Land Rover Fuel Injection System Manual
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1987 KANCltROVER ”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. All openings left open after the removal of any component from the fuel system, MUST be sealed off (0 prevent ingress of dirt. ENGINE SEllING PROCEDURE If a major overhaul has been undertaken on the fuelinjection/engine system, the following check and adjustments must be carried out before attempting to start the engine. A.Throttle potentiometer setting - see ‘Throttle potentiometer’ setting procedure. B.Spark plug gaps -see ‘Section 05 Engine tuning data’. C.Throttle levers - see ‘Throttle lever setting procedure’. D.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 circuitorymust be checkedusing theappropriate recommended equipment. 6Recommended Equipment -Lucas ‘Electronic Ignition Analyser’Lucas Part Number - YWB 119. Lucas Diagnostic Equipment Lucas Part Number - 60600965 (complete kit) Individual part numbers for the above kit are as follows:Hand held test unit - Model 2HHTLucas Part Number - 84772 Interface unit Lucas Part Number - Model 21U - 84773 Serial link lead Lucas Part Number - 54744753 Memory card Lucas Part Number - 54744754 Operating manual Lucas Part Number Plastic case Lucas Part Number ::. XXB825 .I 1. - 54744755 NOTE: The Lucas diagnostic equipment can be connected to the diagnostic plug located by the E.C.U. 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:- A. B. C. D. E. F.Fuse 18 - in main fuse panel - is intact. Inertia switch - not tripped. Fuel - ample fuel in fuel tank. Battery Condition - state ofcha ge.IAir Leaks -no unmetered air entering engine system.Electrical Connections - dry, clean and secure... .\REVISED: jlJLY 88
‘. ro;;; 1987 FUEL INJECTION SYSTEM CONTINUITY TEST PROCEDURE : ” ..’.IThe 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. If the probes are inserted into the plug sockets, damage will occur to the sockets resulting in poor connections when the plug is reconnected. TESTING 1. 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 enoughclearanceenablingmeter 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 positionidentification asshownin the illustration below, (for clarity the electrical leads have been omitted). ,’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. :’3 .-.RR2016E4028 PIN NOS.CABLE COLOUR 1.Red/green 2.Brown/orange 3.Yellow 4.Black 5.Brown/purple 6.Yellow 7.Green/blue 8.Not used 9.White/lightgreen 10.Black/Yellow 11.Yellow/white 12.Blue/red I 3.Yellow/blue 14.Black 15. Brown 16.Blue/purple 17.Not usedI 8. White/pink 19.Whitelgrey 20.Red 21.Yellow/blue 22.Blue/red 23.Blue 24.Blue 25. Red/black 26.Green/white 27.Black/grey 28.Blue/grey 29.Orange 30.Not used 31.Not used 32.Greylwhite 33.Not used 34.Black/orange 35.Blue/green 36.Not used 37.White/yellow 38.Not used 39.White/black 40.Black The last colour denotes the wire tracer colour.Continued ; . .REVISED: APR. 88
FUEL INJECTION SYSTEM1987 ;;“d’;‘;;iTESTS - Using a Muhi-MeterThe 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. KEY TO SYMBOLS OHMMETER CONNECTIONS ROAD SPEED INPUT (SPEED TRANSDUCER)COOLANT TEMPERATURE SENSOR RR1782E8 iNlTlON SWITCb VOLTMETER CONNECTIONS GEARINPUT SWITCH INHIBITORSWITCH AIR BYPASSVALVEELECTRONIC CONTROL UNIT AND MULTIPLUG MAIN RELAY INJECTORPUMP RELAY IGNITION COIL TEMPORARY CONNECTIONFUEL PUMP FUEL TEMPERATURE SENSORTHROTTLE ’ ‘OTENTIOMETER 1HOT WIRE AIRFLOW SENSOR REVISED: APR. 88
