2006 LAND ROVER FRELANDER 2 fuel cap

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.

Dies el, Des cript ion and Operat ion).
Fuel i njecti on pres sure is generat ed i ndependent ly of engine s peed and fuel inject ion events . The HP fuel s ys tem iscont rol lable t o t he opti mum level for smoot h operat ion, and is capabl e of devel opi ng an i nject ion press ure up t o 1,600 bar(23,206 psi ). The fuel i njecti on ti ming and vol ume are cal cul at ed by t he ECM t hat als o energizes t he appropriat e piezo-act uated i njector.
The fuel s yst em features a pre-inject ion (pilot ) phas e t o reduce combus ti on noi s e and mechani cal load. On vehiclesins t al led wi th a Di es el Part iculate Fi lt er (DPF), t he fuel s ys tem als o provides a pos t -i nject ion phas e t hat is requi red forregenerat ing t he DPF.For addit ional informat ion, refer t o: Exhaus t Sys t em (309-00B Exhaus t Syst em - TD4 2.2L Di es el, Des cri pt ion andOperat ion).
This t ype of fuel sys t em all ows t he TD4 engi ne t o achi eve excellent l evels of performance and engine res pons e, whilebeing able to meet current and fut ure exhaus t emi s si on legis l at ion.
Fuel charging is achieved wit h a LP and HP fuel s ys t em. The LP fuel s yst em compris es:
Saddl e t ype fuel tankTank mount ed fuel deli very module and integral t rans fer pumpFuel s upply and return li nesFil ter and water s eparator as s embly.For addit ional informat ion, refer t o: Fuel Tank and Lines (310-01B Fuel Tank and Lines - TD4 2.2L Dies el ,Des cript ion and Operat ion).
The HP fuel s ys tem compris es :
HP fuel pump wit h int egral mounted l ift pump and Volume Cont rol Valve (VCV)Common fuel rail wi th integral PCV and press ure s ens or4 pi ezo-injectorsHP connect ing pipesFuel l eak-off pipes .
HIGH-PRESSURE FUEL PUMP
ItemPart NumberDescription
A-Fuel supply connect ion - fil ter t o l ift pumpB-LP fuel return connecti on t o fi lt er
C-HP fuel s upply connect ion to fuel rail
1-HP pump element (3 off)2-HP pump dri ve s haft
3-VCV
4-Li ft pumpThe HP fuel pump is mount ed to the rear of t he cylinder head (t rans mi ss ion si de), and is driven by t he exhaus t cams haft.The fuel pump i s a 3-pis ton, radi al pl unger type, wit h t he pumping el ement s s paced equall y at 120 degrees apart. Thehigh-press ure out put from t he pump el ement s i s connected t o a fuel ri ng ci rcuit wi thi n t he fuel pump, and provi des acons t ant press uri zed fuel s upply to the fuel rail . The pump is capable of producing a maxi mum fuel pres sure of 1,600 bar

