Land Rover Range Rover (1988) Manual Engine

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Page 1

;;^d;‘;r;

1987

FUEL INJECTION SYSTEM

119 1

RR1752E

FUEL INJECTION - Circuit Diagram

1. 40 way connector to Electronic Control Unit (ECU).

2. Lambda sensor (left side - bank A).

3. Lambda sensor (right side - bank

4. By-pass air valve (stepper motor) (fast idle).

5. Lambda sensor screened ground.

6. Fuse 18 - main fuse panel.

7. Inertia switch.

8. Fuel pump.

Ignition

switch.

10. Speed transducer (road speed input).

1. Neutral input).

12.

Pick-up point-air conditioning circuit (load

input).

switch (automatic gearbox) (load

8).

““I

13. Battery.

14. Diagnostic plug.

15. In-line resistor.

16. Coil/-ve (engine RPM input).

17. Coolant (input).

18. Fuel temperature thermistor (sensor) (input).

19. Throttle potentiometer.

20. Air

21. Fuel pump relay.

22. Main

23. Injectors-l to 8.

24. Pick-up point

= = =

flow

binnacle).

temperature

sensor.

relay.

E.F.I. warninasymbol

Denotes screened ground.

thermistor (sensor)

(instrument

NOTE: Reference to left and right side is made when viewing vehicle from rear.

Cable colour code

Black U Blue N

Brown

The last letter of a colour code denotes the tracer.

Green

Orange

Purple

REVISED: JULY 88

R Red

M’

White

Y Yellow

K LG

Crey Pink

Light green

:, :.

Page 2

FUEL INJECTION SYSTEM

l-l

1987

rot;;

FWL

41 RCA1

RCOULATOR

ENOINE

lNJcc10ns

FOR ENONE

ECU AND

UNDER RIGHT

RELAY8

FRONTOEAT

:lJEL

FILTER ON

CHAlllll#

FUEL

WYP

111

FUEL

TANA

ROAO OFEED WUt

TIIANOOUCER

CNAIOW

FUEL TEYFEIIATURE

l EN10R

liNOiNE

FULL

COOLANT

LNIOR FRONT OF

RR2178E

RAIL

tEYPERATU(IE

ENOM

\ .:-.

‘i..J /

TWROTTLE FOTENTIOYETE

FRONT OF

THROTTLE

VALVE

REVISED: JULY 88

A-

HOT WIG ARFLOW

8ENaoR FRONT

l EIE OF

LNONE

LEFT

A1111 IV’cA1I

REAR

VALVE

ENOWE BAV

. .

lONRlON

IDE OF

COL

ENWIE

‘,

‘, ., ,. :

LEFT

Page 3

ggf;i

1987

FUEL INJECTION SYSTEM

119 1

INTRODUCTION

The Electronic Fuel injection system provides a

reliable and efficient microprocessor controlled fuel management system.

The function of the system is to supply the exact

amount of fuel directly into the inlet manifold according to the prevailing engine operating conditions.

To monitor these conditions, various sensors are fitted to the engine to measure engine parameters. Data from the sensors is received by the Electronic Control Unit (E.C.U.), the E.C.U. will then determine the exact amount of fuel required at any condition.

The E.C.U. having received data from the sensors

produces pulses, the length of which will determine the simultaneous open time of each bank of injectors in turn, which will govern the amount of fuel injected.

DESCRIPTION

ELECTRONIC CONTROL UNIT-ECU

The Electronic Fuel Injection system is controlled by

the E.C.U. which is located under the front right hand seat. The control unit is a microprocessor with integrated circuits and components mounted on printed circuit boards. The E.C.U. is connected to the main harness by a 40 pin plug.

ENGINE COOLANT TEMPERATURE THERMISTOR (SENSOR)

The coolant thermistor (sensor) is located by the

front left hand branch of the intake manifold. The thermistor provides engine coolant information to the E.C.U. The E.C.U. on receiving the signal from the thermistor will lengthen slightly the time that the injectors are open, and reducing this time as the engine reaches normal operating temperature.

FUEL TEMPERATURE THERMISTOR (SENSOR)

The fuel temperature thermistor (sensor) is located

in the fuel rail forward of the ram housing. The thermistor sends fuel temperature data to the E.C.U, the E.C.U on receiving the data will adjust the injector open time accordingly to produce good hot starting in high ambient temperatures.

BYPASS AIR VALVE (STEPPER MOTOR)

The bypass valve is screwed into a housing attached to the rear of the plenum chamber, between the plenum chamber and bulkhead. The bypass valve has two windings which enable the motor to be energised in both directions thus opening or closing the air valve as required by the E.C.U. The bypass valve will open and allow extra air into the plenum chamber to maintain engine idle speed when the engine is under increased (Electrical and

Mechanical) loads.

The bypass valve will control engine idle speed

when the vehicle is stationary.

INJECTORS

The eight fuel injectors are fitted between the pressurized fuel rail and inlet manifold. Each injector comprises a solenoid operated needle valve with a

movable plunger rigidly attached to the nozzle

valve. When the solenoid is energized the plunger

is attracted off its seat and allows pressurized fuel into the intake manifold.

LAMBDA SENSORS

The two Lambda sensors are located catalysts mounted in the exhaust downpipes. The sensors monitor the oxygen content of the exhaust gases and provide feedback information of the air/fuel ratio to the E.C.U. Each sensor is heated

by an electrical element to improve its response time when the ignition is switched on.

(0,

SENSORS)

Continued

fonvard

of the

REVISED: APR. 87

Page 4

FUEL INJECTION SYSTEM

1987

rGv;;

FUEL PRESSURE REGULATOR

The fuel pressure regulator is mounted in the fuel

rail at the rear of the plenum chamber. The

regulator is a mechanical device controlled by

plenum chamber vacuum, it ensures that fuel rail pressure is maintained at a constant pressure difference of 2.5 bar above that of the manifold. When pressure exceeds the regulator setting excess fuel is returned to the fuel tank.

FUEL PUMP

The electric fuel pump is located in the fuel tank,

and is a self priming ‘wet’ pump, the motor is

immersed in the fuel within the tank.

AIR FLOW SENSOR

The hot-wire air flow sensor is mounted on a

bracket attached to the left hand valance, rigidly

connected to the air cleaner and by hose to the

plenum chamber inlet neck.

The air flow sensor consists of a cast alloy body

through which air flows. A proportion of this air

flows through a bypass in which two wire elements

are situated: one is a sensing wire and the other is

a compensating wire. Under the control of an

electronic module which is mounted on the air flow

sensor body, a small current is passed through the sensing wire to produce a heating effect. The compensating wire is also connected to the module but is not heated, but reacts to the temperature of the air taken in, as engine intake air passes over the

wires a cooling effect takes place.

The electronic module monitors the reaction of the

wires in proportion to the air stream and provides output signals in proportion to the air mass flow rate which are compatible with the requirements of the E.C.U.

THROlTLE

The throttle potentiometer is mounted on the side of the plenum chamber inlet neck and is directly coupled to the throttle valve shaft. The potentiometer is a resistive device supplied with a voltage from the E.C.U. Movement of the

throttle pedal causes the throttle valve to open, thus potentiometer which in turn varies the resistance in proportion to the valve position. The E.C.U. lengthens the injector open time when it detects a change potentiometer.

In addition the E.C.U. will weaken the mixture when it detects the potentiometer output voltage is decreasing under deceleration and will shorten the

length of time the injectors are open. When the throttle is fully open, the E.C.U. will

detect the corresponding throttle potentiometer

voltage and will apply full load enrichment. This is a

fixed

temperature. Full load enrichment is also achieved

by adjusting the length of the injector open time.

When the throttle is closed, overrun fuel cut off or

idle speed control may be facilitated dependant on

other inputs to the E.C.U.

POTENTIOMETER

rotating

percentage

the

output

wiper

voltage (rising) from the

and is

within

arm

independent of

the

ROAD SPEED TRANSDUCER

The road speed transducer is fitted between the

upper and lower speedometer cables. It is mounted on a bracket located on the left hand chassis side member adjacent to the rear engine mounting. The transducer provides road speed data to the ECU. The ECU in turn detects vehicle movement from the road speed input and ensures that idle speed control mode is disengaged. Should the speed transducer fail in service the ECU idle speed control would become erratic.

:.....

REVISED: APR. 87

Page 5

: ..

FOE;

1987

FUEL INJECTION SYSTEM b

ii\

INERTIA SWITCH

The inertia switch is a mechanically operated switch

located under the left hand front seat attached to the seat base rear cross-member.

The switch is normally closed and is in the ignition

feed (fuse to fuel pump). In the event of a sudden impact the switch opens, and disconnects the electrical feed to the fuel pump. The switch is reset by pressing down the button.

RELAYS

The two electronic fuel injection relays are located

under the front right hand seat mounted forward of the E.C.U. The main relay is energized via the

E.C.U

when the ignition is switched on and supplies

current to the fuel injection system. The fuel pump relay is energized by the E.C.U. which in turn operates the fuel pump to pressurize the fuel system.

E.F.I. WARNING SYMBOL (Instrument binnacle)

., .’

‘.’ :

‘. ,‘,‘.‘. ::

:, ..i.’

An E.F.I. warning symbol incorporated into the instrument binnacle will illuminate when the E.C.U. detects that it cannot maintain correct air/fuel ratio due to a fault in one of the system components.

follolOring

‘:.

fuel injection

,.*a

Air flow sensor.

Lambda sensor.

Water temperature thermistor. (sensor) Throttle potentiometer.

The symbol will illuminate on initial turn of the

ignition key as part of the bulb check feature, and

will go out after a few seconds.

If the symbol illuminates when the engine is idling or the vehicle is being driven it indicates a failure of one of the four functions, the vehicle should be driven with care, and the cause rectified, refer to test procedure for the particular functions. Should one of the functions fail, the vehicle can still be driven due to a limp home feature incorporated into the fuel injection system.

.‘.,. 2: :_

‘. ‘*. . .

. .

..:

REVISED: JULY 88

Page 6

1987

KANClt

ROVER

”

FUEL INJECTION SYSTEM

CAUTION: The fuel system incorporates fine metering components that would be affected by any dirt in the system; therefore it is essential

that working conditions are scrupulously clean.

If it is necessary to disconnect any part of the fuel injection system, the system MUST be

depressurized.

removal of any component from the fuel system, MUST be sealed off (0 prevent ingress of dirt.

ENGINE

All openings left open after the

SEllING

PROCEDURE

If a major overhaul has been undertaken on the fuel injection/engine system, the following check and adjustments must be carried out before attempting to start the engine.

Throttle potentiometer setting

see ‘Throttle

potentiometer’ setting procedure.

Spark plug gaps

see ‘Section 05 Engine

tuning data’.

Throttle levers

see ‘Throttle lever setting

procedure’.

Ignition timing

static - see ‘Section 86

Electrical’.

CAUTION: IF THE ENGINE IS MISFIRING, IT SHOULD BE IMMEDIATELY SHUT DOWN AND

THE CAUSE RECTIFIED. FAILURE TO DO SO WILL

RESULT IN IRREPARABLE DAMAGE TO THE CATALYSTS.

NOTE: If the previous checks and adjustments are satisfactory but the engine will not start the

ignition and fuel injection electrical must be recommended equipment.

checked

using

the

circuitory

appropriate

Recommended Equipment

Lucas ‘Electronic Ignition Lucas Part Number - YWB 119.

Lucas Diagnostic Equipment Lucas Part Number - 60600965 (complete kit)

Analyser’

Individual part numbers for the above kit are as follows:

Hand held test unit Lucas Part Number

Interface unit Lucas Part Number

Serial link lead Lucas Part Number

Memory card Lucas Part Number

Operating manual

Lucas Part Number

Plastic case Lucas Part Number

NOTE: The Lucas diagnostic equipment can be connected to the diagnostic plug located by the E.C.U.

Model

84772

Model 21U

84773

54744753

54744754

. XXB825

54744755

2HHT

Use in conjunction with the Lucas Operating Instruction Manuals.

If the above equipment is unavailable the tests can be carried out using a multi-meter, following the instructions given in the charts.

. .

CAUTION: Ensure the multi-meter is correctly set to volts or ohms, dependent upon which test is being undertaken.

Carry

out the following static checks before

undertaking the continuity procedure:-

Fuse 18

Inertia switch

Fuel

Battery Condition

Air Leaks

in main fuse panel - is intact.

not tripped.

ample fuel in

no unmetered air entering engine

fuel

tank.

state of

cha ge.

system.

Electrical Connections

secure.

REVISED:

jlJLY

dry, clean and

Page 7

ro;;;

1987

FUEL INJECTION SYSTEM

CONTINUITY TEST PROCEDURE

”

..’

The continuity procedure and instructions on the following pages must be followed precisely to

prevent damage occurring to any of the fuel system components.

To enable the tests to be carried out when the 40

way multi-plug is connected to the E.C.U., it is necessary to remove the two screws securing the shroud to the plug to enable the multi-meter probes to be inserted into the back of the appropriate pin.

CAUTION: Tests that require the plug to be removed from the E.C.U., must also have the meter probes inserted into the back of the plug.

the probes are inserted into the plug sockets, damage will occur to the sockets resulting in poor connections when the plug is reconnected.

TESTING

Remove the E.C.U., and harness plug from

beneath the front right hand seat, access is gained through the rear opening of the seat base.

..‘.,

.’

2. Remove the plug shroud and maneuver it along the harness until there is enough clearance

enabling

meter probes to be

inserted into the back of the plug.

