Land Rover Defender Workshop 1993 Rover Manual

							FUEL SYSTEM 
MULTI PORT FUEL INJECTION  (MFI) CIRCUIT DIAGRAM ST3358M 
EF1  Idle air control  valve  (IACV)  EF15 Tune resistor  connector 
EF2 
EF3  Engine coolant  temperature sensor  (ECTS)  EF17  Fuel injectors 
EF4  Engine  fuel  temperature  sensor (EFTS)  EF18 Fan control  timer 
EF5  Throttle position  sensor (TPS)  EF19  Resistor (manual transmission) 
EF6  Main relay  module  EF20 Onboard  diagnostic  module 
(OBDM) 
EF7 Canister  purge valve  (CANPV)  EM1 Service  reminder  indicator unit 
EF8  Fuel pump  relay module  EM2 Vehicle  speed sensor  (VSS) 
EF9  Inertia fuel  shut
-off  switch (IFS)  EM3 Service  reminder  light (SRI) 
EF10 Fuel pump  (FP)  IB1 Instrument  binnacle 
EF12  Malfunction indicator  lamp (MIL) 
IG5 Ignition coil 
EF13  Heated  oxygen sensor (H02S)  ST2 Terminal  post  starter  solenoid 
EF14  Heated  oxygen sensor (H02S)  ST5 Starter/ignition  switch 
Mass air 
flow sensor  (MAFS)  EF16 
Data link  connector  (DLC) 
AC24  Air conditioning  connections 
F20  20  amp  fuse,  dash fuse  box 
F3  15 amp  fuse,  dash fuse box 
REISSUED:  FEB 1993 5  
						

							FUEL SYSTEM 
BASE IDLE SPEED  SETTlNG 
NOTE: 
Base  idle speed  is set  at factory. It should 
not  require  further adjustment  unless plenum 
Adjusting  base idle speed 
chamber  is changed.  The adjustment  screw is 
sealed  with 
a plug to prevent  unauthorised 6. Drill tamper  proof  plug and insert  a self 
alteration.  Check ignition  timing before  tapping screw  to  enable plug 
to be extracted. 
attempting  following procedure,  since this will 
affect  idle speed. 
Equipment  required 
Two blanking  hoses. these are manufactured  using 
a  new  idle air control  valve  hose 
- Part No. 
ETC7874.  Cut two equal pieces  90mm long from 
hose and seal  one  end  of each,  using 13mm 
diameter  bar.  Use  a suitable  clamp to ensure  an  air 
tight  seal. 
Checking  procedure 
5. Start  engine  and check  idle speed is within 
limits. 
1. Drive  vehicle  at least two miles  until engine 
and  transmission  are 
hot. Switch off engine. 
2. Check all electrical loads are  OFF,  including 
air  conditioning. 
3. Remove  idle air control  valve  hose. 
4. Fit blanking  hoses to both  plenum  chamber 
and  idle air control  valve.  Ensure  hoses  are 
securely  fitted to prevent  air  leaks.  Note 
throttle  cable  has  been  omitted  from 
illustration. 
7. Start  engine,  adjust idle screw  clockwise  to 
decrease  or anti
-clockwise  to increase  idle 
speed. 
8. Stop  engine,  remove  blanking  hoses. 
Reconnect hose to  plenum. 
9. Fit new  tamper  proof  plug. 
6 REISSUED: FEB 1993  
						

