Land Rover Fuel Injection System Manual

							:,.._,. ”FUEL INJECTION SYSTEM1987 
&INGEROVER
‘.
THROlTLE POTENTIOMETERSetting the Potentiometer using a multi meter.
Remove, refit and reset
RemoveENSURE THE MULTI METER USED TO CARRY OUTTHIS CHECK IS SET TO VOLTS. A MULTI METER
SETTING OTHER THAN VOLTS WILL RESULT IN
DAMAGE TO THE POTENTIOMETER.
1. Disconnect the battery negative terminal.
2. Disconnect the electrical three-pin plug.
3. Remove the two screws securing the switch tothe plenum chamber and carefully pull the
switch off the throttle valve shaft.
8.
9.
10.
11.
12.
13.
Loosen the potentiometer securing screws.Reconnect the potentiometer three-pin plug
and reconnect the battery. Switch on the
ignition.Connect the multi meter between the red and
green leads at the potentiometer electrical
plug.Rotatethe potentiometer clockwise or
counter-clockwise, until the multi meter reads
325 2 35 mV.
Tighten the potentiometer securing screws.Re-check the multi-meter reading. Check also
for a ‘smooth swing’ of the meter needle
between minimum and maximum throttle
opening between the voltage reading of 4.6 
-
5.0 volts4. Remove the old gasket.
Refit
5. Fit a new gasket between the throttle switch
and plenum chamber.6. Align the switch and shaft fiats; slide the
switch on to the throttle shaft and secure the
switch to the plenum chamber.7. The throttle potentiometer must be reset
using the following procedure.CAUTION: The throttle mechanism must not be
operated while the potentiometer is loosely
fitted, otherwise damage may be caused to the
potentiometer wiper track.
26REVISED: SEPT. 88NOTE: After setting the potentiometer, lock
and tamperproof each screw head by
coating them with yellow paint. 
						

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R”d;‘;r; 1987
FUEL INJECTION SYSTEM 119 1BY-PASS AIR VALVE
(STEPPER MOTOR)
: ;...Remove and refit
Removing
1.
2.
3.4.Disconnect the battery negative terminal.
Remove the multi-plug from the unit.
Unscrew the valve from its location at the rear
of the plenum chamber.
Remove the captive washer.
Refitting
5. Fit a NEWsealing washer.
,..NOTE: If::::.’refittedthe same by-pass valve is being
cleananyprevioussealing
compounds from the threads. Apply Loctite
241 to threadsof the valve before
reassembly.SPEED TRANSDUCER
Remove and refit
Removing
1.
2.
3.
4.
5.
6Place the vehicle on a hydraulic hoist and
apply the parking brake.
Disconnect the battery negative terminal.
Raise the hoist and disconnect the speed
transducer electrical plug.
Disconnect the speedometer cable from the
transducer to the binnacle at the transducer.
Disconnect the speedometer cable from the
transducer to the speedometer housing at the
transducer.
Removethesingle bolt securing
transducer to its mounting bracket
withdraw the unit from the vehicle.the
andRefitting
7. Reverse the removal instructions.
6. Tighten the valve to the specified torque 
(seeTorque values-section 
06).7. Reverse the remaining removal instructions.
J27  
						

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I
.’FUEL INJECTIONSYSTEM
ELECTRONIC FUEL INJECTION RELAYS
incorporated into the fuel injection electrical circuits
are two relays. The relays are located beneath the
front
1.right-hand seat, adjacent to the E.C.U.
Fuel pump relay (mounted on a blue
terminal block).
Main relay (mounted on a black terminal
block).
Diagnostic plug.
RRl867ERRl867ERemove and refit Remove and refit
Removing Removing
1. Disconnect the battery negative terminal. 1. Disconnect the battery negative terminal.
2. Pull the relay(s) from the multi-plug(s). 2. Pull the relay(s) from the multi-plug(s).
Refitting Refitting
3. Reverse the removal procedure. 3. Reverse the removal procedure.ELECTRONIC CONTROL UNIT-ECU
‘,,,NOTE: The ECU is not itself a serviceable
item, in the event of a unit failure, the ECU
must be replaced.
Remove and refit
Removing
1.
2.
3.
4.
5.
6.
7.Disconnect the battery negative terminal.
The ECU is located under the front right hand
seat and is accessible through the rear
opening of the seat base when the seat is in
its most forward position.
Release the E.C.U plug retaining clip.
Pull the rear of the multi-plug out of the ECU.
Maneuver the tront of the plug fin the
direction of the bold arrow) to release the
1hooked rear end of the plug from the
retaining peg.
Release the screws securing the ECU to the
mounting bracket.
Withdraw the ECU from the spring clip and
remove it from the vehicle.,:’ .i .rRefitting
8. Refit the E.C.U. securely 
in’the spring clip and
tighten the two screws.
9. Re-connect the E.C.U. harness plug, ensure
the plug is firmly pushed into its location and
that the retaining clip secures the plug in
position.
4
.’8.:‘,28:,: ‘...,.. 
						

