multiplug to harness.
19.Fit and align tunnel cover, fit and tighten screws.
20.Position hand-brake lever and tighten bolts to25
Nm (18 lbf.ft).
21.Secure bulkhead carpet to LH side of tunnel.
22.Position relay/fuse panel, fit spacers and tighten
screws.
23.Fit insulation pad around gear levers.
24.Fit gear lever (s) gaiter.
25.Fit gearbox tunnel carpet.
26.Fit gear lever knobs.
27.Reconnect battery negative lead.
28.Fit battery cover.
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