							FUEL SYSTEM 
FUEL PRESSURE CHECK 1. Remove fuel pump  relay  module, see Fuel 
injection  relays. 
In  order 
to check  the  fuel pressure  it is  necessary  to 2. Start and run engine. 
first  depressurise  the fuel  system  as follows: 
3. When  sufficient  fuel  has  been  used to cause 
fuel  line pressure 
to drop,  injectors will 
WARNING:  Under normal  operating  conditions  become inoperative,  resulting  in engine  stall. 
the  fuel  injection  system is pressurised  by a high 
pressure 
fuel pump,  operating at up to 2.3 to 2.5 
bar.  When  engine  is stationary  pressure is 
maintained  within system. 
To prevent NOTE: Fuel at low pressure will remain in 
pressurised fuel escaping  and to avoid  personal  system. To remove low pressure fuel, place 
injury  it is  necessary  to depressurise  fuel absorbent  cloth 
around fuel pipe  at the  filter 
injection  system before any service  operations 
are  carried  out. 
5. 
Connect  the pressure gauge on the  outlet 
If vehicle  has not been  run there  will be a small  from the filter, located on the  chassis. 
amount  of residual  pressure 
in fuel line. The 6. Reconnect  the  battery  and turn  the  ignition to 
depressurising  procedure must still be carried 
posititon 
II while observing the pressure  gauge. 
out  before  disconnecting  any component  within 
the  fuel  system. 
Expected reading 2,39 
- 2,672 kgf/cm² 
Pressure  drop
-max 0.7 kgf/cm² in one  minute. 
The  spilling  of fuel  is unavoidable  during this 
If pressure  is low check that filter  is not 
operation.  Ensure that all necessary  precautions  blocked and pump  is operating  satisfactorily. 
are  taken  to prevent  fire and  explosion.  Then recheck  pressure. 
If pressure  is still low 
renew  regutator,  see Fuel  pressure 
regulator.  Switch 
off ignition. 
4.  Disconnect battery ground  terminal. 
during  disconnection 
NOTE: Before  removing  any of the  injectors, 
remove  and examine  the spark  plugs,  check for 
consistent  colouration  of plugs. 
A leaking 
injector  will result  in the  appropriate  spark plug 
being  sooted 
up. 
The  following test may only  be carried  out using 
suitable  injector test  equipment. 
Leak Test 
Leak test with  the  injectors closed but pressurise to 
2.54  Kgf/cm². No injector  should  leak  more  than 2 
drops of fuel  per minute. 
A Pressure  gauge 18G1500 
B  Fuel  tank and pump 
Fuel  Delivery  Test 
C Fuel filter 
D Fuel injectors x 8 Fuel  delivery  test with  the injector open and 
E Regulator  pressurised as above, fuel delivery from each 
injector  should 
be 160-175cc  per minute  using  white 
spirit,  or 180
-195cc  per minute  using petrol  at 20°C ± 
2°C. 
REISSUED: FEB 1993 7 
Results  
						

							FUEL SYSTEM 
REMOVING AIR CLEANER 
To  Remove  To Remove 
REMOVING 
MASS AIR FLOW  SENSOR 
1. Release two clips securing  air  cleaner to NOTE: The air flow  sensor  is not  a serviceable 
item.  In event  of failure  or damage  complete  unit 
2.  Release  two nuts  and bolts  securing  air must be replaced. 
3. Detach  mass airflow  sensor from air cleaner, 1. Disconnect battery  ground terminal . 
4. Detach  air cleaner  from centre  mounting  sensor. 
mass 
airflow  sensor. 
cleaner 
to left  hand  valance  mounting bracket. 
and  lay  carefully 
to one  side. 
bracket  and withdraw  from engine 
3. Disconnect multi-plug. 
compartment. 
4. Release two clips  securing  air  cleaner  case to 
5. Remove large O ring  from  outlet  tube of air  air  flow  sensor.  Remove  sensor  from  engine 
cleaner.  Fit  a new  O ring  if in  poor  condition.  compartment. 
6. Unclip  three  catches and remove  inlet tube. 
7. Remove  nut  and end plate  securing  air 
cleaner  element  in position. 
8. Withdraw  air cleaner  element  and discard. 
9. Inspect dump valve for condition  and free  of 
obstructions. 
2. Release  intake  hose  clamp, disconnect from 
To Refit 
5. Reverse  removal procedure.  Ensure multi-plug 
is firmly reconnected,  and hose  clamp  at the 
rear 
of sensor  is securely  tightened,  to 
prevent  unmetered  air entering engine. 
To  Refit 
10. Fit  new  element  and secure in position. 
11. Refit  inlet  tube. 
12. Refit air  cleaner  to mounting  bracket  and 
secure. 
13. Clip  air  cleaner to mass air flow sensor. 
8 REISSUED: FEB 1993  
						

