engine LAND ROVER FRELANDER 2 2006 Repair Manual

Publi s hed: 11-May-2011
Fuel Charging and Controls - I6 3.2L Petrol - Fuel Charging and Controls
Des cript ion and Operat ion
Authori ng Templat e
COMPONENT LOCATION
ItemPart NumberDescription1-Fuel rai l
2-Fuel inject or
3-Fuel li ne4-Fuel rai l press ure and fuel temperature s ens or
OVERVIEW
The fuel pump module, l ocat ed in the fuel t ank, i s electronical ly regulated by the Engine Management Sys t em (EMS) toprovide controll ed pres sure in the fuel railFor addit ional informat ion, refer t o: Fuel Tank and Lines (310-01A Fuel Tank and Lines - I6 3.2L Pet rol, Des cri pt ion andOperat ion)..
Suppl yi ng t he correct amount of fuel as required by the engine at any gi ven moment, eli minat es the requirement foraddi ti onal pi pes returning exces s fuel t o t he fuel t ank. The benefit s of t hi s t ype of s ys tem are:
Reduced l oad on the el ect ri cal s yst em

Improved fuel economyEli minat es the effects of fuel press uri zat ion and depres s uri zat ionEli minat es the effects of engine-heat caus i ng ext ra fuel vapor being generat ed in the fuel t ank by ret urning fuel
Clos ed-l oop Pul se W i dt h Modulat ion (PW M) control, of the fuel pump module, via t he Engine Control Modul e (ECM)regulat es the amount of fuel s uppl ied by the fuel pump to the fuel rail . The ECM receives s ignals from the combi ned fuelrai l pres sure and fuel t emperature s ens or, l ocat ed on t he fuel rai l to indicate t he pres s ure of fuel i n t he fuel rai l. Inres ponse to thes e s ignals , plus other engine and driver demand s i gnal s, t he ECM calculat es the amount of fuel requiredand reques ts t he fuel pump modul e t o vary t he fuel pump deli very t o s uit t he engi ne’s requirements .For addit ional informat ion, refer t o: Electroni c Engi ne Controls (303-14A Electroni c Engine Controls - I6 3.2L Pet rol ,Des cript ion and Operat ion).
The fuel pump mai ntains a fuel rai l pres sure 3.8 bar above manifold depres s ion under normal operati ng condit ions , thought hi s is programmed to ri se to 4.2 bar in res pons e t o eit her:
col d s t art condi ti ons , t o improve fuel vaporizati oncol d fuel condi ti ons, as t he colder the fuel the hi gher it s vis cosi ty
The fuel rai l has an int egrated puls at ion damper and a connecti on for drai ning t he fuel s yst em.
The inject ors s upplied by the fuel rail ; each have 4 micro-nozzles capabl e of injecting up to 18 mg of fuel under hi gh-loadcondi ti ons , t he inject ors als o provi de precis ion fueli ng across al l engi ne s peed and l oad condit ions .

Publi s hed: 11-May-2011
Fuel Charging and Controls - I6 3.2L Petrol - 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 (303-04A Fuel Chargi ng and Cont rol s - I6 3.2L Pet rol, 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.
• NOTE: For di agnos t ic purpos es the cyli nders are divided i nt o t wo banks: Bank 1 - Cyl inder numbers 1, 2 and 3. Bank 2 -Cylinders 4, 5 and 6
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
MechanicalElectricalFuel l evelFuel l eaksDamaged fuel l inesDamaged push connect fit t ingsFuel contami nati on/grade/quali tyThrot tl e bodyDamaged fuel t ank fi ller pipe capDamaged fuel t ank fi ller pipe
FusesLoos e or corroded elect rical connect orsHarnes s esSensor(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, 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 , but does not fi reEngine breat her s ys temdis connected/res trictedIgni ti on s ys t emFuel s ys temElectronic engine control
Ens ure the engine breat her sys tem isfree from rest ri ct ion and is correct lyi nst all edFor igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).Read DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).
