relay LAND ROVER FRELANDER 2 2006 User Guide

Publi s hed: 11-May-2011
Starting System - I6 3.2L Petrol - Starting System
Des cript ion and Operat ion
COMPONENT LOCATION
OVERVIEW
The s tarter mot or rated at 1.4 kW uses permanent magnet s ins tead of field windings to provide a low-weight s tartermot or; wi th t he us e of planetary gears t o deli ver a good t orque t o weight rati o.
The s tarter rel ay is energi zed by a s ignal from t he engine cont rol module (ECM) when t he i gni ti on is i n engine crank mode.The ECM checks t hat a valid code has been received before grant ing t he engine crank mode reques t . W hen t he request i sgrant ed the s t art er relay energi zes t he s t arter s olenoid to engage t he st art er motor's pi ni on wi th t he flexplate's ri ng gear.Once the engi ne has st art ed and engine s peed exceeds st art er motor s peed the pi nion di sengages to preventover-cranking of t he s t arter mot or.
The electrical power for st art er operat ion is s upplied vi a a cable connect ed direct ly from t he bat t ery pos it ive t ermi nal t ot he sol enoi d.

Publi s hed: 11-May-2011
Starting System - I6 3.2L Petrol - Starting System
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the st art ing s ys tem, refer t o the relevant Descri pti on and Operat ion s ect ion in t he works hopmanual.REFER to: St art ing Syst em (303-06A St art ing Sys tem - I6 3.2L Petrol, Des cript ion and Operat ion) /Starti ng Sys t em (303-06B St arti ng Syst em - 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
Gear s el ect or lever cable adjust mentSt arter Mot orBatt ery
Bat teryFus esW iring harnes sDamaged, loos e or corroded connectorsSt art er relayEngine Cont rol Module (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
The engine does notcrank (s tart er mot ordoes not t urn)
Gear s el ect or not i n Por N pos it ionBatt eryHarnes s /Connect orsSt arter mot orSt arter relaySt art s wit chTrans mi ss ion cont rolmodule (TCM)Engine control modul e(ECM)Engine s eized
Make s ure the gear s elector is in t he P or N posi ti on and correct lyadjus t ed.REFER t o: Sel ect or Lever Cabl e Adjus t ment (307-05 Aut omati cTrans mi s si on/Trans axl e External Controls , General Procedures ).Check the bat tery condi ti on and s tat e of charge.REFER t o: Bat t ery (414-01 Batt ery, Mounti ng and Cabl es, Di agnos isand Tes ti ng).Check the st art er motor and harnes s . Check for DTCs and refer t orelevant DTC Index
The engine does notcrank (s tart er mot ordoes t urn)
St arter mot ori ns t allat ionSt arter mot orRing gear
Check the st art er motor i ns t allat ion (fas t eners t ight, s t arter mot ors quare t o engine, etc). Check t he ri ng gear t eeth for damage,foreign object s , et c.
Engine cranks t oos lowl yBatt eryHarnes s /Connect orsSt arter mot orEngine oil i ncorrectgrade
Check the bat tery condi ti on and s tat e of charge.REFER t o: Bat t ery (414-01 Batt ery, Mounti ng and Cabl es, Di agnos isand Tes ti ng).Refer t o t he electrical ci rcuit di agrams and t est t he s tarter mot orand s t art er motor circuit s
Engine cranks t oo fas tLow enginecompres s ionCheck the engi ne compress i ons .REFER t o: Engi ne (303-00 Engine Sys t em - General Informat ion,Di agnos is and Tes t ing).Exces s ive s t artermot or noi seSt arter mot orSt arter mot ori ns t allat ion/cas ingRing gear
Check the st art er motor i ns t allat ion (fas t eners t ight, mot or squaret o engine, etc). Check t he s tart er mot or cas ing condi ti on. Check t hering gear t eet h for damage, foreign objects , et c.