							FUEL INJECTION
SYSTEM
INERTIA SWITCH
The inertia switch is located under the left hand
front seat attached to the inner face of the rear
front seat base. Access to the switch is gained
through the opening at the rear of the seat base.
Remove and refit
Removing
1. Ensure the seat is in its fully forward position.
2. Disconnect the battery negative terminal.
3. Remove the two screws securing the switch to
the cross member.
4. Withdraw the switch and disconnect the
electrical multi-plug.
5. Remove the switch from the vehicle.
Refitting
6. Reverse the removal procedure ensuring that
the multi-plug clips firmly into position, and
that the plunger is reset (plunger is in its
lowest position).FUEL TEMPERATURE THERMISTOR (SENSOR)
Remove and refit
Removing
NOTE: No fuel leakage will occur when the
thermistor is
removed from the fuel rail
therefore it is not necessary to depressurize the
fuel system before removal.
1. Disconnect the battery negative terminal.
2. Remove the electrical multi - plug from the
thermistor.
3. Release the thermistor from the fuel feed rail.
Refitting
4. Reverse the removal procedure, ensuring that
the thermistor is tightened securely in the fuel
rail.REVISED: APR. 88
29
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							-KANW
19 FUEL INJECTION SYSTEM1987-88 R(-j”ERCOOLANT TEMPERATURE THERMISTOR (SENSOR)
Remove and refit
Removing
1.
2.
3.4.
5.Remove the multi-plug from the thermistor.
Release the radiator bottom hose and partially
drain the cooling system.
Refit the hose and tighten the clamp securely.
Remove the thermistor from the left hand
front branch of the intake manifold.
Remove the copper washer.
Refitting
6.
7.
8.
9.30Fit a NEW copper washer to the thermistor.
Fit the thermistor to the intake manifold and
tighten securely.
Refill the cooling system.
Run the engine, check for water leaks around
the coolant temperature thermistor.RESETTING THROTTLE LEVERS
NOTE: The setting procedure outlined is
applicable at minimum throttle condition
only.
Ensure that the throttle valve is retained at its
90” vertical setting by holding down the stop
lever and throttle/kick down lever denoted by
the bold arrow while adjusting the throttle
operating levers.
Release the throttle operating lever securing
screw and adjust the lever until contact is
made with the top end of the slot in the
throttle lever mounting bracket; retaining the
lever in this position retighten the screw.
Lightly grease all throttle lever bearing surfaces
and torsion spring with 
Admax 13 grease or a
suitable equivalent.
NOTE: Check the clearance between the
cruise control actuator link and throttle
lever(seeCruiseControlActuator
Setting-Section 19, Page 
47).
.__LATER MODELS:- have a redesigned stop lever that
seats on a factory-set adjustment screw which is
located in the plenum chamber casting. The screw
should not normally require adjustment. If new
throttle bracketry and linkages are fitted it is
advisable to check that the throttle valve is vertical
before adjusting the screw.
REVISED: APR. 88
:,.._.. 
						

							FUEL INJECTIONSYSTEM1THROl-FLE CABLERemove and refit
Removing
1.
2.
3.Remove the cotter pin and clevis pin securing
the cable to the lever.
Carefully pry the throttle cable adjustment nut
out of the linkage mounting bracket.
Withdraw the cable from the mounting
bracket.
i,io2,i2
RRl064ERelease the outer cable from the retaining
clips within the engine compartment.
Remove the lower dash pane! from beneath
the steering column.
Disconnect the cable from the throttle pedal
and release the cable locknut.
Feed the cable through the bulkhead grommet
and into the engine compartment.
FIT NEW THROlTlE CABLE8. Feed the newcable from the engine
compartment through the bulkhead grommet.
9. Connect the cable to the throttle pedal.10. Connect the cable to the throttle linkage, fit a
new cotter pin and secure in position.
11. Clip the outer cable adjustment nut into the
mounting bracket.
12. Adjust the outer cable to give 1.57 mm (0.062
in) free play in the throttle cable and check
the throttle operation.
THROlTLE PEDALRemove and refit
Remove
1.Release the six screws securing the lower dash
panel, lower the panel and disconnect the two
electrical leads to the rheostat switch, detach
the bulb check unit from the spring clip and
remove the dash panel from the vehicle.
Remove the cotter pin and clevis pin securing
the throttle cable to the throttle pedal.
Release the tension from the pedal return
spring.Remove the circlip from the pedal pivot pin.
Withdraw the pivot pin.
NOTE: It may be necessary to remove the
steeringcolumn fixings enabling the
column to be lowered to gain access to the
pedal pivot pin circlip.
6.Withdraw the throttle pedal.
Refitting
7. Lightly grease the 
pivot4pin and clevis pin
before re-assembly.
8. Fit a NEW cotter pin to the clevis pin.
9. Reverse the remaining removal instructions.31  
						