Engine cranks and fires , but wil lnot s tartEvaporati ve emis s ions purgevalveFuel pumpSpark pl ugsHT s hort t o ground (t racki ng)check rubber boots forcracks/damageIgni ti on s ys t em
For purge valve t es ts .REFER t o: Evaporat ive Emi ss i ons (303-13Evaporati ve Emis s ions , Diagnosi s andTes ti ng).For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).For igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).
Di fficul t col d s t artEngine coolant level/ant i-freeze cont entBatt eryElectronic engine controlsFuel pumpPurge valve
Check t he engi ne cool ant l evel andcondit ion.REFER t o: Specificati ons (303-03AEngine Cool ing - I6 3.2L Pet rol ,Specificat ions ).Ens ure the bat tery is i n a full y chargedand s ervi ceable condit ionRead DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.

SymptomPossible CauseAction
REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).For purge valve t es ts .REFER t o: Evaporat ive Emi ss i ons (303-13Evaporati ve Emis s ions , Diagnosi s andTes ti ng).
Di fficul t hot st artInjector leakElectronic engine controlPurge valveFuel pumpIgni ti on s ys t em
Check for i njector leak, ins tal l newi njector as neces s ary.REFER t o: Fuel Inject or (303-04A FuelChargi ng and Control s - I6 3.2L Pet rol ,Removal and Ins t al lat ion).Read DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).For purge valve t es ts .REFER t o: Evaporat ive Emi ss i ons (303-13Evaporati ve Emis s ions , Diagnosi s andTes ti ng).For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).For igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).
Di fficul t t o s tart aft er hot s oak(vehi cl e s tanding, engi ne off, aft erengine has reached operati ngt emperature)
Injector leakElectronic engine controlPurge valveFuel pumpIgni ti on s ys t em
Check for i njector leak, ins tal l newi njector as neces s ary.REFER t o: Fuel Inject or (303-04A FuelChargi ng and Control s - I6 3.2L Pet rol ,Removal and Ins t al lat ion).Read DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).For purge valve t es ts .REFER t o: Evaporat ive Emi ss i ons (303-13Evaporati ve Emis s ions , Diagnosi s andTes ti ng).For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).For igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).
Engine s t al ls s oon after s tartBreat her s ys temdis connected/res trictedECM relayElectronic engine controlIgni ti on s ys t emAir i ntake s yst em res trictedAir l eakageFuel l ines
Ens ure the engine breat her sys tem isfree from rest ri ct ion and is correct lyi nst all edRead DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).For igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).Check for bl ockage in ai r fi lt er el ementand ai r int ake s ys temCheck for ai r leakage i n air i ntakes ys temFor fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).
Engine hes it at es /poor accelerat ionFuel press ure, fuel pump, fuell inesInjector leakAir l eakageElectronic engine controlThrot tl e mot orRes tricted accelerat or pedalt ravel (carpet, et c)
For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).Check for i njector leak, ins tal l newi njector as neces s ary.REFER t o: Fuel Inject or (303-04A FuelChargi ng and Control s - I6 3.2L Pet rol ,

SymptomPossible CauseAction
Igni ti on s ys t emTrans mi ss ion malfunct ionRemoval and Ins t al lat ion).Check for ai r leakage i n air i ntakes ys temRead DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).Read DTCs and refer t o t he DTC Index i nt his secti on for t hrot tl e mot or t es tsEns ure accelerat or pedal is free fromres tricti onFor igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).For t rans mis s ion t est s .REFER t o: Diagnos t ics (307-01 Automat icTrans mi s si on/Trans axl e, Diagnos i s andTes ti ng).
Engine backfiresFuel pump/li nesAir l eakageElectronic engine controlsIgni ti on s ys t emSt icki ng variabl e camshaftt imi ng (VCT) hub
For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).Check for ai r leakage i n i nt ake airs ys temRead DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).For igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).Read DTCs and refer t o DTC Index forVCT tes ts .REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).
Engine s urgesFuel pump/li nesElectronic engine controlsThrot tl e mot orIgni ti on s ys t em
For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).Read DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).Read DTCs and refer t o DTC Index in t hiss ecti on for t hrot tl e mot or t es ts .For igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).