DTC Index
• NOTE: If the control modul e or a component i s s us pect and the vehicle remains under manufacturer warrant y, refer t o 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 addi ti onal

DT CDescriptionPossible CauseAction
B108C23St art butt on circui t "B" -s i gnal s tuck lowSW 2 cons tant ly acti vefor l ong ti me whi lebutt on pres s detect edat SW 1
Carry out t he pinpoint t est s as s ociat ed t o t hi s DTC us ingthe manufact urer approved di agnos t ic s yst em
B108C24St art butt on circui t "B" -s i gnal s tuck highSW 2 never act ive whi lebutt on pres s detect edat SW 1
Carry out t he pinpoint t est s as s ociat ed t o t hi s DTC us ingthe manufact urer approved di agnos t ic s yst em
B108D24St art butt on circui t "C"s i gnal s tuck highSW 3 never act ive whi lebutt on pres s detect edat SW 1
Carry out t he pinpoint t est s as s ociat ed t o t hi s DTC us ingthe manufact urer approved di agnos t ic s yst em
B10D794PATS Key - unexpect edoperat ionNo respons e fromt rans ponder in keyRepl ace key
C1A4121Cl utch Pedal Sens or -s i gnal ampli tude s ignal<3% ofs uppl y(5V)Carry out t he pinpoint t est s as s ociat ed t o t hi s DTC us ingthe manufact urer approved di agnos t ic s yst em
C1A4122Cl utch Pedal Sens or -s i gnal ampli tude >maxi mum
s ignal>=97% ofs uppl y(5V)Carry out t he pinpoint t est s as s ociat ed t o t hi s DTC us ingthe manufact urer approved di agnos t ic s yst em
P051300Incorrect immobi li zerkeySecurit y key invalidProgram the keys us ing t he approved diagnos t ic s yst em.
P061511St art er relay circui tStarter relay cont rolcircui t: s hort circui t togroundStarter relay cont rolcircui t: open circui tStarter relay fai lure
Check t he s tarter rel ay and ci rcuit s . Refer to theel ect ri cal guides . Ins t al l a new relay as neces s ary.
P061512St art er relay circui tStarter relay cont rolcircui t: s hort circui t topowerStarter relay fai lure
Check t he s tarter rel ay and ci rcuit s . Refer to theel ect ri cal guides . Ins t al l a new relay as neces s ary.
P061513St art er relay circui tStarter relay cont rolcircui t: open circui tStarter relay fai lure
Check t he s tarter rel ay and ci rcuit s . Refer to theel ect ri cal guides . Ins t al l a new relay as neces s ary.
P061711St art er Rel ay Circui tHi ghStarter mot or relaycont rol circui t, hi gh si de- s hort t o ground
Carry out t he pinpoint t est s as s ociat ed wi th t his DTCus i ng the manufact urer approved diagnos t ic s ys tem
P061712St art er Rel ay Circui tHi ghStarter mot or relaycont rol circui t, hi gh si de- s hort t o power
Carry out t he pinpoint t est s as s ociat ed wi th t his DTCus i ng the manufact urer approved diagnos t ic s ys tem
P085086Park/Neutral s wi tchi nput circui tSignal invalidCarry out a compl ete vehicle read for relat ed DTCs.Rect ify as neces s ary.
P0A0F68Engine fail ed to st artLong cranki ng t imeNo act ion neces sary. Code for informati on only.
