Page 1602 of 3229
29.
NOTE: Pet rol i llus t rat ion s hown, di esel s imi lar.
Remove t he fuel pump module.
29.
Pus h down t o rel eas e t he fuel s ender from clip. Sli de fuel s ender as sembl y forward to releas e
from the bracket. Manoeuvre fuel s ender out of the t ank.30.
Remove t he fuel tank cradl e.
31.
Installation To i nst all , revers e t he removal procedure.
1.
Page 1604 of 3229
Publi s hed: 11-May-2011
Fuel Tank and Lines - TD4 2.2L Diesel - Fuel Level Sender
Removal and Inst all ati on
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
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.
2. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
2.
Remove t he fuel pump and s ender unit .
Refer t o: Fuel Pump and Sender Uni t (310-01B Fuel Tank and Li nes -TD4 2.2L Dies el, Removal and Inst all ati on).
3.
Remove t he LH fuel l evel s ender.4.
Installation
To i nst all , revers e t he removal procedure.1.
Page 1609 of 3229
Publi s hed: 11-May-2011
Fuel Tank and Lines - TD4 2.2L Diesel - Fuel Pump and Sender Unit
Removal and Inst all ati on
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
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 fuel fi lt er.
Refer t o: Fuel Fil ter (310-01B Fuel Tank and Lines - TD4 2.2L Dies el ,Removal and Ins tall ati on).
2.
3. CAUTION: Extreme cleanli nes s mus t beexercis ed when handl ing t hese components .3.
Installation
To i nst all , revers e t he removal procedure.1.
Page 1629 of 3229

Publi shed: 06-Jul-2011
Climate Control System - General Information - Climate Control System
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the cl imat e cont rol s yst em, refer to the relevant Des cri pti on and Operati on s ect ion i n t heworks hop manual . REFER to:
Air Dis t ri but ion and Fi lt ering (412-01 Cl imat e Control, Des cript ion and Operat ion),Heat ing and Vent il at ion (412-01 Cl imat e Control, Des cript ion and Operat ion),Air Condi ti oning (412-01 Cli mate Cont rol , Des cri pti on and Operati on),Cont rol Component s (412-01 Cli mate Cont rol , Des cri pti on and Operati on),Elect ric Boost er Heater (412-02B Auxi liary Cli mate Cont rol , Descri pti on and Operat ion),Fuel Fired Boos t er Heat er (412-02B Auxil iary Cli mate Cont 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.
1. Verify t he cus t omer concern.1.
2. Vis ually ins pect for obvious s igns of damage and s ys t em i ntegri ty.2.
Visual InspectionMechanicalElectrical
Coolant levelRefrigerant l eaks (UV l amp)Drive beltCompres s orCooli ng fanControl flap(s)Duct(s )Regis ter(s )Cabin ai r fi lt erHos e(s )Coolant pumpFuel Fi red Boos ter HeaterFuel Fi red Boos ter Heater fuel pumpFuel Fi red Boos ter Heater fuel pipes
Fus e(s)Circui tBlower mot orElectrical connect or(s)Compres s orCool ing fanAct uatorsCli mate cont rol ass embly
3. Lis ten for any unus ual noi ses during cli mate cont rol s ys t em operat ion.3.
4. Ins pect t he refri gerant s ys t em wi th an ult raviolet (UV) lamp for t races of UV s ens i ti ve leak t race dye.4.
5. 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 ep5.
6. If t he caus e is not vis ually evi dent , check Cli mate Cont rol Module, Engi ne Control Module (ECM), Fuel FiredBoos ter Heater and Central Juncti on Box (CJB) for Di agnos ti c Trouble Codes (DTCs ) and refer to the DTC Index.6.
Climate Control System
• NOTE: If a cont rol module or component i s s uspect and the vehicl e remai ns under manufacturer warrant y, refer t o t heW arranty Pol icy and Procedures manual (s ect ion B1.2), or determine i f any pri or approval program is i n operat ion, beforet he replacement of a component.
• NOTE: Generic scan t ool s may not read the codes li st ed, or may read only 5-digi t codes . Match t he 5 digi ts from t he s cant ool t o t he fi rs t 5 di gi ts of the 7-digit code li s ted t o i dent ify the fault (the last 2 digi ts gi ve ext ra informati on read by themanufacturer-approved di agnos ti c s ys t em).
• 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 .
Cli mate Cont rol Syst em
For a compl ete lis t of all Di agnos ti c Trouble Codes (DTCs) t hat could be logged on this vehicle, pleas e refer to Sect ion100-00.
REFER to: Di agnos ti c Trouble Code (DTC) Index - DTC: Heati ng Vent il ati on and Air Condit ioning Control Modul e (HVAC)(100-00 General Informati on, Des cri pti on and Operati on).
Page 1737 of 3229

