Land Rover Defender Workshop 1993 Rover Manual
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E MISSION CONTROL EVAPORATIVE EMISSION CONTROL The opening of the purge valve (2), which IS controlled by the MFI ECM occurs when the Fuel tank evaporative control following conditions prevail: The specification for certain countries requires the When the engine is running at speeds above recycling of petrol evaporation from the fuel tank. For 1700 rev/min and temperatures above 54°C the ECM these countries only, a charcoal canister and purge will hold open the purge valve as necessary. valve are installed in the engine compartment. At speeds below 1700 rev/min the ECM will only pulse the purge valve open for short periods. While the purge valve (2) is open, engine depression draws air through vent (3) and fuel tank fumes via (4) into the engine combustion chambers, where they are burned. Air entering at (3), passes through the charcoal, where any accumulation of condensed fuel is also extracted and burned in the engine. A permanent leakage of air into the plenum chamber through the purge system will effect engine performance. Fuel tank evaporative control system The system consists of a fuel separator/expansion tank located at a higher level than the fuel tank, between the inner body side and the right rear fender. The tank is vented to atmosphere through a relief valve and is connected to the fuel tank and the charcoal canister purge system in the engine Evaporative purge system 1 Charcoal canister compartment. 2 Purge valve 3 Charcoal canister air vent 4. Fuel purge connecion from separator/expansion tank 5 Plenum chamber connection Operation When the engine is not running, the purge valve (2) seals the plenum chamber connection (5). Any vapour entering the canister at (4) from separator/expansion tank, is condensed by the air entering at (3) which is then absorbed by the charcoal. 2 REISSUED: FEB 1993
Operation FUEL EXPANSION TANK As the temperature rises, fuel vapour in the fuel tank IS allowed to vent into the separator/expansion tank (1) via three pipes and a manifold connector (3). Any vapour which condenses into liquid fuel drains WARNING: Ensure all necessay precautions are through pipe (6) back into the main fuel tank and taken against spillage of fuel when disconnecting residual vapour is dealt with by the purge system expansion tank hoses. connection (4) in the engine compartment. The atmosphere relief valve (2) will only open if a DEFENDER 110 blockage occurs in the charcoal canister or purge system. Remove The fuel expansion tank is located under the wheel arch of the right rear fender. 1. Loosen fuel tank filler cap to release any 2. Disconnect battery negative lead. 3. Disconnect pipe connection at joint under chassis member. 4. Disconnect evaporative control pipes. Use LRS -19-002, press down on collet and pull connector. pressure in tank. ST3416M Defender 110 ST3417M ST3460M 5. Remove four nuts and remove expansion tank. Refit 6. Reverse removal instructions. Defender 90 Fuel tank evaporative control system 1 Fuel expansion tank 2 Relief valve to atmosphere 3 Fuel tank vent 4 Relief valve to charcoal canister 5 Charcoal Canister in engine compartment 6 Fuel tank REVISED: OCT 1993 3
DEFENDER 90 Remove 1. Loosen filler cap to release any pressure in 2. Disconnect battery negative terminal. 3. Disconnect pipe connection to charcoal canister, using Special Tool LRT -19-002, press down on collet and pull connector. 4. Disconnect pipe to fuel tank using tank. LRS-19-002. 5. Remove four nuts and remove expansion tank. ST3440M RR2872M Refit 4. Coat threads of sensor with anti-seize compound. CAUTION: To ensure efficiency of sensor is not impaired, DO NOT allow anti-seize compound to come into contact with sensor nose. 5. Fit sensor and tighten to a torque of 20 Nm. using service tool LST-134. Refit 6. Connect electrical plugs and battery lead. 6. Reverse removal instructions. CHARCOAL CANISTER DEFENDER 110 HEATEDOXYGENSENSOR NOTE: If crimped hoses are removed it is essential that they are recrimped on reassembly Remove sensors from exhaust system only when to ensure a leak free joint. engine is cold. Remove Remove 1. Disconnect battery negative lead. 2. Disconnect both purge lines. 3. Release canister from mounting. 1. Disconnect battery negative lead. 2. Disconnect electrical plugs from sensors. 3. Remove sensors from exhaust downpipes. 4 REVISED: OCT 1993