							FUEL SYSTEM 
REMOVING THROTTLE POSITION SENSOR 
To Remove  To Remove 
REMOVING 
IDLE 
AIR CONTROL VALVE 
1. Disconnect  battery ground  terminal. 1. Disconnect  battery ground  terminal. 
2. Disconnect  electrical plug. 2. Remove multi-plug. 
3. Remove two screws securing  throttle position 3. Unscrew  idle air control  valve from rear 
sensor  to plenum  chamber  and carefully  pull  plenum chamber. 
throttle  position  sensor 
off throttle shaft. 4. Remove  washer. 
4. Remove old gasket. 
To  Refit 
5. Fit new  gasket. 
6. Align  throttle  position  sensor and shaft  fiats, 
slide  switch 
on to throttle  shaft. Secure  throttle 
position  sensor to plenum  chamber. To  Refit 
5. Fit NEW sealing washer. 
CAUTION: DO NOT  operate  throttle mechanism 
while  throttle  position  sensor is loosely  fitted, 
NOTE: If same idle air control  valve is being 
damage  may be caused  to throttle  position  refitted clean sealing  compounds  from threads. 
sensor  wiper track.  Apply 
Loctite  241 to threads  of idle  air control 
valve  before  reassembly. 
6.  Tighten  idle air control  valve to 20  Nm. 
7.  Reverse  removal instructions. 
REISSUED: FEB 1993 9  
						

							FUEL SYSTEM 
REMOVING VEHICLE SPEED SENSOR  REMOVING 
FUEL INJECTION-RELAY  MODULES 
To  Remove 
Incorporated  in fuel  injection  electrical  system  are 
two relays  modules and a diagnostic  plug.  Access to 
the modules  and  plug  is gained  by removing  the toe 
board  from the  front  passenger’s  footwell.  For  exact 
location,  refer 
to illustration  ST 3362M in Electrical 
1. Place  vehicle  on ramp,  apply parking  brake. 
2. Disconnect battery ground  terminal . 
3. Raise ramp,  disconnect  electrical plug. 
4. Disconnect  speedometer  cable.  Section 86. 
5. Do not remove  blanking  cap. 
6. Remove  single  bolt.  Remove vehicle speed REMOVING  ELECTRONIC  CONTROL MODULE 
NOTE: The ECM  is not  serviceable,  in event  of 
module  failure 
it must be replaced. 
To  Remove 
sensor  from mounting  bracket. (ECM) - 14 CUX 
1. Disconnect battery  ground  terminal. 
2. Remove  toe  board  from  front passenger’s 
footwell. 
3. Release  ECM plug retaining  clip. 
4. Detach plug from  ECM. 
5. Remove  securing  screws  and withdraw ECM. 
To Refit 
6. 
Refit  ECM  by reversing  the  removal 
procedure. 
To Refit 
7.  Reverse  the removal  instructions. 
10 REISSUED: FEB 1993  
						

