LAND ROVER FRELANDER 2 2006 Repair Manual

ItemPart NumberDescription
1-Inject or leak-off port connect ion
2-Connector l ocking cl ip3-Connector release cl ip
4-Non-ret urn val ve
The inject or leak-off pi pe forms a s i ngl e component , and is provi ded as a complete ass embly. The i nject or connect orcompris es 2 movi ng part s . Thi s 2-pi ece t ype of connect ion must be correctl y removed from the injector ot herwis e t heconnector wi ll be damaged.
To remove the i njector leak-off connect or, t he cent er locking cli p mus t fi rs t be pull ed upward and t hen removed us ing t he 2lugs on t he connector release cl ip. To i nst all t he leak-off connect or, t he connector mus t be pushed on to the i njectorleak-off port us ing t he 2 l ugs on the connect or releas e cli p, and t hen locked by pushi ng down on t he cent er l ocki ng cl ip. Apronounced 'cl ick' wi ll be heard when removing or i nst all ing t he cent er locki ng clip.
A 10 bar (145 psi ) non-ret urn val ve is i nst all ed in t he fuel i njector leak-off pipe junct ion, and ret ai ns pres s ure wi thi n theinject or. The 10 bar (145 ps i ) pres sure is neces sary to maint ain fuel i n t he hydraulic chamber, and for correct operat ion oft he inject or.

Publi s hed: 11-May-2011
Fuel Charging and Controls - TD4 2.2L Diesel - Fuel Charging and Controls
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the fuel chargi ng and cont rol s, refer t o the relevant Descri pti on and Operat ion s ect ion in t heworks hop manual .REFER to: Fuel Chargi ng and Controls (303-04B Fuel Chargi ng and Cont rol s - TD4 2.2L Dies el , Descripti on and Operat ion) /Turbocharger (303-04C Fuel Chargi ng and Cont rol s - Turbocharger - TD4 2.2L Di es el, Des cri pt ion and Operati on).
Inspection and Verification
CAUTION: Di agnos is by s ubs ti tut ion from a donor vehicle is NO T acceptabl e. Subs ti tut ion of cont rol modules doesnot guarant ee confirmat ion of a faul t, and may als o caus e addit ional fault s i n t he vehi cl e being t est ed and/or t he donorvehi cl e.
1. Verify t he cus t omer concern.1.
2. Vis ually ins pect for obvious s igns of mechani cal or electrical damage.2.
Visual Inspection
MechanicalElectrical
Fuel l evelFuel l eaksDamaged fuel l inesDamaged push connect fit t ingsFuel contami nati on/grade/quali tyThrot tl e body
Fus esLoos e or corroded electrical connect orsHarnes s esSens or(s)Engine Cont rol Modul e (ECM)
3. If an obvious cause for an obs erved or report ed concern is found, correct t he caus e (if pos s ible) beforeproceeding t o t he next s t ep3.
4. If t he caus e is not vis ually evi dent , verify t he sympt om and refer t o t he Sympt om Chart, al ternat ively, check forDi agnos ti c Trouble Codes (DTCs) and refer t o t he DTC Index.4.
Symptom Chart
SymptomPossible CauseAction
Engine cranks butdoes not st artFuel l evelContami nat ed fuelFuel s ys temleaking/bl ockedAir i ntake s yst emElectronic enginecont rol s
Check fuel level and for cont aminat ion. Check fuel and air i ntakes yst em integrit y. Check for DTCs and refer to the relevant DTC Index
Di fficul t t o s tartFuel l evelContami nat ed fuelFuel s ys temleaking/bl ockedAir i ntake s yst emElectronic enginecont rol s
Check fuel level and for cont aminat ion. Check fuel and air i ntakes yst em integrit y. Check for DTCs and refer to the relevant DTC Index
Rough idl eLow/contami nat ed fuelFuel s ys temleaking/bl ockedElectronic enginecont rol s
Check fuel level/condit ion. Check i ntegri ty of fuel and engine cont rols yst ems . Check for DTCs and refer t o relevant DTC Index.