3. There are 4 pin numbers, 1, 13, 28, 40 moulded onto the rear of the plug for pin position

identification as

shown

in the illustration below, (for clarity the electrical leads have been omitted).

PIN NOS.

Red/green

Brown/orange

Yellow

Black

Brown/purple

Yellow

Green/blue

Not used

White/light

10.

Black/Yellow

11.

Yellow/white

12.

Blue/red

Yellow/blue

14. Black

15.

Brown

16.

Blue/purple

17.

Not used

I 8.

White/pink

19.

Whitelgrey

20.

Red

21.

Yellow/blue

22.

Blue/red

23. Blue

24. Blue

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

,’

Pins 1 to 13 top row. Pins 14 to 27 centre row (Pin 14 is below pin 13 but is not identified on the rear of the plug).

Pins 28 to 40 bottom row.

36.

37.

38.

39.

CABLE COLOUR

green

Red/black Green/white

Black/grey Blue/grey

Orange

Not used Not used

Greylwhite

Not used Black/orange Blue/green Not used White/yellow

Not used

White/black

40. Black

The last colour denotes the wire tracer colour.

Continued

:’

.-.

; . .

‘.

RR2016E

Page 8

FUEL INJECTION SYSTEM

1987

;;“d’;‘;;i

TESTS - Using a

The following continuity tests are intended as a guide to identifying where a fault may be within a circuit;

reference should be made to the fuel injection circuit diagram for full circuit information.

Muhi-Meter

KEY

TO SYMBOLS

TEMPORARY

CONNECTION

iNlTlON SWITCb

ELECTRONIC CONTROL UNIT

AND MULTIPLUG

OHMMETER

CONNECTIONS

ROAD SPEED

INPUT (SPEED

TRANSDUCER)

COOLANT

TEMPERATURE

SENSOR

VOLTMETER

CONNECTIONS

GEAR

INPUT SWITCH

INHIBITOR

SWITCH

AIR

BYPASS

VALVE

MAIN RELAY

INJECTOR

THROTTLE

‘OTENTIOMETER 1

PUMP RELAY

FUEL PUMP

TEMPERATURE

IGNITION COIL

SENSOR

’

HOT WIRE AIRFLOW SENSOR

FUEL

RR1782E

REVISED: APR. 88

Page 9

”

R”;;;

1987

FUEL INJECTION

SYSTEM

b-6 1

NOTE: All tests are carried out from the electronic control unit (ECU) harness multi-plug unless stated otherwise in the test procedure.

rEST

PROCEDURE

Check battery supply to ECU

RESULTS . Check cables and units shown in bold

Voltmeter reading of battery volts

(mimimum

Proceed to Test 2 Voltmeter reading of zero volts

Check:-

battery voltage 10 volts)

IGNlTlON

OFF

RRl816E

rEST

PROCEDURE

Check ignition supply to ECU

RESULTS - Check cables and units shown in bold

Voltmeter reading of battery volts (minimum battery voltage 10 volts) Proceed to Test 3 Incorrect reading

check:-

:,:.:.A

RR1817E

Continued

REVISED: APR. 88

:.,

Page 10

FUEL INJECTION SYSTEM

l-l

lg8’

RANGE

ROVER

rEST

PROCEDURE

Check operation of

Main relay

RR1818E

‘EST PROCEDURE

IGNITION ON

RESULTS - Check cables and units shown in bold

Voltmeter reading of battery volts

Proceed to Test 5

Voltmeter reading of zero volts

Proceed to Test 4

RESULTS - Check cables and units shown in bold

Fault Diagnosis Main relay circuits

I-

lGNsnoNoPF

iR1810E

Voltmeter reading of battery volts

Check:-

If OK Suspect ECU

Voltmeter reading of zero volts

Check:-

--..~

REVISED: APR.

‘- ‘\

Page 11

k”d;‘;r;

REVISED: APR. 88

1987

FUEL INJECTION SYSTEM

119 1

‘EST PROCEDURE

Check operation Listen for audible ‘click’ from pump

of pump relay

IGNtTION

RR182OE

RESULTS - Check cables and units shown in bold

relay. If

0.K -

Proceed to Test 7

No audible ‘click’ from pump relay Check:If OK proceed to Test 6.

[EST

PROCEDURE

Fault diagnosis

Pump relay circuits

?R1821E

RESULTS - Check cables and units shown in bold

Voltmeter reading of battery volts Suspect ECU

Voltmeter reading of zero volts

Check:-

IGNITION ON

Continued

Page 12

rEST

PROCEDURE

RESULTS - Check cables and units shown in bold

Check operation of Fuel pump

NOTE: It is not possible lo place the multi-meter probes directly onto the pump terminals. A link lead attached to the pump is accessible behind the

real

left hand wheel located between the chassis and stowage panel.

KEY:

1. Inertia switch

2. Fuse 18

area

floor

Voltmeter reading of battery volts

Pump operating - Proceed to Test

(A)

Voltmeter reading of battery

volts

Pump not operating Check:‘-

(6)

Voltmeter reading of zero volts

Check:-

REVISED: APR. 88

Page 13

K’^d;\ir;

1987

FUEL INJECTION SYSTEM

119 1

‘EST PROCEDURE

Check engine speed signal

Cable and resistor

W1823E

TEST PROCEDURE

RESULTS - Check cables and units shown in bold

Voltmeter reading of battery volts

Proceed to Test 9

Voltmeter reading of zero volts

Check:-

RESULTS - Check cables and units shown in bold

Check injectors,

Injector circuit

(Pin 13 left bank injectors

I-

IGNITION OFF

lR1824

1,3,5,7).

Ohm-meter reading of

Proceed to Test 10

Ohm-meter reading of 5-6 Ohms

Suspect 1 injector Ohm-meter reading of Suspect 2 injectors Ohm-meter reading of 16-17 Ohms Suspect 3 injectors Check for open circuit injector(s) or wiring faults.

Ohm-meter reading of Infinity Check:

4-5

8-9

Ohms

‘:

; .( : . .

,‘. .::i.. .~

Continued

REVISED: APR. 88

..:“,

‘.;.

Page 14

FUEL INJECTION

SYSTEM

.. ‘.

. . i.

‘EST PROCEDURE

Check injectors

. .

.’

-:;,

.i :

..’

. .

::’

Injeclor

circuit

pin II rightbank

njectors 2,4,6,6)

RESULTS - Check cables and units shown in bold

Ohm-meter reading of 4-5 Ohms

Proceed to Test 11.

Ohm-meter reading of 5-6 Ohms

Suspect 1 injector Ohm-meter reading of Suspect 2 injectors Ohm-meter reading of 16-17 Ohms Suspect 3 injectors Check for open circuit injector(s) or wiring faults.

Ohm-meter reading of Infinity Check:

8-9

Ohms

L-

IGNITION OFF

RR1825E

TEST PROCEDURE

Check fuel temperature

11. thermistor (sensor)

I-

IGNITION OFF

RR1826E

RESULTS - Check cables and units shown in bold

Correct reading-temperature to resistance

Proceed to Test 12 (Refer to Temperature Conversion Charts in Test 12

Incorrect Ohm-meter reading

Check

REVISED: APR. 88

Page 15

;;^d;;t;

1987

FUEL INJECTION SYSTEM

119 1

‘EST PROCEDURE

Check coolant temperature

thermistor (sensor)

RESULTS - Check cables and units shown in bold

Correct reading-Temperature to resistance

Proceed to Test 13

(Refer to Temperature Conversion

Chart below.

Fuel and Coolant

Temperature

“C

-100

00 200 400 1040

60" 1400

80° 176O

1000 2120

140

32" 5700

680

“F

Ohm-meter Reading

Should be

Ohms

9100

9300

5900

2400

2600

1100

1300

500

700

300

400

150

200

Incorrect Ohm-meter reading

Check:-

IGNtllON OFF

RR1827E

I-

Continued

Page 16

FUEL INJECTION SYSTEM

r-t

PROCEDURE

13.

Check air bypass valve - Part

-.- - -.w

RESULTS - Check cables and units shown in bold

Ohm-meter reading of Proceed to Test 14

Incorrect reading

Check:-

48-58

Ohms

IGNlTtON

RR1828E

TEST PROCEDURE

14.

OFF

Check air bypass valve - Part 2

IGNITION

OFF

RESULTS - Check cables and units shown in bold

Ohm-meter reading of Proceed to Test 15

Incorrect

Check:-

reading

48-58

Ohms

Y. .,

::, ‘.

‘.

‘.*

REVISED: APR. 88

Page 17

KHNCIt

ROVER

1987

FUEL INJECTION SYSTEM

119 1

[EST

PROCEDURE

Check throttle potentiometer - Part 1

15.

u3NIlloN OfT

RA1830E

rEST

PROCEDURE

16.

Check throttle potentiometer - Part

RESULTS - Check cables and units shown in bold

Ohm-meter reading of Proceed to Test 16

Incorrect reading of Infinity

Check:-

RESULTS - Check cables and units shown in bold

Correct voltmeter Proceed to Test 17

5000

readings-

Ohms

Incorrect voltmeter readings

Check:-

-ICI-

’

RRl831E

IGNITION ON

’

Continued

Throttle

closed

0.29

0.36

)

smooth

)

__....__...___________

)

swing

)

Throttle

open

(

4.6 Volts

( (

(

5.0 Volts

REVISED: JUNE 87

Page 18

FUEL INJECTION SYSTEM

“*’

RANGE

ROVER

‘EST

PROCEDURE

17.

Check Airflow sensor

ou~pul

RESULTS

Voltmeter reading of 0.3-0.6 volts-

Proceed to Test 18

Incorrect voltmeter reading Check:-

IGNITION ON

. Check cables and units shown in bold

PRECAUTION:

Depressurize the fuel system when fitting the fuel pressure gauge or components.

disconnecting/replacing fuel system

CAUTION: Thoroughly clean the immediate area around the fuel filter and hose connections before disconnecting the fuel feed line from the filter. Failure to do so could cause foreign matter to be present in the fuel system which would be detrimental to the fuel system components.

WARNING: The spillage of fuel from the fuel filter is unavoidable when disconnecting the fuel feed line, ensure that all necessary precautions are taken to prevent fire and explosion due to fuel vapour and fuel seepage.

DEPRESSURIZING PROCEDURE

Ignition off, pull pump relay off its terminal block.

a) b)

Crank engine for a few seconds - engine may fire and run until fuel pressure is reduced.

Switch off the ignition.

cl d)

Connect fuel pressure gauge in the fuel supply line between the fuel rail and the fuel filter, adjacent to the filter (see Test 18). Reconnect the pump relay.

1. ,i

REVISED: JUNE 87

,.,:.:

Page 19

FUEL

INIECTION

SYSTEM

119 1

NOTE: Insert the pressure gauge in the fuel feed line immediately after the fuel line filter. The filter is

(34.0-37.0

(6)

Pressure drop-max 0.7 kgflcm’ (IO

p.s.i.)

p.s.9

in one minute

located beneath the right hand rear wheel arch attached to the chassis

,’

‘.’

IGMTION

1R1833E

:; : ‘..

(. ‘.

OFF

Continued

Page 20

FUEL

INJECTION SYSTEM

lg8’

RANGE

ROVER

EST PROCEDURE

Check for leaking injector

NOTE: Before removing any

of the injectors, remove and examine the spark plugs. check for

colouration

A leaking injector will

result in the appropriate spark plug being ‘sooted up’.

Remove all injectors from manifold but do not disconnect from fuel rail

consistenl

of plugs.

RESULTS - Check cables and units shown in bold

WARNING: Ensure that all necessary precautions are taken

IO prevent fire and explosion.

Replace any injector which leaks

more than 2 drops of fuel per minute.

tR1834E

,’

Page 21

I---

;

rot;;

rEST

!O.

1987

PROCEDURE

Check for injector operation Left bank injectors

1,3,5,7

FUEL INJECTION SYSTEM

RESULTS - Check cables and units shown in bold

WARNING: Ensure that necessary precautions are taken

IO prevent fire and explosion.

Repeat test for other injectors Replace any injector which does not operate.

NOTE: Fuel flow is per minute per

167cc

injeclor

all

minimum

rEST

PROCEDURE

11.

Right bank injectors

2,4,6,6

RESULTS - Check cables and units shown in bold

WARNING: Ensure that

necessary precautions are taken

prevent fire and explosion

Repeat test for other injectors

Replace any injector which does not

operate

NOTE: Fuel flow is minute per injector

all

167cc

minimum per

IGNITION ON

Continued

Page 22

FUEL INJECTION

SYSTEM

lg8’

RANGE

ROVER

‘EST PROCEDURE

Check gear switch input

!2.

RESULTS - Check cables and units shown in bold

Voltmeter reading of zero

volts-

Neutral and park

Voltmeter reading of

-R.D.3.2.1 -

Proceed to Test 23

4.5-5.0

Volts

Incorrect reading Check:

1otw10r-d

RR1837E

‘.‘.

‘: .,:.

‘. .’ ,‘:

. . .

‘<

,’ :.,

Page 23

ro7;;

1987

FUEL INJECTION SYSTEM

Ii9 1

.‘,,::. :

;...i

; ]

‘..,‘. .

‘. : ;

‘. *

‘EST PROCEDURE

:3.

‘_’

Check road speed input

RESULTS - Check cables and units shown in bold

Voltmeter reading of 0 to 12V fluctuating 6 times per

revolution - Proceed to Test 24 NOTE: Raise and rotate the left hand rear road wheel slowly

Incorrect reading

Check:

IGNITCON

RR1838E

rEST

PROCEDURE

24.