Engine detonat es /knocksElectronic engine controlsFuel pump/li nesAir l eakageSt icki ng VCT hub
Read DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).Check for ai r leakage i n i nt ake airs ys temRead DTCs and refer t o DTC Index forVCT tes ts .REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).
No t hrot tl e res ponseElectronic engine controlsThrot tl e mot orRead DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).Read DTCs and refer t o DTC Index in t hiss ecti on for t hrot tl e mot or t es ts .

SymptomPossible CauseAction
Poor throt t le respons eBreat her s ys temdis connected/res trictedElectronic engine controlTrans mi ss ion malfunct ionTract ion cont rol eventAir l eakage
Ens ure the engine breat her sys tem isfree from rest ri ct ion and is correct lyi nst all edRead DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).For t rans mis s ion s ys tem tes ts .REFER t o: Diagnos t ics (307-01 Automat icTrans mi s si on/Trans axl e, Diagnos i s andTes ti ng).Check for ai r leakage i n i nt ake airs ys tem
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 CauseActionP008700Fuel rail /s yst em pres sure -t oo lowLeakage at the fuel linesFuel pres s ure s ensor faul tFuel pump faul tFuel pump control modul e fault
Check t he fuel s yst em for leaks.REFER to: Fuel Tank and Lines (310-01A FuelTank and Li nes - I6 3.2L Petrol, Diagnos isand Tes t ing).Rect ify as neces s ary. Check for DTCsindicati ng a fuel press ure, fuel pres s ures ens or, pump or pump modul e faul t.
P008800Fuel rail /s yst em pres sure -t oo highRes t ri ct ed fuel l inesFuel pres s ure s ensor faul tFuel pump faul tFuel pump control modul e fault
Check t he fuel s yst em fordamage/res trict ions.REFER to: Fuel Tank and Lines (310-01A FuelTank and Li nes - I6 3.2L Petrol, Diagnos isand Tes t ing).Rect ify as neces s ary. Check for DTCsindicati ng a fuel press ure, fuel pres s ures ens or, pump or pump modul e faul t.P008968Fuel press ure regulat orperformance - algorit hmbas ed fail ures
Low fuel pres s ureCheck for DTCs indicati ng a fuel pres s ure,fuel pres s ure s ensor, pump or pump modulefault .
P017068Fuel t rim, bank 1HO2S cont rol outs ide limit sNo acti on is necess ary. The code wil l cl earwhen the condit ions no l onger apply.
P017100Syst em too l ean (bank 1)Int ake ai r leak- Bet ween MAF s ensor andcyli nder headFuel s ys t em rest ricti onMAF s ens or fault- Low int ake flowExhaust leak, before catal yt icconvert er
Check for intake ai r leaks . Check for low fuelpres sure and MAF s ens or DTCs . Rect ify asneces sary. Check for exhaus t l eaks beforethe cat al yti c convert er
P017200Syst em too rich (bank 1)Res t ri ct ed air fil terOil cont aminat ed wit h fuel- Too many col d s tarts wit hvehicle s ubs equent ly notget ti ng hot enough for longenoughLeaking fuel i njectorsMAF s ens or fault- High i nt ake fl owLeaking evaporati ve emis s ionsys tem purge valve
Check t he condi ti on of the ai r cl eanerelement:REFER to: Air Cl eaner (303-12B Int ake AirDis t ribut ion and Fil tering - TD4 2.2L Dies el,Removal and Inst all at ion).Check engine t he oil condi ti on. Check forleaking i nject ors . Check for MAF s ensor,inject or and evaporati ve emis s ion sys temDTCs.
P017368Fuel t rim (bank 2)HO2S cont rol outs ide limit sNo acti on is necess ary. The code wil l cl earwhen the condit ions no l onger apply.
