ignition LAND ROVER DEFENDER 1999 Workshop Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 1999, Model line: DEFENDER, Model: LAND ROVER DEFENDER 1999Pages: 667, PDF Size: 8.76 MB
Page 9 of 667
01INTRODUCTION
2
INFORMATION FUEL HANDLING PRECAUTIONS
The following information provides basic precautions
which must be observed if fuel is to be handled safely.
It also outlines the other areas of risk which must not
be ignored.
This information is issued for basic guidance only, and
in any case of doubt, appropriate enquiries should be
made of your local Fire Officer or Fire Department.
Fuel vapour is highly flammable and in confined
spaces is also very explosive and toxic and when
diluted with air becomes a readily ignitable mixture.
The vapour is heavier than air and will always fall to
the lowest level. It can readily be distributed
throughout a workshop by air current, consequently,
even a small spillage of fuel is very dangerous.
Always have a fire extinguisher containingFOAM CO
2
GAS,orPOWDERclose at hand when handling fuel,
or when dismantling fuel systems and in areas where
fuel containers are stored.
WARNING: lt is imperative that the battery
is not disconnected during fuel system
repairs as arcing at the battery terminal
could ignite fuel vapour in the atmosphere.
Always disconnect the vehicle battery BEFORE
carrying out work on the fuel system.
Whenever fuel is being handled, transferred or
stored, or when fuel systems are being dismantled
all forms of ignition must be extinguished or
removed, any leadlamps used must be flame proof
and kept clear of spillage.
No one should be permitted to repair components
associated with fuel without first having had fuel
system training.Hot fuel handling precautions
WARNING: Before commencing any
operation requiring fuel to be drained from
the fuel tank, the following procedure must
be adhered to:
1.Allow sufficient time for the fuel to cool, thus
avoiding contact with hot fuels.
2.Vent the system by removing the fuel filler cap in
a well ventilated area. Refit the filler cap until the
commencement of fuel drainage.
Fuel transfer
WARNING: Fuel must not be extracted or
drained from any vehicle while it is
standing over a pit.
The transfer of fuel from the vehicle fuel tank must be
carried out in a well ventilated area. An approved
transfer tank must be used according to the transfer
tank manufacturer’s instructions and local regulations,
including attention to grounding of tanks.
Fuel tank removal
AFUEL VAPOURwarning label must be attached to
the fuel tank upon removal from the vehicle.
Fuel tank repair
Under no circumstances should a repair to any tank
be attempted.
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Page 14 of 667
INTRODUCTION
7
INFORMATION TOWING
CAUTION: The vehicle has permanent
four-wheel drive. The following towing
instructions must be adhered to:
Towing the vehicle on all four wheels with driver
operating steering and brakes.
1.Turn ignition key to position’1’to release
steering lock.
2.Select neutral in main gearbox and transfer
gearbox.
3.Secure tow rope, chain or cable to front towing
eyes (alternative types shown).
4.Release the parking brake.
CAUTION: The brake servo and power
assisted steering system will not be
functional without the engine running.
Greater pedal pressure will be required to apply
the brakes, the steering system will require
greater effort to turn the front road wheels.
The vehicle tow connection should be used only
in normal road conditions,’snatch’recovery
should be avoided.Rear suspended tow by breakdown vehicle
1.If the front axle is to be trailed turn ignition key to
position’1’to release steering lock.
2.Select neutral in main gearbox and transfer box.
CAUTION: The steering wheel and/or
linkage must be secured in a straight
ahead position. DO NOT use the steering
lock mechanism for this purpose.
TRANSPORTING THE VEHICLE BY TRAILER
Lashing/towing eyes are provided on front and rear of
the chassis side members, see J6085, to facilitate the
securing of the vehicle to a trailer or other means of
transportation.
CAUTION: Underbody components must
not be used as lashing points.
Install vehicle on trailer and apply park brake. Select
neutral in main gearbox.