Lack of power underaccel erati onContami nat ed fuelAir i ntake s yst emBlockedexhaus t/catalyt icconvert erTurbocharger faultFuel s ys temElectronic enginecont rol sLow enginecompres si ons
Check for fuel cont ami nat ion. Check for DTCs and refer t o relevantDTC Index. Check int egrit y of air i nt ake, exhaus t , turbocharger, andengine control s ys tems
Engine s t ops /st all sLow/contami nat ed fuelFuel s ys temAir i ntake s yst emElectronic enginecont rol s
Check for fuel cont ami nat ion. Check for DTCs and refer t o t he rel evantDTC Index. Check int egrit y of fuel, ai r int ake, and engi ne s yst ems

DTC Index
• NOTE: If the control modul e/component i s s us pect and the vehicle remains under manufacturer warranty, refer to theW arranty Pol icy and Procedures manual (s ect ion B1.2), or determine i f any pri or approval programme is in operat ion, pri ort o the ins tall ati on of a new module/component.
• NOTE: Generic scan t ool s may not read the codes li st ed, or may read only fi ve digit codes . Mat ch the five di git s from t hes can tool to the firs t fi ve di git s of the seven digi t code l is ted to ident ify t he faul t (t he las t t wo digi ts gi ve ext rainformat ion read by the manufact urer-approved diagnost ic s ys tem).
• NOTE: W hen performing volt age or res is t ance t est s , always use a digi tal mult imeter (DMM) accurat e t o t hree deci malplaces and wit h a current cal ibrat ion cert ificate. W hen tes ti ng res i st ance, always take the res is tance of the DMM l eads i ntoaccount.
• NOTE: Check and recti fy bas ic faul ts before beginni ng diagnos t ic rout ines t hat invol ve pinpoint t es t s .
• NOTE: If DTCs are recorded and, aft er performi ng the pi npoi nt tes ts , a fault is not present , an int ermi tt ent concern maybe t he caus e. Always check for loose connect ions and corroded terminals .
DT CDescriptionPossible CauseActionP004513Turbo charger/SuperchargerBoos t Cont rol A Circuit /Open
Turbo charger actuat orpower s tage out put 2ci rcuit - open load
Carry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P004518Turbo charger/SuperchargerBoos t Cont rol A Circuit /Open
Power s tage t emperat uredependant currentlimit at ion
Carry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P004519Turbo charger/SuperchargerBoos t Cont rol A Circuit /Open
Turbo charger actuat orpower s tage out put 1ci rcuit - over current
Carry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P004619Turbo charger/SuperchargerBoos t Cont rol A CircuitRange/Performance
Power s tage excesstemperat ureCarry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P004711Turbo charger/SuperchargerBoos t Cont rol A Circuit LowTurbo charger actuat orpower s tage out put 1ci rcuit - s hort t o ground
Carry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P004714Turbo charger/SuperchargerBoos t Cont rol A Circuit LowTurbo charger actuat orpower s tage out put 2ci rcuit - s hort t o ground
Carry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P004718Turbo charger/SuperchargerBoos t Cont rol A Circuit LowPower s tage currentlimit at ionCarry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P004800Turbo charger/SuperchargerBoos t Cont rol A Circuit Hi ghAct uat or power s t ageerrorCarry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t emP004812Turbo charger/SuperchargerBoos t Cont rol A Circuit Hi ghTurbo charger actuat orpower s tage out put 1ci rcuit - s hort t o power
Carry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P004815Turbo charger/SuperchargerBoos t Cont rol A Circuit Hi ghTurbo charger actuat orpower s tage out put 2ci rcuit - s hort t o power
Carry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P008821Fuel Rai l/Sys t em Press ure -Too Hi ghPress ure cont rol valveci rcuit - s hort t o powerPress ure cont rol valvest uck cl osed
Check for pres sure cont rol valve DTCs and refer torel evant DTC Index
P008822Fuel Rai l/Sys t em Press ure -Too Hi ghLeaking fuel s ys temVol ume cont rol valveci rcuit - s hort t o ground,open circui tVol ume cont rol valvest uck open
Check for fuel leaks. Refer t o el ect ri cal circuitdiagrams and check vol ume control valve ci rcuit fors hort to ground, open circui t. Inst all a new highpres sure fuel pump as required