P017400Syst em too l ean (bank 2)Int ake ai r leak- Bet ween MAF s ensor andcyli nder headFuel s ys t em rest ricti on
Check for intake ai r leaks . Check for low fuelpres sure and MAF s ens or DTCs . Rect ify asneces sary. Check for exhaus t l eaks beforethe cat al yti c convert er

DT CDescriptionPossible CauseAction
MAF s ens or fault- Low int ake flowExhaust leak, before catal yt icconvert er
P017500Syst em too rich (bank 2)Res t ri ct ed air fil terOil cont aminat ed wit h fuel- Too many col d s tarts wit hvehicle s ubs equent ly notget ti ng hot enough for longenoughLeaking fuel i njectorsMAF s ens or fault- High i nt ake fl owLeaking evaporati ve emis s ionsys tem purge valve
Check t he condi ti on of the ai r cl eanerelement:REFER to: Air Cl eaner (303-12B Int ake AirDis t ribut ion and Fil tering - TD4 2.2L Dies el,Removal and Inst all at ion).Check engine t he oil condi ti on. Check forleaking i nject ors . Check for MAF s ensor,inject or and evaporati ve emis s ion sys temDTCs.
P018100Fuel t emperat ure s ens or Acircui t range/performanceFuel t emperature s ens or Aci rcuit : high resi st anceFuel t emperature s ens or fai lure
Check t he fuel t emperature s ens or andci rcuit s . Refer to the el ect ri cal guides .Ins t al l a new s ensor as necess ary (t he fueltemperat ure sens or is i ncorporated i nto thefuel rai l press ure s ens or).REFER to: Fuel Rai l Press ure (FRP) Sens or(303-14A El ect ronic Engi ne Cont rol s - I6 3.2LPet rol , Removal and Inst all at ion).
P018200Fuel t emperat ure s ens or Acircui t lowFuel t emperature s ens or Aci rcuit : s hort ci rcuit t o groundFuel t emperature s ens or Aci rcuit : high resi st anceFuel t emperature s ens or fai lure
Check t he fuel t emperature s ens or andci rcuit s . Refer to the el ect ri cal guides .Ins t al l a new s ensor as necess ary (t he fueltemperat ure sens or is i ncorporated i nto thefuel rai l press ure s ens or).REFER to: Fuel Rai l Press ure (FRP) Sens or(303-14A El ect ronic Engi ne Cont rol s - I6 3.2LPet rol , Removal and Inst all at ion).
P018300Fuel t emperat ure s ens or Acircui t highFuel t emperature s ens or Aci rcuit : s hort ci rcuit t o powerFuel t emperature s ens or Aci rcuit : open ci rcuitFuel t emperature s ens or fai lure
Check t he fuel t emperature s ens or andci rcuit s . Refer to the el ect ri cal guides .Ins t al l a new s ensor as necess ary (t he fueltemperat ure sens or is i ncorporated i nto thefuel rai l press ure s ens or).REFER to: Fuel Rai l Press ure (FRP) Sens or(303-14A El ect ronic Engi ne Cont rol s - I6 3.2LPet rol , Removal and Inst all at ion).
P019100Fuel rail pres s ure s ens or Acircui t range/performanceFuel rai l pres sure (FRP) s ensorA circui t: high res is tanceFuel rai l pres sure (FRP) s ensorfail ureFuel pump driver modul e fai lure
Check t he FRP s ens or and circui ts . Refer t othe el ect ri cal guides . Ins tal l a new s ensor asneces sary.REFER to: Fuel Rai l Press ure (FRP) Sens or(303-14A El ect ronic Engi ne Cont rol s - I6 3.2LPet rol , Removal and Inst all at ion).Check for DTCs indicati ng fuel pump dri vermodule faul ts . Recti fy as necess ary.P019121Fuel rail pres s ure s ens or Acircui t range/performance -s ignal amplit ude les s t hanmi nimum
Fuel rai l pres sure (FRP) s ensorA circui t: high res is tanceFuel rai l pres sure (FRP) s ensorfail ure
Check t he FRP s ens or and circui ts . Refer t othe el ect ri cal guides . Ins tal l a new s ensor asneces sary.REFER to: Fuel Rai l Press ure (FRP) Sens or(303-14A El ect ronic Engi ne Cont rol s - I6 3.2LPet rol , Removal and Inst all at ion).P019122Fuel rail pres s ure s ens or Acircui t range/performance -s ignal amplit ude great ert han maximum
Fuel rai l pres sure (FRP) s ensorA circui t: s hort circui t to powerFuel rai l pres sure (FRP) s ensorfail ure
Check t he FRP s ens or and circui ts . Refer t othe el ect ri cal guides . Ins tal l a new s ensor asneces sary.REFER to: Fuel Rai l Press ure (FRP) Sens or(303-14A El ect ronic Engi ne Cont rol s - I6 3.2LPet rol , Removal and Inst all at ion).