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Page 15 of 667
01INTRODUCTION
8
INFORMATION JUMP STARTING
WARNING: Hydrogen and oxygen gases
are produced during normal battery
operation. This gas mixture can explode if
flames, sparks or lighted tobacco are brought
near battery. When charging or using a battery in
an enclosed space, always provide ventilation and
shield your eyes.
Keep out of reach of children. Batteries contain
sulphuric acid. Avoid contact with skin, eyes, or
clothing. Also, shield eyes when working near
battery to protect against possible splashing of
acid solution. In case of acid contact with skin,
eyes, or clothing, flush immediately with water for
a minimum of fifteen minutes. If acid is swallowed,
drink large quantities of milk or water, followed by
milk of magnesia, a beaten egg, or vegetable oil.
SEEK MEDICAL AID IMMEDIATELY.
To Jump Start - Negative Ground Battery
WARNING: To avoid any possibility of
injury use particular care when connecting
a booster battery to a discharged battery.
1.Position vehicles so that jump leads will reach,
ensuring that vehiclesDO NOT TOUCH,
alternatively a fully charged slave battery may be
positioned on floor adjacent to vehicle.
2.Ensuring that ignition and all electrical
accessories are switched off, that parking brake
is applied and neutral is selected, connect the
jump leads as follows;
A.Connect one end of first jumper cable to positive
(+) terminal of booster battery.
B.Connect other end of first jumper cable to positive
(+) terminal of discharged battery.
C.Connect one end of second jumper cable to
negative terminal of booster battery.
D.Connect other end of second jumper cable to a
good earth point on the disabled vehicle (eg. engine
front lifting eye, as shown in J6086),NOT TO
NEGATIVE TERMINAL OF DISCHARGED
BATTERY.Keep jumper lead away from moving
parts, pulleys, drive belts and fan blade assembly.
WARNING: Making final cable connection
could cause an electrical arc which if
made near battery could cause an
explosion.
3.If booster battery is installed in another vehicle,
start engine and allow to idle.
4.Start engine of vehicle with discharged battery,
following starting procedure in Owners’Manual.
CAUTION: If vehicle fails to start within a
maximum time of 12 seconds, switch
ignition off and investigate cause. Failing
to follow this instruction could result in
irrepairable damage to catalyst, if fitted.
5.Remove negative (-) jumper cable from the
engine and then terminal of booster battery.
6.Remove positive (+) jumper cable from positive
terminals of booster battery and discharged
battery.
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Page 17 of 667
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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Page 63 of 667
10MAINTENANCE
4
MAINTENANCE BATTERY CONDITION - Td5
Remove
1.Remove drivers seat base.
2.Release clip securing battery cover.
3.Remove battery cover.
NOTE: The vehicle may be fitted with an
alarm and immobilisation system. To
prevent the alarm from sounding, it is
important that the following procedure is used
when disconnecting the battery.
4.Turn the ignition switch to position’II’, and then
to position’0’.
5.Remove the ignition key.
6.Disconnect the vehicle -ve terminal within 15
seconds.
NOTE: Always disconnect the -ve terminal
first. When replacing, connect the +ve
terminal first.
Check
The battery fitted to Td5 models is designed to be
maintenance free, so topping-up is not possible. On
the top of the battery is a battery indicator. When the
indicator shows:
GREEN - The battery is in a good state of charge.
DARK (turning to black) - The battery needs
charging.
CLEAR (or light yellow) - The battery needs
replacing. Do not charge the battery or jump start
the vehicle in this condition.
If the green dot is missing, the battery needs
charging.
NOTE: If the indicator shows clear or
yellow, tap the indicator with the handle of
a screwdriver to disperse any air bubbles.
If the indicator colour remains unchanged, the
battery will need replacing.
Refit
7.Clean and grease battery terminals and leads
with petroleum jelly.
8.Connect leads to battery (+ve first) and tighten
clamp bolts.
9.Fit battery cover and secure with clip.
10.Fit drivers seat base.
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Page 64 of 667
MAINTENANCE
5
MAINTENANCE HANDSET BATTERY
Remove
NOTE: Do not remove a battery until you
are ready to install the replacement.
Always fit a Land Rover STC4080 or a
Panasonic CR2032 replacement battery.