Publi shed: 26-Jul-2011
Auxiliary Heating - Fuel Fired Booster Heater
Diagnosi s and Tes ti ng
Overview
For informati on on t he des cri pti on and operati on of the s ys tem, refer t o s ect ion 412-02 -REFER to:
Fuel Fired Boos t er Heat er (412-02B Auxil iary Cli mate Cont rol, Des cri pt ion and Operati on),Fuel Fired Boos t er Heat er (412-02B, Des cript ion and Operat ion),Fuel Fired Boos t er Heat er (412-02B Auxil iary Cli mate Cont rol, Removal and Ins t al lat ion),Fuel Fired Boos t er Heat er Fuel Pump (412-02B Auxili ary Cl imat e Control, Removal and Ins tall ati on),Fuel Fired Boos t er Heat er Cool ant Pump (412-02B Auxil iary Cli mate Cont rol, Removal and Ins t al lat ion),Fuel Fired Boos t er Heat er Glow Pl ug And Burner As sembl y (412-02B Auxi liary Cli mate Cont rol , Removal andIns tal lat ion).Auxi li ary Heat ing i n the works hop manual .
Inspection and Verification
1. Verify t he cus t omer concern.1.
2. Vis ually ins pect for obvious mechani cal or electrical fault s .2.
Visual inspectionMechanicalElectrical
Fuel fired heater as sembl y- Combus ti on air fan- Coolant inl et /out let- Heat exchanger- Temperat ure s ens or- Exhaus t- Fuel inlet- Ai r inlet- EvaporatorAuxili ary fuel pump and li nesAuxili ary coolant pump
Fus esHarness esEl ect ri cal connector(s )Cont roll er area network (CAN) ci rcuit sCont rol module(s)
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. Us e the approved di agnos ti c s ys t em or a s can t ool t o ret rieve any diagnos t ic t rouble codes (DTCs ) before movingont o t he sympt om chart or DTC i ndex.4.
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: 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 5-digi t codes . Match t he 5 digi ts from t he s cant ool t o t he fi rs t 5 di gi ts of the 7-digit code li s ted t o i dent ify the fault (the last 2 digi ts gi ve ext ra informati on read by themanufacturer-approved di agnos ti c s ys t em).
• 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 .
The t abl e below l is t s all Diagnos ti c Trouble Codes (DTCs ) t hat could be logged in the Fuel Fi red Boos ter Heater Module, foraddi ti onal Di agnos is and Tes ti ng informat ion refer t o t he relevant Diagnosi s and Test ing Secti on
DTC index
For a compl ete lis t of all Di agnos ti c Trouble Codes (DTCs) t hat could be logged on this vehicle, pleas e refer to Sect ion100-00. REFER t o: Diagnost ic Troubl e Code (DTC) Index - DTC: Auxi li ary Heater Control Modul e (AHCM) (100-00 GeneralInformat ion, Des cript ion and Operat ion).
Page 1738 of 3229
Publi s hed: 11-May-2011
Auxiliary Climate Control -
Torque SpecificationsDescriptionNmlb-ft
Electric boos ter heater Torx screws21
Fuel fired boost er heat er bol ts107Feul fired boost er heat er fuel pump bolt s107
Page 1741 of 3229
Publi s hed: 11-May-2011
Auxiliary Climate Control - Fuel Fired Booster Heater
Des cript ion and Operat ion
COMPONENT LOCATION - VEHICLES WITHOUT FFBH REMOTE CONTROL
ItemPart NumberDescription1-Automat ic Temperat ure Cont rol (ATC) modul e
2-Fuel Fi red Boos ter Heater (FFBH)
3-Auxili ary coolant pump4-Ambi ent ai r temperat ure s ens or
5-Auxili ary fuel pump
COMPONENT LOCATION - VEHICLES FROM 2009MY WITH FFBH REMOTE CONTROL
Page 1742 of 3229

ItemPart NumberDescription
1-Automat ic Temperat ure Cont rol (ATC) modul e2-Fuel Fi red Boos ter Heater (FFBH)
3-Auxili ary coolant pump
4-Ambi ent ai r temperat ure s ens or5-Auxili ary fuel pump
6-FFBH Recei ver
7-FFBH antenna mat chi ng unit
OVERVIEW
The Fuel fired Boos t er Heat er (FFBH) is rated at 5 kW and compensat es for t he rel ativel y low coolant t emperaturesinherent i n the di esel engine. The uni t is locat ed behind t he Right Hand (RH) front fender s plas h s hield and heat s enginecool ant downs tream of t he heat er core.
Operat ion of t he FFBH is controlled by the Aut omati c Temperature Control (ATC) module via the medi um s peed ControllerArea Net work (CAN) bus . Operati on of the FFBH i s influenced by:
Ambient air t emperat ureEngi ne cool ant temperat ure.
The FFBH wil l operate i f the ambient air t emperature is lower than 5 °C (41 °F) and s top if ambient t emperature reaches 8°C (46 °F). Operat ion of t he FFBH may als o be inhibit ed if t he fuel l evel drops below a predet ermi ned level .
Remote Operation - Vehicles from 2009MY
On vehicles from 2009MY the FFBH has remote operati on. The remote sys tem includes t he addi ti on of a FFBH receiver,