stop start LAND ROVER DEFENDER 1999 Workshop Manual

ENGINE
23
REPAIR FILTER - OIL
Service repair no - 12.60.04
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Release clip and disconnect breather hose from
camshaft cover.
3.Release clips and disconnect air flow meter from
air filter.
4.Disconnect multiplug from air flow meter.
5.Loosen clip screw and remove air inlet hose
from turbocharger.
6.Remove 3 bolts and remove manifold heat
shield.
7.Clean area around filter head and place a
container beneath engine.
8.Using a strap wrench, unscrew and discard filter.
Refit
9.Clean mating face of filter head.
10.Lubricate sealing ring of new filter with clean
engine oil.
11.Fit filter and tighten by hand until it seats then
tighten a further half turn.
12.Start and run engine to check for leaks.
13.Stop engine, wait a few minutes, then check oil
level.
14.Top up engine oil.
15.Position exhaust manifold heat shield and
tighten 3 bolts.
16.Position air inlet hose to turbocharger and
tighten clip screw.
17.Connect air flow meter to air filter and secure
clips.
18.Connect air flow meter multiplug.
19.Connect breather hose and secure with clip.
20.Position engine acoustic cover.
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ENGINE MANAGEMENT SYSTEM
13
DESCRIPTION AND OPERATION Voltage generation from the CKP sensor is relative to engine speed. The values from a good CKP sensor are as
follows:
2 to 3 volts with engine cranking.
Rising to 6 to 6.5 volts from 1000 rev/min upwards.
The above readings are dependent upon the correct air gap between the tip of the CKP sensor and the passing
teeth of the reluctor ring.
The CKP sensor can fail or supply an incorrect signal if one or more of the following occurs:
Sensor assembly loose.
Incorrect spacer fitted.
Sensor open circuit.
Sensor short circuit.
Incorrect fitting and integrity of the sensor.
Water ingress.
In the event of a CKP sensor signal failure, any of the following symptoms may be observed:
Engine cranks but fails to start.
Engine misfires (CKP sensor incorrectly fitted).
Engine runs roughly or stalls (CKP sensor incorrectly fitted).
The CKP sensor does not have a back-up strategy. If it fails the engine will stop running and fail to start.
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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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FUEL SYSTEM
1
ADJUSTMENT HEATER PLUG TEST
Service repair no - 19.90.20.01
Check
1. Test out of engine
2.Remove heater plug.See Repair.
3.UsingLRT-12-511,connect RED lead to battery
’+’positive and the BLACK lead to battery’-’
negative.
4.Position heater plug into tester and retain with
spring loaded bar.
5.Connect YELLOW lead to heater plug terminal.
6.Press red button on tester and note ammeter
reading. Keep button depressed, heater plug tip
should start to glow after 5 seconds
CAUTION: The heater plug tip must glow
first, if it fails to do so, replace heater plug.
7.The ammeter reading should show an initial
current draw of 25 amps, which should fall to 12
amps after 20 seconds.
8.Refit heater plug.See Repair.FUEL SYSTEM - BLEED
Service repair no - 19.50.07
Fuel Purging Procedure
1.If the vehicle runs out of fuel, or the fuel level is
so low that the fuel system draws air into the fuel
rail, the fuel rail will need to be purged before the
engine will start. This can be achieved by
following a set procedure. The process does not
require the use of any specialist equipment and
can be performed by the driver of the vehicle.
The process is as follows:
2.Switch off ignition and wait 15 seconds.
3.Turn ignition key to position 2 and wait 3
minutes, (this ensures that the fuel system
purges all the air from the fuel rail within the
cylinder head).
4.Depress the throttle pedal to more than 90% of
its total travel, (to the throttle stop).
5.Crank the engine keeping the throttle pedal
depressed.
NOTE: This operation is controlled by the
ECM and it is important that the purging
operation is not carried out on a vehicle
that has not run out of fuel. If it is carried out
unnecessarily it can lead to the engine flooding
and failing to start.
This operation will be cancelled:
6.As soon as engine speed exceeds 600 rev/min.
7.The driver allows the throttle pedal to close to a
position less than 90% of its travel.
8.The ignition key is released from the start
position.
NOTE: The engine must not be cranked for
more than 30 seconds in any one period.
9.Repeat the above procedure if the engine fails to
start.
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86 - ELECTRICAL
CONTENTS
Page
DESCRIPTION AND OPERATION
SECURITY AND CENTRAL DOOR LOCKING 1....................................................