P019200Fuel rail pres s ure s ens or Acircui t lowFuel rai l pres sure (FRP) s ensorA circui t: s hort circui t to groundFuel rai l pres sure (FRP) s ensorA circui t: open circui tFuel rai l pres sure (FRP) s ensorfail ure
Check t he FRP s ens or and circui ts . Refer t othe el ect ri cal guides . Ins tal l a new s ensor asneces sary.REFER to: Fuel Rai l Press ure (FRP) Sens or(303-14A El ect ronic Engi ne Cont rol s - I6 3.2LPet rol , Removal and Inst all at ion).
P019300Fuel rail pres s ure s ens or Acircui t highFuel rai l pres sure (FRP) s ensorA circui t: s hort circui t to powerFuel rai l pres sure (FRP) s ensorfail ure
Check t he FRP s ens or and circui ts . Refer t othe el ect ri cal guides . Ins tal l a new s ensor asneces sary.REFER to: Fuel Rai l Press ure (FRP) Sens or(303-14A El ect ronic Engi ne Cont rol s - I6 3.2LPet rol , Removal and Inst all at ion).P020100Cyli nder 1 i njectorcircui t/openInject or ci rcuit : short ci rcuit t opowerInject or ci rcuit : open ci rcuitInject or ci rcuit power supply:open ci rcuitInject or fail ure
Check t he inject or and ci rcuit s . Refer to theelectrical gui des . Ins t all a new i njector asneces sary.REFER to: Fuel Injector (303-04A FuelCharging and Controls - I6 3.2L Petrol ,Removal and Inst all at ion).

Publi s hed: 11-May-2011
Fuel Charging and Controls - TD4 2.2L Diesel -
General SpecificationItemSpecification
Maximum cont inuous fl ow160 l /hr
Maximum engine cons umpt ion40 l /hrMaximum ret urn fl ow90 l /hr
Maximum pres s ure on return l ine0.7 bar (10.2 lb/in²)
Mi ni mum pres sure at engi ne0.5 bar (7.3 lb/in²)Mi ni mum pres sure at fi lt er0.3 bar (4.4 lb/in²)
Recommended fuelEN590
Fuel Pressures
Componentbarlb/in²
Fuel pump (vacuum pressure):Cranking0.1331.9
Full load0.2673.9
Hi gh pres sure fuel i nject ion pump160023206
Torque SpecificationsDescriptionNmlb-ft
EGR pi pe107
Fuel i njector clamp ret ai ning bolt s5 + 110°4 + 110°Fuel rail ret aini ng bol ts1813
Fuel pump to fuel rail hi gh-pres s ure fuel l ine retaini ng bolt107
Fuel pump to fuel rail high-pressure fuel line unions:Stage 12216
Stage 22518
Fuel i njecti on pump s ecuring bolt s2216Fuel pump bracket107
High pressure fuel supply line unions:
Stage 12216Stage 22518
Throt tl e body s crews97

chambers. Thi s provides opti mum performance, all owing t he engi ne t o be extremely respons ive t o dri ver demands for al ldri vi ng condi ti ons . The fuel s yst em features a Bos ch Generat ion 3 common rai l injection s yst em that is moni tored andcont rol led by an engine control modul e (ECM), t o precis ely cont rol the fueli ng st rategy.
Fuel charging is achieved wit h a l ow and hi gh-pres sure fuel s yst em. The l ow-pres s ure fuel s ys tem compris es ;
a s addle t ype fuel tankt ank mount ed fuel deli very module wi th int egral trans fer pumpfuel s uppl y and ret urn linesfi lt er and water s eparator as sembl ya connect ing hos e between t he fuel filt er ass embly and the fuel lift pump.