”NOTE: All tests are carried out from the electronic control unit (ECU) harness multi-plug unless stated otherwise in the test procedure. .. :,:.:.A R”;;; 1987 FUELINJECTIONSYSTEM b-6 1 1rEST PROCEDURE 2.Check ignition supply to ECU rEST PROCEDURE 1.Check battery supply to ECURESULTS . Check cables and units shown in bold Voltmeter reading of battery volts - (mimimum battery voltage 10 volts) Proceed to Test 2 Voltmeter reading of zero volts Check:- 1 IGNlTlON OFF RRl816ERESULTS - Check cables and units shown in bold Voltmeter reading of battery volts -(minimum battery voltage 10 volts) Proceed to Test 3 Incorrect reading check:- RR1817E YContinued REVISED: APR. 88 :g .: :.,
l-l RANGE 19 FUEL INJECTION SYSTEMlg8’ ROVER rEST PROCEDURE I.Check operation of Main relay RESULTS - Check cables and units shown in boldVoltmeter reading of battery volts -Proceed to Test 5 Voltmeter reading of zero volts -Proceed to Test 4 IGNITION ON RR1818E ‘EST PROCEDURE1RESULTS - Check cables and units shown in bold I. 1. 5 4 R10 Fault DiagnosisMain relay circuitsA.Voltmeter reading of battery volts -Check:-If OK Suspect ECU 6.Voltmeter reading of zero voltsCheck:- clI- lGNsnoNoPF --..~ - iR1810E 4REVISED: APR. 88 ‘- ‘\
k”d;‘;r; 1987 FUEL INJECTION SYSTEM 119 1 ‘EST PROCEDURE i.Check operationListen for audible ‘click’ from pump of pump relayrelay.If 0.K - Proceed to Test 7 IGNtTION ON RR182OE [EST PROCEDURE i.Fault diagnosisPump relay circuits 1I?R1821EIGNITION ONRESULTS - Check cables and units shown in bold No audible ‘click’ from pump relay Check:-If OK proceed to Test 6. RESULTS - Check cables and units shown in bold Voltmeter reading of battery volts -Suspect ECU Voltmeter reading of zero volts Check:- YContinuedREVISED: APR. 88
rEST PROCEDURERESULTS - Check cables and units shown in bold 7.Check operation of Fuel pumpVoltmeter reading of battery volts -Pump operating - Proceed to Test 8NOTE: 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 area floor panel. (A)Voltmeter reading of battery volts -Pump not operating Check:‘- KEY:1. Inertia switch 2. Fuse 18(6)Voltmeter reading of zero voltsCheck:-REVISED: APR. 88
1.‘:; .( : . .,‘. .::i.. .~ K’^d;\ir; 1987 FUEL INJECTION SYSTEM 119 1 ~~‘EST PROCEDURE I.Check engine speed signal Cable and resistor W1823E TEST PROCEDURE 9.Check injectors, Injector circuit (Pin 13 left bank injectors 1,3,5,7). clI-IGNITION OFF lR1824 ERESULTS - 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 Ohm-meter reading of 4-5 Ohms -Proceed to Test 10 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 REVISED: APR. 88 13 .. . :. ..:“,‘.;.
. ..’-:;,.i :.. ‘...’ . .::’?, . . i.FUEL INJECTION SYSTEM ‘EST PROCEDURE 0.Check injectorsInjeclor 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 injectorOhm-meter reading of 8-9 Ohms -Suspect 2 injectorsOhm-meter reading of 16-17 Ohms - Suspect 3 injectorsCheck for open circuit injector(s) or wiring faults. Ohm-meter reading of Infinity Check: 10 0L- IGNITION OFF RR1825E TEST PROCEDURE 11.Check fuel temperature thermistor (sensor) 11RESULTS - Check cables and units shown in bold Correct reading-temperature to resistance- Proceed to Test 12(Refer to Temperature Conversion Charts in Test 12Incorrect Ohm-meter reading Checkcl I- IGNITION OFFRR1826E .\14REVISED: APR. 88
;;^d;;t; 1987 FUEL INJECTION SYSTEM 119 1 ‘EST PROCEDURE 2.Check coolant temperature thermistor (sensor)RESULTS - Check cables and units shown in bold Correct reading-Temperature to resistance -ProceedtoTest 13 (Refer to Temperature Conversion Chart below. Fuel and CoolantOhm-meter Reading TemperatureShould be “C“FOhms-1001409100-930000 325700-59002006802400-260040010401100-1300601400 500-70080°176O 300-40010002120150-200Incorrect Ohm-meter reading Check:- 0 I-- - IGNtllON OFF RR1827EContinuedREVISED: APR. 8815