2006 LAND ROVER FRELANDER 2 engine

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SymptomPossible CauseAction
Igni ti on, Di agnos is and Tes t ing).For VCT s ys t em t est s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).
Engine s urgesFuel pump, fuel l inesEl ect ronic engine controlsIgnit ion s yst em
For fuel pump t es t s , read DTCs and refer toDTC Index in t his secti on. For fuel l ine t est s .GO to Pi npoi nt Tes t A.For elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).For ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A EngineIgni ti on, Di agnos is and Tes t ing).
Engine detonat es /knocksEl ect ronic engine controlsFuel pump, fuel l ines , fuelquali tyAi r leakageSt icking VCT hub
For elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).For fuel pump t es t s , read DTCs and refer toDTC Index in t his secti on. For fuel l ine t est s .GO to Pi npoi nt Tes t A.Check for leakage from ai r intake s ys temFor VCT s ys t em t est s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).
DTC Index
• NOTE: If a module or component i s s uspect, and t he vehi cl e remains under t he Manufacturers warranty, refer to theW arranty Pol icy and Procedure manual (s ecti on B1.2), or det ermi ne if any pri or approval programme i s in operat ion, pri or tot he ins tal lati on of a new modul e/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 el ect ri cal volt age or resi s tance tes t s, al ways us e a digit al mult imet er (DMM) accurate to threedeci mal places , and wi th an up-to-date cali brat ion cert ificate. W hen t es ti ng res is t ance, always take t he res i st ance of t heDMM leads int 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: 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 .
For a compl ete lis t of all di agnos ti c troubl e codes that coul d be l ogged on t his vehicle, pleas e refer to s ect ion 100-00.REFER to:
Diagnos t ic Troubl e Code (DTC) Index - I6 3.2L Petrol, DTC: Engi ne Control Module (ECM) (100-00 GeneralInformat ion, Descri pti on and Operat ion),Diagnos t ic Troubl e Code (DTC) Index - I6 3.2L Petrol, DTC: Engi ne Control Module (ECM) - From 10MY (100-00,Descri pti on and Operat ion).
PINPOINT TEST A : CHECK THE FU EL LINES
T ESTCONDIT IONSDET AILS/RESULT S/ACT IONS
A1: CHECK T HE FUEL LINES FOR REST RICT IONS
W ARNING: This procedure invol ves fuel handl ing. Be prepared for fuel s pi ll age at al l ti mes andal ways obs erve fuel handli ng precaut ions . Fai lure to fol low t hese ins truct ions may res ul t in pers onali njury.
Det ach the fuel li ne from t he fuel rai l and from t he fuel pump modul e.
Usi ng an air l ine gentl y blow through the l ine checking for blockages or res t ri ct ions .
Is a bl ockage or res t ri ct ion evident?YesCLEAR/REPAIR t he blocked or rest ri cted fuel l ine and t es t the s ys tem for normal operat ion.NoGO t o A2.
A2: CHECK T HE FUEL T ANK LINES FOR REST RICT IONSRemove the fuel pump modul e l ocking ring.REFER t o: Fuel Pump and Sender Uni t (310-01A Fuel Tank and Lines - I6 3.2L Pet rol, Removal andIns tal lati on).
Det ach the fuel li nes from t he fuel pump module.
Usi ng an air l ine gentl y blow through the t ank li nes checki ng for blockages or rest ri cti ons .