• NOTE: The fuel l ift pump is i ntegral wi th the hi gh-pres s ure pump.
A return li ne and fuel leak off hos es from the hi gh-pres s ure pump, i nject ors and common fuel rai l form t he remai nder oft he low-pres sure fuel ret urn ci rcuit .For addit ional informat ion, refer t o: Fuel Tank and Lines - 2.2L Duratorq-TDCi (DW ) Dies el (310-01 Fuel Tank and Li nes ,Des cript ion and Operat ion).
The high-press ure fuel s ys t em compri s es ;
a hi gh-pres sure fuel pumpcommon fuel rail4 pi ezo-injectors wit h hi gh-pres s ure connecti on pipesa fuel press ure sens or.
The fuel charging and control s ys tem provides i nject ion press ures of up to 1800 bar (26,106 psi ). Fi ner at omizati on of theinject ed fuel is achieved wi th the 7 hol e piezo i njectors that are capable of near ins tant aneous res ponse to the ECMcommands , all owing up to 5 individual inject ions per st roke.
The high-press ure fuel pump i s mounted at t he rear of t he cyl inder head and i s dri ven by the exhaust cams haft . A fuel l iftpump i s int egral wit h t he high-pres s ure pump and is therefore al so driven when t he exhaus t cams haft rot ates . The li ftpump creat es suct ion i n the supply line to t he fuel t ank and draws t he fuel from the t ank. The fuel pas s es through the fuelfi lt er and is t hen delivered at lift pump pres s ure to the hi gh-pres sure pump i nlet port .
The advanced high-press ure fueli ng s ys t em enables pil ot inject ions to be delivered ahead of t he main charge of fuel. Thisproduces a s teady fl ame front and creates a progres s ive pres s ure ris e in t he cyl inder s imi lar to that achi eved wit h petrolengi nes. This reduct ion i n combust ion lag between t he i nject ion of fuel and combus tion occurring al lows fuel t o be i njectedwhil e combus t ion i s t aki ng place, creat ing i ncreas ed power and reducing creat ed combus t ion nois e, vibrat ion andhars hnes s (NVH) and emis s ions .
For model s fi tt ed wi th an exhaus t sys t em dies el parti cul ate fil ter, the hi gh-pres s ure fueling sys tem als o provi des pos tcombus t ion i njecti on of fuel into the combus ti on chambers. W hen regenerati on of the di esel part iculat e fi lt er is reques t ed,t he ECM all ows the fueli ng s ys t em t o deli ver fuel after t he combus t ion s troke and int o t he commencement of the exhausts troke. This pos t combus t ion i njecti on proces s caus es fuel to be burnt in the exhaust s ys tem and creates t he high exhaus tgas temperatures that are required to regenerate t he dies el part icul ate fi lt er.

Publi s hed: 11-May-2011
Fuel Charging and Controls - TD4 2.2L Diesel - Fuel Charging and Controls
Des cript ion and Operat ion
COMPONENT LOCATION
ItemPart NumberDescription1-High-Pres sure (HP) common fuel rail
2-HP pi pe – fuel rai l to inject or (4 off)
3-HP pi pe – HP pump to fuel rail4-Low Pres s ure (LP) pipe – fuel rail l eak-off
5-Pres s ure Control Val ve (PCV)
6-LP pipe - HP pump l eak-off7-HP fuel pump and integral l ift pump
8-Fuel s upply pipe - fi lt er t o l ift pump
9-LP pipe - injector l eak-off10-Inject or (4 off)
11-Fuel rail pres s ure s ensor
OVERVIEW
The TD4 dies el engi ne fuel charging and cont rol s ys tem provides precis e and i nst antaneous fuel del ivery t o t he enginecombus t ion chambers . The fuel s ys t em feat ures a Bosch Generat ion 3 common rai l i njecti on s ys t em t hat is moni tored andcont rol led by t he Engine Control Modul e (ECM), to precis ely control t he fuel ing s t rat egy.For addit ional informat ion, refer t o: Electroni c Engi ne Controls - 2.2L Dies el (303-14 El ect ronic Engine Cont rols - 2.2L