RR2606E RR3899M EMISSION CONTROL Refit 5. Reverse removal procedure ensuring pipes are securely crimped. CHARCOAL CANISTER DEFENDER 90 Remove 1. Disconnect battery negative lead. 2. Pry out purge valve. 4. Loosen bracket retaining bolt. Refit 3. Disconnect pipe. 4. Reverse removal procedure. Ensure that 5. Remove charcoal canister. canister is securely located and both purge lines are fitted correctly to canister. CHARCOAL CANISTER - PURGE VALVE DEFENDER 110 Remove 1. Disconnect battery negative lead. 2. Disconnect two purge valve pipes. 3 Disconnect electrical connection. 4 Remove edge clip retaining purge valve and withdraw purge valve. Refit 6. Reverse removal procedure REVISED: OCT 1993
EMISSION CONTROL RR595M POSITIVE CRANKCASE VENTILATION AIR POSITIVE CRANKCASE VENTILATION INTAKE FILTER BREATHER FILTER The PCV air intake filter is located at rear of left Remove hand rocker cover, beneath throttle linkage bracket. Remove 2. Unscrew canister and remove. 1. Release hose clamp, pull hose off canister 3. Remove large rubber O ring, inspect for 1. Pry filter cover upwards to release it. deterioration. 2. Remove filter from cover and discard. 4. Inspect condition of wire screen within canister, if necessary, replace assembly. If filter unit is in acceptable condition, clean as follows. 3. Insert new filter into filter cover. 5. Immerse canister in small amount of solvent 4. Press filter onto mounting until it clips firmly (mineral spirits), allow solvent to dissolve or into position. loosen debris. 6. Remove canister from solvent, allow to dry in still air. WARNING: Do not use compressed air to dry, clean or remove particles of debris within the canister. This could cause fire or personal injury. Refit 7. Fit a new 0 ring to original Canister 8 Screw canister into rocker cover securely - hand tight only. 9 Refit hose, tighten hose clamp securely Refit 6 RE-ISSUED: FEB 1993
ST3418M Defender 90 Emissions label - 1994 Model Year ST3459M EMISSION CONTROL EMISSION LABEL A vehicle Emission Control information label is located in the engine compartment. On Defender 110 vehicles it is attached to the air conditioning unit. On Defender 90 vehicles it is adhered to the underside of the hood. The label gives Engine Tune Details to ensure that correct emission levels are achieved. The label is fitted to comply with U.S Federal and State of California Regulations and should not be removed from its location within the vehicle. Defender 110 Emissions label - 1993 Model Year REVISED: OCT 1993 7
FUEL SYSTEM DIAGNOSTIC EQUIPMENT IGNITION Electronic Ignition Analsyer Lucas Part No. - YWB 119 Supplied by Lucas Complete with instruction manual. MEMORY CARDS Land Rover Part Numbers include two memory card and instruction manual in appropriate language Suitable for 14CUX ECU ENGLISH ..................... RTC 6835 USA .............................. RTC 6836 FRENCH ...................... RTC 6837 GERMANY ................... RTC 6838 ITALIAN ....................... RTC 6839 SPANISH ..................... RTC 6840 DUTCH ........................ RTC 6842 JAPANESE .................. STC 127 LUCAS MFI DIAGNOSTIC EQUIPMENT Complete kit Land Rover Part No. RTC 6834 Kit Comprises:- A Hand held tester B Interface unit C Foam lined carrying case Serial link cable (Spare part Lucas No. 54744753). Memory cards are supplied separately see below RR3838M REISSUED: FEB 1993 1
FUEL SYSTEM HOT WIRE MULTIPORT FUEL INJECTION Engine fuel temperature sensor Description The engine fuel temperature sensor is located in the fuel rail forward of the ram housing. The engine fuel The ’Hot Wire’ Multiport Fuel Injection system temperature sensor sends fuel temperature data to derives its name from the air flow meter which uses the ECM, the ECM on receiving the data will adjust one cold wire and one electrically heated wire to the injector open time accordingly to produce good measure the volume of air entering the engine. hot starting in high ambient temperatures. The function of the system is to supply the exact Idle air control valve amount of fuel directly into the inlet manifold according to the prevailing engine operating The idle air control valve is screwed into a housing conditions. attached to the rear of the plenum chamber, between the plenum chamber and bulkhead. The idle air To monitor these conditions, various sensors are control valve has two windings which enable the fitted to the