Check Lambda sensor heater coils

RESULTS . Check cables and

Ohm-meter reading of 2.65-3.35 Ohms

unils

shown in bold

Incorrect reading Check:

NOTE: Remove pump relay from its

conneclor

NOTE: A reading of 5.3 lo 6.7 Ohms indicates a faulty

Lambda sensor

‘.

,,,

:‘:

IGNITION OFF

RR1840E

After completing the tests with either the ‘Diagnostic’ equipment or multi-meter, re-test the vehicle to ensure

the faults have been rectified. If faults still persist, recheck using the Lucas diagnostic equipment.

Page 24

FUEL

INJECrlON

ENGINE TUNING PROCEDURE

Before carrying out ‘Engine Tuning’ on fuel injection vehicles, it is important that all other engine related setting procedures are undertaken first; air flow sensor to air cleaner correctly fitted, ignition and throttle potentiometer correctly fitted and secured.

These checks should be carried out with the engine coolant temperature beween 80” to 95°C (176” to

203°F).

CHECK AND ADJUST IGNITION TIMING

1. Check that ignition timing is at 6” 2 1” BTDC.

2. Timing to be checked when engine speed is less than 800 lamp.

3. If adjustment is necessary, loosen the distributor clamp nut and rotate clockwise to retard or ‘counter -clockwise to advance. When the required setting has been attained, tighten the clamp nut and recheck the setting.

rev/min

SYSTEM

correcty

set; all hoses

using a stroboscopic

NOTE: Timing to be checked with vacuum hose connected.

IDLE SPEED is preset at the factory and should not normally require adjustment.

CAUTION:

A. If engine fails to start within a maximum time

of 12 seconds the cause must be rectified. Following rectification the engine must be run at 1500 rpm (no load) for 3 minutes to clear any accumulation of fuel in the catalysts.

B. If the engine is misfiring, it should be

immediately rectified.

Failure to comply with A or B will result in irreparable damage to the catalysts.

shut down

and the cause

Page 25

yo;;;

1987

FUEL INJECTION SYSTEM

119 1

:j,,

“.’

:..

., .,

AIR CLEANER

Remove and Refit

Removing

Release the two clamps securing the air

cleaner to the airflow sensor.

Release the two nuts and bolts securing the air

AIR FLOW SENSOR

Remove and refit

Removing

NOTE: The air flow sensor is not a

serviceable item. In the event of failure or

damage the complete unit is to be replaced.

cleaner to the left hand valance mounting bracket.

Detach the airflow sensor from the air cleaner, and lay carefully to one side.

Detach the air cleaner from the centre mounting bracket and withdraw from the engine compartment.

Remove the large

‘0’

ring from the outlet tube of the air cleaner, inspect for condition, fit a new

‘0’

ring if in poor condition.

Disconnect the battery negative terminal. Release the large hose clamp at the rear of the air flow meter and disconnect the hose from the sensor. Disconnect the multi-plug. Release the two clips securing the air flow sensor to the air cleaner case detach the sensor from the case and withdraw it from the

engine compartment. Unclip the three catches securing the inlet tube to the air cleaner canister and remove the inlet tube.

Remove the nut and end plate securing the air cleaner element in position.

Withdraw the air cleaner element and discard.

Inspect the dump valve for condition and that it is clear of obstructions.

. .

,;;: ‘.,

,..

‘, ‘.’

;’ ‘.

.. ‘. :

‘,.

,:’

.’

,’ . .

.,.

‘.,

“.

; . .

Refitting

5. Reverse the removal procedure ensuring that the multi-plug is firmly reconnected to the air flow sensor and that the hose clamp at the rear of the sensor is securely tightened, to

RFiI854E

prevent un-metered air entering the engine.

Refitting

10. Fit a new element and secure in position.

11.

Refit the inlet tube to the air cleaner canister.

.‘.

12. Refit the air cleaner to the mounting bracket and tighten the two nuts and bolts.

13. Clip the air flow sensor to the air cleaner.

‘.

REVISED: SEPT. 88

.:...

Page 26

FUEL INJECTION SYSTEM

1987

&INGE

ROVER

‘.

._,. ”

THROlTLE

:,.

Remove, refit and reset

POTENTIOMETER

Setting the Potentiometer using a multi meter.

ENSURE THE MULTI METER USED TO CARRY OUT

THIS CHECK IS SET TO VOLTS. A MULTI METER

Remove

SETTING OTHER THAN VOLTS WILL RESULT IN

DAMAGE TO THE POTENTIOMETER.

1. Disconnect the battery negative terminal. Loosen the potentiometer securing screws.

Disconnect the electrical three-pin plug.

3. Remove the two screws securing the switch to

the plenum chamber and carefully pull the switch off the throttle valve shaft.

8. Reconnect the potentiometer three-pin plug

9. and reconnect the battery. Switch on the ignition. Connect the multi meter between the red and

10.

green leads at the potentiometer electrical

plug.

11.

Rotate

the potentiometer clockwise or

counter-clockwise, until the multi meter reads

325 2 35

12.

Tighten the potentiometer securing screws.

Re-check the multi-meter reading. Check also

13.

mV.

for a ‘smooth swing’ of the meter needle between minimum and maximum throttle

4. Remove the old gasket.

opening between the voltage reading of 4.6

5.0

volts

NOTE: After setting the potentiometer, lock and tamperproof each screw head by coating them with yellow paint.

Refit

5. Fit a new gasket between the throttle switch and plenum chamber.

6. Align the switch and shaft fiats; slide the switch on to the throttle shaft and secure the switch to the plenum chamber.

7. The throttle potentiometer must be reset using the following procedure.

CAUTION: The throttle mechanism must not be

operated while the potentiometer is loosely

fitted, otherwise damage may be caused to the

potentiometer wiper track.

REVISED: SEPT. 88

Page 27

R”d;‘;r;

the

1987

FUEL INJECTION SYSTEM

119 1

,’ :

..’ .:

,’ ,~:

BY-PASS AIR VALVE

SPEED TRANSDUCER

(STEPPER MOTOR)

: ;...

Remove and refit

Removing

Place the vehicle on a hydraulic hoist and

Disconnect the battery negative terminal.

Remove the multi-plug from the unit.

2. Unscrew the valve from its location at the rear

3. of the plenum chamber. Remove the captive washer.

apply the parking brake. Disconnect the battery negative terminal.

2. Raise the hoist and disconnect the speed

3. transducer electrical plug.

Disconnect the speedometer cable from the transducer to the binnacle at the transducer. Disconnect the speedometer cable from the

transducer to the speedometer housing at the transducer.

single bolt securing

Remove

transducer to its mounting bracket

withdraw the unit from the vehicle.

the

and

‘. 1

‘, :.

,, ‘,

‘,, :

.: ‘, :.:,: .‘: :

., ,’ ‘, ,‘.,

,,;,. ; : :

Refitting

5. Fit a NEW sealing washer.

,..

::::

.’

NOTE: If refitted compounds from the threads. Apply Loctite 241 to threads

the same by-pass valve is being

clean

previous sealing

any

of the valve before

Refitting

7. Reverse the removal instructions.

reassembly.

I.‘,

6. Tighten the valve to the specified torque Torque values-section

06).

(see

7. Reverse the remaining removal instructions.

:,, ..,‘. :,.

Page 28

FUEL INJECTION

SYSTEM

ELECTRONIC FUEL INJECTION RELAYS

incorporated into the fuel injection electrical circuits

are two relays. The relays are located beneath the

right-hand seat, adjacent to the E.C.U.

front

Fuel pump relay (mounted on a blue

ELECTRONIC CONTROL UNIT-ECU

‘,,,

NOTE: The ECU is not itself a serviceable item, in the event of a unit failure, the ECU must be replaced.

Remove and refit

terminal block).

Removing

Main relay (mounted on a black terminal

block).

Diagnostic plug.

Disconnect the battery negative terminal. The ECU is located under the front right hand

seat and is accessible through the rear

opening of the seat base when the seat is in its most forward position. Release the E.C.U plug retaining clip.

Pull the rear of the multi-plug out of the ECU.

Maneuver the tront of the plug fin the

direction of the bold arrow) to release the hooked rear end of the plug from the

retaining peg. Release the screws securing the ECU to the

.’

mounting bracket.

Withdraw the ECU from the spring clip and

,:’ .i

remove it from the vehicle.

RRl867ERRl867E

Remove and refitRemove and refit

RemovingRemoving

1. Disconnect the battery negative terminal.1. Disconnect the battery negative terminal.

2. Pull the relay(s) from the multi-plug(s).2. Pull the relay(s) from the multi-plug(s).

RefittingRefitting

3. Reverse the removal procedure.3. Reverse the removal procedure.

Refitting

8. Refit the E.C.U. securely

in’the

spring clip and

tighten the two screws.

9. Re-connect the E.C.U. harness plug, ensure the plug is firmly pushed into its location and

that the retaining clip secures the plug in position.

:‘,

:,: ‘.

..,..

.’

Page 29

FUEL INJECTION

SYSTEM

INERTIA SWITCH

The inertia switch is located under the left hand

front seat attached to the inner face of the rear front seat base. Access to the switch is gained through the opening at the rear of the seat base.

Remove and refit

Removing

1. Ensure the seat is in its fully forward position.

2. Disconnect the battery negative terminal.

3. Remove the two screws securing the switch to the cross member.

4. Withdraw the switch and disconnect the electrical multi-plug.

5. Remove the switch from the vehicle.

FUEL TEMPERATURE THERMISTOR (SENSOR)

Remove and refit

Removing

NOTE: No fuel leakage will occur when the thermistor is

therefore it is not necessary to depressurize the

fuel system before removal.

1. Disconnect the battery negative terminal.

2. Remove the electrical multi - plug from the thermistor.

3. Release the thermistor from the fuel feed rail.

removed from the fuel rail

Refitting

6. Reverse the removal procedure ensuring that the multi-plug clips firmly into position, and that the plunger is reset (plunger is in its lowest position).

Refitting

4. Reverse the removal procedure, ensuring that the thermistor is tightened securely in the fuel

rail.

REVISED: APR. 88

Page 30

FUEL INJECTION SYSTEM

1987-88

KANW

R(-j”ER

COOLANT TEMPERATURE THERMISTOR (SENSOR)

Remove and refit

Removing

Remove the multi-plug from the thermistor.

Release the radiator bottom hose and partially

2. drain the cooling system.

Refit the hose and tighten the clamp securely.

3. Remove the thermistor from the left hand

4. front branch of the intake manifold. Remove the copper washer.

RESETTING THROTTLE LEVERS

NOTE: The setting procedure outlined is applicable at minimum throttle condition only.

Ensure that the throttle valve is retained at its 90” vertical setting by holding down the stop lever and throttle/kick down lever denoted by the bold arrow while adjusting the throttle operating levers. Release the throttle operating lever securing screw and adjust the lever until contact is made with the top end of the slot in the throttle lever mounting bracket; retaining the lever in this position retighten the screw.

Lightly grease all throttle lever bearing surfaces

and torsion spring with

suitable equivalent.

Admax

13 grease or a

Refitting

Fit a NEW copper washer to the thermistor.

6. Fit the thermistor to the intake manifold and

tighten securely.

Refill the cooling system.

8. Run the engine, check for water leaks around

9. the coolant temperature thermistor.

NOTE: Check the clearance between the cruise control actuator link and throttle lever (see Setting-Section 19, Page

LATER MODELS:- have a redesigned stop lever that

seats on a factory-set adjustment screw which is located in the plenum chamber casting. The screw should not normally require adjustment. If new throttle bracketry and linkages are fitted it is advisable to check that the throttle valve is vertical before adjusting the screw.

Cruise

Control

47).

Actuator

.__

REVISED: APR. 88

:, .._..

Page 31

THROl-FLE

Remove and refit

Removing

CABLE

Remove the cotter pin and clevis pin securing the cable to the lever. Carefully pry the throttle cable adjustment nut out of the linkage mounting bracket.

Withdraw the cable from the mounting

bracket.

i,io

2,i2

FUEL INJECTION SYSTEM

10. Connect the cable to the throttle linkage, fit a

new cotter pin and secure in position.

11. Clip the outer cable adjustment nut into the mounting bracket.

12. Adjust the outer cable to give 1.57 mm (0.062 in) free play in the throttle cable and check the throttle operation.

THROlTLE PEDAL

Remove and refit

Remove

Release the six screws securing the lower dash

1. panel, lower the panel and disconnect the two electrical leads to the rheostat switch, detach the bulb check unit from the spring clip and remove the dash panel from the vehicle. Remove the cotter pin and clevis pin securing the throttle cable to the throttle pedal.

Release the tension from the pedal return spring. Remove the circlip from the pedal pivot pin. Withdraw the pivot pin.

RRl064E

Release the outer cable from the retaining

clips within the engine compartment.

Remove the lower dash pane! from beneath the steering column. Disconnect the cable from the throttle pedal and release the cable locknut. Feed the cable through the bulkhead grommet and into the engine compartment.

NOTE: It may be necessary to remove the

steering

column fixings enabling the column to be lowered to gain access to the pedal pivot pin circlip.

Withdraw the throttle pedal.

Refitting

7. Lightly grease the before re-assembly.

8. Fit a NEW cotter pin to the clevis pin.

9. Reverse the remaining removal instructions.

pivot4pin

and clevis pin

FIT NEW

THROlTlE

8. Feed the new cable from the engine compartment through the bulkhead grommet.

9. Connect the cable to the throttle pedal.

CABLE

Page 32

FUEL INJECTION SYSTEM

1987-88 PO;;;

PLENUM CHAMBER

Remove and refit

12. Release the two throttle return springs.

13.