P008824Fuel Rai l/Sys t em Press ure -Too Hi ghLeaking fuel s ys temPress ure cont rol valvest uckPress ure cont rol valveci rcuit - s hort t o ground,power, open ci rcuit
Check for fuel leaks. Refer t o el ect ri cal circuitdiagrams and check pres sure cont rol valve circui tfor s hort t o ground, power, open ci rcuit . Ins tal l anew pres s ure control val ve as required
P008827Fuel Rai l/Sys t em Press ure -Too Hi ghLeak i n high press uresecti onInject or nozzle s t uckopen/wornW orn hi gh pres s urepump, fil ter blockedLeaking pres s ure cont rolval ve
Check for fuel leaks in hi gh and low pres sures ys t ems, check for addit ional DTCs and refer t oDTC Index

DT CDescriptionPossible CauseAction
Low pres sure s ect ionpress ure low (l eak insys tem, pump out putlow)
P009B00Fuel Pres sure Reli ef Cont rolCi rcuit /OpenPress ure cont rol valvecontrol ci rcuit - open l oadCarry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t emP009C00Fuel Pres sure Reli ef Cont rolCi rcuit LowPress ure cont rol valvecontrol ci rcuit - s hort t oground
Carry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P009D00Fuel Pres sure Reli ef Cont rolCi rcuit Hi ghPress ure cont rol valvecontrol ci rcuit - s hort t opower
Carry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P009E00Fuel Pres sure Reli ef Cont rolPerformance/St uck OffPress ure cont rol valvepower s tage excesstemperat ure
Refer to electrical ci rcuit diagrams and checkpres sure cont rol valve circui t for hi gh res is t ance, ifno faul t identi fied ins tall new ECM. Refer to t henew module/component ins tall ati on note at t hetop of t he DTC Index
P00AF75Turbo charger/SuperchargerBoos t Cont rol A Modul ePerformance
Variable Gat e Turbocharger s ens or circui t -short to ground, power,open circui tVariable Gat e Turbocharger s ens or fai lure
Refer to electrical ci rcuit diagrams and checkvariable gat e Turbo charger s ensor circui t for s hortto ground, power, open circui t. Ins tall a new Turbocharger as requi red
P018200Fuel Temperature Sens or ACi rcuit LowFuel temperature s ens orvol tage below lower li mitCarry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P018300Fuel Temperature Sens or ACi rcuit Hi ghFuel temperature s ens orvol tage above upper li mi tCarry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P023422Turbo charger/SuperchargerA Over boos t Condi ti onBoos t pres s ure controldeviat ion below lowerlimit at ful l load
Check for turbo charger related DTCs and refer t othe relevant DTC Index
P023700Turbo charger/SuperchargerBoos t Sens or A Ci rcuit LowBoos t pres s ure s ensorci rcuit - s hort t o ground,open circui t
Carry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P023800Turbo charger/SuperchargerBoos t Sens or A Ci rcuit Hi ghBoos t pres s ure s ensorci rcuit - s hort t o powerCarry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t emP025100Injecti on Pump Fuel Met eri ngCont rol AFuel met ering uni t cont rolci rcuit - open loadCarry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P02CC21Cyli nder 1 Fuel Inject orOffs et Learning at Mi n LimitInject or energi si ng t imecali brat ion duri ng overrun- ti me below lower li mit
Ins t al l a new i njector
P02CD22Cyli nder 1 Fuel Inject orOffs et Learning at Max Li mitInject or energi si ng t imecali brat ion duri ng overrun- ti me above upper l imi t
Ins t al l a new i njector
P02CE21Cyli nder 2 Fuel Inject orOffs et Learning at Mi n LimitInject or energi si ng t imecali brat ion duri ng overrun- ti me below lower li mit
Ins t al l a new i njector
P02CF22Cyli nder 2 Fuel Inject orOffs et Learning at Max Li mitInject or energi si ng t imecali brat ion duri ng overrun- ti me above upper l imi t
Ins t al l a new i njector
P02D021Cyli nder 3 Fuel Inject orOffs et Learning at Mi n LimitInject or energi si ng t imecali brat ion duri ng overrun- ti me below lower li mit
Ins t al l a new i njector
P02D122Cyli nder 3 Fuel Inject orOffs et Learning at Max Li mitInject or energi si ng t imecali brat ion duri ng overrun- ti me above upper l imi t
Ins t al l a new i njector
P02D221Cyli nder 4 Fuel Inject orOffs et Learning at Mi n LimitInject or energi si ng t imecali brat ion duri ng overrun- ti me below lower li mit
