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ItemPart NumberDescription
1-Combus t ion ai r fan2-Cool ant out let
3-Cool ant inlet
4-Burner ins ert5-Heat exchanger
6-Temperature s ens or
7-Exhaus t8-Fuel i nl et
9-Evaporat or
10-Air i nl et
Combustion Air Fan
The combus t ion ai r fan regul at es t he fl ow of air i nto t he FFBH t o s upport combus ti on of the fuel suppli ed by t he auxi liaryfuel pump. It i s als o us ed t o purge and cool the FFBH.
Burner Housing
The burner hous ing cont ai ns the burner i nsert and als o i ncorporat es connecti ons for t he exhaus t pipe, the coolant inl etfrom the auxil iary coolant pump and t he cool ant out let t o t he vehi cl e heater.
The burner ins ert i ncorporat es t he fuel combus t ion chamber, an evaporator and a gl ow pin and fl ame s ens or. Fuel from t heauxi li ary fuel pump is s uppl ied t o a vent uri, where it evaporat es and ent ers t he combust ion chamber to mix wit h air fromt he combus ti on air fan. The gl ow pin and fl ame s ens or provides t he igni ti on source for t he fuel:air mi xture and, oncecombus t ion i s es tabli shed, monit ors t he flame.
Heat Exchang er
The heat exchanger t ransfers heat generated by combus ti on t o the coolant . Two s ens ors are i nst all ed in t he heatexchanger cas ing t o provide the control modul e wi th i nput s of Engine Coolant Temperature (ECT). The cont rol module us est he temperat ure inputs t o control s ys tem operati on.
Air Inlet Hose and Muffler
A canis ter t ype muffler i s included in the ai r inlet s upply l ine. The muffler reduces the noi se caus ed by inducti on roar.
Exhaust Pipe and Muffler
The exhaus t pipe and muffl er di rects exhaus t combus ti on gases t o at mos phere below t he front RH wheel arch. Exhaus tvapor may be vi s ible when the FFBH i s running, dependi ng on atmos pheri c condit ions .
Control Module
The cont rol module cont rols and moni tors operati on of the FFBH sys tem. An int ernal flow of ai r from t he combust ion ai r fanvent il ates t he cont rol module to prevent i t overheat ing.
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The cont rol module is powered by a permanent feed from the Bat t ery Junct ion Box (BJB), and communi cat es wi th t he ATCmodule over the medium speed Controller Area Network (CAN) bus .
AUXILIARY COOLANT PUMP
The auxi li ary coolant pump is mount ed on t he heater cas i ng and is us ed t o as si s t coolant flow through t he FFBH and t heheat er core.
The auxi li ary coolant pump runs conti nuous ly whi le the FFBH i s act ive. W hen t he FFBH is inact ive, cool ant flow is reli ant ont he engi ne cool ant pump. Operat ion of t he auxi li ary cool ant pump is controll ed by a power feed di rect from t he cont rolmodule wit hi n t he FFBH.
Stop/Start Vehicles - From 2010 MY
Duri ng a St op/Start cycle when the engine i s s hutdown and consequent ly the engine-driven coolant pump is st ati onary, thedesi red s et cabi n t emperature cannot be mai ntai ned for a prol onged period, especially in col d ambient t emperatures . Tocount eract this an auxi li ary electric coolant -pump, cont rol led by t he ECM (engi ne cont rol module), has been i ntegrat ed int ot he cooli ng s yst em t o mai ntai n the coolant flow t hrough t he cabi n’s heater core. This s upporti ng circulat ion prolongs thes et temperat ure set ti ng in the cabin and accordingly prevent s an earl y engi ne res t art .
On vehicles fit ted wit h a Fuel Fi red Boos ter Heat er (FFBH) t he addit ional auxil iary cool ant pump is not ins t al led. In it splace t he FFBH auxi liary cool ant pump is ut il ized t o circulat e t he cool ant i n an engine s hutdown s i tuati on. The pump isact ivat ed via t he FFBH by t he CJB (central junct ion box).For addit ional informat ion, refer t o: Starti ng Sys t em (303-06C Starti ng Syst em - TD4 2.2L Di es el, Vehicles Bui lt From:01-03-2009, Descripti on and Operat ion).
