LAND ROVER FRELANDER 2 2006 Repair Manual

Publi s hed: 11-May-2011
Fuel Tank and Lines - TD4 2.2L Diesel - Fuel Tank and Lines
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the fuel tank and l ines s ys t ems , refer t o t he rel evant Des cript ion and Operat ion s ecti on in the
works hop manual .
REFER to: Fuel Tank and Lines (310-01B Fuel Tank and Lines - TD4 2.2L Dies el, Des cript ion and Operat ion).
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 does
not guarant ee confirmat ion of a faul t, and may als o caus e addit ional fault s i n t he v ehi cl e being t est ed and/or t he donor
vehi 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 Mechanical Electrical
Fuel l eaks Damaged fuel l ines
Damaged push connect fit t ings
Fuel l evel
Fuel contami nati on/grade/quali ty
Damaged fuel t ank fi ller pipe cap
Damaged fuel t ank fi ller pipe Fuses
Loos e or corroded elect rical connect ors
Harnes s es
Fuel Pump Dri ver Module (FPDM)
Central Junct ion Box (CJB)
Fuel pump relay
Engine Control 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) before
proceeding t o t he next s t ep.
3.
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 Ch art, al ternat ively, check for
Di agnos ti c Trouble Codes (DTCs) and refer t o t he DTC Index.
4.
Symptom Chart Symptom Possible Cause Action
Engine cranks , but
does not fi re Low/contaminated fuel Intake air l eakage
Fuel sys tem leak, blocked/res tricted
El ect ronic engine controls Check for l ow/contami nat ed fuel
Check int egrit y of i nt ake air s yst em
Check fuel s yst em for leaks and
bl ockage/res t ri ct ion. Read DTCs and refer to
relevant DTC Index For electronic engine control t es ts .
REFER t o: Electroni c Engi ne Control s (303-14,
Diagnos is and Tes t ing). Di fficul t t o s tart
Gl owpl ug faul t Low/contaminated fuel
Check engi ne cool ant l evel /anti -
freeze cont ent Bat tery
Intake air s ys tem leak
El ect ronic engine controls
Injector l eak
Fuel sys tem leak, blocked/res tricted Check int egrit y of glowpl ug sys t em
Check for l ow/contami nat ed fuel
Check t he engi ne cool ant l evel and condi ti on.
REFER t o: Specificati ons (303-03B Engine Cool ing
- TD4 2.2L Di es el, Specificat ions ). Ens ure the bat tery is i n a full y charged and
servi ceable condit ion Check int ake air s yst em for leaks
For electronic engine control t es ts .
REFER t o: Electroni c Engi ne Control s (303-14,
Diagnos is and Tes t ing). Carry out i njector leak t est s , ins tal l new inject ors
as neces sary.
REFER t o: Fuel Injector (303-04B Fuel Charging
and Cont rols - TD4 2.2L Di esel , Removal and
Ins tal lati on). Check fuel s yst em for leaks and
bl ockage/res t ri ct ion. Read DTCs and refer to
relevant DTC Index Rough idl e
Intake air s ys tem leak Low/contaminated fuel
Fuel sys tem leak, blocked/res tricted
EGR val ve fault Check int ake air s yst em for leaks
Check for l ow/contami nat ed fuel
Check fuel s yst em for leaks and
bl ockage/res t ri ct ion. Read DTCs and refer to
relevant DTC Index Check EGR s ys tem for fai lure.
REFER t o: Engi ne Emis s ion Cont rol (303-08B
Engine Emis s ion Control - TD4 2.2L Di esel ,
Diagnos is and Tes t ing).