P125983Immobi lizer t o PCMSi gnal ErrorChecks um error• NOTE: If t he vehi cle s t art s, i gnore t hi s DTC
Check t he CAN network between t he ECM, ABS moduleand CJB. Carry out CAN network int egrit y t est s us ing t hemanufact urer approved diagnos t ic s ys temP125984Immobi lizer t o PCMSi gnal ErrorSignal bel ow all owabl erange• NOTE: If t he vehi cle s t art s, i gnore t hi s DTC
Check t he CAN network between t he ECM and ABSmodul e. Carry out CAN net work integrit y tes t s usi ng t hemanufact urer approved diagnos t ic s ys tem
P125985Immobi lizer t o PCMSi gnal ErrorSignal above al lowablerange• NOTE: If t he vehi cle s t art s, i gnore t hi s DTC
Run the ECM renew procedure us i ng the manufact urerapproved di agnos ti c s ys t em. If DTC remains , s uspectECM. Refer to t he new modul e/component ins t al lat ionnot e at t he top of t he DTC Index
P125986Immobi lizer t o PCMSi gnal ErrorSignal invalid• NOTE: If t he vehi cle s t art s, i gnore t hi s DTC
Run the ECM renew procedure us i ng the manufact urerapproved di agnos ti c s ys t em. If DTC remains , s uspectECM. Refer to t he new modul e/component ins t al lat ionnot e at t he top of t he DTC Index
P125987Immobi lizer t o PCMSi gnal ErrorMi ss ing mess age• NOTE: If t he vehi cle s t art s, i gnore t hi s DTC
Check t he CAN network between t he ECM and CJB. Carryout CAN net work integrit y tes t s usi ng t he manufacturerapproved di agnos ti c s ys t emU010000Los t Communicati onW it h ECM/PCM 'A'Lost communi cat ionwi th ECMCarry out t he as sociat ed network tes t for t his DTC usi ngthe manufact urer approved di agnos t ic s yst em

Convent ional bat teries los e t heir capacit y t o hold charge overt ime as t hei r int ernal l ead plat es st eadi ly det eri orate wit ht he cont inual vi brati on and eros ion t hat occurs wit h normal us e. The rate of det eri orati on depends on a number of fact ors ,including charge and di s charge cycling rat es . Therefore t he ext reme power cons umpti on of a Stop/St art s ys tem would havea det riment al effect on t he li fe-s pan of t his t ype of bat t ery.
To count eract the deeper dis charge and recharge cycl es of a Stop/St art s ys tem, a hi gh-performance batt ery bas ed onAbsorpti on Glas s Mat t echnology has been developed t o reduce batt ery det eri orati on caus ed by exces s ive us age. Thebatt ery owes i ts succes s t o t he ‘abs orbent glas s mat’ whi ch is a fi ne fi breglas s mat compres sed bet ween t he lead plat es.The ‘abs orbent gl ass mat’ als o abs orbs t he batt ery acid, enabling a more efficient us e of the cell ’s volume.
W hi le t he ‘abs orbent glas s mat ’ permit s t he electrol yte to funct ion normall y, i t also provides mechanical s upport for t helead pl at es , therefore reducing vi brat ion and s ubsequent degradat ion. Thi s t echnology s ubs t ant ial ly i ncreas es t he effect ivecharge and dis charge li fe of t he batt ery. The batt ery al s o has an extremely l ow int ernal res is t ance, res ult ing i n a quickerreacti on between acid and pl ate material.
Absorpti on glas s mat batt ery t echnology offers s everal advant ages :
The batt ery remains complet ely s pil l and leak proof due to the abs orpt ion of t he fi breglas s mat .In freezi ng condit ions , expanding flui d is unable to caus e any damage as the pl ates are packed i n fibreglas s mat s ;cons equent ly t here is virtual ly no pl at e movement .Vibrat ion or s hock does not damage t he batt ery.As electrolyt e is contai ned through t he acid i n t he mat , there is no need for bat t ery mai nt enance.
The batt ery's capaci ty is 80Ah, meani ng t he bat t ery i s theoret icall y capable of s upplying an 80 amp current for one hour. At ypi cal engi ne res t art wi ll draw a very hi gh current for a fract ion of a second, s o wi ll have very l it tl e impact on t he batt ery'st ot al st ate of charge. An engine res tart may typicall y cons ume about 0.001% of a new batt ery's full -charge capaci ty.
If a new batt ery is fit ted t o t he vehicle, the BMS (bat tery monit ori ng s ys t em) module wi ll requi re recal ibrat ing t o regi s tert he greater charge holding capaci ty of the bat tery, t his i s performed us ing Land Rover approved di agnos ti c equi pment. Ifdiagnost ic equipment i s not avail able t he BMS modul e wil l recalibrate aut omati cal ly however, thi s coul d t ake 48 hours t ocomplete depending on vehicle usage. The Stop/St art s ys tem wil l not funct ion correctly unt il t he BMS module isrecali brated.