AMBIENT AIR TEMPERATURE SENSOR
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The ambient air t emperat ure s ensor i s a Negati ve Temperature Co-effi ci ent (NTC) thermis t or, and is mount ed in the LeftHand (LH) door mi rror. The s ens or is connect ed t o the Engi ne Cont rol Module (ECM) which t rans mit s an ambi ent ai rt emperature val ue over t he high speed CAN bus . This value i s rel ayed to the ATC modul e by t he Cent ral Junct ion Box (CJB)over t he medium s peed CAN bus.For addit ional informat ion, refer t o: Cont rol Component s (412-01 Cli mat e Cont rol , Descripti on and Operat ion).
REMOTE CONTROL COMPONENTS - VEHICLES FROM 2009MY WITH FFBH REMOTE
CONTROL
The addi ti on of remot e control retai ns the FFBH component s fit ted t o pre 2009MY vehicl es wit h t he addi ti on of thefol lowing components :
FFBH wit h upgraded s oft ware and cali brat ionFFBH remot e handsetFFBH remot e receiverRecei ver power, communicati on and antenna harnes sesAntenna mat chi ng unit harnes s to connect recei ver co-axial cable t o exis t ing DAB antenna in s ide window.
FFBH Remote Handset
ItemPart NumberDescription
1-On butt on2-Off butt on
3-LED operat ion indicator
4-Ant ennaThe remot e handset al lows t he dri ver t o remotely act ivate the FFBH wi thout entering t he vehi cl e. The hands et has a rangeof at leas t 100 m (328 ft ) i n free s pace, alt hough t his di s tance may be decreas ed depending on t he l ocat ion of obst acl ess uch as bui ldings . The hands et is powered by a 3.3 vol t CR1/3N replaceable bat t ery whi ch can be access ed by removi ng acover from the rear of t he hands et . The bat tery li fe in t he remote hands et is approximat ely 300 FFBH cycl es. One cycle i sdefi ned as a hands et butt on pres s fol lowed by 30-minut e burn t ime wi th flas hing LED feedback.
The remot e handset has a green Light Emit ti ng Diode (LED) to indicate the FFBH i s act ive. W hen t he 'O N' but ton i spres s ed on t he hands et for more t han 2 s econds, t he LED wi ll il lumi nat e for 2 s econds . Aft er t he 2 s econd period haspass ed, the LED wil l i ll uminate for 50 ms every 2 s econds for up to the 30 minut e on t ime of t he FFBH. The LED wil l onl ys top flas hing i f the 'OFF' but ton i s pres s ed or the 30 minute on t imer has elaps ed.
Remote Hands et LED Indi cat or Functi onal it y
The LED il lumi nat es i n different ways t o alert the driver to the various s tat es of the FFBH remote control sys t em asfol lows :
Illumi nates green for 2 s econds when t he ON but ton has been press ed t o s how t hat t he receiver unit hass uccess fully recei ved the hands et on request . The FFBH may now s t art operat ing providi ng that fuel l evel , bat teryvolt age and coolant t emperature variabl es are wi thi n li mit s .Flas hes green for 50 ms every 2 s econds t o i ndi cat e t hat the FFBH may be act ive.Illumi nates red for 2 seconds when the OFF but ton has been pres s ed t o s how t hat t he receiver unit has s uccess fullyreceived t he hands et off reques t. The FFBH s hould t hen s top operat ing.Flas hes green or red for 2 s econds when pres s ing t he ON or OFF but t ons t o i ndi cat e that the s i gnal was notreceived by t he FFBH receiverIllumi nates orange before changi ng to green or red to s how t hat remot e hands et batt ery vol tage i s lowFlas hes orange for 5 s econds t o s how t hat si gnal was not received by t he FFBH and t hat t he remote hands etbatt ery requi res replacement .