Remove the two bolts (with spring washers)

securing the throttle cable and kick-down

cable anchor bracket to the throttle lever

Removing

.’ 1

Disconnect the battery negative terminal.

Release the radiator bottom hose and partially

support bracket, lay the assembly to one side.

drain the cooling system, reconnect the hose

to the radiator.

Release the two large hose clamps from the neck of the plenum chamber and outlet bore of the airflow sensor and remove the hose from its location.

Release the clamps and remove the two

4. coolant hoses from the bottom of the plenum chamber inlet neck. Identify each hose to aid re-assembly. Remove the vacuum supply hose from the cruise control actuator. Disconnect the actuating link at the cruise control actuator.

Remove the distributor vacuum hose, positive

crankcase ventilation breather filter hose and servo hose.

Disconnect

throttle potentiometer

the

multi-plug.

Remove the six socket head bolts (with plain

14. washers) securing the plenum chamber to the ram housing. Maneuver the plenum chamber and remove it

15. from the ram housing.

NOTE: To prevent ingress of dirt ram tubes, place a protective cover

ram tube openings.

into the over the

Disconnect the multi-plug from the air by-pass

valve.

Disconnect the small vacuum hose at the rear

10. of the plenum chamber, located below the air by-pass valve.

11.

Remove the hose from the air by-pass valve to plenum chamber to enable the small return

spring located below the throttle levers to be

unhooked.

: :

‘,, .:,:::,: ‘,‘.

Page 33

;;“d;‘;;i

1987-91

FUEL INJECTION SYSTEM

Refitting

16. Ensure that all mating faces are free from any previous sealing compounds.

17.

Coat the mating faces of the plenum chamber

and ram housing with ‘Hylomar’ sealant.

18. Refit the plenum chamber and tighten the six bolts to the specified torque (see torque values-section

19. When refitting the small return spring, item 11

in the removal procedure, it must be noted that the ‘hooked’ open end of the spring MUST face the plenum chamber as shown in illustration

06).

RR2292E

below.

RAM HOUSING

Remove and refit

Removing

Disconnect the battery negative terminal.

2. Remove the plenum chamber (see Plenum Chamber remove and refit).

3. Release the hoses from around the outer edges of the ram housing.

4. Remove the six through bolts (with plain washers) securing the ram housing to the intake manifold.

20. Reverse the remaining removal instructions.

NOTE: Ensure that all hoses are connected securely to prevent un-metered air entering the engine.

REVISED: SEPT. SO

5. Lift the ram housing off the intake manifold and remove it from the engine compartment.

6. Place a protective cover over the top of the

intake manifold inlet bores to prevent ingress of dirt.

Refitting

7. Ensure that all mating faces are clean and free dirt

from compounds.

8. Apply ‘Hylomar’ sealant to the intake manifold

face before refitting the

9. Fit the ram housing and retighten the bolts,

working from the two centre bolts, towards the outer four bolts.

10. Tighten to the correct torque (See section 06-Torque values).

and

previous sealing

any

ram

housing.

diagonal11

;: _:

Page 34

FUEL INJECTION SYSTEM

1987-91

PO;;;

DEPRESSURIZING

WARNING: Under normal operating conditions the fuel injection system is pressurized by a high pressure fuel pump, operating at up to 2.3 to 2.5 bar (34 to 37 stationary this pressure is maintained within the system. To prevent pressurized fuel escaping and to avoid personal injury it is necessary to

depressurize

any service operations are carried out.

NOTE: If the vehicle has not been run there will still be a small amount of residual pressure in the fuel line. The still be carried out before disconnecting the

component within the fuel system.

WARNING: The spilling of fuel is unavoidable

during this operation. Ensure that all necessary

precautions are taken to prevent fire and

explosion.

The fuel pump relay is located under the front

right hand seat.

Pull the fuel pump relay off its multi-plug (see Electronic Fuel Injection Relays-Section 19, Page 28). Start and run the engine.

3. When sufficient fuel has been used up causing

4. the fuel line pressure to drop, the injectors will become inoperative, resulting in engine stall. Switch the ignition off. Disconnect the battery negative terminal.

THE FUEL SYSTEM

p.s.i.1.

When the engine is

the fuel injection system before

depressurizing

procedure must

FUEL PRESSURE REGULATOR

Remove and refit

Removing

Depressurize the fuel system.

Disconnect the negative battery terminal.

Release the hose clamp securing the fuel return hose to the regulator and remove the hose. Pull the vacuum hose from the rear of the

4. regulator.

Remove the two nuts and bolts securing the

5. regulator to the fuel rail, carefully ease the regulator fuel inlet pipe out of the fuel rail.

Withdraw the regulator from the engine

6. compartment.

NOTE: Fuel at low pressure will remain in the system. To remove this low pressure fuel, place an absorbent cloth around the fuel feed hose at the fuel rail and release the fuel feed hose at the appropriate end.

Disconnect either: a) The nut and ferrule at the fuel rail OR b) The hose at the inlet end of the fuel filter.

Refitting

7. Refit the fuel feed hose.

8. Refit the fuel pump relay, reconnect the battery.

9. Crank the engine (engine will fire within approximately 6 to 8 seconds).

NOTE: If the original regulator refitted, fit a NEW pipe.

Refitting

Lightly coat the

7. 300 before fitting the regulator to the fuel rail. Reverse the removal procedure.

8. Reconnect the batter), and pressurize the fuel

9. system and check that there are xo fuel leaks around the regulator connections.

‘0’

ring to the

‘0’

ring with silicon grease

is being

fuel inlet

REVISED: SEPT. 90

Page 35

,’

,’ .’

. .‘.‘...‘,

. .

.,‘,.,., .

, ,‘..

._ .’ ..,

‘..: ‘:

;;^d;‘;;

1987-88

FUEL RAIL-INJECTORS R/H AND UH

Remove and refit

Removing

Depressurize the fuel system. Disconnect the negative battery terminal.

Remove the plenum chamber. (See Plenum

Chamber, remove and refit).

Remove the ram housing.

(See

Ram Housing

remove and refit).

NOTE: Place a cloth over the ram tube openings to prevent ingress of dirt into the engine.

Release the hose clamp and remove the fuel

return hose from the pressure regulator.

Disconnect the multi-plug from the fuel

temperature thermistor (sensor).

Disconnect the multi-plugs from the eight injectors. Remove the five bolts securing the fuel rail

support and heater pipe brackets to the intake manifold. Lay the heater pipes to one side.

FUEL INJECTION SYSTEM

11. If necessary, remove the two nuts and bolts securing the regulator to the fuel rail, and carefully pull the regulator away from the rail.

Refitting

12. Fit NEW

supporting disc to the injectors, lightly coat the

‘0’

the injectors into the fuel rail, multi-plug connections facing outwards.

13. Refit the retaining clips.

‘0’

rings, protective cap and

rings with silicon grease 300 and insert

--- .,

9. Remove the fuel rail, complete with injectors, from the intake manifold.

10. Remove

the retaining clips securing the injectors to the fuel rail, ease the injectors from the rail.

CAUTION: Care must be taken when refitting the

fuel rail and injectors to the intake manifold to

prevent damage occurring to the ‘0’ rings.

Fit a NEW

14.

lightly coat the

and secure the regulator to the fuel rail. Fit the fuel rail and heater pipe assemblies to

15.

the intake manifold, secure the rail and pipes in position with the five bolts. Reverse the remaining removal instructions.

16.

Pressurize the fuel system and check for fuel

17.

leaks around the injectors and pressure

regulator.

‘0’

ring to the pressure regulator

‘0’

ring with silicon grease 300

. .. . .

‘...

Page 36

FUEL INJECTION SYSTEM

INTAKE MANIFOLD

Remove and refit

Removing

Depressurize the fuel system. Disconnect the battery negative terminal. Release the hose clamp and remove the radiator bottom hose to enable the cooling system to be partially drained, so that coolant level is below the thermostat housing, refit the hose and secure in position with the hose clamp.

Remove the plenum chamber (see Plenum

Chamber, remove and refit).

Remove the ram housing (see ram housing remove and refit).

CAUTION: Place a protective cover over the intake manifold openings to prevent ingress of

dirt.

Disconnect the electrical multi-plugs to the fuel temperature thermistor (sensor), coolant

temperature thermistor (sensor) and injectors.

Remove the two nuts and bolts securing the pressure regulator to the fuel rail, ease the regulator out of the rail, seal the end of the fuel rail with suitable plastic plugs to prevent ingress of dirt.

NOTE: The intake manifold can be removed from the cylinder block without removing the fuel rail and injectors.

1987-88

13.

Lay the heater pipe assembly to one side.

14.

Release the twelve bolts securing the intake

manifold to the cylinder heads.

15.

Lift the manifold off the cylinder heads and

remove from the engine compartment.

16. Remove the two gasket clamps from the top of the cylinder block.

17.

Lift off the gasket and remove the gasket

seals.

yo$;;

18. Remove previous sealing compound from

around the water passage openings of the cylinder heads.

Refitting

19. Locate the NEW seals in position with their

ends engaged in the notches formed between the cylinder heads and block.

Disconnect the electrical leads from the air-conditioning engine coolant sensor located on the thermostat elbow.

Disconnect the electrical leads to the coolant temperature transmitter (sensor) located at the front of the intake manifold.

10.

Remove the injector harnesses from behind

the fuel rail and lay to one side.

11.

Release the hose clamps securing the two heater hoses to the rigid heater pipes at the front of the right hand rocker cover.

12.

Remove the two bolts securing the rigid heater pipes to the intake manifold and ease the pipes out of the hoses.

20.

Lightly apply

outside of the water passage openings on the

cylinder heads, manifold gasket and intake manifold.

‘Hylomar’

sealant around the

, ‘.

‘I,

‘.,

z,‘..

Page 37

FOE;

1987-91

FUEL INJECTION SYSTEM

FUEL FILTER

.,:: :

: ”

‘. :.

. .

201

Remove and refit

Refitting

WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are

taken to prevent fire and

explosion.

Depressurize the fuel system.

The fuel filter is located on the right hand

2. chassis side member

fotward

of the fuel tank filler neck. Access to the filter is gained through the right hand rear wheel arch.

21.

Fit the manifold gasket with the word ‘FRONT’ to the front and the open bolt hole to the front right hand side.

22.

Fit the

gasket

clamps but DO NOT fully tighten the bolts at this stage. Locate the intake manifold onto the cylinder

23. heads, clean the threads of the manifold securing bolts.

24.

Fit all manifold bolts and tighten them a little

at a time, evenly, alternate sides working from

Thoroughly clean the immediate area around

3. the hose connections to prevent ingress of foreign matter into the fuel system.

Loosen the two hose clamps nearest the filter to enable the hoses to be removed from the filter canister. Plug the end of the hoses to prevent ingress of dirt. Release the securing bolt and bracket and

remove the filter from the chassis side member.

the centre outwards. Tighten to correct torque (see section 06

25. Torque values). Tighten the gasket clamps to the correct

26. torque (see section 06 Torque values). Reverse remaining removal instructions.

27. Replenish the cooling system.

28. Start the engine, check for water and fuel

29. leaks.

Refitting

6. Fit a new filter observing the direction of flow arrows stamped on the canister.

7. Start the engine and inspect for fuel leaks around the hose connections.

REVISED: SEPT. 90

Page 38

‘. 8.

‘. .’

‘,

FUEL INJECTION

‘_’

FUEL TANK

SYSTEM

IO. Release the two large hose clamps, securing

1987-91

the inter-connecting hose to tank and filler

Remove and refit

tube, maneuver the hose up the outside of

KANGIZ

ROVER

*f .,

‘..

‘-’

the filler tube to enable it to be withdrawn

Removing

from the tank filler neck.

11. With assistance from a second person

WARNING: Ensure that the Fuel Handling

Precautions given in Section 01 - Introduction

supporting the fuel tank, remove the four tank fixings.

regarding fuel handling are strictly adhered to

when carrying out the following instructions.

CAUTION: Before disconnecting any part of the fuel system it is imperative that all dust, dirt and debris is removed from around the components to prevent ingress of foreign matter into the fuel system.

Drive the vehicle onto a suitable hoist.

Depressurize

the fuel depressurizing procedure-page Disconnect the battery negative terminal.

Disconnect the electrical leads to the fuel tank

4. sender unit.

Disconnect the fuel pump

system.

34)

(see

.,,‘Y.:

,..

‘.

:..

electrical multiplug, access to which is gained

through the left hand rear wheel arch, the plug is located between the underside of the body and chassis side member. Raise the hoist.

‘_

,. .’

: ”

; ‘:

: ”

..,

.’

Remove the drain plug from the bottom of the

fuel tank and drain the fuel into a suitable container that can be sealed afterwards. ENSURE THAT THE TANK IS DRAINED COMPLETELY. Refit the drain plug (refer to Warning concerning fuel handling at start of this procedure.

From underneath the vehicle

Disconnect the fuel hose from the inlet side

of the fuel filter.

Disconnect the fuel return pipe to the fuel

tank.

Remove

the breather hose and three evaporative loss hoses from the fuel tank, seal all hose and pipe openings to prevent ingress of foreign matter.

Tilt the left hand side of the tank downwards

12.

and maneuver it out of the chassis frame. Care should be taken to ensure that the fuel feed pipe to filter is not damaged when lowering the tank.

Place the tank in a safe area and ensure that all

13.

necessary precautions are undertaken to make all personnel within the vicinity aware that the tank will give off residual fuel fumes.

14.