1.Unlock the vehicle and disarm the alarm system.
2.Turn the ignition switch to position’II’, then turn
to position’0’and remove the key.
3.Carefully prise the handset apart, starting from
the keyring end. Avoid damaging the seal
between the two halves of the case.
CAUTION: Do not allow moisture to get
inside the handset.
4.Slide the battery out of its clip, taking care to
avoid touching the circuit board or the contact
surfaces of the clip.
5.Press and hold one of the buttons for at least 5
seconds to drain any residual power from the
handset.
Refit
6.Fit the new battery, ensuring that correct polarity
is maintained (+ve side facing up). Finger marks
will adversely affect battery life. Avoid touching
the flat surfaces of the battery, and wipe clean
before fitment.
7.Reassemble the two halves of the handset.
Operate the Padlock symbol button at least 4
times within range of the vehicle to
resynchronise the hanset.HEADLAMP ALIGNMENT
1.Check alignment of headlamps.See
ELECTRICAL, Adjustment.
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Page 124 of 667
ENGINE
1
ADJUSTMENT ENGINE OIL PRESSURE CHECK
Service repair no - 12.90.09.01
Check
1.Remove oil pressure switch.See Repair.
2.Connect pressure check kitLRT-12-052C
adaptor and gauge to oil pressure switch
position on oil cooler.
3.Check and if necessary, top-up engine oil.
4.Run engine at idle speed and check that oil
pressure is within limits given.
5.Switch off ignition.
6.Remove oil pressure check kitLRT-12-052C.
7.Clean oil spillage.
8.Fit oil pressure switch.See Repair.
Adjust
1.If engine oil pressure is not within specified
limits, check condition of oil pump and/or main
and connecting rod bearings.
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Page 244 of 667
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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Page 258 of 667
FUEL SYSTEM
3
DESCRIPTION AND OPERATION FUEL PUMP AND FUEL GAUGE SENDER
1.Fuel burning heater feed pipe (not used)
2.Air bleed connection (natural)
3.HP feed connection (green)
4.LP feed connection (blue)
5.LP return connection (black)
6.Pump feed pipe.
7.Spring
8.Fuel gauge sender unit9.Swirl pot
10.Gauze filter
11.Fuel gauge sender float
12.Electrical connections
13.HP/LP two stage pump
14.Pump LP return pipe
15.Electrical connector
The fuel pump is a self priming, wet type, two stage pump, which is emersed in fuel in the tank. It operates at all
times when the ignition switch is in position’II’. If the engine is not started, the ECM will’time-out’after three
minutes and de-energise the fuel pump relay.
The fuel pump assembly is retained with a locking ring and sealed with a rubber seal. The locking ring requires a
special tool for removal and refitment. The fuel gauge sender is integral with the fuel pump. The sender is
submerged in the fuel and is operated by a float which moves with the fuel level in the tank.
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Page 265 of 667
19FUEL SYSTEM
10
DESCRIPTION AND OPERATION WATER SENSOR
The water sensor has a three pin electrical connector. When the sensor detects water in the fuel filter it illuminates
a warning lamp in the instrument pack.
The water sensor attachment thread has a slot machined down one side. The filter can be purged of water by
partially unscrewing the sensor which aligns the slot in the threads with a corresponding hole in the sensor. When
aligned, water and fuel can flow down the slot and flows from a small cast tube on the side of the sensor.
Re-tightening the sensor mis-aligns the slot and stops the flow of fuel.
The sensor operates by measuring the resistance between its two electrodes, which are submerged in fuel, and
activated by the presence of water. When the ignition switch is moved to position’II’, the warning lamp will
illuminate for approximately 2 seconds to check warning lamp functionality.
When the filter is full with fuel and no water is present, the resistance of the Diesel fuel will show a reading of 15
mA maximum on the feed wire to the instrument pack. When sufficient water surrounds both electrodes, the
resistance of the water will show a reading of 130 mA maximum. This will supply sufficient voltage to the
instrument pack to illuminate the warning lamp, and alert the driver to the presence of water in the fuel system.
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