Range Rover Classic. Manual — part 39
19
FUEL SYSTEM
10
REPAIR
EGR THROTTLE POSITION SENSOR
Service repair no - 19.30.14
Remove
1. Remove 2 screws securing throttle position
sensor mounting plate to injection pump.
2. Disconnect throttle position sensor multiplug
from harness.
3. Remove throttle position sensor assembly.
Refit
4. Locate throttle position sensor assembly on
injection pump and fit and tighten screws.
5. Connect multiplug.
6. Adjust throttle position sensor.
See
Adjustment, EGR Throttle Position sensor
INJECTORS
Service repair no - 19.60.10
Remove
1. Remove oil filler cap and remove sound
deadening pad from top of engine.
2. Remove high pressure pipe from relevant
injector and injection pump.
3. Disconnect spill return hose(s) from injector.
4. Plug pipes and injector connections to prevent
the ingress of dirt and foreign matter.
5. Remove nut securing injector clamp plate to
cylinder head.
6. Remove injector.
Refit
7. Reverse removal procedure. Renew copper
washer on injector. Tighten injector clamp plate
nut to
25 Nm.
Tdi
11
REPAIR
FUEL INJECTION PUMP AND TIMING
Service repair no - 19.30.07
NOTE: The following text refers to a Tdi
vehicle with a manual gearbox without
electronic diesel control. Where reference
is made to the timing tool substitute the following
information for automatic and EDC variants.
If manual gearbox: Timing tool LRT-12-044 fits into
the base of the flywheel housing
If manual gearbox with EDC: Timing tool
LRT-12-085 must be used and also fits into the base
of the flywheel housing.
If automatic gearbox: Timing tool LRT-12-044 fits
into the larger bolt hole of coverplate on engine
backplate, sited near to the rear of sump. Pin locates
in ring gear.
Remove
1. Disconnect battery negative lead.
2. Remove injection pipes, pump to injector.
3. Remove oil filler cap from rocker cover.
4. Viewing valve mechanism through filler aperture,
turn crankshaft clockwise until No. 1 cylinder is
just before TDC.
5. Refit oil filler cap.
6. Remove blanking plug from flywheel housing.
7. Fit timing tool LRT-12-044 to flywheel housing,
do not engage centre pin.
8. Continue rotating crankshaft clockwise until
centre pin engages with timing slot in flywheel.
9. Remove injection pump access plate, complete
with gasket, from front cover plate.
10. Fit pin from LRT-12-045 to injection pump gear.
19
FUEL SYSTEM
12
REPAIR
11. Remove drive gear to pump hub fixing bolts and
plate.
12. Remove pin from pump gear.
13. Fit gear retaining tool LRT-12-045 with an 8 mm
washer, 1.5 to 2 mm thick, under each bolt head
in addition to the existing washer.
14. Remove throttle cable and hand throttle cable if
fitted.
15. Disconnect stop control solenoid connector.
16. Remove banjo bolts securing spill return, main
fuel and boost signal pipes, refit banjo bolts after
disconnecting pipes.
17. Remove pump mounting bracket bolts 2 off.
18. Loosen pump support bracket bolts to block,
sufficient for bracket to just move.
19. Remove pump securing nuts at flange and
withdraw pump and gasket.
20. Fit blanks to pipe connections.
Tdi
13
REPAIR
Refit
21. Remove blanks from pump.
22. Remove special tool pin from pump.
23. Clean mating faces of pump and front cover.
24. Fit pump to cover with a new gasket and secure
with nuts. Tighten to
25 Nm.
25. Attach pump to bracket and finger tighten nuts
and bolts
26. First tighten bolts securing bracket to block and
then bolts securing pump to bracket.
27. Connect spill return, main fuel pipes. Tighten to
25 Nm.
28. Connect boost signal pipe and secure with banjo
bolts. Tighten to
10 Nm.
29. Connect stop control solenoid lead.
30. Connect throttle cable and where applicable
hand throttle cable.
31. Remove special tool LRT-12-045.
32. Fit gear lock plate.
33. Fit pin from special tool LRT-12-045.
34. Secure gear with bolts.
35. Remove special tool pin.
36. Turn crankshaft two complete revolutions, check
timing pin from LRT-12-045 can be fully and
easily inserted into the pump. At the same time
check flywheel timing pin LST-12-044 can also
be inserted in the flywheel slot.
37. If, with the flywheel timing pin located, the timing
pin cannot be inserted cleanly into the injection
pump, carry out the following:
(a)
Ensure flywheel timing pin is disengaged
from slot in flywheel.
(b)
Turn the crankshaft the small amount
necessary to enable the timing pin to be
inserted into the pump.
(c)
Loosen the three pump gear retaining
bolts.
(d)
Turn the crankshaft to T.D.C..
(e)
Check that the timing pin is an easy fit in
the pump and that the flywheel timing pin
locates.
(f)
Tighten the pump gear retaining bolts to
the correct torque.
(g)
Remove the timing pin from the pump and
the timing tool from the flywheel housing.
38. Using antisieze compound, fit the blanking plug
to flywheel housing. Tighten to
12 Nm.
39. Fit access plate with gasket to front cover plate.
Tighten to
25 Nm.
40. Refit injector pipes. Tighten to
29 Nm.
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