engine to measure engine parameters. motor to be energised in both directions thus Data from the sensors is received by the Electronic opening or closing the idle air control valve as Control Module (ECM), the ECM will then determine required by the ECM. the exact amount of fuel required at any condition. The bypass valve will open and allow extra air into the plenum chamber to maintain engine idle speed The ECM having received data from the sensors when the engine is under increased (Electrical and produces pulses, the length of which will determine Mechanical) loads. the simultaneous open time of each bank of injectors The idle air control valve will control engine idle in turn, which will govern the amount of fuel injected. speed when the vehicle IS stationary. Electronic control module - ECM Heated oxygen sensors The Multiport Fuel Injection system is controlled by The two heated oxygen sensors are located forward the ECM which is located behind the front of the catalysts mounted in the exhaust downpipes. passenger’s toe board. The control unit is a The sensors monitor the oxygen content of the microprocessor with integrated circuits and exhaust gases and provide feedback information of components mounted on printed circuit boards. The the air/fuel ratio to the ECM. Each heated oxygen ECM is connected to the main harness by a 40 pin sensor is heated by an electrical element to improve plug. its response time when the ignition is switched on. Injectors Fuel pressure regulator The eight fuel injectors are fitted between the The fuel pressure regulator is mounted in the fuel rail pressurized fuel rail and inlet manifold. Each injector at the rear of the plenum chamber. The regulator is comprises a solenoid operated needle valve with a a mechanical device controlled by plenum chamber movable plunger rigidly attached to the nozzle valve. vacuum, it ensures that fuel rail pressure is When the solenoid is energized the plunger is maintained at a constant pressure difference of 2.5 attracted off its seat and allows pressurized fuel into bar above that of the manifold. the intake manifold. When pressure exceeds the regulator setting excess fuel is returned to the fuel tank. Engine coolant temperature sensor Fuel pump The engine coolant temperature sensor is located by the front left hand branch of the intake manifold. The The electric fuel pump is located in the fuel tank, engine coolant temperature sensor provides engine and is a self priming ‘wet’ pump, the motor is coolant information to the ECM. The ECM on immersed in the fuel within the tank. receiving the signal from the engine coolant temperature sensor will lengthen slightly the time that the injectors are open, and reducing this time as the engine reaches normal operating temperature. 2 REISSUED: FEB 1993
FUEL SYSTEM Mass air flow sensor The hot-wire mass air flow sensor is mounted on a It should be noted that under high coolant bracket attached to the left hand valance, rigidly temperatures, when the engine is switched off, the connected to the air cleaner and by hose to the condenser fans will be activated and will run for plenum chamber inlet neck. approximately ten minutes. The mass air flow sensor consists of a cast alloy body through which air flows. A proportion of this air Vehicle speed sensor flows through a bypass in which two wire elements are situated: one is a sensing wire and the other is a The vehicle speed sensor is mounted on a bracket Compensating wire. Under the control of an located on the left hand chassis side member electronic module which is mounted on the air flow adjacent to the rear engine mounting. The vehicle sensor body, a small current is passed through the speed sensor provides road speed data to the ECM. sensing wire to produce a heating effect. The The ECM in turn detects vehicle movement from the compensating wire is also connected to the module road speed input and ensures that idle speed control but is not heated, but reacts to the temperature of mode is disengaged. Should the vehicle speed the air taken in, as engine intake air passes over the sensor fail in service the ECM idle speed control wires a cooling effect takes place. would become erratic. The electronic module monitors the reaction of the The vehicle speed sensor also provides road speed wires in proportion to the air stream and provides data to the electric speedometer. output signals in proportion to the