Symptom
Possible Cause Action
Engine
hes it at es /poor
accel erati on Intake air s ys tem leak Res trict ed exhaus t sys tem
Fuel sys tem leak, blocked/res tricted
EGR val ve fault
Turbocharger act uat or fault Check int ake air s yst em for leaks
Check exhaus t s ys t em for blockage/rest ri cti on
Check fuel s yst em for leaks and
bl ockage/res t ri ct ion. Read DTCs and refer to
relevant DTC Index Check EGR s ys tem for fai lure.
REFER t o: Engi ne Emis s ion Cont rol (303-08B
Engine Emis s ion Control - TD4 2.2L Di esel ,
Diagnos is and Tes t ing). Check for t urbocharger act uat or fault . Read DTCs
and refer t o rel evant DTC Index Engine s t ops /st all s
Breat her sys tem
di sconnect ed/res trict ed Intake air s ys tem leak/rest ri cted
El ect ronic engine controls
Fuel sys tem leak, blocked/res tricted
EGR val ve fault Ens ure the engine breat her sys t em i s free from
res tricti on and is correctl y ins tal led Check int ake air s yst em for leaks/res t ri ct ion
For electronic engine control t es ts .
REFER t o: Electroni c Engi ne Control s (303-14B
El ect ronic Engi ne Cont rol s - TD4 2.2L Dies el ,
Diagnos is and Tes t ing). Check fuel s yst em for leaks and
bl ockage/res t ri ct ion. Read DTCs and refer to
relevant DTC Index Check EGR s ys tem for fai lure.
REFER t o: Engi ne Emis s ion Cont rol (303-08B
Engine Emis s ion Control - TD4 2.2L Di esel ,
Diagnos is and Tes t ing). Exces s ive fuel
cons umpt ion Fuel pres sure, fuel pump, fuel l ines
bl ocked/cont aminat ed, l eaki ng Injector l eak
El ect ronic engine controls
EGR val ve fault Check fuel l ines for l eakage, bl ockage/res t ri ct ion.
For fuel pump t es ts , check DTCs and refer to
relevant DTC Index Carry out fuel i njector leak t es ts , ins tal l new
injectors as neces s ary.
REFER t o: Fuel Injector (303-04B Fuel Charging
and Cont rols - TD4 2.2L Di esel , Removal and
Ins tal lati on). For electronic engine control t es ts .
REFER t o: Electroni c Engi ne Control s (303-14,
Diagnos is and Tes t ing). Check EGR s ys tem for fai lure.
REFER t o: Engi ne Emis s ion Cont rol (303-08B
Engine Emis s ion Control - TD4 2.2L Di esel ,
Diagnos is and Tes t ing). DTC Index
• NOTE: If a module or component i s s uspect, and t he vehi cl e remains under t he Manuf acturers warranty, refer to the
W arranty Pol icy and Procedure manual (s ecti on B1.2), or det ermi ne if any pri or appro val programme i s in operat ion, pri or to
t he ins tal lati on of a new modul e/component.
• NOTE: Generic scan t ool s may not read the codes li st ed, or may read only fi ve digi t codes . Mat ch the five di git s from t he
s 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 fa ul t (t he las t t wo digi ts gi ve ext ra
informat ion read by the manufact urer-approved diagnost ic s ys tem).
• NOTE: W hen performing el ect ri cal volt age or resi s tance tes t s, al ways us e a digit al mult imet er (DMM) accurate to three
deci mal places , and wi th an up-to-date cali brat ion cert ificate. W hen t es ti ng res is t a nce, always take t he res i st ance of t he
DMM leads int o account.
• NOTE: Check and recti fy bas ic faul ts before beginni ng diagnos t ic rout ines i nvol vi n g pinpoint t es t s.
• NOTE: If DTCs are recorded and, aft er performi ng the pi npoi nt tes ts , a fault is no t present , an int ermi tt ent concern may
be t he caus e. Always check for loose connect ions and corroded terminals .
DT C Description Possible Cause Action
P008821 Fuel Rai l/Sys t em Pres s ure -
Too Hi gh Press ure cont rol valve
ci rcuit - s hort t o power Press ure cont rol valve
s t uck cl os ed Check for pres sure cont rol valve DTCs and refer to
rel evant DTC Index
P008822 Fuel Rai l/Sys t em Pres s ure -
Too Hi gh Leaking fuel s ys tem Vol ume cont rol valve
ci rcuit - s hort t o
ground, open circuit Vol ume cont rol valve
s t uck open Check for fuel leaks. Refer t o el ect ri cal circuit di agrams
and check volume control val ve ci rcuit for short to
ground, open circui t. Ins tall a new high pres s ure fuel
pump as requi red
P008824 Fuel Rai l/Sys t em Pres s ure -
Too Hi gh Leaking fuel s ys tem Press ure cont rol valve
s t uck Press ure cont rol valve
ci rcuit - s hort t o
ground, power, open
ci rcuit Check for fuel leaks. Refer t o el ect ri cal circuit di agrams
and check pres s ure control val ve ci rcuit for short to
ground, power, open circui t. Ins tall a new pres s ure
cont rol valve as requi red