							.’ 1
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:.‘,, .:,:::,: ‘,‘.FUEL INJECTION SYSTEM
1987-88 PO;;;
PLENUM CHAMBERRemove and refit
Removing
1.
2.
3.4.
8.Disconnect the battery negative terminal.
Release the radiator bottom hose and partially
drain the cooling system, reconnect the hose
to the radiator.
Release the two large hose clamps from the
neck of the plenum chamber and outlet bore
of the airflow sensor and remove the hose
from its location.
Release the clamps and remove the two
coolant hoses from the bottom of the plenum
chamber inlet neck. Identify each hose to aid
re-assembly.Remove the vacuum supply hose from the
cruise control actuator.
Disconnect the actuating link at the cruise
control actuator.
Remove the distributor vacuum hose, positive
crankcase ventilation breather filter hose and
servo hose.
Disconnect
thethrottlepotentiometer
multi-plug.
9.10.
11.Disconnect the multi-plug from the air by-pass
valve.Disconnect the small vacuum hose at the rear
of the plenum chamber, located below the air
by-pass valve.Remove the hose from the air by-pass valve to
plenum chamber to enable the small return
spring located below the throttle levers to be
unhooked.12. Release the two throttle return springs.
13. Remove the two bolts (with spring washers)
securing the throttle cable and kick-down
cable anchor bracket to the throttle lever
support bracket, lay the assembly to one side.
14.
15.Remove the six socket head bolts (with plain
washers) securing the plenum chamber to the
ram housing.
Maneuver the plenum chamber and remove it
from the ram housing.
NOTE: To prevent ingress of dirt
ram tubes, place a protective cover
ram tube openings.into the
over the
i32 
						