Remote Hands et Pairi ng
Each remot e hands et mus t be 'paired' t o t he receiver t o enabl e communicati ons . Each hands et has a unique identi fi cat ionnumber whi ch is st ored by t he receiver. The recei ver can s t ore up 3 hands et identi ficat ion numbers . If a fourth hands et ispaired to the recei ver, the recei ver wi ll repl ace the first pai red handset number wit h t hat for t he fourt h handset i n t hereceiver memory. Subsequentl y, t he first paired hands et wi ll no l onger be paired and wil l not be recognis ed by t he receiver.
The fol lowing procedure det ail s t he pai ri ng process :
Remove fus e FA5 from the Rear Junct ion Box (RJB)W ai t for a minimum of 5 s econdsReplace fus e t o pos it ion FA5 i n the RJBW i thi n 5 s econds of repl aci ng the fus e (and res toring t he receiver power s upply), pres s and hol d the remot e
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hands et OFF butt onConfirmat ion of s ucces sful pai ri ng is di spl ayed by t he remote hands et LED ill uminat ing i n a red col or for 2 s econds .
• NOTE: The pairing proces s rel ies on t he FFBH receiver havi ng the power s uppl y removed and t hen t he power s upplyre-ins tat ed. The fus e met hod is t he easi est method but it can al so be achi eved by bat tery dis connect ion or removal of t heharnes s connect or from t he receiver unit .
Receiver
The receiver is l ocat ed in the LH si de of the luggage compart ment . The recei ver i s mounted on an int egral bracket which i nt urn i s att ached t o t he audio s ys tem bracket whi ch locat es t he High Definit ion (HD) radi o receiver.
The receiver is connect ed to the ant enna on the LH s ide wi ndow wit h a co-axi al cable. Radi o Frequency (RF) s ignals fromt he remot e hands et are received by t he ant enna and pas s ed via the ant enna matching unit and co-axial cable t o t hereceiver. The recei ver proces ses t he s ignals and t rans mi ts appropriate mes sages t o the FFBH on a dedicated bus .
Antenna and Antenna Matching Unit
Antenna Mat chi ng Unit
The FFBH antenna is locat ed i n the LH rear s ide wi ndow and us es the s ame ant enna el ements as us ed by t he audio Di git al
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Audio Broadcast (DAB) s yst em.
Sit uat ed above the DAB antenna unit , behi nd the headli ni ng, is an ant enna matching unit . A flying lead from this uni tconnects di rectl y t o a s t ud on the gl ass ant enna. The recei ver unit connect s to the matching unit vi a a co-axial cabl e.
The glas s mounted ant enna recei ves RF transmit ted s i gnals from t he remot e handset and t rans mi ts t hem, via t hemat chi ng uni t and co-axial cable, t o t he FFBH receiver.
CONTROL DIAGRAM - VEHICLES WITHOUT FFBH REMOTE CONTROL
• NOTE: A = Hardwi red; D = High speed CAN bus ; N = Medium s peed CAN bus
ItemPart NumberDescription
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1-Batt ery
2-Fuse 17, BJB
3-Fuse 27, CJB4-ATC module
5-CJB
6-Engi ne Control Module (ECM)7-Ambient air t emperat ure s ensor
8-Auxi li ary coolant pump
9-Auxi li ary fuel pump10-Fuel fired boos t er heat er
11-Fuse 32, BJB
CONTROL DIAGRAM - VEHICLES FROM 2009MY WITH FFBH REMOTE CONTROL
• NOTE: A = Hardwi red; D = High speed CAN bus ; F = RF Trans mis s ion; N = Medium s peed CAN bus; T = Co-axi al; AA =W ebas to 'W ' bus
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ItemPart NumberDescription
1-Bat tery2-Fus e 17, BJB
3-Fus e 27, CJB
4-ATC modul e5-CJB
6-Engine Cont rol Modul e (ECM)
7-Ambi ent ai r temperat ure sens or8-Auxil iary fuel pump
9-Auxil iary coolant pump
10-FFBH Receiver (Vehicles from 2009MY )11-Ant enna matching unit
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12-Fuel fi red boos ter heat er
13-FFBH/DAB ant enna (Vehicles from 2009MY )
14-Fus e 32, BJB15-Fus e FA5, RJB
16-FFBH Remot e hands et (Vehi cl es from 2009MY )
PRINCIPLES OF OPERATION
If a heat ing reques t i s received and t he ambient air t emperature is les s t han or equal to 5°C (41 °F), t he ATC modulet ransmit s a 'supplement al heat' mes s age to the FFBH control modul e over the medi um speed CAN bus . The control modul eres ponds by ret urning a 's uppl ement al heat ' st atus mess age back to the ATC modul e. The control modul e wi ll now i nit iatet he FFBH st art s equence.