SECURITY AND CENTRAL DOOR LOCKING 2....................................................
ANTI-THEFT ALARM - FROM 02MY 3...................................................................
IMMOBILISATION SYSTEM - FROM 02MY 12......................................................
CENTRAL DOOR LOCKING (CDL) - FROM 02MY 15...........................................
ANTI-THEFT ALARM SYSTEM SELF TEST 17.....................................................
FASCIA CONSOLE 18............................................................................................
HEATED FRONT SCREEN - FROM 02MY 20.......................................................
HEATED FRONT SEATS - FROM 02MY 22..........................................................
ELECTRIC FRONT WINDOWS - FROM 02MY 24.................................................
PASSENGER COMPARTMENT FUSE BOX 26.....................................................
UNDER SEAT FUSE BOX 27.................................................................................
ADJUSTMENT
HEADLAMPS - ALIGN BEAM 1..............................................................................
SOLENOID/MOTOR - FRONT DOOR - ADJUST 1................................................
REPAIR
BELT - AUXILLARY DRIVE 1.................................................................................
HARNESS - INJECTORS 1....................................................................................
STARTER MOTOR 2..............................................................................................
CENTRE HIGH MOUNTED STOP LIGHT (CHMSL) - UP TO 02MY 2...................
ALTERNATOR 3.....................................................................................................
HORN - LH 4...........................................................................................................
HEADLAMP 5.........................................................................................................
LAMP - TAIL 6.........................................................................................................
RADIO6 ..................................................................................................................
SPEAKER - FRONT 7.............................................................................................
SWITCH - TRANSMISSION BRAKE 7...................................................................
LAMP - FRONT FLASHER 8..................................................................................
BATTERY - DISCONNECT - FROM 02MY 8..........................................................
MOTOR & REGULATOR - FRONT DOOR - FROM 02MY 9..................................
SWITCH - FASCIA - FROM 02MY 10.....................................................................
HARNESS - FRONT DOOR - FROM 02MY 10.......................................................
SOLENOID/MOTOR - TAIL DOOR - FROM 02MY 11............................................
SOLENOID/MOTOR - FRONT DOOR - FROM 02MY 12.......................................
SOLENOID/MOTOR - REAR DOOR - FROM 02MY 13.........................................
HARNESS - REAR DOOR - FROM 02MY 14.........................................................
REVERSE AND FOG GUARD LAMP - BULB 15....................................................
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86 - ELECTRICAL
CONTENTS
Page
LAMP ASSEMBLY - CENTRE HIGH MOUNTED STOP LIGHT (CHMSL) -
FROM 02MY 16......................................................................................................
FLASHER UNIT - HAZARD WARNING - FROM 02MY 16.....................................
RELAY - HEATED FRONT SCREEN - FROM 02MY 17........................................
RELAY - REAR FOG GUARD - FROM 02MY 18...................................................
RELAY - STARTER - FROM 02MY 19...................................................................
SWITCH - HEADLAMP LEVELLING - FROM 02MY 19.........................................
CIGAR LIGHTER - FRONT - FROM 02MY 20........................................................
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86ELECTRICAL
2
REPAIR STARTER MOTOR
Service repair no - 86.60.01
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove fixings and remove underbelly panel.
4.Disconnect Lucar from starter solenoid.
5.Remove nut and disconnect battery lead from
starter solenoid.
6.Remove nut and 2 bolts securing starter to
gearbox housing. Remove starter.
Refit
7.Clean starter motor and mating face.
8.Position starter and tighten nut and 2 bolts to27
Nm (20 lbf.ft)
9.Connect lead to starter solenoid and tighten nut.
10.Connect Lucar to starter solenoid.
11.Fit underbelly panel.
12.Reconnect battery negative lead.
13.Fit battery cover.CENTRE HIGH MOUNTED STOP LIGHT (CHMSL) -
UP TO 02MY
Service repair no - 86.41.32
Remove
1.Remove 2 screws securing lamp cover.
2.Remove lamp cover.
3.Disconnect 2 Lucars from bulb holder.
4.Remove 2 nuts securing lamp to tail door.
5.Remove lamp.
6.Collect gasket.
Refit
7.Position gasket.
8.Position lamp.
9.Secure lamp with nuts.
10.Connect Lucars to bulb holder.
11.Fit lamp cover.
12.Secure cover with screws.
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