Land Rover Fuel Injection System Manual

LAND ROVER 
 
 
 
 
 
LAND ROVER 
FUEL INJECTION SYSTEM
 
DESIGN AND FABRICATION  
AUTHOR: CIARAN J BRADY
(cbrady at conehead dot org)
 
PROJECT DURATION: Feb to May 2010
 
Document version – 2.06 – 28th Aug 2010
 
 
 
 
 
 
http://www.conehead.org/Projects/Landrover/EFi/efi%20-%20web.htm (1 of \
55)16/10/2010 9:03:18 a.m. 

LAND ROVER 
Main Index
 
Main Index
Figure index
Introduction
Overview
Selected Donor Vehicle
Donor vehicle parts supplied
Missing parts
Project duration
Refurbishment process
Fabrication / Design process
Fitting the injection Intake manifold
Selection of orientation of plenum and trumpets
Throttle linkage
Mass air flow sensor and air filter
Positive crank case ventilation (PCV)
The fuel system
The fuel tank
Vacuum plumbing design
Engine cooling
Idle control system
Exhaust and Lambda sensors
Bench...

LAND ROVER 
Figure 13 – Rover V8 cleared down to the valley
Figure 14 – Left and right views of the V8
Figure 15 – Underside of original carburettor manifold (showing the \
plumbing)
Figure 16 – Underside of injection manifold
Figure 17 – Cooling plumbing for the heater matrix
Figure 18 – Intake front and rear view
Figure 19 – Injector testing results
Figure 20 – Finalised injection intake base
Figure 21 – Underside of plenum intake trumpet housing (note vacuum \
ports)
Figure 22 – Final position of the...

LAND ROVER 
 
Introduction
The land rover came with a standard induction system consisting of twin \
1.75” SU carburettors 
fitted to a 3.5 litre 9.35:1 compression ratio rover V8 using electronic\
 ignition. The vehicle 
employed a stainless steel exhaust system coupled with log style exhaust\
 manifolds. However, 
even after rolling road jetting of the carburettors and with good and ti\
ght linkages for both throttle 
and choke, they were the usual SU horror to drive with. The mixture was \
generally...

LAND ROVER 
There are advantages and disadvantages to these systems – but it is w\
orth factoring into the 
decision land rover research leading to a flexible, self adaptive system\
 known as the C family and 
which culminated in the 14CUX. This system has two major advantages. Fir\
stly it is self adaptive 
because it measures air flow into the engine using a mass air flow senso\
r – using that to determine 
the required amount of fuel. The air flow sensor employs a hot wire anem\
ometer to sense air...

LAND ROVER 
l     A=Built at: Solihull, UK
l     XXXXXX is serial number off the line
 
Donor vehicle parts supplied
The donor vehicle supplied the following parts. 
  1.  Full wiring loom including main and fuel relays and a socket for the\
 air conditioning control  relay
2.  ECU – stamped 14CUX
3.  Intake manifold
4.  Air horns 
5.  Plenum
6.  Throttle blade and linkage control
7.  Throttle potentiometer
8.  Air bypass valve stepper motor
9.  Under plenum heater
10.  Pipe work linking to mass air...

LAND ROVER 
Figure 1 – 1992 3.9EFi donor vehicle parts as shipped
 
The general condition of the donor parts was good and it was clear that \
the seller had done a good 
job of carefully removing the components in order to minimise damage. 
 
Figure 2 – Plenum side view
 
The idle control system was intact, as was the throttle linkages and the\
 fuel regulator (at the back 
of the fuel rail). The throttle linkages did however appear to be in a \
bad state of repair....

LAND ROVER 
Figure 3 – Plenum rear quarter view – fuel flow and return
 
In the above photograph, you can see the flow and return feed pipes to t\
he fuel rail, connected to 
the even bank of injectors (with the injector for cylinder 7 visible at\
 the back left). Note the fuel rail 
connections – using a standard hose jubilee pipe on the low pressure \
side of the fuel regulator, but 
a machined fitment on the input high pressure side. This machined connec\
tion was tackled by 
removing the olive and...

LAND ROVER 
Figure 4 – View of stripped intake manifold
 
The above photograph details the front of the intake manifold when both \
the upper plenum and the 
inner runner manifold have been removed (shown just in shot on the left\
). Looking at the intake 
reveals all 8 injectors (the even set of four on the left of the photo,\
 the odd set on the right) 
connected between the fuel rail and the intake manifold. Note the four b\
olts (one was missing) 
fastening the intake to the manifold. You can see...

LAND ROVER 
fans – but which was not employed in my design) and just underneath \
that is a coolant temp 
sensor used to drive the dash board gauge. On the front right hand of th\
e manifold you can see the 
coolant temperature sensor used by the fuel injection system screwed int\
o the manifold. Just 
above that is a water coolant pipe that feeds hot engine water to the un\
der plenum preheating 
plate. 
 
At the back of the manifold fuel rail you can see the fuel inlet right a\
t the back coming into...