DT C
Description Possible Cause Action
P008827 Fuel Rai l/Sys t em Pres s ure -
Too Hi gh Leak i n high pres s ure
s ecti on Injector nozzl e s t uck
open/worn W orn hi gh pres s ure
pump, fil ter blocked Leaking pres s ure
control val ve Low pres sure s ect ion
press ure low (l eak in
s ys tem, pump out put
l ow) Check for fuel leaks in hi gh and low pres sure s yst ems ,
check for addit ional DTCs and refer t o DTC Index
P009B00 Fuel Pres sure Reli ef Cont rol
Ci rcuit /Open Press ure cont rol valve
control ci rcuit - open
l oad Carry out the pi npoint t es ts as s oci at ed wi th this DTC
usi ng t he manufact urer approved diagnost ic s ys tem
P009C00 Fuel Pres sure Reli ef Cont rol
Ci rcuit Low Press ure cont rol valve
control ci rcuit - s hort
t o ground Carry out the pi npoint t es ts as s oci at ed wi th this DTC
usi ng t he manufact urer approved diagnost ic s ys tem
P009D00 Fuel Pres sure Reli ef Cont rol
Ci rcuit Hi gh Press ure cont rol valve
control ci rcuit - s hort
t o power Carry out the pi npoint t es ts as s oci at ed wi th this DTC
usi ng t he manufact urer approved diagnost ic s ys tem
P009E00 Fuel Pres sure Reli ef Cont rol
Performance/St uck O ff Press ure cont rol valve
power s tage exces s
t emperat ure Refer to electrical ci rcuit diagrams and check pres s ure
cont rol valve circui t for high resi s tance, i f no faul t
identi fi ed ins tal l new ECM. Refer to the new
module/component i nst all at ion not e at t he top of t he
DTC Index
P031300 Mi s fire Det ect ed W i th Low
Fuel Low fuel - mis fire
i nduced by ECM to
warn driver before
s hut off Carry out the pi npoint t es ts as s oci at ed wi th this DTC
usi ng t he manufact urer approved diagnost ic s ys tem
P115A68 Low Fuel Level - Forced
Limit ed Power (event
i nformat ion DTC only) Low fuel - s econd
warning after clus ter
warning l amp
i ll uminated Check for addi ti onal rel ated DTCs and refer t o rel evant
DTC Index
P115B68 Low Fuel Level - Forced
Engine Shutdown (event
i nformat ion DTC only) Low fuel - fi rs t
warning after clus ter
warning l amp
i ll uminated Low fuel - fuel empty,
engine shut off Check fuel l evel . Check for addit ional rel at ed DTCs and
refer t o relevant DTC Index
P226600 W ater in Fuel Sensor Circui t
Low Fuel Filt er W at er In
Fuel s wit ch short
ci rcuit t o ground Carry out the pi npoint t es ts as s oci at ed wi th this DTC
usi ng t he manufact urer approved diagnost ic s ys tem
P226700 W ater in Fuel Sensor Circui t
Hi gh Fuel Filt er W at er In
Fuel s wit ch short
ci rcuit t o batt ery Carry out the pi npoint t es ts as s oci at ed wi th this DTC
usi ng t he manufact urer approved diagnost ic s ys tem
P228800 Injector Control Press ure
Too Hi gh Leaking fuel s ys tem Fuel high pres s ure
pump ci rcuit - s hort t o
ground, open circuit Fuel high pres s ure
pump fail ure Check for fuel leaks. Refer t o t he electrical ci rcuit
diagrams and check fuel high pres s ure pump circuit for
s hort to ground, open circui t. Inst all a new high
pres sure pump as requi red