Ins t al l a new i njector
P02D322Cyli nder 4 Fuel Inject orOffs et Learning at Max Li mitInject or energi si ng t imecali brat ion duri ng overrun- ti me above upper l imi t
Ins t al l a new i njector
P02E013Di esel Intake Air Fl owCont rol Circui t/OpenThrott le motor cont rolci rcuit - open circui tRefer to electrical ci rcuit diagrams and checkthrott le control ci rcuit for open circui t

DT CDescriptionPossible CauseAction
P02E100Di esel Intake Air Fl owCont rol PerformanceThrott le valve st uckduring after run learni ngrouti neError i n dri ver IC (CJ230power s tage) for Throt t leVal ve Act uator
Clear the DTC and re-tes t. If t he DTC remai ns,ins tal l a new ECM. Refer t o t he newmodule/component i nst all at ion not e at t he top ofthe DTC Index
P02E119Di esel Intake Air Fl owCont rol PerformanceThrott le motor cont rolci rcuit - s hort circui toverl oad error
Refer to electrical ci rcuit diagrams and checkthrott le control ci rcuit for short ci rcuit faul t
P02E14BDi esel Intake Air Fl owCont rol PerformanceExcess Temperature inCJ230 power st age forThrott le Val ve Act uator
Clear the DTC and re-tes t. If t he DTC remai ns,ins tal l a new ECM. Refer t o t he newmodule/component i nst all at ion not e at t he top ofthe DTC Index
P02E211Di esel Intake Air Fl owCont rol Circui t LowThrott le motor cont rolci rcuit - s hort t o groundRefer to electrical ci rcuit diagrams and checkthrott le control ci rcuit for short to ground
P02E214Di esel Intake Air Fl owCont rol Circui t LowThrott le motor cont rolci rcuit - s hort t o groundRefer to electrical ci rcuit diagrams and checkthrott le control ci rcuit for short to ground
P02E312Di esel Intake Air Fl owCont rol Circui t HighThrott le motor cont rolci rcuit - s hort t o powerRefer to electrical ci rcuit diagrams and checkthrott le control ci rcuit for short to power
P02E315Di esel Intake Air Fl owCont rol Circui t HighThrott le motor cont rolci rcuit - s hort t o powerRefer to electrical ci rcuit diagrams and checkthrott le control ci rcuit for short to power
P02E471Di esel Intake Air Fl owCont rol Stuck OpenThrott le valve st uckduring normal enginerunning - at tempt t ouns t ick val veuns ucces sful
Check/clear t hrott le val ve from obs truct ion/st icking
P02E571Di esel Intake Air Fl owCont rol Stuck Clos edThrott le valve st uckcl os ed during normalengine running - at temptto uns ti ck val veuns ucces sful
Check/clear t hrott le val ve from obs truct ion/st icking
P02E728Di esel Intake Air Fl owPos it ion Sens orRange/Performance
Thrott le valve open orcl os ed pos it ion offs etdi fference wit h firstlearning too l argeThrott le valve open orcl os ed pos it ion offs etdi fference wit h previ ouslearning too l arge
Check/clear t hrott le val ve fromobs t ructi on/s ti cki ng, clear DTC and re-t est . If theDTC remai ns, i nst all a new thrott le body
P02E800Di esel Intake Air Fl owPos it ion Sens or Ci rcuit LowThrott le pos it ion s ens orci rcuit - s hort t o ground,open circui t
Refer to electrical ci rcuit diagrams and checkthrott le pos it ion s ens or ci rcuit for s hort t o ground,open ci rcuit
P02E872Di esel Intake Air Fl owPos it ion Sens or Ci rcuit LowThrott le valve pos it iondeviat ion - valve st uckopen
Check/clear t hrott le val ve from obs truct ion/st icking
P02E900Di esel Intake Air Fl owPos it ion Sens or Ci rcuit Hi ghThrott le pos it ion s ens orci rcuit - s hort t o powerRefer to electrical ci rcuit diagrams and checkthrott le pos it ion s ens or ci rcuit for s hort t o power
P02E973Di esel Intake Air Fl owPos it ion Sens or Ci rcuit Hi ghThrott le valve pos it iondeviat ion - valve st uckcl os ed
Check/clear t hrott le val ve from obs truct ion/st icking
P031300Mi s fi re Det ect ed W i th LowFuelLow fuel - mi sfire inducedby ECM t o warn driverbefore s hut off
Carry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P062B00Internal Control Modul e FuelInjector Control PerformanceOverrun Moni tor - inject orenergi s ing t imes t oo l ongduring overrunRedundant s hut off patherror
Ins t al l a new ECM, refer to the newmodule/component i nst all at ion not e at t he top ofthe DTC Index.REFER to: Powert rain Cont rol Module (PCM)(303-14 El ect roni c Engi ne Cont rol s - 2.2L Di esel ,Removal and Inst all at ion).