							;;“d;‘;;i 1987-91
FUEL INJECTION SYSTEM
RefittingRAM HOUSING
16. Ensure that all mating faces are free from any
previous sealing compounds.
17. Coat the mating faces of the plenum chamber
and ram housing with ‘Hylomar’ sealant.
18. Refit the plenum chamber and tighten the six
bolts to the specified torque (see torque
values-section 
06).19. When refitting the small return spring, item 11
in the removal procedure, it must be noted
that the ‘hooked’ open end of the spring
MUST face the plenum chamber as shown in
illustration 
RR2292E below.
20. Reverse the remaining removal instructions.
NOTE: Ensure that all hoses are connected
securely to prevent un-metered air entering
the engine.Remove and refit
Removing
1. Disconnect the battery negative terminal.
2. Remove the plenum chamber (see Plenum
Chamber remove and refit).
3. Release the hoses from around the outer
edges of the ram housing.
4. Remove the six through bolts (with plain
washers) securing the ram housing to the
intake manifold.
5. Lift the ram housing off the intake manifold
and remove it from the engine compartment.
6. Place a protective cover over the top of the
intake manifold inlet bores to prevent ingress
of dirt.
Refitting
7. Ensure that all mating faces are clean and free
fromdirt
andanyprevioussealing
compounds.
8. Apply ‘Hylomar’ sealant to the intake manifold
face before refitting the 
ram housing.
9. Fit the ram housing and retighten the bolts,
working from the two centre bolts, 
diagonal11towards the outer four bolts.
10. Tighten to the correct torque (See section
06-Torque values).
REVISED: SEPT. SO
33
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							FUEL INJECTION SYSTEM1987-91 PO;;;
DEPRESSURIZING THE FUEL SYSTEMWARNING: Under normal operating conditions
the fuel injection system is pressurized by a high
pressure fuel pump, operating at up to 2.3 to 2.5
bar (34 to 37 
p.s.i.1. When the engine is
stationary this pressure is maintained within the
system. To prevent pressurized fuel escaping and
to avoid personal injury it is necessary to
depressurize the fuel injection system before
any service operations are carried out.
NOTE: If the vehicle has not been run there will
still be a small amount of residual pressure in
the fuel line. The 
depressurizing procedure must
still be carried out before disconnecting the
component within the fuel system.
WARNING: The spilling of fuel is unavoidable
during this operation. Ensure that all necessary
precautions are taken to prevent fire and
explosion.
1.
2.
3.
4.
5.
6.
The fuel pump relay is located under the front
right hand seat.Pull the fuel pump relay off its multi-plug (see
Electronic Fuel Injection Relays-Section 19,
Page 28).
Start and run the engine.
When sufficient fuel has been used up causingthe fuel line pressure to drop, the injectors
will become inoperative, resulting in engine
stall. Switch the ignition off.
Disconnect the battery negative terminal.NOTE: Fuel at low pressure will remain in
the system. To remove this low pressure
fuel, place an absorbent cloth around the
fuel feed hose at the fuel rail and release
the fuel feed hose at the appropriate end.
Disconnect either:
a) The nut and ferrule at the fuel rail
ORNOTE: If the original regulator
refitted, fit a NEW 
‘0’ ring to the
pipe.
b) The hose at the inlet end of the fuel filter.Refitting
Refitting
7.7. Refit the fuel feed hose.
8. Refit the fuel pump relay, reconnect the
battery.9. Crank the engine (engine will fire within
approximately 6 to 8 seconds).
FUEL PRESSURE REGULATORRemove and refit
Removing
1.
2.
3.
4.
5.
6.
Depressurize the fuel system.
Disconnect the negative battery terminal.Release the hose clamp securing the fuel
return hose to the regulator and remove the
hose.Pull the vacuum hose from the rear of the
regulator.Remove the two nuts and bolts securing the
regulator to the fuel rail, carefully ease the
regulator fuel inlet pipe out of the fuel rail.Withdraw the regulator from the engine
compartment.is being
fuel inlet
8.
9.Lightly coat the 
‘0’ ring with silicon grease
300 before fitting the regulator to the fuel rail.
Reverse the removal procedure.
Reconnect the batter), and pressurize the fuelsystem and check that there are 
xo fuel leaks
around the regulator connections.
34REVISED: SEPT. 90 
						

							;;^d;‘;; 1987-88
FUEL INJECTION SYSTEM
,’,’ .’FUEL RAIL-INJECTORS R/H AND UHRemove and refit
Removing
1.
2.
3.
4.
5.
. .‘.‘...‘,. ..,‘,.,., ., ,‘..._ .’ ..,6.‘..: ‘:
7.
8.Depressurize the fuel system.
Disconnect the negative battery terminal.
Remove the plenum chamber. (See Plenum
Chamber, remove and refit).
Remove the ram housing. 
(See Ram Housing
remove and refit).
NOTE: Place a cloth over the ram tube
openings to prevent ingress of dirt into the
engine.Release the hose clamp and remove the fuel
return hose from the pressure regulator.
Disconnect the multi-plug from the fuel
temperature thermistor (sensor).
Disconnect the multi-plugs from the eight
injectors.
Remove the five bolts securing the fuel rail
support and heater pipe brackets to the intake
manifold. Lay the heater pipes to one side.11. If necessary, remove the two nuts and bolts
securing the regulator to the fuel rail, and
carefully pull the regulator away from the rail.
Refitting
12. Fit NEW 
‘0’ rings, protective cap and
supporting disc to the injectors, lightly coat
the 
‘0’ rings with silicon grease 300 and insert
the injectors into the fuel rail, multi-plug
connections facing outwards.
13. Refit the retaining clips.
CAUTION: Care must be taken when refitting the
fuel rail and injectors to the intake manifold to
prevent damage occurring to the ‘0’ rings.
14.
15.
16.
17.Fit a NEW 
‘0’ ring to the pressure regulator
lightly coat the 
‘0’ ring with silicon grease 300
and secure the regulator to the fuel rail.
Fit the fuel rail and heater pipe assemblies to
the intake manifold, secure the rail and pipes
in position with the five bolts.
Reverse the remaining removal instructions.
Pressurize the fuel system and check for fuel
leaks around the injectors and pressure
regulator.
9. Remove the fuel rail, complete with injectors,
from the intake manifold.
10. Removethe retaining clips securing the
injectors to the fuel rail, ease the injectors
from the rail.
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