Publi s hed: 11-May-2011
Fuel Tank and Lines - TD4 2.2L Diesel - Fuel Tank
Removal and Inst all ati on
Special T ool(s) 310-123
Locki ng Ring, Fuel Tank
General Equipment Powert rai n Jack
Removal
• W ARNINGS: Fuel may s ti ll be pres ent in the fuel t ank aft er draining.
Avoid flames , s parks or li ght ed s ubs t ances .
• CAUTIO NS: Extreme cleanli nes s mus t be exercis ed when handli ng thes e component s.
Make s ure that all openi ngs are s ealed. Us e new bl anking caps .
• NOTE: Some vari ati on in the i ll us t rat ions may occur, but the es s ent ial informat ion i s always correct .
All vehicles
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.
Drai n t he fuel t ank.
Refer t o: Fuel Tank Drai ni ng (310-00 Fuel Syst em - General
Informat ion, General Procedures).
2. Remove t he coi n t ray.
3.

Releas e t he adjus ti ng nut and di sconnect t he parking
brake cables from the compens at or.
4.
Fold t he RH rear s eat cus hi on forwards .
5. Releas e t he carpet and remove t he grommet .
6.
Vehicles with fuel fired heater 7.
CAUTIONS: Ext reme cl eanli ness must be exerci sed when
handl ing t hese components . Make s ure that all openings are sealed. Us e new
blanking caps.
7.
All vehicles

Di sconnect t he electrical connect or and the breat her
hos e.
8.
9. W ARNING: Do not work on or under a vehi cle s upported onl y
by a jack. Al ways support t he vehi cl e on s afet y s tands .
Rais e and s upport t he vehi cl e.
9.
Remove t he exhaus t sys t em.
Refer t o: Exhaus t Sys t em (309-00A Exhaus t Sys t em - I6 3.2L Pet rol ,
Removal and Ins tall ati on).
10. 11.
12. W ARNING: Do not l ever t he dri ves haft joints
to rel eas e from the power t rans fer unit or t he rear
different ial fl anges .
• CAUTIONS: Make s ure that the drives haft is support ed wit h
s ui tabl e ret aining s t raps . Make s ure that new bolt s are ins tal led.
T orque: 40 Nm 12.

13.
NOTE: All vehi cl es built up to VIN 180237, and al l
TD4 Aut omati cs bui lt from VIN 180238
T orque: 25 Nm 13.
14.
NOTE: All vehi cl es.
• NOTE: This st ep requires t he aid of another
t echnician.
T orque: 25 Nm 14.
15.
CAUTIONS: Make s ure that t he cent re drives haft joi nt is
compres s ed. Fail ure t o follow thi s ins truct ion may
res ult in damage t o t he component. To avoid damage to the joint or gai ter, do not
all ow t he dri ves haft t o hang.
• NOTE: This st ep requires t he aid of another
t echnician.
Compres s t he props haft cent re joi nt . Tie the props haft t o t he right hand si de of the
vehicle. 15.

16.
NOTE: TD4 Manual buil t from VIN 180238
T orque: 25 Nm 16.
17.
18.

Releas e t he parking brake cables from t he fuel tank
cradle.
19. Remove t he fuel li ne cover.
20. 21.
CAUTIONS: Ext reme cl eanli ness must be exerci sed when
handl ing t hese components . Make s ure that all openings are sealed. Us e new
blanking caps.
Di sconnect t he 2 fuel l ines.
21.
Vehicles with fuel fired heater

22.
CAUTIONS: Ext reme cl eanli ness must be exerci sed when
handl ing t hese components . Make s ure that all openings are sealed. Us e new
blanking caps.
22.
All vehicles 23.
24. W ARNING: Thi s s tep requi res t he aid of
another technician. CAUTION: Make s ure that new bolt s are ins tal led.
Remove t he fuel tank.
General Equi pment: Powert rai n Jack T orque:
25 Nm 24.
25.
NOTE: Do not dis ass emble further if t he component
i s removed for acces s onl y.
Remove t he fuel tank pad.
25.