P062B16Internal Control Modul e FuelInjector Control PerformanceRedundant s hut off pathvol tage t oo lowIns t al l a new ECM, refer to the newmodule/component i nst all at ion not e at t he top ofthe DTC Index.REFER to: Powert rain Cont rol Module (PCM)(303-14 El ect roni c Engi ne Cont rol s - 2.2L Di esel ,Removal and Inst all at ion).
P062B17Internal Control Modul e FuelInjector Control PerformanceRedundant s hut off pathvol tage t oo highIns t al l a new ECM, refer to the newmodule/component i nst all at ion not e at t he top ofthe DTC Index.REFER to: Powert rain Cont rol Module (PCM)

DT CDescriptionPossible CauseAction
(303-14 El ect roni c Engi ne Cont rol s - 2.2L Di esel ,Removal and Inst all at ion).P129800Injector Driver Modul eFail ureECM int ernal fail ureIns t al l a new module, refer t o the newmodule/component i nst all at ion not e at t he top ofthe DTC Index
P228800Injector Control Pres sure TooHi ghLeaking fuel s ys temFuel high pres s ure pumpci rcuit - s hort t o ground,open circui tFuel high pres s ure pumpfail ure
Check for fuel leaks. Refer t o t he electrical ci rcuitdiagrams and check fuel high pres s ure pump circuitfor s hort t o ground, open ci rcuit . Ins tal l a new highpres sure pump as requi red
P256263Turbo charger Boos t Cont rolPos it ion Sens or A Circui tPos it ion Error above s tallti mer limit for ti merdurati on
Carry out ODST and ins tal l new turbo if failcondit ion ident ified
P256271Turbo charger Boos t Cont rolPos it ion Sens or A Circui tTurbo charger Act uat orPos it ion sens or det ect sact uat or st uck duringafter run learni ng
Carry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P256275Turbo charger Boos t Cont rolPos it ion Sens or A Circui tTurbo charger actuat orst uck - motor s wit chedoff
Check Turbo charger vane act uator mechani sm i sfree from obs t ructi on and carbon bui ld-up
P256277Turbo charger Boos t Cont rolPos it ion Sens or A Circui tTurbo charger Act uat orPos it ion sens or det ect sact uat or st uck duringafter run learni ng
Carry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em
P256371Turbo charger Boos t Cont rolPos it ion Sens or A Circui tTurbo charger actuat or isst ickingCheck Turbo charger vane act uator mechani sm i sfree from obs t ructi on and carbon bui ld-up
P256372Turbo charger Boos t Cont rolPos it ion Sens or A Circui tRange/Performance
Turbo charger vaneact uat or st uck open -unable to reach requiredpos it ion
Check Turbo charger vane act uator mechani sm i sfree from obs t ructi on and carbon bui ld-up
P256373Turbo charger Boos t Cont rolPos it ion Sens or A Circui tRange/Performance
Turbo charger vaneact uat or st uck cl osed -unable to reach requiredpos it ion
Check Turbo charger vane act uator mechani sm i sfree from obs t ructi on and carbon bui ld-up
P256436Turbo charger Boos t Cont rolPos it ion Sens or A Circui t LowTurbo charger boos tcontrol pos i ti on sens or Aci rcuit - s hort t o ground,power, open ci rcuitTurbo charger boos tcontrol pos i ti on sens orfail ure
Carry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em . Inst all a new sens or as required.REFER to: Turbocharger (303-04C Fuel Chargi ngand Cont rol s - Turbocharger - TD4 2.2L Dies el,Removal and Inst all at ion).
P256437Turbo charger Boos t Cont rolPos it ion Sens or A Circui t LowTurbo charger boos tcontrol pos i ti on sens or Aci rcuit - s hort t o ground,power, open ci rcuitTurbo charger boos tcontrol pos i ti on sens orfail ure
Carry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em . Inst all a new sens or as required.REFER to: Turbocharger (303-04C Fuel Chargi ngand Cont rol s - Turbocharger - TD4 2.2L Dies el,Removal and Inst all at ion).
P256537Turbo charger Boos t Cont rolPos it ion Sens or A Circui tHi gh
Turbo charger boos tcontrol pos i ti on sens or Aci rcuit - s hort t o ground,power, open ci rcuitTurbo charger boos tcontrol pos i ti on sens orfail ure
Carry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em . Inst all a new sens or as required.REFER to: Turbocharger (303-04C Fuel Chargi ngand Cont rol s - Turbocharger - TD4 2.2L Dies el,Removal and Inst all at ion).
