Range Rover Classic. Manual — part 36
Tdi
5
DESCRIPTION AND OPERATION
Exhaust Gas Recirculation (EGR)
Operation of the EGR system is dependent on the
following:
a. Engine temperature - must be between 20
°
C
and 100
°
C approx.
b. Engine speed - must be between 630 and 2850
rev/min.
c. Engine load - calculated by throttle
potentiometer position.
d. EGR valve lift position.
e. Duration of engine idling.
Under varying engine speed and load conditions the
control unit sends a signal to open the vacuum
modulator which allows a vacuum to be applied above
the EGR valve diaphragm, the vacuum supply being
taken from a ’T’ connector in the brake servo hose.
This process is controlled by an engine speed/load
map stored in the EGR control unit memory.
Engine speed is measured by monitoring the
waveform present on one phase of the generator.
Throttle position is measured via a potentiometer
mounted on the fuel injection pump throttle lever.
Closed loop control is achieved by allowing the control
unit to continually monitor EGR valve lift via a
potentiometer mounted on the valve; this valve lift is
compared with the actual valve lift required on the
control unit map and adjusted if necessary.
With coolant temperature between 20
°
C and 100
°
C;
the engine having just returned to idle, EGR will shut
off after 25-30 seconds idling.
Tdi
1
ADJUSTMENT
THROTTLE CABLE
Adjust
1. Loosen throttle cable adjustment ferrule.
2. Hold throttle lever in fully closed position.
3. Adjust outer cable, by rotating ferrule, to give
1.57 mm (0.062 in) of free play in the inner
cable.
4. Check that throttle opens fully when the throttle
is depressed.
EGR THROTTLE POSITION SENSOR
Check
1. Run engine until normal operating temperature is
reached.
2. Switch off engine and disconnect throttle position
sensor multiplug.
3. Connect an Ohmmeter across pins 1 and 3 of
multiplug. Ohmmeter should read between 1K
and 1.05K ohms.
4. Connect an Ohmmeter across pins 1 and 2 of
multiplug. Ohmmeter should read between 850
and 900 ohms.
5. If the readings are correct, EGR position sensor
is OK - reconnect multiplug.
6. Loosen 2 Torx screws securing position sensor.
7. Rotate position sensor to achieve correct
Ohmmeter readings, then tighten Torx screws.
8. Re-check Ohmmeter readings, then reconnect
multiplug.
19
FUEL SYSTEM
2
ADJUSTMENT
LOW AND HIGH IDLE SPEED
Adjust
The high idle speed (cold start idle) is
automatically set by the setting of the low idle
speed and can not be adjusted individually.
1. Check and adjust throttle cable.
2. Start engine and run it until normal operating
temperature is reached.
3. Using a suitable tachometer, check the engine
idle speed.
See ENGINE TUNING DATA,
Information, Engine - 300Tdi
4. If adjustment is necessary, loosen the locknut on
the injector pump.
5. Turn the adjustment screw either clockwise to
increase the engine speed or anti-clockwise to
decrease the speed. Run the engine at an
increased speed for a few seconds then check
the idle speed again.
6. When the correct speed has been achieved,
hold the adjuster screw steady while tightening
the locknut.
NOTE: The low idle speed control is the
only permitted adjustment in service. Any
additional adjustments required must be
entrusted to authorised Bosch agents.
CHECK TURBOCHARGER BOOST PRESSURE
For boost pressure.
See ENGINE TUNING DATA,
Information, Turbocharger
1. Disconnect, from turbocharger, hose to actuator.
Insert into a suitable "T" piece.
2. Connect a short length of suitable hose to
turbocharger and connect other end to "T" piece.
3. Connect a further length of hose to third leg of
the "T" piece and other end to a pressure gauge
capable of reading in excess of 61 cm Hg. The
pressure gauge hose must be capable of
reaching passenger compartment so that gauge
may be observed.
4. To check maximum boost pressure, drive
vehicle normally but in such a manner that full
throttle can be maintained whilst climbing a hill
with engine speed held steady between 2,500
and 3,000 rev/min.
Tdi
1
REPAIR
TANK SENDER UNIT
Service repair no - 88.25.32
WARNING: Ensure that the WARNINGS
and FUEL HANDLING PRECAUTIONS
given in Section 01 are adhered to before
carrying out the following operations.
Special tool - LST131
Remove
1. Disconnect battery negative lead.
2. Remove the rear carpet retainer.
3. Ease the carpet from under the lower trim panels
at the rear of the fold down seats.
4. Raise the carpet to expose the sound insulation.
5. Fold back the sound insulation to reveal the
access panel.
6. Remove the securing screws and detach the
access panel from the floor.
7. Disconnect the multi-plug from sender unit.
8. Disconnect the fuel pipes from the sender unit.
9. Using special tool LST131 remove the locking
ring and withdraw the sender unit from the fuel
tank.
Refit
10. Fit the sender unit to the fuel tank and secure
with the locking ring. Tighten to
45 to 50 Nm.
11. Connect the fuel pipes to the sender unit.
12. Connect multi-plug to sender unit.
13. Inspect the access panel seal to ensure that it is
satisfactory for further use, renew as necessary.
14. Fit the access panel to the aperture in the floor
and secure with the screws.
15. Reverse removal procedure. 1 to 5. Refit the
sound insulation and carpet.
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