If necessary remove the fuel pump from the tank. (See Fuel

Pump

remove and refit).

Refitting

Refit the fuel tank to the chassis, taking care

15. to relocate the fuel feed pipe grommets between the fuel tank and chassis. Reverse the removal procedure, ensuring that

16.

the

sealing

ring.

fuel line

connections are secure.

17.

Run the engine and re-check all connections

and hose

to ensure no fuel leaks exist. Reverse the

remaining removal procedure. Recode the radio.

RRPOIOE

REVISED: SEPT.

‘l..,

Page 39

FUEL PUMP

REVISED: SEPT. 90

Remove and refit

Removing

FUEL INJECTION SYSTEM

iI-9 1

WARNING: Ensure

that the Fuel Handling Precautions given in Section 01 - Introduction regarding fuel handling are strictly adhered to

when carrying out the following instructions.

1. Drive the vehicle onto a suitable hoist.

2. Depressurize the fuel pump system. (see depressurizing procedure-page

3. Disconnect the battery negative terminal.

4. Remove the fuel tank from the chassis frame.

(see fuel tank remove and refit-page 38)

5. Place the tank in a safe area.

6. Disconnect the fuel supply hose from the

pump.

7. Remove any previous sealant from the top of the pump flange.

8. Remove the five screws and withdraw the pump from the tank.

34)

Refitting

9. Clean the immediate area around the pump

opening in the fuel tank.

10. Fit a NEW pump seal.

11.

Secure the pump to the tank and tighten the

screws securely.

12. Liberally coat the heads of the screws and flange of the fuel pump with Sikaflex 221 flexible adhesive sealant.

13.

Reverse the removal procedure, ensuring that

sealing ring,

the

connections are secure. Recode the radio.

14. Run the engine and re-check all connections to ensure no fuel leaks exist. Reverse the remaining removal procedure.

fuel line and hose

Continued

Page 40

FUEL INJECTION SYSTEM

1987-91

KANGE

ROVER

FUEL PIPES

WARNING: Depressurize fuel disconnecting any of the fuel pipes and ensure

that

all necessary precautions are taken against

fuel spillage.

system before

KEY

1. Fuel feed hose to fuel rail.

2. Fuel return hose to fuel tank.

3. Rigid fuel feed pipe.

4. Rigid fuel return pipe.

5. Fuel filter.

6. Rigid fuel feed pipe to filter.

7. Breather hose.

in-tank fuel pump.

9. Fuel filler neck.

10.

Fuel tank.

RRPOISE

REVISED: SEPT. SO

Page 41

;;^d;&

1989

FUEL INJECTION SYSTEM

11%) 1

1 26 26

I’

‘,

AF32884E

FUEL INJECTION - Circuit Diagram - 1989 Model Year

1. 40 way connector to Electronic Control Unit (ECU).

2. Lambda sensor (left side - bank A).

3. Lambda sensor fright side - bank

6).

4. By-pass air valve (stepper motor) (fast idle).

5. Lambda sensor screened ground.

6. Fuse 18 - main fuse panel.

7. Inertia switch.

8. Fuel pump.

9. Ignition switch.

10. Speed transducer (road speed input).

11. Neutral switch (automatic gearbox) (load

input).

12. Main cable connector.

13. Battery.

14. Diagnostic plug.

15. In-line resistor.

16. Coil/-ve (engine RPM input).

17. Coolant

temperature thermistor (sensor)

(input).

18. Fuel temperature thermistor (sensor) (input).

19. Throttle potentiometer.

20. Air flow sensor.

21. Fuel pump relay.

22. Main relay.

23. Injectors-l to 8.

24. Pick-up point

E.F.I.

binnacle).

25. Heated front screen sense.

26. Purge control valve.

27.

12\/

from fan relay.

28. Air conditioning switch sense.

29. Air conditioning output

30. Air conditioning load input.

31. Fan relay feed.

32. Heater/air con. cable connector.

33. Condenser fan timer control.

= = =

Denotes screened ground.

NOTE: Reference to left and right side is made when viewing vehicle from rear.

warning symbol (instrument

co?itrof.

ADDITION: SEPT. 88 / REVISED: MAY 89

Page 42

FUEL INJECTION SYSTEM

lg8’

RANGE

ROVER

FUEL INJECFION SYSTEM

For 1989 model year, the EFI system has a Lucas 14CU electronic control unit. This is a development

of the

13CU

used on 3.5 litre vehicles.

most respects the

using the same engine components, it does however have additional capacity, enabling it to control fuel tank vapour purging and air

conditioning.

14CU

works in the same way

Condenser fans

It should be noted that under high coolant

temperatures, when the engine is switched off, the

condenser fans will be activated and will run for

approximately ten minutes.

Throttle potentiometer

A further improvement is the fitting of a ‘self

adaptive’ throttle potentiometer. This means that adjustment of the throttle potentiometer is no longer possible. It potentiometer setting is not lost, for example,

when throttle stop wear occurs.

also means

that

the

Purge valve

The operation of the charcoal canister purge valve is checked during the fuel injection system test. See TESTS 9 and 10 Section 19, page 48.

Recommended equipment

The diagnostic equipment used for checking out

the

l4CU

system is the same as that used for

I~CU,

with the addition of a new memory card for

the Hand held test unit.

14CU

Memory card

Lucas Part Number - 54746500

CONTINUITY TEST PROCEDURE

Test procedure using a multi-meter is carried out as

for

13CU,

with the addition of tests for the purge control valve, air conditioning, heated front screen and condenser fan inputs. The use of a hand held vacuum pump, for example a

‘Mityvac’,

Note that the 40 way multi-plug to the ECU is

wired as in the following table.

PIN NOS.

5. Black/white

10.

11. Yellow/white

12.

13. Yellow/blue

14.

15. Brown

16. Blue/purple

17.

18. White/pink

19.

20.

21.

22.

23. Blue

24. Blue

25.

26. Green/white

27.

28.

29.

30. Not used

31. Not used

32.

33.

34.

35.

36.

37. White/yellow

38. Not used

39. White/black

40.

is required to carry out Tests 9 and IO.

CABLE COLOUR

Redigreen Brown/orange

Yellow

Black

Yellow Green/blue Purple/yellow White/light green Black/Yellow

Blue/red

Black

Grey/yellow

Whitelgrey

Red

Yellow/black

Blue/red

Red/black

BlackIgrey Blue/grey

Orange

Creylwhite Black/grey

Black/orange Blue/green Black/green

Black

ADDiTlON:

The last colour denotes the wire tracer colour.

SEPT. 88 / REVISED: MAY 89

Page 43

K”d;‘;rt

ADDITION: SEPT. 88

REVISED: MAY 89

1989

FUEL INJECTION SYSTEM

TESTS - Using a Multi-Meter -

The following continuity tests are intended as a guide to identifying where a fault may be within a circuit; reference should be made to the fuel injection circuit diagram for full circuit information.

14CU

system - Key to Symbols

ELECTRONIC CON

AND MULTIPLUG

CONNECTION

ROAD SPEED

INPUT (SPEED

TRANSDUCER)

TEMPERATURE

POTENTIOMETER

PUMP RELAY FUEL PUMP

HOT WIRE AIRFLOW

METER

Page 44

FUEL INJECTION SYSTEM

l-1

1989

t(ANbt

ROVER

,.’ .

,.. 1

NOTE: otherwise in the test procedure.

..’

Ail

tests are carried out from the electronic control unit (ECU) harness multi-plug unless stated

‘EST PROCEDURE

Check battery supply to ECU

IGNITION OFF

RESULTS - Check cables and units shown in bold

Voltmeter reading of batten/ volts

(mimimum

Proceed to Test 2

Voltmeter reading of zero volts

Check:-

battery voltage IO volts)

TEST

PROCEDURE

Check ignition supply to ECU

RR262OE

1 1 /

-mI-

’

IGNITION ON

RESULTS - Check cables and units shown in bold

Voltmeter reading of battery volts (minimum battery voltage 10 volts)

Proceed to Test 3 Incorrect reading check:-

’

ADDITION: SEPT. 88 I REVISED: MAY 89

Page 45

k”d;‘ir;

1989

rEST

PROCEDURE

Check operation of Main relay

FUEL

INIECTION

RESULTS - Check cables and units shown in bold

Voltmeter reading of battery volts

Proceed to Test 5

SYSTEM

119 1

-4

Fault Diagnosis

Main relay circuits

\ 1 /

-aI-

’

IGNITION ON

Voltmeter reading of zero volts

Proceed to Test

Voltmeter reading

of battery volt

IGNITION OFF

Continued

ADDITION: SEPT. 88 ! REVISED: MARCH SO

Page 46

1191

FUEL INJECTION SYSTEM

1989

K”d;;;

.. I

rEST

PROCEDURE

Check engine speed signal

Cable and

resislor

RESULTS - Check cables and units shown in bold

Voltmeter reading of 9.5 volts + 1 volt Proceed to Test 6

Voltmeter reading of zero volts Check:-

1 1 /

..:

-a-

’ I

‘.

.’

RR2631E

-EST PROCEDURE

Check operation of pump relay

IGNITION ON

’

RESULTS - Check cables and units shown in bold

Test lamp will illuminate for approximately

1 second when ignition is switched on

0.K -

Proceed to Test 8

,;. .‘.,

Lamp does not illuminate

Check:-

If OK proceed to Test 8

.’

RR2632E

IGNlTtON

1,:

‘,: ,.:

,’

ADDITION: SEPT. 88 / REVISED: MARCH 90

Page 47

FUEL INJECTION SYSTEM

ADDITION: SEPT. 88 I REVISED: DEC. 88

119 1

TEST PROCEDURE

Fault diagnosis Pump relay circuits

RR2833E

TEST PROCEDURE

Check operation of Fuel pump

NOTE: II is not possible to place the multi-meter probes directly onto the pump lerminals. A link lead attached lo the pump is accessible behind the rear left hand wheel located between the chassis and stowage area floor panel.

IGNITION ON

RESULTS - Check cables and units shown in bold

Voltmeter reading of battery volts

Suspect ECU

Voltmeter reading of zero volts

Check:-

RESULTS - Check cables and

Voltmeter reading of battery volts

unhs

shown in bold

Pump operating - Proceed to Test 10

(A)

Voltmeter reading of battery volts

Pump not operating

Check:-

., -.

KEY:

1. Inertia switch

2. Fuse 18

(B)

Voltmeter reading of zero volts

Check:-

IGNITION ON

RR2634E

1,‘.

Continued

Page 48

1191

FUEL INJECTION SYSTEM

TEST

PROCEDURE

Check purge valve. Part 1 - seating

1. Disconnect pipe from purge plenum (al plenum)

2. Connect vacuum pump to pipe to purge valve

3. Apply vacuum of 2.5

I-

IGNITION OFF

9R2212E

in/Hg

.--

valve

1989

RESULTS - Check cables and units shown in bold

Vacuum should hold for 2.5 minutes If vacuum correct proceed to test 10

If vacuum incorrect check:

Tv\IYUC

P(\VFR

m.v . L..

TEST PROCEDURE

10.

Check purge valve. Part 2 - operation

1. Apply vacuum - 2.5 ignition on

2. Connect pins 16 and 17 to earth to energise pump relay.

RR2OlSE

in/Hg,

switch

-m0

’

IGNITION ON

’

RESULTS - Check cables and units shown in bold

Vacuum should be released

If OK proceed to test 11

If vacuum not released check:

ADDITION: SEPT. 88 / REVISED: DEC. 88

._\

. .

:. .;

Page 49

R”d;;;i

rEST

‘.*

Il. Check injectors,

1989

PROCEDURE

Injector circuit

FUEL

INIECTION

SYSTEM

RESULTS - Check cables and units shown in bold

Ohm-meter reading of 4-4.5 Ohms Proceed to Test

119 1

” ,

Pin 13 left bank ‘A’ injectors

IGNITION OFF

RR2535E

I-EST

PROCEDURE

1,3,5,7).

Ohm-meter reading of 5-6 Ohms Suspect 1 injector Ohm-meter reading of 8-9 Ohms Suspect 2 injectors Ohm-meter reading of 16-17 Ohms Suspect 3 injectors

Check for open circuit injector(s) or wiring faults.

Ohm-meter reading of Infinity Check:

RESULTS - Check cables and units shown in bold

12.

.,”

:’

; :’

(. .‘.

;:. .: .::F.‘,

. .

‘. ,:

Check injectors, Injector circuit

IPin

11 rightbank

IGNITION OFF

I.L”““b

‘B’

injectors

2,4,6,6)

Ohm-meter reading of 4-4.5 Ohms Proceed to Test 13

Ohm-meter reading of 5-6 Ohms Suspect 1 injector Ohm-meter reading of 8-9 Ohms Suspect 2 injectors Ohm-meter reading of 16-17 Ohms

Suspect 3 injectors Check for open circuit injector(s) or wiring faults.

Ohm-meter reading of Infinity Check:

Continued

ADDITION: SEPT. 88 / REVISED: DEC. 88

”

Page 50

1191

FUEL

INIECT’ION

SYSTEM

1989

k”d;\;;i

..:

.‘i,

. . .

‘. . .

,: 0

.:.

. X

reading-temperature to

ature Conversion

IGNITION OFF

ADDITION: SEPT. 88 / REVISED: DEC. 88

Page 51

FUEL INJECTION SYSTEM

Temperature Conversion

Should be

9100 - 9300 5700 -5900

119 1

Ohms

,::

IGNITION OFF

Continued

Page 52

FUEL INJECTION SYSTEM

l-i

MT PROCEDURE

Check air bypass valve -

15.