If the BMS modul e i s replaced t he module wi ll recali brat e automat ically; for addit ional informat ion refer to the Bat teryMonit oring Sys t em s ect ion, below.
CONTROL DIAGRAM
New s oft ware added t o t he ECM controls t he operat ion of t he Stop/St art s yst em where i n addi ti on t o it s own dedicatedcomponents the St op/St art s ys t em encompas s es many ot her vehicle sys tems . Complex technol ogy i nterconnect s t hes es ys t ems and many of t he inputs as s oci ated wit h the St op/St art s yst em are relayed to the ECM and trans mi tt ed via theCJB, whi ch has al s o been upgraded wit h new s oft ware. The control l ogi c for i nhi bit ing an engine shut down during aStart/Stop cycle resi des in t he CJB. The CJB al s o act s as a gat eway rel ayi ng thi s informat ion t o t he ECM over the medi umand high-s peed CAN bus net works.
Eight vehi cl e harnes s es have been modi fied to accommodate t he St op/Start sys t em.
Stop/St art Cont rol Diagram
• NOTE: A = Hardwi red; D = Hi gh Speed CAN bus ; N = Medium Speed CAN bus; O = LIN bus ; AC = Di agnos ti c Link.

25-Fuel fired heat er (i f fi tt ed)
26-Auxili ary coolant pump **
* Vehicles wit hout fuel fired heat er.
** Vehicles wi th fuel fi red heater.
INTELLIGENT TECHNOLOGY
New and revi s ed components as di s cus s ed in this secti on have been developed t o ensure t hat al l vehicl e s ys t ems operatevirtuall y uninterrupt ed in a Stop/St art cycl e.
Voltage Quality Module
Duri ng an engine St op/Start cycle t he VQM (volt age qual it y module) mai ntains t he vehicle’s el ect ri cal s yst ems by s upplyinga s upport volt age around the vehicle's electroni c components during an engine res tart. This al lows crucial vehicle s ys temst o cont inue unint errupt ed when t here i s a s udden draw of amps from the bat tery.
The vehi cl e’s s t art er mot or cons umes 2kW of el ect ri cal power and can draw s everal hundred amps of current from thebatt ery during cranking. Thi s s udden draw of current causes a momentary volt age drop around al l t he vehicle ci rcuit s. Manyof the vehicle's electroni c s ys t ems are des i gned t o operat e at a nomi nal 12 volt s , so thi s s udden drop in bat tery volt agewit hout the VQM ins t al led woul d temporaril y i nt errupt servi ces such as :
audi o s yst emcel lul ar phonenavi gat ion sys temmes s age Cent er.
Once the engi ne is runni ng a s ignal from t he ECM triggers a relay wit hi n t he VQM t o bypass the converter s t age andvolt age control is gi ven back t o t he vehi cl e's normal charging sys tem. The VQM is specified t o boost vol tage for ones econd, alt hough i n many s it uati ons i t can s upply a volt age boos t for up t o 5 seconds .
The VQM is effecti vel y a DC (direct current) converter, which convert s a variable DC input vol tage from as l ow as 6V up t oa s t abl e 12V DC out put ± 0.5V.
Rated at a nominal 180W , it can s uppl y up t o 15 amps of load at 12 vol ts . The VQM can t olerat e i ns t ant aneous s pikes upt o 300 W at ts , enough to maintai n uninterrupt ed power t o vehicle s ys tems during engine cranking.
VQM fault s are trans mi tt ed via a diagnost ic l ink t o t he CJB where they are hel d; the fault codes can be di agnos ed us ingLand Rover approved diagnos t ic equipment .
Battery Monitoring System
Mounted on t he batt ery negat ive t ermi nal t he BMS (batt ery moni toring s yst em) module is i ntegral wi th t he batt erynegat ive cable.