							FUEL SYSTEM 
REMOVING INERTIA FUEL  SHUT-OFF SWITCH  REMOVING  ENGINE  COOLANT  TEMPERATURE 
The  inertia  fuel shut 
off switch  is located 
adjacent  to the  auxiliary  fuse  panel. Access 
is 
gained by  removing the fuse  panel  cover. 
To  Remove  multi
-plug. 
SENSOR 
To  Remove 
1. Disconnect  engine coolant temperature  sensor 
1. Disconnect battery ground terminal . 2. Release  radiator  bottom  hose, partially  drain 
2. Remove two screws  securing  inertia  fuel  cooling  system. 
3. Withdraw inertia fuel  shut-off switch  and 4. Remove  engine  coolant  temperature  sensor 
shut
-off 
switch. 3. Refit  hose  and tighten  clamp. 
disconnect  multi
-plug.  from 
left hand  front branch of intake  manifold. 
5. Remove copper  washer. 
To Refit 
4. Reverse  removal  procedure.  Ensure  that 
switch  is reset  (plunger  in lowest  position). 
REMOVlNG  ENGINE FUEL TEMPERATURE 
SENSOR 
To Remove 
NOTE: Fuel  leakage  will not  occur  when  engine 
fuel  temperature sensor  is removed  from fuel rail, 
therefore 
it is not  necessary to depressurise  the 
fuel  system. 
1. Disconnect battery ground  terminal . To Refit 2.  Remove  multi-plug  from  engine  fuel 
temperature  sensor . 
3. Release engine fuel temperature  sensor from 
fuel  feed  rail.  tighten  securely. 6. Fit a NEW  copper  washer. 
7. Fit engine  coolant  temperature  sensor  and 
8. Refill cooling system. 
9. Run  engine,  check  for water leaks around 
engine coolant  temperature  sensor 
. 
To Refit 
4. Reverse  removal  procedure.  Ensure  engine 
fuel  temperature  sensor is tightened  securely 
in fuel rail. 
REISSUED: FEB 1993 11  
						

							FUEL SYSTEM 
DEPRESSURISING FUEL SYSTEM 
WARNING: 
Under  normal  operating  conditions To Remove 
the  fuel  injection  system is pressurised  by a high 
pressure  fuel pump,  operating 
at up to 2.3 to 2.5 
bar  When engine is stationary  pressure is 2. Disconnect battery ground terminal. 
maintained  within system.  To prevent 
3. Release hose  clamp securing  fuel  return hose 
pressurised  fuel escaping  and to avoid  personal 
to fuel  pressure regulator.  Remove the hose. 
injury  it is  necessary  to depressurise  fuel 
4. Pull vacuum  hose  from  rear of fuel  pressure 
injection  system before any service  operations  regulator. 
are  carried  out. 
5. Remove two nuts and bolts  securing  fuel 
pressure  regulator 
to fuel  rail, ease  regulator 
If vehicle  has not been  run there  will be a small  fuel inlet  pipe out of fuel  rail. 
amount  of residual  pressure  in fuel  line.  The 
6. Withdraw  fuel  pressure  regulator  from  engine 
depressurising  procedure must still 
be carried  compartment. 
out  before  disconnecting  any component  within 
the  fuel  system. 
The  spilling  of fuel  is unavoidable  during this 
operation.  Ensure that all necessary  precautions 
are  taken  to prevent  fire and  explosion. 
REMOVING  FUEL PRESSURE  REGULATOR 
1. Depressurise fuel  system. 
1. Remove fuel pump  relay module. 
2. Start and run engine. 
3. When  sufficient  fuel  has  been  used to cause 
fuel  line pressure  to  drop, injectors 
will 
become  inoperative,  resulting in engine  stall. 
Switch 
off ignition. 
4. Disconnect battery  ground  terminal . 
NOTE: Fuel  at low  pressure  will remain  in 
system.  To remove 
low pressure  fuel, place 
absorbent  cloth around  fuel feed  hose  at fuel  rail. 
5. Disconnect either: 
a)  Nut  and olive  at fuel  rail 
OR 
b)  Hose  at inlet  end of fuel  filter. 
NOTE: Fit a NEW ’0’ ring  to fuel  inlet  pipe  if 
original  fuel pressure  regulator  is refitted. 
To Refit 
6. Refit  fuel feed  hose. 
7. Refit  fuel pump  relay module,  reconnect 7. Lightly  coat ‘0’ ring with  silicon  grease  300 
before  fitting fuel pressure regulator. 
8. Crank  engine  (engine will  fire in approximately 8. Reverse removal procedure. 
9. Reconnect battery  and  pressurise fuel system. 
Check  there are no fuel  leaks  around  fuel 
pressure  regulator  connections. 
battery. 6 to 8 seconds). 
12 REISSUED: FEB 1993  
						