IGNITION

‘EST

PROCEDURE

16.

OFF

Check air bypass valve - Part 2

Par(

RESULTS - Check cables and units shown in bold

Ohm-meter reading of 40-60 Ohms

Proceed to Test

Incorrect reading

Check:-

RESULTS - Check cables and units shown in bold

Ohm-meter reading of 40-60 Ohms Proceed to Test 17

IWMOE

Incorrect reading

Check:-

ADDITION: SEPT. 88

Page 53

,.;

__.

iEST

PROCEDURE

17.

Check throttle potentiometer - Part

RESULTS - Check cables and

Ohm-meter reading of 4000-6000 Ohms

unils

shown in bold

Proceed to Test 18

Incorrect reading of Infinity

Check:-

:_ ,’

KiNlTlON

IW641E

OFF

Throttle closed:

0.085-0.545

volts

)

smooth

)

swing

)

between

RR2642E

Continued

ADDITION: SEPT. 88 ! REVISED: MAY 89

Page 54

.,‘i

TEST

‘. ‘,I

PROCEDURE

IS.

Check

,.:

output of

Airflow sensor

RESULTS - Check cables and units

Voltmeter reading of

Proceed to Test 20

Incorrect voltmeter reading

Check:-

0.2-0.7 volts-

shown in bold

.’

..:j

: .,

(’ :

‘..,.

.>.s (.

.. ‘._,,

,.’ ::

‘.

::.

‘.’ ?.

.’

IR2f343E

PRECAUTION:

Depressurize the fuel system when fitting the fuel pressure gauge or disconnecting/replacing fuel system components.

IGNITION ON

WARNING: The spillage of fuel from the fuel filter is unavoidable when disconnecting the fuel feed

line, ensure that all necessary precautions are taken to prevent fire and explosion due to fuel vapour and fuel seepage,

DEPRESSURIZING PROCEDURE

Ignition off, pull pump relay off its terminal block.

a) b)

Crank engine for a few seconds Switch off the ignition.

cl d)

Connect fuel pressure gauge in the fuel supply line between the fuel rail and the fuel filter, adjacent to

the filter

Reconnect the pump relay.

(see

Test 20).

engine may fire and run until fuel pressure is reduced.

‘.

’

ADDITION: SEPT. 88 / REVISED: MAY 89

Page 55

.“.. .‘C--

ROVER

lg8’

FUEL INJECTION SYSTEM

I19

‘. 1.1.:.

rEST

PROCEDURE

Check fuel system pressure

10.

Service

NOTE: Insert the pressure gauge in the fuel feed line immediately after the fuel line filter. The filter is located beneath the right hand rear wheel arch attached lo the chassis

tool 18C

1500

RESULTS - Check cables and units shown in bold

(A)

Expected reading

(34.0-38.0

(B)

Pressure drop-max 0.7

(10 p.s.i.)

Proceed to Test

in one minute

2,39-2,672 kgf/cm’

p.s.i.)

kgf/cm2

RR2644E

IQNITION

I-

IGNITION OFF

Continued

ADDITION: SEPT. 88 / REVISED: MAY 89

Page 56

FUEL INJECTION SYSTEM

r-l

1989

wiNClt

ROVER

.,,

,’ :’

EST PROCEDURE

Check for leaking injector

!l.

NOTE: Before removing any of the injectors, remove and examine the spark plugs, check for consistent

colouralion

A leaking injector will result in the appropriate spark plug being ‘sooted up’.

Remove all injectors from

manifold but do not disconnect from fuel rail

of plugs.

RESULTS - Check cables and units shown in bold

WARNING: Ensure that all

necessary precautions are taken to prevent fire and explosion.

Replace any injector which leaks more than 2 drops of fuel per minute.

IGNITION ON

RR2648E

‘EST PROCEDURE

12.

Check for injector operation Left bank ‘A’ injectors

. . .

1,3,5,7

RESULTS - Check cables and units shown in bold

WARNING: Ensure that necessary precautions are taken

prevent fire and explosion.

Repeat test for other injectors Replace any injector which does not operate.

NOTE: Fuel flow is 160-175 cc (using white spirit) or

180-195

per minute per injector, al 2.54 system pressure at

cc fusing petrol) (minimum)

all

20% 2

2°C

kgflcm’

(36.25 psi)

IR2646E

IGNITION ON

ADDITION: SEPT. 88 / REVISED: MAY

Page 57

k”d;;r;

1989

FUEL INJECTION SYSTEM

119 1

‘EST PROCEDURE

Right bank ‘B’ injectors

!3.

RRz64R

2,4,6,8

‘; ,, \I\,

IJ’

\ 1 /

-aI-

’I

IGNITION ON

RESULTS - Check cables and units shown in bold

WARNING: Ensure that

necessary precautions are taken

IO prevent fire and explosion

Repeat test for other injectors Replace any injector which does not operate NOTE: Fuel flow is or 180-195 cc (using gasoline) (minimum) per minute per

injeclor,

al 2.54

pressure at 20°C + 2°C

aIf

160-175

cc fusing mineral

kghcm’

(36.25 psi) system

’

spirils)

rEST

PROCEDURE

14.

Check gear switch input

IGNlTlbN

RR2646E

RESULTS - Check cables and

Voltmeter reading of zero Neutral and park

Voltmeter reading of 2.5-5.0 Volts

-R.D.3.2.1 -

Incorrect reading Check:

Proceed to Test 25

unils

volts-

shown in bold

ADDITION: SEPT. 88 / REVISED: SEPT. 90

Page 58

FUEL INJECTION SYSTEM

l-l

1989

;;^o”v‘;r;

. .

rEST

PROCEDURE

15.

Check road speed input

NOTE: Raise and rotate the

teat road wheel slowly

\ 1 /

.‘,

----

’

IGNITION ON

RRw4aE

’

left

hand

RESULTS - Check cables and units shown in bold

Voltmeter reading of 0 to revolution - Proceed to Test 26

Incorrect reading

Check:

12V

fluctuating 6 times per

.(...

.i .;

VOTE: Remove pump relay from its connector

..)

,,:,.

IGNITION OFF

. . . c’

58 ADDITION: SEPT. 88 / REVISED: SEPT. 90

. .

‘.. :I

Page 59

rEST

ADDITION:

SEPT

88 / REVISED: SEPT. 89

PROCEDURE

16a.

Check Lambda sensor supply

FUEL INJECTION SYSTEM

RESULTS - Check cables and units shown in bold

Correct Vl and V2 - 12 volts Proceed to Test 26b

119 1

’

A. LH Lambda sensor

RH Lambda sensor

I-

IGNITION OFF

RA2707E

rEST

PROCEDURE

26b. Check Lambda sensor operation

Nole: Select ‘P’ in main gearbox and run engine at 1000 revlmin, normal operating temperature

LH Lambda sensor

B. RH Lambda sensor

Incorrect reading Check:

RESULTS - Check cables and units shown in bold

Correct

contaminated injectors, low fuel pressure - if OK fit

0.5OV - l.OOV

Incorrect 0.050 V - Check: Air leaks, faulty or

new Lambda sensor

Incorrect injectors, saturated carbon canister - if OK fit new Lambda sensor.

l.OOV -

fluctuating

Check: High fuel pressure, leaking

RR2708E

Page 60

FUEL INJECTION SYSTEM

1191

1989

k”d;;i;i

,;. ”

‘EST PROCEDURE

Check air conditioning thermostat input

!7.

NOTE: Select air conditioning position

and move thermostat switch to cold

KEY:

1. Fuse

2. Air conditioning switch

3. Air conditioning thermostat

4. High pressure switch - air conditioning

Compressor clutch

relay

IR2651E

RESULTS - Check cables and units shown in bold

Voltmeter reading of battery volts

Proceed lo Test 28

Incorrect reading Check:

NOTE: Select heater fan speed I. II or

KEY:

1. Fuse 6

kRZOS2E

Ill

; ..‘. . .

ADDITION: SEPT. 88 / REVISED: SEPT. 89

Page 61

KAl~bJr

ROVER

“*’

FUEL

INIECTION

SYSTEM

119 1

TEST PROCEDURE

29.

Check operation ot compressor clutch relay

NOTE: Select air conditioning position, thermostat cold, and tan speed I, II, or Ill

30.

Fault diagnosis - compressor clutch relay

RESULTS - Check cables and units shown in bold

Voltmeter reading of 12 volts

Proceed to Test 31

Incorrect reading of zero volts Proceed to Test

r reading of 12 volts

NOTEz

Select air conditioning position,

thermostat cold, and tan speed I, II or

KEY:

1. Compressor clutch relay

2. Compressor clutch

3. High pressure switch

Thermostat

Ill

Continued

ADDITION: SEPT. 88 / REVISED: DEC. 88

‘.’

‘.

y:...

Page 62

1191

FUEL INJECTION SYSTEM

1989

;;^d;&

EST

PROCEDURE

Check heated front screen input

Il.

NOTE: Engine running, heated front screen switched ‘ON’

KEY:

1. Oil pressure switch

2. Front screen timer unit

3. Front screen switch

RESULTS - Check cables and units shown in bold

Voltmeter reading of 12 volts Proceed to Test 32

Incorrect reading of zero volts Check:

rEST

PROCEDURE

Check operation of condenser fan output

12.

Disconnect coolant temperature sensor and fuel temperature sensor and bridge plug connectors

NOTE: Switch ignition ‘ON’ for 5 seconds, switch ignition ‘OFF’

The fan timer will operate the fans for

approximately 10 minutes unless it is disconnected

KEY:

1. Condenser fan timer

2. Condenser fan relay

RESULTS - Check cables and units shown in bold

Voltmeter reading of

Voltmeter reading of zero volts

Proceed lo Test 33

volts

end of tests

RR2660E

ADDITION: SEPT. 88 / REVISED: DEC. 88

Page 63

ADDITION: SEPT. 88 I REVISED: SEPT. 90

.‘;

‘EST PROCEDURE

RESULTS

FUEL INJECTION SYSTEM

Check cables and units shown in bold

119 1

::.

,’ X

Fault diagnosis - condenser fan

13.

outpul

Voltmeter reading of 12 volts Suspect ECU

Incorrect reading Check:

KEY:

1. Condenser fan timer

2. Condenser fan relay

3. Fuses Al and A2

4. Condenser fans

\ 1 /

-a-

’

2676E

IGNITION ON

After completing the tests with either the ‘Diagnostic’ equipment or multi-meter, re-test the vehicle to ensure the faults have been rectified. If faults still persist, recheck using the Lucas diagnostic equipment.

Page 64

,, ,. :’

ov-

RWOlOE

Condenser fan circuit diagram

12V from EFI main relay.

Condenser fan timer unit.

3. Fan relay.

4. 12V battery feed. Trigger, from ECU.

12V from fan relay. Fuse Al-20 amp.

7. Fuse

A2-20

Fan

amp.

motors

RR2610E

N .+

---

Condenser fans/Condenser fan timer

Check operation

Start engine. Move air con/heater control to air conditioning

position. Check condenser fans, if working the condenser fan relay and wiring to the fans is functioning.

If not working check fuses Al and A2, and the

voltage between connections 86 on fan relay

and earth. If 12 volts is not present, check

wiring back to air con switch.

If 12 volts is present, but fans NOT working, short out connections 30 and 87 on fan relay. If fans work fit new relay. If fans NOT working, check supply to fan relay from main harness. Apply a 12 volt supply for at least two seconds

connection 5 on fan timer within SIX

SECONDS of switching

condenser fans should run for 9.

0.5 minutes, and switch off. If the fans do not work after applying voltage to timer, short out connections 4 and 8 on fan timer, if fans work fit new fan timer. If fans do not work, check wiring.

engin

minutes

off.

The

ADDITION: SEPT. 88 / REVISED: SEPT. 90

Page 65

KANbt

ROVER

lg8’

FUEL INJECTION

SYSTEM

OVERHAUL VALVE - 3.9 V8 Model

Preparation, remove, overhaul and refit

Preparation

10.

THROlTLE

Disconnect the battery negative terminal.

Disconnect the electrical multi-plug from the

bypass air valve (stepper motor).

Disconnect the small vacuum hose at the rear

of the plenum chamber, located below the

bypass air valve.

To assist re-assembly mark an identification

line on the throttle cable outer covering directly behind the adjustment thumb wheel before disconnecting the throttle cable from the throttle lever.

Remove the cotter pin and clevis pin securing the throttle cable to the lever. Carefully pry the adjustment thumb wheel from the throttle bracket. Lay the cable aside. Release the retaining clip from the kick down cable and remove the clevis pin. To assist re-assembly apply adhesive tape

behind the rear adjustment nut on the kick down cable outer sleeve to prevent the nut moving out of position. Release the front lock nut and remove it from the outer sleeve to enable the cable to be

removed from the throttle bracket. Lay the cable aside. Remove the vacuum hose from the cruise control actuator.

LEVERS AND THROTTLE

11. Remove the large hose from the neck of the plenum chamber.

12.

Disconnect the multi-plug to the throttle

potentiometer.

13. Remove the PCV breather hose.

14.

Disconnect the two coolant hoses in turn and

immediately plug the end of each hose to prevent excessive loss of coolant. Identify each hose for re-assembly.