Batt ery healt h s t at us i s a fundamental fact or in t he correct operat ion of t he Stop/St art s ys tem. Computat ion of t he batt erys tat us is performed by t he BMS module and will i nit iate a ‘St op Inhi bit or’ or ‘Start Ini ti at or’ i n a St op/Start cycle if t hebatt ery cannot meet t he requi red demand. For addit ional informati on refer to the ‘Stop Inhi bit ors , Start Init iat ors and St art

Inhi bi tors ’ s ecti on, below.
The batt ery s t atus i nformat ion is t rans mit t ed from t he BMS modul e over t he LIN (l ocal i nt erconnect network) bus t o t heCJB which has a t wo-way communi cat ion wit h the BMS module. The cont rol l ogi c for i nhi bi ti ng engine s hutdown andini ti at ing an early engi ne res tart during a Start/Stop cycl e resi des in t he CJB. The CJB al so act s as t he gateway relayingt hi s informat ion t o t he ECM over the hi gh-s peed CAN bus.
Batt ery s t atus i nformat ion is al so trans mi tt ed from the CJB over the medi um-speed CAN bus t o t he ins t rument clus ter. Theins t rument clus ter dis plays batt ery charge warning mes s ages to indicate generat or or bat tery monit oring sys tem faul ts t ot he driver.
The BMS module cons tant ly computes t he s t at us of the el ect ri cal s ys tem on the bas is of the followi ng data:
batt ery det eriorati onbatt ery s t ate of chargebatt ery current demand.
If any of t hese factors s how a l ow meas urement, t he ECM s us pends t he Stop/Start feature unti l more bat tery power i savai lable. The fact ors are dis cus s ed below:
Batt ery det eriorati on
Alt hough fit t ed wit h a hi gh-performance batt ery bas ed on AGM (abs orpti on glas s mat ) technol ogy, t he charge holdingcapacit y of the bat tery wi ll s ti ll deteriorat e, however at a much s lower rat e t han a conventi onal bat tery. This degradat ionwil l reflect on the amount of charge t he bat t ery can hold unt il it reduces t o a condit ion where the bat tery wi ll needrepl acing.
The batt ery moni toring s yst em cal culat es t he condit ion of t he batt ery by obs erving a range of i nput s including:
ambient t emperaturecharge and dis charge act ivi tyvolt age andint ernal res is t ance.
The lat est condit ion value of t he batt ery i s s tored in the dedicated memory of t he BMS t o ens ure t he mos t accurat eforecas t of the bat teries condi ti on.
Stat e of charge
The BMS analys es how much charge has been drawn or repl enis hed to det ermi ne t he bat tery’s pres ent s tat e of charge.
Current demand
Duri ng a St op/Start cycle when vehicl e s ys t em us e i s in hi gh demand, for exampl e t he fol lowing are operat ing:
head li ght sclimate controlaudi o s yst em.
The batt ery wi ll dis charge more rapi dly due t o t he high current demand.
In thi s event t he BMS calculat es various fact ors t o determine how long t he batt ery can s upply a current at the presentlevel of demand. This calculat ion i s used by the CJB t o determine if t o authori ze whichever i s needed i n t he Stop/St artcycle, ei ther to:
prevent an engi ne s top, orini ti at e an engine res tart.
To provide this informati on t o t he CJB the BMS modul e calculates a range of batt ery variables , including:
s tat e of chargebatt ery s urface temperat ure to cal culat e t he int ernal temperat ureint ernal res is t ancevolt agecurrent flow into and from t he batt ery.
The batt ery moni toring s yst em cal culat es t hes e vari abl es agai nst programmed det ailed bat tery li fe model s t o determinehow l ong the gi ven current can be s upport ed.
Batt ery moni toring s ys tem modes
The batt ery moni toring s yst em has three di s ti nct modes :
Acti ve mode: during normal vehicle operat ion, batt ery dat a i s upl oaded and calculat ed every s econd.Sleep mode: duri ng ignit ion off, bat tery dat a i s uploaded every s econd and calculated every hour t o reduce i nacti vecurrent drai n.Trans port mode: bat t ery moni tori ng int ervals are mi nimi zed.