							FUEL SYSTEM 
REMOVING FUEL RAIL-INJECTORS R/H  AND L/H 
To Remove 
11.  Remove  fuel pressure regulator if required. 
1. Depressurise fuel  system. 
2. Disconnect battery ground terminal. 
3.  Remove plenum  chamber. 
4.  Remove  ram housing. 
NOTE: Place cloth over  ram  tube  openings  to 
prevent  ingress of 
dirt. 
5. Release  hose clamp  and  remove  fuel return 
hose from  fuel  pressure regulator. 
6. Disconnect  multi-plug from  engine  fuel 
temperature  sensor. 
7. Disconnect multi-plugs from injectors. To Refit 8. Remove five bolts  securing  fuel  rail support 
brackets  to  intake  manifold. Lay heater  pipes 
to  one  side. 
12. Fit NEW 0 rings,  to injectors.  Lightly  coat ‘O’ 
rings  with  silicon  grease 300.  Insert  injectors 
into  fuel  rail,  multi
-plug  connections  facing 
outwards. 
13.  Refit  retaining clips. 
CAUTION: Care  must be taken  when refitting  the 
fuel  rail  and injectors  to intake  manifold  to 
prevent  damage  to 
0 rings. 
14.  Fit a 
NEW O ring  to  fuel  pressure  regulator 
lightly  coat 
0 ring  with  silicon grease  300 
and  secure regulator  to the  fuel  rail. 
15. Fit  fuel  rail and  heater  pipe  assemblies  to 
intake  manifold.  Secure  rail and  pipes  in 
position 
with five  bolts. 
16.  Reverse 
removal instructions 2 to 7. 
17.  Pressurise fuel system  and  check  for  fuel 
leaks  around  injectors  and fuel  pressure 
regulator. 
9. Remove  fuel rail and  injectors. 
from  rail. 
10. 
Remove  injector retaining  clips,  ease  injectors 
REISSUED FEB 
1993 13  
						

							FUEL SYSTEM 
REMOVING PLENUM CHAMBER 
Includes throttle levers and  throttle disc 
To Remove 
1.  Disconnect battery ground terminal. 
2.  Disconnect  electrical  multi
-plug from  idle air 
control  valve. 
3. Disconnect  vacuum  hose adjacent to idle air 
control  valve. 
4. Mark an identification  line on throttle  cable 
outer  to  assist  re
-assembly. 
5. Remove clevis pin  from throttle  cable. 
6.  Pry  adjustment  thumb  wheel  from  throttle 
bracket.  Lay cable  aside. 
7. Remove  retaining clip  and  clevis bin from  kick 
down  cable  (automatic vehicles). 
8.  Apply  adhesive  tape behind  rear adjustment  15.  Remove distributor  vacuum  hose. 
nut  on kick  down  cable 
to prevent nut moving.  16. Release two screws  and remove  throttle 
9. Remove front  lock  nut.  Remove  cable  and lay 
aside.  17. Remove  six screws  securing  plenum chamber. 
fitted).  18. 
Remove idle air control valve hose. 
position sensor. 
10.  Remove  cruise control  vacuum  hose  (where  Remove plenum chamber. 
Removing  throttle lever assembly 
19. 
If fitted - unclip  cruise  control  actuator link. 
Hold  throttle  fully  open,  release link from 
countershaft  assembly.  Carefully  return lever 
assembly  to close  throttle. 
20.  Release tension  on inboard throttle spring. 
21.  Bend  back lock washer  tabs. 
22.  Hold  throttle  stop lever 
in closed  position, 
release  nut from  throttle  shaft. 
23.  Release  tension on outboard throttle  spring. 
24. Remove overtravel spring. 
11.  Remove  intake  hose 
from neck of plenum 
chamber. 
12.  Disconnect  throttle 
position sensor multi-plug. 
13.  Remove  PCV breather  hose. 
14. Disconnect  two  coolant  hoses and plug  each 
hose 
to prevent  excessive  loss of coolant. 
Identify each  hose for re
-assembly. 
14 REISSUED: FEB 1993