15. Remove the distributor vacuum hose.

16. Release the two screws and remove the potentiometer.

ADDITION: SEPT. 88

Page 66

RR2400E

KEY

I. Spherical bearing

2. Retaining clips

3. Countershaft assembly

4. Overtravel spring

5. Throttle spindle nut

6. Throttle return spring

7. Tab washer

8. Throttle stop lever

Throttle bracket assembly

10. Pop rivets

Remove throttle lever assembly

Remove the six screws securing the plenum

17.

chamber to the ram housing. Lift off the plenum chamber. Remove the hose from the air bypass valve

18.

housing and plenum chamber air inlet pipe. Unclip the cruise control actuator link. While

19.

holding the throttle valve fully open release the link from the countershaft assembly. Carefully return the lever assembly to the

closed throttle position. Release the tension on the inboard throttle

20.

return spring and slide the spring along the countershaft assembly to give access to the throttle shaft nut.

(2)

21.

Bend back the the tabs of the lock washer. While holding the throttle stop lever in the

22.

closed position, release the nut until it is free of the throttle valve shaft.

Release the tension on the outboard throttle

23.

return spring.

Unhook and remove the over-travel spring.

24.

ADDITION: SEPT. 88

‘.

. . .

Page 67

FUEL INJECTION SYSTEM

25. Remove the three bolts securing the throttle bracket to the plenum chamber and withdraw the bracket assembly.

26. Remove the tab washer and throttle stop lever from the throttle valve shaft.

Pre-grease a new bush with

31.

Energrease LS3 assemble the bush into the

bearing retaining plates and pop-rivet the

assembly to the throttle bracket with two 4.7 mm

(3116

in) diameter domed head rivets 9

Admax

L3 or

mm (0.361 in) long.

32.

Examine

the bearing surface of the countershaft assembly. If worn fit a new assembly, otherwise wind the throttle return spring off the levers.

Inspect and overhaul throttle lever assembly

Remove the two retaining clips from either

27.

side of the spherical bearing. Remove the countershaft assembly from the

28.

bearing. If the spherical bush appears to be worn,

29.

dismantle as follows. Using a

4,7

(3116

in) diameter drill, drill out the two pop rivets securing the spherical bearing to the throttle bracket assembly.

Split the bearing assembly and discard the

30.

bearing bush.

RR2308E

33. Wind a new spring onto the countershaft assembly noting that the small hooked end of the spring is wound on first.

RR2309E

’

34. Pre-grease the shaft with

Admax

L3 or

Energrease LS3 and fit the countershaft assembly to the spherical bearing and secure with the two clips.

-RR2307E ‘9

,,,::

35. Examine the throttle stop lever new lever if necessary.

ior

wear, fit a

’

Continued

ADDITION: SEPT. 88

Page 68

Inspect and overhaul throttle valve

36.

Examine the throttle valve shaft for excessive wear between the bearing bushes in the plenum chamber and the shaft. A small amount

clearance

is permissible. If excessive wear is evident fit new shaft and bushes as follows.

37.

Remove the two split screws securing the throttle valve disc and withdraw the disc, taking care not to damage the shaft.

RR2402E

41.

Fit the throttle valve shaft and disc, secure in

.’

position with the two split screws. Do not fully tighten the screws at this stage.

42.

Rotate the throttle shaft 360” once or twice to

centralise

the disc in the bore. Tighten the

.‘(,

two screws.

43.

Rotate the shaft until the split end of the screws are accessible. Using the blade of a

screw driver spread the split to secure the screws in the shaft.

FIR24iIOE

I-

38. Remove the shaft and air seal from the plenum chamber.

RR2401E

39. Using a suitable drift, drive out the bushes taking care not damage the bores in the plenum chamber.

40. Press in new bushes until they are flush with the throttle valve bore.

RR2409E

44. Pre-grease a new air seal with

Admax

Energrease LS3. Fit the seal pushing it down the shaft and into the counterbore until the seal is 6.0 mm

plenum chamber.

(0.236

in) below the face of the

L3 or

CAUTION: Ensure that the bushes do not protrude into the bore as they will interfere with the movement of the throttle valve disc.

. .

ADDITION: SEPT. 88

Page 69

FUEL INJECTION

SYSTEM

Assemble throttle levers and bracket

Fit the stop lever to the throttle valve shaft

45. followed by a new tab washer and secure with

the interconnecting nut. Holding the stop lever on its stop, tighten the

46. interconnecting nut securely and bend over the tabs of the tab washer to lock the nut in position. Fit the inboard throttle return spring noting

47. that the small hooked end of the spring is nearest the plenum chamber.

Locate the hooked end of the inboard spring

40. on the stop lever and wind up the straight end

one full turn and anchor it in the appropriate

slot. Fit the countershaft to the interconnecting nut

49. of the throttle valve shaft. Fit the throttle bracket assembly and secure

50. with the three retaining bolts. Ensuring that the hooked end of the outboard

51. spring is anchored by the lever, wind the spring up one full turn and locate the free end in its appropriate slot. Fit the over-travel spring.

Lightly grease the throttle return and over-travel springs with

Admax

L3 or Energrease LS3.

Using a depth vernier or depth micrometer

53. from the mouth of the bore check the top and bottom of the valve disc. The disc must be within 0.5 mm reading across the full diameter of the disc.

54.

the throttle disc is out of limits adjust the small set screw below the stop lever. Access to the screw is gained from the bottom of the plenum chamber neck adjacent to the throttle levers support bracket.

(0.019

in) total indicator

NOTE: If new throttle levers have been fitted the minimum throttle setting of the disc must be checked to ensure that it is SO” to the bore.

46 48

Refitting

Reconnect and adjust the cruise control

55. actuator link. (See cruise control-actuator link

setting)

Clean any previous sealant from the joint face

56. of the plenum chamber and ram housing. Apply

‘Hylomar’

the plenum chamber. Tighten the bolts to the correct torque value-see section 06. Reverse the remaining preparation instructions.

57.

sealant to the faces and refit

ADDITEON: SEPT. 88 / REVISED: MARCH SO

Page 70

ELECTRONIC FUEL INJECTION-RELAYS

ELECTRONIC CONTROL UNIT (ECU)-14 CU

Incorporated in the fuel injection electrical system are two relays which are located beneath the front right hand seat adjacent to the cruise control relay and emission maintenance reminder. Access to the relays is gained through the opening at the bottom of the seat when the seat is in its fully forward position on the seat slides.

1. Fuel pump relay (mounted on a blue terminal block).

2. Main relay (mounted on a black terminal block).

3. Diagnostic plug.

4. Condenser fan timer unit.

NOTE: The ECU is not a serviceable item. In the event of a unit failure the ECU must be replaced.

Remove and refit

Removing

Remove the front and side seat base trim of the front right hand seat.

Adjust the seat to its most rearward position and raise the seat cushion height to allow access to the ECU fixings.

Disconnect the battery negative terminal. Release the ECU plug retaining clip.

Maneuver the front of the plug (in the direction of the bold arrow) and detach the

other end of the plug from the retaining peg.

Release the two screws securing the ECU to the mounting bracket.

Withdraw the ECU from the spring clip and

remove it from the vehicle.

RR2555E

Remove and refit

Removing

1. Disconnect the battery negative terminal.

2. Pull the relay(s) from the terminal block(s).

Refitting

3. Reverse the removal procedure.

,‘/

RR2667S

Refitting

8. Refit the ECU securely in the spring clip and fit and tighten the two screws.

9. Reconnect the ECU harness plug. Ensure that the plug is pushed firmly into its location and that the retaining clip secures the plug in position.

10. Remove remaining removal procedure.

ADDITION: SEPT. 88 / REVISED: MARCH 90

Page 71

.., _. . --

ROVER

26 28 29

2.3 10

lyy”

:. ”

21lV”B

36 30 19

2 25 35 20

RR2

955E

FUEL

1. 40

INFECTION -

-way

Circuit Diagram -

connector to Electronic Control Unit

I. I II,

1990/91

model

(ECU).

2. Lambda sensor (left side - bank

3. Lambda sensor (right side - bank

A).

8).

4. By-pass air valve (stepper motor) (fast idle).

Lambda sensor screened ground.

6. Fuse C4 - main fuse panel.

7. Inertia switch.

8. Fuel pump.

9. Ignition switch.

10. Speed transducer (road speed input). Il. Neutral switch (automatic gearbox) (load

input).

12. Main cable connector.

13. Battery.

14.

Diagnostic plug.

15. In-line resistor.

16. Coil/-ve (engine RPM input). 1 i. Coolant

temperature

thermistor

(sensor)

’ WG-30

vear

18. Fuel temperature thermistor (sensor) (input).

19. Throttle potentiometer.

20. Air flow sensor.

21. Fuel pump relay.

22. Main relay.

23. Injectors-l to 8.

24. Pick-up point E.F.I. warning symbol (instrument binnacle).

25. Heated front screen sense.

26. Purge control valve.

27.

12\’

from fan relay.

28. Air conditioning output

29. Air conditioning load input.

30. Fan relay feed.

31. Tune resistor (early vehicles).

32. Heater/air con. cable connector.

33. Condenser fan timer control.

34. Fault display input.

= = =

Denotes screened ground.

co@trol.

(input).

NOTE: Reference to left and right side is made when viewing the vehicle from the rear.

ADDITION: SEPT.

89/REVISED:

SEPT. 90

Page 72

FUEL INJECTION SYSTEM

ELECTRONIC FUEL INJECTION

-LUCAS 14CUX SYSTEM

1990

model year vehicles have an enhanced fuel injection system, using a Lucas 14CUX electronic control unit, The system is a development of the

14Cu sytem introduced on 3.9 litre vehicles.

The system components being a tune select resistor and a fault code display unit.

works in the same way, new

17EM

FAULT CODE DISPLAY UNIT -

1990

RR2814h-l

KANClt

ROVER

TUNE SELECT RESISTOR - RR281

Rd28llM

The 14CUX system is used in various markets, but a common ECU is used. To suit individual market

requirements a tune select resistor is connected across pins 5 and 27 of the ECU. It is located adjacent to the ECU, and strapped to the EFI cable assembly. The value of the resistor is dependent on the market application.

NOTE: For USA market models the resistor value is

3900

Ohms, wire

colour,

white.

NOTE: Vehicles after VIN No 451518 are fitted with a new ECU, Part No. PRC 8747 to replace PRC 7081. This ECU no longer requires the tune select resistor, which is therefore deleted. Fault code 21 is no longer stored by the ECU.

1990 model year vehicles have a fault code display unit which is located underneath the right hand front seat, adjacent to the EFI ECU. The unit will

display the relevant fault code, in addition to the

EFI warning light being illuminated.

NOTE: Fault code 59 will NOT be indicated by

the EFI warning light.

Recommended equipment

The diagnostic equipment for checking out the

14CuX

system is the same as that used for

14CU,

with the addition of two new memory cards for

Hand Held Tester.

14CUX

Memory cards, Lucas Part Number:

606 01 379.

CONTINUITY TEST PROCEDURE

NOTE: The continuity test procedure for 14CUX systems is similar to that for

14CU.

Note the addition of the tune select resistor test and the deletion of Test 28, which does not apply to

14CUX systems.

(’

. . . . t

” ;._.,.

ADDITION: SEPT.

89iREVISED:

SEPT. 90

‘:.

v'.

.>...'

‘.

...a

.;“.i

Page 73

K"i;;‘;ir

1990

FUEL INJECTION SYSTEM

119 1

TESTING

Release the ECU plug retaining clip and remove the plug from the ECU. Access is gained by removing the front seat base trim of the right hand front seat. Remove the plug shroud and manoeuver it along the harness until there is enough clearance to enable meter probes to be

inserted into the back of the plug.

There are six pin numbers 1, 13, 14, 27, 28

and 40 moulded onto the rear of the plug as shown in the illustration below, for clarity the electrical leads have been omitted.

28 40

Pins

1 to 13 bottom row.

Pins

14 to 27 centre row.

Pins

28 to 40 top row.

CONNECTIONS TO 40 WAY CONNECTOR

PIN Nos. CABLE COLOUR

Red/green

Brown/orange

Yellow

4. Blak

Grey/Black

Yellow

Green/blue

Purple/yellow

White/light green

10. Black/yellow

11,

Yellow/white

12.

Blue/red

Yellow/blue

14. Black

15.

Brown

16. Blue/purple

17.

Grey/yellow

18. White/pink

79.

White/grey

20.

Red

21.

Yellow/black

22. Blue/red

23. Blue

24.

Blue

25. Red/black

26. Green/white

27.

Black/grey

28.

Bluelgrey

29. Orange

30.

-14

Pink

31.

Black/green

32.

Creyhvhite

33.

BlackIgrey

34.

Orange/black

35. Blue/green

36.

Black/green

37. Not used

38.

Brown/pink

39. White/black

40.

Black

The last colour denotes the wire tracer colour

ADDITION: SEPT.

89!REVISED:

SEPT. 90

Page 74

Tune select resistor test

lt is recommended that this test is carried out before Test 1. of Continuity Test Procedure, Section

19,

page 44.

FUNE

SELECT RESISTOR TEST

KEY 1) Tune select resistor

Description of fault codes

The fault codes are listed in order of priority. Where more than one fault exists, clearing the first fault code will permit the next code to be displayed.

NOTE: This test is not required on vehicles after VIN No 451518, which are no longer fitted with a tune select resistor.

Code 29 - ECU MEMORY CHECK

detected, all other faults are unreliable and must therefore be ignored.

Proceed as follows:

If this fault is

‘I ,,

‘.,

.‘..

: ‘.

NOTE: Fault code 02 will show if the ECU has just been reconnected. Switch on ignition to clear the display.