Batt ery replacement
If a new batt ery is fit ted t o t he vehicle, the BMS (bat tery monit ori ng s ys t em) module wi ll requi re recal ibrat ing t o regi s tert he greater charge holding capaci ty of the bat tery, t his i s performed us ing Land Rover approved di agnos ti c equi pment. If adiagnost ic s ys tem is not avail abl e t he BMS module will recal ibrat e automat icall y however, this could take 48 hours tocomplete depending on vehicle usage. The Stop/St art s ys tem wil l not funct ion correctly unt il t he BMS module isrecali brated.
If the BMS modul e i s replaced t he module wi ll re-calibrate aut omati cal ly.

CAUTION: To avoid damage/malfuncti oni ng of the BMS module, always us e a s uit able body ground point rather thant he bat t ery negat ive terminal when connect ing a s lave power supply.
For addit ional informat ion, refer t o: Batt ery (414-01 Bat tery, Mounti ng and Cables , Diagnos is and Tes t ing).
Gear Neutral Sensor
A PLCD (permanent magnet l inear cont act les s dis placement) s ensor i s located on the exterior of the trans mi s si on cas i ngand hardwired t o t he ECM. The sens or’s functi on is t o det ect t hat neut ral gear has been s elected wi thi n a cali bratedwindow.
No cali brati on is neces sary for t he Gear Neut ral Sensor upon repl acement, i t is however monit ored and a DTC wil l belogged s houl d a fault occur. Fault codes can be diagnos ed us ing Land Rover approved di agnos ti c equi pment.
Linear Clutch Sensor
To ens ure an engine res tart during a St op/St art cycl e does not del ay the get away demands of cit y dri ving, the engine i sres t art ed in approximately 800 mil li seconds . This i s achi eved through t he li near clut ch s ens or triggeri ng an engine rest artwhen t he cl utch pedal is at t he s tart of i ts downward t ravel. So whil e t he dri ver conti nues t o depres s t he clutch t hrought he res t of it s t ravel t he engine rest art i s already i n progress .
The li near clut ch s ens or is a PLCD (permanent magnet li near contactl es s di spl acement) type and i s located on t he clut chmas ter cylinder and hardwired t o t he CJB. The s ensor provi des t he CJB wi th a cont inuous input of the clut ch pedal ’sposi ti on; this informati on is relayed t o t he ECM on t he high-speed CAN bus . The ‘t op of travel ’ si gnal i s used to aut horizean automat ic engine res tart if all ot her s ys tem condit ions are approved.
The li near clut ch s ens or als o provides a ‘bott om of t ravel’ s ignal near t he end of the cl ut ch pedal ’s t ravel. This si gnal i sus ed if t he engi ne s tal ls and i s a requi rement t o authori ze a s tal l recovery. This is unique funct ion t hat allows the enginet o res t art automat ically if all ot her s ys tem condit ions are approved. For addi ti onal i nformat ion refer t o t he Stall Recoverys ect ion, below.
A magnet ins ide the clut ch mas ter cylinder provides t he posi ti on indicator for the linear cl utch s ensor. For t his reason, ift he mas ter cyl inder is replaced the correct replacement mas t er cyli nder mus t be i dent ified and fit t ed.
The t wo exis ti ng clutch pos it ion-s wi tches, l ocat ed on t he cl utch pedal hous ing and us ed as i nput s for vari ous vehi cl es ys t ems , are al so ut il ized by t he Stop/Start sys tem for pl aus ibi lit y checks .
If a fault develops wi th the l inear cl utch s ensor a DTC wil l be logged in the CJB.
• NOTE: The Stop/Start sys tem wil l not funct ion correctl y if t he dri ver rest s t hei r foot on t he clut ch pedal whil e dri vi ng t hevehi cl e.
Brake Vacuum Sensor

Publi s hed: 11-May-2011
Glow Plug System - Glow Plug System
Des cript ion and Operat ion
COMPONENT LOCATION
ItemPart NumberDescription
1-Glow plugs2-Glow plug warning i ndi cat or lamp
3-BJB
OVERVIEW
A gl ow plug i s i ns t alled in t he inl et si de of each cyli nder, to heat t he combus t ion chambers before and duri ng cranki ng.This ai ds col d s tarti ng, reduces emis s ions and engine nois e when idli ng from a col d engine.