P256538Turbo charger Boos t Cont rolPos it ion Sens or A Circui tHi gh
Turbo charger boos tcontrol pos i ti on sens or Aci rcuit - s hort t o ground,power, open ci rcuitTurbo charger boos tcontrol pos i ti on sens orfail ure
Carry out the pi npoint t es ts as s oci at ed wi th thisDTC us ing t he manufacturer approved diagnos ti cs ys t em . Inst all a new sens or as required.REFER to: Turbocharger (303-04C Fuel Chargi ngand Cont rol s - Turbocharger - TD4 2.2L Dies el,Removal and Inst all at ion).

Publi s hed: 11-May-2011
Fuel Charging and Controls - TD4 2.2L Diesel - Fuel Injector
Removal and Inst all ati on
Removal
• W ARNINGS:
Avoid flames , s parks or li ght ed s ubs t ances .
W ai t for a mini mum of 1 minute aft er the engine has s t opped before carryi ng out any repair t o t he fuel inject ions ys t em.
• CAUTIO NS:
Make s ure that t he area around t he component i s cl ean and free of foreign mat eri al .
Make s ure that all openi ngs are s ealed. Us e new bl anking caps .
Fuel injectors mus t not be dis mantl ed or the nozzles cleaned, not even wit h ul tras onic equipment . Ins tal l new fuelinject ors i f neces sary.
Fuel injectors mus t be ins t al led t o t heir ori ginal pos it ion.
Cap t he fuel i nject or nozzle to prevent damage before s toring vert icall y.
Fuel injectors mus t be s tored vert ical ly and immedi at ely capped when removed, to prevent t he fuel from draini ng.
If a new component has been i ns t alled, configure usi ng Land Rover approved diagnos tic equipment .
Bl eed the fuel s ys tem by cranki ng t he engi ne to purge t he air from the s ys tem.
• NOTE: If the fuel i njectors are to be removed or replaced as a s et , ins tall ati on shoul d be done in pai rs . Inject ors 2 and3, 1 and 4 res pecti vel y.
Di sconnect t he bat t ery ground cable.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
1.
Remove t he engi ne cover.
Refer t o: Engi ne Cover - TD4 2.2L Dies el (501-05 Interior Tri m andOrnament ati on, Removal and Ins tal lat ion).
2.
3.

4. CAUTIONS:
Make s ure that t he fuel li ne remai ns in cont act atboth ends unt il both uni ons nut s have been uns crewedand t he area around the joints thoroughly cl eaned.
Make s ure that all openings are sealed. Us e newblanking caps.
Remove and dis card t he high-pres sure fuel s uppl y li ne.
4.
5.

6. CAUTION: Not e the pos it ion of t he i nject orclamp peg6.
7. CAUTIONS:
Cap t he fuel i njector nozzl e to prevent damagebefore s toring vert icall y.
Fuel inject ors mus t be s t ored vert ically andi mmediat el y capped when removed, t o prevent the fuelfrom draini ng.
Replace t he was her.
Not e t he posi ti on of the pl ast ic al ignment s leeve.
7.
Installation
1. CAUTIONS:1.

Stage 1:
Stage 2:
Stage 1:
Stage 2: Make s ure that t he component is cl ean, free of foreign
mat eri al and l ubricant. Make s ure that a new seal ing was her i s i ns t alled.
Inst all t he fuel inject or.
T orque: 5 Nm 130°
2. CAUTION: Make s ure that the component is clean, free of
foreign mat eri al and lubri cant.
Inst all a new hi gh-pres s ure fuel supply l ine but do not ful ly
t ighten at t his st age. Tight en the hi gh-pres s ure fuel s upply l ine.
T orque: 22 Nm 25 Nm2.
At tach t he s pi ll ret urn li ne and secure wit h t he keeper.
3.
Inst all t he engi ne cover.
Refer t o: Engi ne Cover - TD4 2.2L Dies el (501-05 Interior Tri m and
Ornament ati on, Removal and Ins tal lat ion).
4.
5. CAUTION: Bleed t he fuel s ys tem by cranki ng t he engi ne to
purge t he air from t he s ys t em.
Bleed t he fuel s ys tem.
5.
If a new component has been ins t al led, configure usi ng Land Rover
approved diagnos t ic equipment .
6.