Land Rover Fuel Injection System Manual

LAND ROVER 
The underside of the plenum in the figure above and below shows the plen\
um pre-heater plate with 
two water hoses and the idle bypass air valve stepper motor as well as t\
he throttle linkages. Note 
also the cable and plug for the throttle potentiometer sensor.
 
Figure 7 – Close up of plenum chamber pre-heater
 
The above figure shows the plenum upside down. The primary metered air e\
ntry point is the large 
round point, and the pre-heater plate is shown above with the two heater\...

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replacing. 
 
Figure 9 – Drilled throttle assembly rivets
 
With the degreasing and refurbishment complete, a new coat of paint was \
required. Matt black was 
used for everything other than the fuel rail (which was sprayed a brigh\
t red colour from Rover). 
 
Figure 10 – Painted plenum - minus all ancillary components
 
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Figure 11 – Sprayed idle bypass air valve housing and plenum pre-heat\
er
 
 
 
Figure 12 – Sprayed plenum complete with rebuilt throttle linkages
 
Meanwhile – all the work required to clear the old carburetion system\
 on the land rover had 
commenced to the point of leaving the valley clear
 
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Figure 13 – Rover V8 cleared down to the valley
 
 
 
 
Figure 14 – Left and right views of the V8
 
A good deal of time was spent carefully cleaning the matting surfaces of\
 the two heads, and also 
thread chasing all the intake mounting bolts using a stainless steel hea\
d bolt cut with a slot 
(obtained from Real Steel).
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Figure 15 – Underside of original carburettor manifold (showing the \
plumbing)
 
With the original intake manifold the top and bottom radiator hoses foll\
owed a conventional route – 
although the top hose was interrupted (close to the radiator) by a met\
al unit holding two 
temperature switches designed to operate the two electric radiator fans.\
 Closer to the manifold, the 
water pump had two ports which connected to hoses – one which was abo\
ut 4” long and which 
connected to a...

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The existing steel port on the front of the injection manifold was conne\
cted to a 19-19mm U bend 
in silicon, and routed under the intake using a steel metal pipe. Undern\
eath the manifold (towards 
the rear) the steel pipe connected to a 19mm to 16mm silicon hose reduc\
er (still under the 
manifold) and the 16mm outlet was then connected via domestic half inch\
 copper to an upright 
which connected to a 16-16mm right angle in silicon, connecting to the h\
eater control valve (a 
sluice...

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Figure 18 – Intake front and rear view
 
As part of the refurbishment, all eight injectors were sent to a special\
ist cleaning company (who 
also supplied the oxygen lambda sensors). Their injector cleaning servi\
ce included replacing the 
pintle heads, all O rings (2 per injector) followed by ultrasonic clea\
ning and then a testing phase to 
assess the coil electrically, and to check the flow rating for each inje\
ctor at 3 bar pressure along 
with measured leak down loss and spray...

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Figure 20 – Finalised injection intake base
 
The figure above shows the fully built injection manifold complete with \
refurbished injectors and 
fuel rail – note the converted fuel pipe connection on the rear of th\
e fuel rail - now converted to 
use a standard hose connection
 
The injector and fuel rail refit involved the following steps.
 1.  Oil the manifold injector bores
2.  Lightly oil the O-rings on the bases of the injectors
3.  Carefully push fit all eight injectors into the...

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10.  Fit all four fuel rail mounting screws and tighten to 10ft/lbs
Fabrication / Design process
Following the refurbishment of the injection hardware, the engine fittin\
g process began. 
 
Broadly this involved the following steps
 1.  Fitting the intake manifold with new valley gasket and front and rea\
r valley seals. 
2.  Deciding on the orientation for both the intake runners and the plen\
um
3.  Fabricating and fitting the throttle linkage
4.  Fabricating the air intake filter and...

LAND ROVER 
Figure 21 – Underside of plenum intake trumpet housing (note vacuum \
ports)
 
The plenum orientation again was an easy choice given it is also reversi\
ble. Fitted correctly (ie: 
with the 3.9 emblem visible at the front) the air intake fouled the lan\
d rover wing. Flipping the 
plenum with the air intake onto the drivers side of the vehicle not only\
 resolved the fouling 
problem but also meant it was possible to reuse the existing carburettor\
 throttle cable.
 
The one downside with...