A wi ri ng harnes s on each bank of glow plugs is connect ed t o a s eparat e rel ay and fusible li nk in t he BJB (bat t ery junct ionbox) . Each glow plug i s grounded through i ts fi xi ng in the cyli nder head. Operati on of the gl ow plug relays is cont roll ed byt he ECM , which al so cont rols the i ll uminati on of the gl ow plug indicator in the instrument cl us t er.
Each gl ow pl ug is a tubular heati ng element which cont ains a spi ral fi lament encas ed i n magnesi um oxide powder. At t het ip of t he tubular heati ng element is the heater coil . Behi nd the heat er coil , and connect ed i n s eries , is a cont rol coil . Thecont rol coil regulat es the current to the heat er coil t o s afeguard agains t overheat ing.
OPERATION
There are t hree phases of glow plug heati ng: Pre heati ng, crank heat ing and pos t heat ing. The ECM (engi ne cont rolmodule) determines t he heat ing ti mes from the ECT (engi ne cool ant temperat ure) . The lower t he ECT (engi ne coolantt emperature) , t he l onger t he heat ing t imes .
W hen t he i gni ti on s wit ch is s wi tched to mode II, t he ECM (engi ne cont rol module) calculates any requi red heat ing t imesand, i f heat ing is requi red, energizes the gl ow pl ug relays i n t he BJB (bat tery juncti on box) . W hen pre heati ng is required,t he ECM (engi ne cont rol module) als o s ends a mes s age to the i nst rument clus t er, on the high s peed CAN (cont roll er areanetwork) bus , to request i ll uminati on of the gl ow pl ug indicator. The gl ow pl ug indicator remains il lumi nat ed for thedurat ion of t he pre heati ng phase, or unti l the i gni ti on s wit ch is t urned t o t he crank pos it ion, whichever occurs fi rs t. Ifrequired, the ECM (engine control modul e) keeps t he glow pl ug rel ays energi zed during cranking and for the durati on of anypost heat ing phase.
The ECM (engi ne cont rol module) moni tors the drive circui t of the gl ow plug relays for pl aus i bi li ty of operat ion, cont inuit y,and s hort and open ci rcuit s . If a fault i s detected, the ECM (engine cont rol module) s tores a rel ated faul t code andpermanentl y il lumi nat es t he glow pl ug indicator whi le t he i gni ti on s wit ch is i n mode II.
CONTROL DIAGRAM

Publi s hed: 11-May-2011
Glow Plug System - Glow Plug System
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the gl ow plug sys tem, refer t o t he rel evant Des cript ion and Operat ion s ecti on in the works hopmanual.REFER to: Gl ow Plug Sys tem (303-07B Glow Pl ug Syst em, 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 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 damage.2.
Visual InspectionElectrical
Fuse(s )Gl ow plug relayEngine management cont rol rel ayW iri ng harnes sElectrical connect or(s )Gl ow plug(s )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) 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.4.
DTC Index
• NOTE: If the control modul e or a component i s s us pect and the vehicle remains under manufacturer warrant y, refer t o 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 addi ti onalinformat ion read by the manufact urer approved diagnos t 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 wi th an up-t o-date cal ibrat ion cert ificate. W hen tes ti ng res is t ance al ways take t he res is t ance of t he DMMleads i nt o account .
• NOTE: Check and recti fy bas ic faul ts before beginni ng diagnos t ic rout ines i nvol vi ng pinpoint t es t s.
• NOTE: Ins pect connect ors for s igns of water ingres s , and pins for damage and/or corros ion.