If the heati ng reques t is removed, or ambient air t emperat ure ris es t o 8°C (46 °F), the ATC modul e t rans mit s a 'heat er off'mes s age to t he FFBH cont rol module over t he medium s peed CAN bus . Again, t he cont rol module res ponds by returni ng a'heater off' s tat us mes sage back to the ATC modul e. The cont rol module wi ll now de-act ivate the FFBH.
If maxi mum heat ing i s reques ted, Engi ne Cool ant Temperature (ECT) becomes the overriding factor. In t his i nst ance, t heATC module wil l change the CAN bus mes sage from 'heater off' to 's uppl emental heat ' when ECT is bel ow or equal t o 70°C(158°F). If ECT ri ses to 78°C (172°F) t he ATC module returns the mess age t o 'heater off'.
The cont rol module wil l not s t art t he FFBH, or wil l dis cont inue operat ion, if any of the foll owing occur:
The cont rol module is i n t he error l ockout mode (see Diagnostics, below).The engi ne is not runni ng, or s t ops running for approxi mately 4 s econds . The ti me delay i s included for s t alldetecti on.A 'fuel cut -off' mes s age is recei ved from t he CJB over t he medium s peed CAN bus .For addit ional informat ion, refer t o: Air Bag and Safet y Belt Pretens ioner Supplement al Res traint Syst em (SRS)(501-20B Supplement al Res t raint Sys tem, Des cript ion and O perati on).A l ow fuel l evel mes s age is recei ved from t he CJB over t he medium s peed CAN bus (s ee t abl e below).For addit ional informat ion, refer t o: Ins t rument Clus ter (413-01 Inst rument Cl us t er, Des cript ion and Operat ion).
The cont rol module wil l control FFBH operat ion bas ed on t he fol lowi ng levels of fuel i n the tank.
Fuel Level, liters (US Gallons)Description
7.5 (1.98)St art
4.5 (1.18)St op10.5 (2.77)Res tart
Start Sequence
At t he begi nni ng of a s tart s equence, t he FFBH cont rol module;
energizes t he glow pi n and flame s ens or t o pre heat the combust ion chambers tarts t he combust ion ai r fan at s l ow s peedand energizes t he auxi liary cool ant pump.
Aft er approxi matel y 30 s econds , the control modul e energizes t he auxi li ary fuel pump at t he s tarti ng s equence s peed. Thefuel deli vered by the auxil iary fuel pump evaporates i n t he combus t ion chamber, mi xes wi th air from the combus ti on air fanand is ignit ed by t he glow pi n and fl ame s ensor. The cont rol module t hen progres s ively increases t he s peed of the auxil iaryfuel pump and t he combus t ion ai r fan. Once combus ti on is est ablis hed t he cont rol module swi tches t he glow pi n and fl ames ens or t o the fl ame s ens i ng functi on to monit or combus ti on. From t he begi nni ng of the st art s equence t o s tabl ecombus t ion at full load t akes approxi mately 150 seconds .
Full and Part Load Combustion
W hi le t he FFBH is running, the control modul e cycl es the heat er bet ween ful l l oad combus t ion, part load combus ti on and acont rol i dl e phase of operat ion, depending on the temperat ure of t he cool ant in t he heat exchanger.
The heat out put level at part l oad combus t ion i s 2.8 kW . Thi s ris es to 5 kW at full l oad combus ti on. The control modul et ransmit s t he amount of fuel us ed by t he FFBH to the i nst rument clus t er, and t he FFBH coolant t emperature t o t he ATCmodule.
Swit chi ng Point Temperatures