ItemPart NumberDescription
1-HP fuel s uppl y connecti on from fuel rail2-LP fuel leak-off connect ion to fil ter
3-Electrical connect ion t o ECM
4-Inject or 10-digit codeThe 4 fuel i njectors are of t he piezo-el ect ri c act uat ed t ype, each manufactured wit h 7 s pray hol es in the i njector nozzl e.The inject ors are located centrall y wit hin the cyli nder head combus t ion chambers t o s pray at omized fuel direct ly ont o t het oroidal dome of the pi s tons .
Technical Details
O perating ParameterValue
Suppl y volt age 110V to 150V230 bar (3,336 ps i) t o 1,600 bar (23,206 psi )Res is tance180 Kohms at 20°C (68°F)
Mi ni mum chargi ng t ime100 µS
Mi ni mum dis charge ti me100 µSSpray nozzle di amet er143 µm
Maximum capable del ivery11 cm3/s econd
Duri ng manufacture each injector i s tes t ed to measure t he act ual i njected quanti ty of fuel, compared t o a referencequant it y for s i mulat ed condit ions . The tes ts are us ed t o categori ze the i njectors, the difference i n t he inject ion analys isres ult s i s transl ated t o a 10-digit al pha-numerical code t hat is s t amped on t he inject or cas ing.
The 10-digi t codes are s tored in t he ECM memory al ong wit h t he corres pondi ng cyl inder numbers for each inject or, and anengi ne performance s oft ware map. The ECM recogni zes each inject or 10-digit code and adapts t he operat ion of eachinject or to provi de s imi lar i nject ion press ures and quant it y of del ivered fuel for the current operati ng condit ion, inaccordance wit h t he programmed s oft ware map.
The inject or body contai ns a s tack of piezo-electric crys t als mount ed above a cont rol pis ton. The piezo crys t al s areact uated by a s uppl y vol tage from t he ECM. The control pis ton i s s eparated wit h a hydrauli c chamber t hat acts to operat et he needle val ve via a domed pis ton and control dril li ngs . The hydrauli c chamber compens ates for temperat ure changeswit hin the i njector as sembl y, and al so allows the i njector t o operate wit h a cons tant reacti on ti me, even aft er numerousoperati ons .
The hydraulic chamber eliminates t he requi rement for contacti ng moving part s wi thi n t hi s t ype of i njector. In ot her types ofinject or thes e cont act parts will wear, increasi ng t he reacti on ti me of t he inject or and subs equentl y affect ing the enginesperformance and emis s ions .
On t he vehicle, the hydraul ic chamber i s mai nt ained by a 10 bar (145 ps i) check valve locat ed in the injector l eak-off pipejuncti on.
Due t o t he Bosch Generat ion 3 technol ogy and the i njector hydraulic chamber, t he inject ors will operat e wi th a nearins t ant aneous respons e ti me t o ECM commands . This provi des a fi ner at omizat ion of t he inject ed fuel, and al lows t he ECMt o precis ely control the actuat ion peri od of the injector. During certain engi ne operati ng condit ions , each injector i s able t odeliver a s equence of up t o 5 injecti ons during a s ingle i njecti on cycle. The s equence for an injecti on cycle of 5 indivi dualdeliveries is as fol lows :
2 pi lot inject ions up t o 3,200 Revolut ions Per Minute (RPM)

1 control i njecti on up t o 4,500 RPM1 mai n i nject ion above 4,500 RPM2 pos t-inject ions duri ng DPF regenerati on phase (no l oad val ues ).
The pil ot injecti on phas e is deli vered ahead of t he mai n charge of fuel t o produce a s teady flame front , and create aprogres s ive pres s ure ri se in t he cylinder. The pi lot inject ion phas e reduces the l ag between t he i nject ion of fuel andcombus t ion occurri ng, al lowing the remaining charge of fuel t o be injected whi le combus ti on is taking pl ace. This i njecti onpri nci pl e creat es an increas e in power, and als o reduces combus t ion Noi se, Vibrati on and Hars hnes s (NVH) and exhaus temis s ions .
On vehicles i nst all ed wit h an exhaus t s ys tem DPF, t he high-press ure fueli ng s yst em provi des a post -injecti on phase of fuelint o t he combus t ion chambers . During the regenerat ion st age of the DPF, t he ECM all ows fuel t o be i nject ed aft er thecombus t ion s t roke and int o t he commencement of t he exhaus t st roke. The post -i njecti on phas e caus es fuel to burn i n theexhaus t s ys t em, creati ng high exhaus t gas t emperatures required to regenerate the DPF.
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 - 2.2LDies el, Des cript ion and Operat ion) / Exhaus t Sys tem (309-00B Exhaust Sys tem - TD4 2.2L Dies el , Descripti on andOperat ion).
Injector Service Information
CAUTION: This t ype of inject or contai ns a hydraulic chamber. It is important that t he inject or is handled correct ly t oprevent the hydrauli c chamber from emptying. The i nject or is t o be capped and maint ained in an upri ght pos it ion, andmus t not be laid on t he si de or s haken.
Do not att empt t o remove carbon depos it s from t he dies el inject or nozzle.
The inject or is s upplied as a complete ass embly. The ori ginal inject or mus t not be separated.
• NOTE: The TD4 engine cyli nders are numbered from t he rear of t he engi ne (t rans mi ssi on end). Therefore, No. 1 cyli nderand No. 1 i nject or are l ocat ed at the rear of the engine.
A new copper washer mus t be ins t al led and t he old washer dis carded, whenever an inject or i s removed from t he cyl inderhead. The i njector cent eri ng ri ng may be re-us ed.
If an inject or i s removed, the injector mus t be i nst all ed to the original cyl inder, and does not require re-programming i ntot he ECM.
If an inject or i s renewed, the new inject or 10-digit code and corres pondi ng cyl inder number mus t be programmed i nto theECM, usi ng t he Land Rover approved di agnos ti c s yst em.
If the ECM is renewed, all 4 injector 10-di git codes and corres ponding cyli nder numbers must be programmed into the newECM, usi ng t he Land Rover approved di agnos ti c s yst em.
HIGH-PRESSURE FUEL AND LEAK-OFF PIPES
High-Pressure Fuel Pipe
The HP fuel pi pes are connected bet ween t he HP pump and fuel rail , and bet ween the fuel rail and t he 4 i njectors. Thepipes are s hort in lengt h, in order to maintai n t he maximum fuel s ys t em working press ure.
The pipes are s ingle us e only, and mus t be renewed whenever a pipe connecti on is releas ed.
Leak-Off Pipes
The fuel s yst em l eak-off pipes are ins t al led wit h quick rel eas e t ype coupli ngs, and connect t he fuel rai l, inject ors and HPpump t o t he fuel fi lt er.