• 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 CauseAction
P038000Gl ow Plug/Heat er Circuit AGl ow plug s ys tem fault - fail ure of aglow plug, rel ay fail ure, s hort circuiti n a gl ow plug or over current
Carry out t he pinpoint t es t sas s oci ated wi th thi s DTC us ing t hemanufact urer approved diagnos t ics ys tem
P038300Gl ow Plug Cont rol Modul eControl Circuit LowGl ow plug relay control ci rcuit - s hortt o groundRefer to el ect ri cal circui t diagrams andcheck glow pl ug rel ay cont rol ci rcuitfor s hort to ground
P038400Gl ow Plug Cont rol Modul eControl Circuit Hi ghGl ow plug relay control ci rcuit - s hortt o powerRefer to el ect ri cal circui t diagrams andcheck glow pl ug rel ay cont rol ci rcuitfor s hort to powerP138A00Gl ow Plug Cont rol Modul eControl CircuitRange/Performance
Gl ow plug relay exces s t emperat ureCarry out t he pinpoint t es t sas s oci ated wi th thi s DTC us ing t hemanufact urer approved diagnos t ics ys temP138B00Gl ow Plug Cont rol Modul eSys tem Vol tageGl ow plug s ys tem fault - short ci rcuiti n a gl ow plug, over-current or relays t uck
Carry out t he pinpoint t es t sas s oci ated wi th thi s DTC us ing t hemanufact urer approved diagnos t ics ys tem

12-Res trai nts Cont rol Module (RCM)
13-Knock sens ors (2 off)
14-Fuel rail t emperature/pres s ure s ens or15-Clockspring
16-Terrain respons e cont rol module
17-Trans mis s ion Cont rol Module (TCM)18-ABS module
19-Diagnos ti c socket
20-CJB
ENGINE CONTROL MODULE (ECM)
The ECM i s located on a bracket i n a central pos i ti on on the engi ne compartment firewal l. The ECM is at tached to ahous i ng and s ecured wit h 4 s crews . The hous i ng is l ocat ed in the bracket and locked in pos it ion.
The ECM i s s uppl ied wi th bat tery volt age from fuses l ocat ed in the BJB. A permanent batt ery s upply i s provided t o ens ureadapt ive dat a is not l ost when the engine i s s wit ched off.
A regul ator, locat ed wi thin the ECM, s upplies a 5V current t o i nt ernal components such as t he mi cro-proces s or unit . Ot hercomponents or funct ions requi ri ng ful l bat tery vol tage are cont rol led by ext ernal relays or int ernal power s t ages .
The mi cro-proces sor wi thi n the ECM receives s ignals from different component s and cont rol modules and us es a programwit hin the ECM software t o int erpret t he s ignal informat ion and i ss ue s ignals whi ch rel at e t o how the engine component sand functi ons should be cont rol led.
The ECM recei ves i nput s from the foll owing:
CMP s ensorsCKP s ensorFuel rail pres s ure s ensorMAF s ensorKnock s ens orsFuel rail t emperature/pres s ure s ensorECT s ens orEngi ne oil l evel/t emperature s ens orManifol d Abs olute Pres sure (MAP) sens orElectric t hrot tl e - Throt tl e Posi ti on (TP) s ens orAPP s ens orFuel t ank leakage monit oring modul e (NAS onl y)Cooling fan controlHeated Oxygen s ens ors (HO2S)Stop lamp s wi tch (via Central Juncti on Box (CJB))Speed cont rol inhibi t swi tchInt ake Air Temperat ure (IAT) s ens orAmbient Air Temperat ure (AAT) s ens orTrans mis s ion Cont rol Modul e (TCM).
The ECM s ends out puts to t he followi ng:
Main relayAir Condit ioning (A/C) relayFuel i njectorsIgni ti on coi lsEngi ne cool ing fan cont rolElectric t hrot tl eElectric fuel pump driver moduleVari abl e Cams haft Timing (VCT) s olenoidsStarter rel ay cont rolVari abl e int ake manifol d control valvesVari abl e inl et cam profile swit ching sol enoi d val vesTrans mis s ion Cont rol Modul e (TCM).
SENSORS
The ECM opt imi zes engine performance by interpreti ng s ignals from numerous vehicle sens ors and ot her i nput s. Some oft hes e s ignals are produced by t he act ions of t he dri ver, some are s uppli ed by s ens ors locat ed on and around t he engine