air mass flow rate which are compatible with the requirements of the Inertia fuel shut off switch ECM. The inertia fuel shut off switch is a mechanically Throttle position sensor operated switch that is normally closed and is connected to the fuel pump circuit. In the event of a The throttle position sensor is mounted on the side sudden impact the inertia fuel shut off switch opens, of the plenum chamber inlet neck and is directly and disconnects the electrical feed to the fuel pump. coupled to the throttle butterfly shaft. The inertia fuel shut off switch is reset by pressing The throttle position sensor is a resistive device down the button. supplied with a voltage from the ECM. Movement of the throttle pedal causes the throttle butterfly to Relay modules open, thus rotating the wiper arm within the throttle position sensor which in turn varies the resistance in Two multiport fuel injection relay modules are proportion to the valve position. The ECM lengthens located behind the front passenger toe board. The the injector open time when it detects a change in main relay module is energized via the ECM when output voltage (rising) from the throttle position the ignition is switched on and supplies current to sensor. the multiport fuel injection system. The fuel pump In addition the ECM will weaken the mixture when it relay module is energized by the ECM which in turn detects the throttle position sensor output voltage is operates the fuel pump to pressurize the fuel decreasing under deceleration and will shorten the system. length of time the injectors are open. When the throttle is fully open, the ECM will detect the corresponding throttle position sensor voltage and will apply full load enrichment. This is a fixed percentage and is independent of 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 ECM. The throttle position sensor is self adaptive, which means that adjustment is not possible. It also means the the throttle position sensor setting is not lost, for example, when throttle stop wear occurs. CAUTION: Do not attempt to adjust throttle position sensor. Condenser fans REISSUED: FEB 1993 3
FUEL SYSTEM ENGINE TUNING MULTI METER CHECKS ECM - MFI circuit diagnosis To carry out tests when 40 way multi-plug is connected to the ECM, it is necessary to remove the Circuit fault diagnosis may be carried out on all MFI two screws securing the shroud to the plug to enable vehicles, using a good quality Multi Meter or the the multi-meter probes to be inserted into the back of hand held tester RTC6834. The tester displays the the appropriate pin. fault code and guides the operator by visual prompts, through a series of diagnostic checks. Full CAUTION: Tests requiring plug to be removed operational and diagnosis instructions are provided from ECM, must have meter probes inserted into with the unit memory card. back of plug. If probes are inserted into plug sockets, damage will occur to sockets resulting Which ever instrument is used to diagnose the in poor connections when plug is reconnected. problem, the following Preliminary Checks must be carried out first. Testing Preliminary checks 1. Release harness plug from ECM. CAUTION: If engine is misfiring or fails to start within 12 seconds the cause must be rectified. Failure to do so will result in irreparable damage to the catalysts. After rectification the engine are moulded onto rear of plug. must be run at 1500 rev/min (no load) for 3 minutes to purge any accumulation of fuel in the system. 1. Check that the inertia fuel shut off switch is not tripped. 2. Check fuse D in main fuse panel and the fuel pump fuse in the auxiliary fusebox. 3. Check for ample fuel in tank. 4. Check air inlet system for possible leaks into the inlet manifold. 5. Check HT cables for correct firing order and routing. 2. Remove plug shroud and manoeuvre it along harness to enable meter probes to be inserted into back of plug. 3. Only pin numbers 1, 13, 14, 27, 28 and 40 6. Check ignition timing. ETM A1. Only when the above checks have been carried out, should circuit diagnosis begin. For diagnosis procedure using a Multi Meter see The diagnosis procedure using Hand Held Tester is contained in the hand held tester manual. View of plug - cover removed. Pins 1 to 13 bottom row. Pins 14 to 27 centre row. Pins 28 to 40 top row. For clarity electrical leads omitted. For diagnostics using a multi meter, see ETM A1 . 4 REISSUED: FEB 1993