Publi s hed: 11-May-2011
Fuel Charging and Controls - TD4 2.2L Diesel - Fuel Injector
Removal and Inst all ati on
Removal
• W ARNINGS:
Avoid flames , s parks or li ght ed s ubs t ances .
W ai t for a mini mum of 1 minute aft er the engine has s t opped before carryi ng out any repair t o t he fuel inject ions ys t em.
• CAUTIO NS:
Make s ure that t he area around t he component i s cl ean and free of foreign mat eri al .
Make s ure that all openi ngs are s ealed. Us e new bl anking caps .
Fuel injectors mus t not be dis mantl ed or the nozzles cleaned, not even wit h ul tras onic equipment . Ins tal l new fuelinject ors i f neces sary.
Fuel injectors mus t be ins t al led t o t heir ori ginal pos it ion.
Cap t he fuel i nject or nozzle to prevent damage before s toring vert icall y.
Fuel injectors mus t be s tored vert ical ly and immedi at ely capped when removed, to prevent t he fuel from draini ng.
If a new component has been i ns t alled, configure usi ng Land Rover approved diagnos tic equipment .
Bl eed the fuel s ys tem by cranki ng t he engi ne to purge t he air from the s ys tem.
• NOTE: If the fuel i njectors are to be removed or replaced as a s et , ins tall ati on shoul d be done in pai rs . Inject ors 2 and3, 1 and 4 res pecti vel y.
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 engi ne cover.
Refer t o: Engi ne Cover - TD4 2.2L Dies el (501-05 Interior Tri m andOrnament ati on, Removal and Ins tal lat ion).
2.
3.

4. CAUTIONS:
Make s ure that t he fuel li ne remai ns in cont act atboth ends unt il both uni ons nut s have been uns crewedand t he area around the joints thoroughly cl eaned.
Make s ure that all openings are sealed. Us e newblanking caps.
Remove and dis card t he high-pres sure fuel s uppl y li ne.
4.
5.

6. CAUTION: Not e the pos it ion of t he i nject orclamp peg6.
7. CAUTIONS:
Cap t he fuel i njector nozzl e to prevent damagebefore s toring vert icall y.
Fuel inject ors mus t be s t ored vert ically andi mmediat el y capped when removed, t o prevent the fuelfrom draini ng.
Replace t he was her.
Not e t he posi ti on of the pl ast ic al ignment s leeve.
7.
Installation
1. CAUTIONS:1.

Publi s hed: 11-May-2011
Fuel Charging and Controls - TD4 2.2L Diesel - Fuel Rail
Removal and Inst all ati on
Removal
• W ARNINGS:
Avoid flames , s parks or li ght ed s ubs t ances .
W ai t for a mini mum of 1 minute aft er the engine has s t opped before carryi ng out any repair t o t he fuel inject ions ys t em.
• CAUTIO NS:
Make s ure that t he area around t he component i s cl ean and free of foreign mat eri al .
Make s ure that all openi ngs are s ealed. Us e new bl anking caps .
Bl eed the fuel s ys tem by cranki ng t he engi ne to purge t he air from the s ys tem.
• NOTE: The fuel pres s ure and t emperat ure s ens ors are an int egral part of the fuel rail and mus t not be changeds eparately.
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 engi ne cover.
Refer t o: Engi ne Cover - TD4 2.2L Dies el (501-05 Interior Tri m andOrnament ati on, Removal and Ins tal lat ion).
2.
3. CAUTIONS:
Make s ure that t he fuel li ne remai ns in cont act atboth ends unt il both uni ons nut s have been uns crewedand t he area around the joints thoroughly cl eaned.
Make s ure that all openings are sealed. Us e newblanking caps.
Remove and dis card t he 4 hi gh-pres s ure fuel s upplyl ines.
3.
4.