Clearing fault code display

Leave battery connected Switch ignition off

Wait for approximately 5 seconds

Disconnect ECU plug

Re-connect ECU plug

Switch ignition on and check display unit. It is necessary to clear the code displayed when the fault has been rectified, and to access any further fault codes that may exist. Clear the fault code

NOTE: If fault code 29 is detected again,

substitute ECU and restart test sequence.

displayed using the following procedure:

Code 44 - LAMBDA SENSOR A i left bank

Switch On ignition.

Disconnect serial link mating plug, wait 5 seconds, reconnect. Switch OFF ignition, wait for main relay to

Code 45 - LAMBDA SENSOR B - right bank

If one of these fault codes is displayed check the wiring to that particular lambda sensor.

drop out.

Switch ON ignition. The display should now reset. If no other faults exist, and the original fault has been rectified, the display will be

If both codes are displayed, the

the heater coils of the sensors must be checked.

Refer to Test 26, continuity test procedure.

volfage

supply to

blank. If multiple faults exist repeat Steps 1. to 4. as

5. each fault is cleared the code will change, until all faults are cleared. The display will now be blank.

..+

ADDITION: SEPT.

Code 25 - IGNITION MISFIRE - This code indicates that an ignition system misfire has been detected. Codes 40 or 50 indicate on which bank the misfire has

occured.

89/REVISED:

SEPT. 90

. . . . .

..’

. .

.,.

Page 75

FUEL INJECTION

ADDITION: SEPT.

89/REVISED:

SEPT. 90

SYSTEM

:.:.y. : .:.:$c.

Code 40 - MISFIRE BANK A - left bank

Code 50 - MISFIRE BANK B - right bank

both fault codes are displayed check the

following components commom to both banks:

Distributor cap Rotor arm Coil Electrical connections Pick-up (air gap) Amplifier

Injectors - if code 34 or 36 displayed.

If either fault code 40 or 50 is displayed check

components applicable to the particular bank that

the misfire has

Spark plugs HT leads Distributor cap Injectors - if code 34 bank A or 36 bank displayed.

Code 12

continuity test procedure.

Code 21 - FUEL TUNE SELECT

tune select resistor is open circuit - Refer to tune select resistor test.

Code 34

indicate if the injector/s are causing the engine to run rich or lean.

occured

AIRFLOW METER

INJECTOR BANK A

on:

Refer to Test 19,

Identifies that the

The display will

Code 18

- THROlTLE

high/AIRFLOW METER

18 and 19 of the continuity test procedure

Code 19 - THROTTLE POTENTIOMETER input AIRFLOW METER - high.

and 19 of the continuity test procedure

Code 88

and 10 of the continuity test procedure.

Code 28 following areas. Hose, air flow meter to plenum Breather system hoses to plenum Brake servo hose Vacuum reservoir hose (fresh air solenoid) Distributor vacuum advance Hose, purge valve to plenum

Injector seals Joint - By pass air valve to plenum

By pass air valve hose

Code 23

pressure, Test 20 of the continuity test procedure.

Code 48

speed and 16 of the continuity test procedure. Check road speed sensor continuity test procedure.

PURGE VALVE LEAK

AIR LEAK

Plenum chamber to ram housing

Ram housing to inlet manifold

- Inlet

manifold to cylinder head

FUEL SUPPLY

STEPPER MOTOR

see setting procedure. - Refer to Tests 15

POTENTIOMETER input

low. - Refer to Tests 17,

Refer to Tests 17, 18

Refer to Test 9

Check for air leaks in the

Check fuel system

Check base idle

Refer to Test 25 of the

low/

If the bank is running rich, check for:-

- faulty injector wiring and connectors

stuck open injectors

If the bank is running lean, check for:-

- faulty injector wiring and connectors

blocked injectors

Code 36 -

relevant to bank A injectors.

INjECTOR

BANK B - As code 34 except

Code 14 - COOLANT THERMISTOR

14, continuity test procedure.

Code 17 -

Test 17, continuity test procedure.

THROlTLE

POTENTIOMETER

Refer to Test

Refer to

Code 68

25 of the continuity test procedure.

Code 69 - GEARSWITCH

continuity test procedure.

Code 59

that a fault has been registered that is caused by the fuel supply or an air leak but the exact fault cannot be identified. Check all items outlined under code 23 and 28.

ROAD SPEED SENSOR

Refer to Test 24 of the

GROUP FAULTS

Code 15 - FUEL THERMISTOR

the continuity test procedure.

Refer to Test

23/28 -

This indicates

Refer to Test 13 of

Page 76

;

..,..’ :

,: ;

BASE IDLE SPEED SETTING

NOTE: the base idle speed is set at the factory. It

should not require further adjustment unless the plenum chamber is changed. The adjustment screw

unauthorised

timing before

is sealed with a plug to prevent

alteration. Check the ignition

attempting

the

following

procedure, since this will affect the idle speed.

Equipment required

Two blanking hoses. It is recommended that these

are manufactured using a new air by-pass valve hose -

9Omm (3 l/2

one end of each, using 13mm

Pari No.ETC7874.

Cut two equal pieces

inches) long from the hose and seal

(l/2

inch) diameter bar. A suitable clamp can be used to ensure an air tight seal

Checking procedure

1990

Start the engine and check that the idle speed

NINclc

ROVER

is within the limits specified in Section 05 Engine Tuning Data.

Adjusting base idle speed

6. Remove the tamper proof plug that protects the idle speed screw. Drill the plug and insert a self tapping screw to enable the plug to

extracted.

1. i :

“.

‘.’ X

.’ I

,: ,

Drive the vehicle for at least two miles until the engine and transmission are hot. Switch off the engine. Check that all electrical loads are off including air conditioning. Remove the air by-pass valve hose. Fit the blanking hoses to both the plenum chamber and the air by-pass valve. Ensure the hoses are securely fitted to prevent air leaks. Note that the throttle cable and cruise control actuator have been omitted from the illustration for clarity.

RR2953E

Start the engine, and using a suitable Allen

7. adjust the idle screw clockwise to

key,

decrease or counter-clockwise to

increae

the

idle speed.

Check fault code display, and clear the

8. memory

see ‘Clearing fault code display’

section 19, page 74.

. .

‘,;. : :.

ADDITION: SEPT. 89

Page 77

K”i;;l;i

1990

FUEL INJECTION SYSTEM

119 1

.,. ,.

FUEL SYSTEM 1991 MODEL YEAR

A revised fuel sytem is fitted to 1991 model year vehicles. The major change is the fitting of a plastic fuel tank with improved breather system. The

remote expansion tank is now deleted.

A further improvement is the fitting of a combined

fuel pump and sender unit. A panel in the floor of the vehicle permits access to the fuel pump/sender unit

6. Remove the securing screws and detach the access panel from the floor.

7. Disconnect the electrical connections at the multi-plug.

8. Remove the insulation sealant from around the ground lead, and disconnect the ground lead.

9. Disconnect the two fuel line unions from the fuel pump.

10. Using Special Tool No. assembly retaining ring and withdraw the

pump from the fuel tank.

LST131,

remove pump

FUEL PUMP/SENDER UNIT

WARNING: A quantity of fuel will be retained in

WARNING: Ensure that the Fuel Handling

Precautions given in Section 01 - Introduction

the body of the unit, care must be taken to prevent fuel spillage when the unit is removed.

regarding fuel handling are strictly adhered to

when carrying out the following instructions.

CAUTION: Before disconnecting any part of the fuel system, it is imperative that all dust, dirt

:;. ::

,::

‘.‘*‘a’.%’

and debris components to prevent ingress of foreign matter

is removed from around the

into the fuel system.

Special Tool

LST131,

wrench - pump retaining

ring

- LST 144 -‘Speedfit’

disconnector

Remove and refit

Removing

Depressurise the fuel system. Disconnect battery negative lead.

Syphon at least 9 litres (2 gallons) of fuel from

the fuel tank using a suitable container that can be sealed afterwards. Remove carpet from loadspace floor and

tailgate.

Fold back the sound insulation to reveal the

access panel.

ADDITION: SEPT. 89

Page 78

’

FUEL

INJECTION

SYSTEM

Refitting

11.

Insert the fuel pump into the tank. Fit the retaining ring and tighten to a torque of 45-50 Nm (34-37

12.

Connect the fuel lines to the pump.

13.

Connect the electrical leads at the multi-plug.

14.

Connect the ground lead to the pump and insulate with suitable sealant.

15.

When the fuel system has been reassembled

check all fuel pipes, sealing rings and hose connections are secure.

16.

Run the engine to check for fuel leaks before final assembly.

17.

Inspect the access panel seal, fit a new seal if necessary.

18.

Fit the access panel and secure to the floor with the screws.

Reverse operations 4 - 5 to refit the sound

19.

insulation and carpet.

FUEL TANK

WARNING:

Precautions given in Section 01 - Introduction regarding fuel handling are strictly adhered to when carrying out the following instructions.

CAUTION: Before disconnecting any part of the fuel system, it is imperative that all dust, dirt and debris components to prevent ingress of foreign matter

into the fuel system.

Ibf

ft).

Ensure that the Fuel Handling

is removed from around the

Remove the insulation sealant from around the ground lead, and disconnect the ground lead. Disconnect the two fuel line unions from the fuel pump. Working underneath the vehicle, remove the rear anti-roil bar straps, and allow the bar to swing down clear of the tank.

1'3

RR2962E

10.

Remove the tank filler and vent hoses at the fuel tank.

11.

Remove the nut and bolt securing the right hand side of the fuel tank strap.

12.

Disconnect the green end of the ‘speedfit’ connector.

WdpOratiVe

control pipe at the

Remove and refit

Removing

Depressurise fuel system. Disconnect battery negative lead.

Syphon the fuel tank into a suitable container that can be sealed afterwards.

ENSURE THAT THE TANK IS DRAINED

COMPLflELY.

fuel vapor and spillage at start of this procedure). Remove carpet from loadspace floor and tailgate. Fold back the sound insulation to reveal the access panel. Remove the securing screws and detach the access panel from the floor. Disconnect the electrical connections at the multi-plug.

(refer to Warning concerning

NOTE: To disconnect the ‘speedfit’ connector, forked end into the two slots of the connector as shown in the illustation above. Press down on the

collet

and simultaneously pull the connector. Special tool LST 144 is available for this operation.

t&e

pipe from

ADDITION: SEPT. 89

Page 79

yo;;;

1990

FUEL INJECTION SYSTEM

,_ :

‘.’ .,

Clamp the inlet and outlet hoses to prevent the

minimum of

fuel

spillage

when

disconnecting the hoses. Loosen the two fuel line unions and remove the hoses from the filter canister.

Release the single nut and bolt securing the

filter and clamp and remove the filter.

.’

13. Remove the back two bolts and nut plates securing the fuel tank cradle.

14.

Remove the front nuts, bolts and washers, and

remove the fuel tank cradle.

15. With the aid of an assistant, tilt the right hand

RR2966E

-\ 7 “

side of the tank upwards and manouver the tank through the chassis to remove.

Refitting

16.

Reverse the removal procedure, ensuring that

the sealing ring, fuel pipe and hose

connections are secure.

17.

Run the engine and recheck all connections

to ensure no fuel leaks exist. Reverse the remaining removal procedure.

FUEL FILTER

Refitting

Fit a new filter observing the direction of flow

arrow on the canister.

Tighten the single nut and bolt.

Fit the inlet and outlet hoses. Tighten the

unions to a torque of Refit the fuel pump relay, reconnect the

20-25

lb(27-34Nm).

battery. Recode the radio. Start the engine and inspect for fuel leaks

10.

around the hose connections.

:. >,

Remove and refit

WARNING: ENSURE THAT THE FUEL HANDLING PRECAUTIONS GIVEN

IN SECTION 01

INTRODUCTION REGARDING FUEL HANDLING

ARE STRICTLY ADHERED TO WHEN CARRYING

OUT THE FOLLOWING INSTRUCTIONS.

WARNING: UNAVOIDABLE

THE

SPILLING OF

DURING THIS

FUEL IS

OPERATION. ENSURE THAT ALL NECESSARY PRECAUTIONS ARE TAKEN TO PREVENT FIRE AND EXPLOSION.

Removing

1. Depressurise the fuel system.

2. The fuel filter is located on the right-hand chassis side member forward of the fuel tank filler neck. Access to the filter is gained

through the right-hand rear wheel arch.

Page 80

1191

FUEL INJECTION SYSTEM

FUEL FILLER FLAP RELEASE BUTTON

The fuel filler flap is no longer part of the central

FUEL FILLER FLAP RELEASE ACTUATOR

Remove and refit

locking system on 1991 model year vehicles. The filler flap is permanently locked. To release the flap

Removing press the button situated on the steering column shroud. On closing, the filler flap will be locked automatically. Note that the release button will only work with ignition switched OFF.

1. Ensure that the fuel filler flap is released. Disconnect the battery negative lead.

2. Remove eight screws, and withdraw the closure panel, situated in the right hand side

Remove and refit

of the load space.

3. Release two screws and maneuver the actuator

Removing

clear of its mounting.

4. Disconnect the wiring plug.

1. Disconnect the battery negative lead.

5. Withdraw the actuator.

2. Carefully pry the release button from the steering column shroud.

..’

..I ::

‘, ,. ,;

:..

RR2031M

3. Remove the release button from the shroud and disconnect the two wiring connectors. Ensure that the wires protrude through the

RR2932M

shroud to facilitate reassembly.

Refitting

4. Reverse the removal procedure. Recode the radio.

,,:..

‘.’

.’

Refitting

6. Reverse the removal procedure. Recode the radio.

‘.

ADDITION: SEPT. 89

Land Rover Range Rover (1988) Manual Engine

Specifications and Main Features

Frequently Asked Questions

User Manual