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Is a bl ockage or res t ri ct ion evident?YesCLEAR/REPAIR t he blocked or rest ri cted fuel l ine and t es t the s ys tem for normal operat ion.NoCHECK for DTCs and s ymptoms indicati ng anot her caus e for t he problem.REFER t o: Electroni c Engi ne Controls (303-14A Electroni c Engine Controls - I6 3.2L Pet rol , Diagnos i sand Tes t ing).
PINPOINT TEST B : CHECK THE FU EL SYSTEM PRESSURE
T ESTCONDIT IONSDET AILS/RESULT S/ACT IONS
B1: CHECK T HE PUMP ACT IVIT YRemove the rear s eat cus hion.REFER t o: Rear Seat Cus hi on (501-10 Seat ing, Removal and Inst all ati on).
Set i gni ti on s tat us to ON, engi ne OFF.
Li s ten for pump nois e.
Can the fuel pump be heard runni ng?YesGO t o B2.NoCHECK for DTCs .REFER t o: Electroni c Engi ne Controls (303-14A Electroni c Engine Controls - I6 3.2L Pet rol , Diagnos i sand Tes t ing).
B2: CHECK T HE FUEL SYST EM PRESSURE
W ARNING: This procedure invol ves fuel handl ing. Be prepared for fuel s pi ll age at al l ti mes andal ways obs erve fuel handli ng precaut ions . Fai lure to fol low t hese ins truct ions may res ul t in pers onali njury.
Make sure t he vehi cl e is in Park and apply the parki ng brake.
Set i gni ti on s tat us to OFF
• NOTE: Pl ace sui table abs orbent mat erial around t he Schraeder valve t o abs orb any spil lage whenconnect ing t he gauge set .
Connect adapt er 310-162 and gauge as sembl y 310-116 t o t he fuel Schraeder valve. Remove theabs orbent mat erial and dis pos e of safely.Dis connect and pl ug t he vacuum hos e from the press ure regulat or.
Open the valve on the fuel press ure gauge and adapter 310-116/162.
Set i gni ti on s tat us to ON, engi ne OFF.
Record the fuel press ure reading.
Is t he fuel pres s ure 3.6 - 4.2 bar (52.2 - 60.9 l b/in²)?YesGO t o B3.NoCHECK for DTCs .REFER t o: Electroni c Engi ne Controls (303-14A Electroni c Engine Controls - I6 3.2L Pet rol , Diagnos i sand Tes t ing).B3: CHECK T HE FUEL SYST EM PRESSURE WIT H T HE ENGINE CRANKING
Appl y foot brake and pres s s tart but t on.
Record the fuel press ure reading when engine cranki ng.
Is t he fuel pres s ure 3.6 - 4.2 bar (52.2 - 60.9 l b/in²)?YesGO t o B4.NoCHECK for DTCs .REFER t o: Electroni c Engi ne Controls (303-14A Electroni c Engine Controls - I6 3.2L Pet rol , Diagnos i sand Tes t ing).B4: CHECK T HE FUEL SYST EM PRESSURE WIT H T HE ENGINE IDLING (WHERE PO SSIBLE)
W it h engine runni ng.
Is t he fuel pres s ure 3.6 - 4.2 bar (52.2 - 60.9 l b/in²)?YesCHECK for DTCs and s ymptoms indicati ng anot her caus e of the probl em.REFER t o: Electroni c Engi ne Controls (303-14A Electroni c Engine Controls - I6 3.2L Pet rol , Diagnos i sand Tes t ing).NoCHECK the fuel pump module power and ground circui ts .

5-Exhaus t heat s hi eld
6-Fuel line underfloor prot ect ion t ray
7-Fuel ret urn l ine8-Fuel fi lt er as s embly
9-Fuel temperat ure sens or
10-Fuel supply line11-Fuel del ivery modul e
12-Hos e - fuel t ank breather
OVERVIEW
The TD4 dies el fuel s ys t em i ncorporat es a l ow and hi gh-pres sure (HP) ci rcuit t o provide the engine wit h s uffi cient fuel forall operat ing condi ti ons . The l ow-pres s ure (LP) sys tem compri ses :
Molded pl as t ic s addle-t ype fuel t ankFuel deli very module (wi th integral i n-t ank pump)Fuel l evel s ens orsFuel s upply and return li nesFuel fil ter as sembl y.
• NOTE: Fuel i s drawn from t he fuel t ank by the engine mount ed li ft pump. The i n-t ank pump does not deli ver fuel t o t heengi ne, and onl y delivers fuel through the 2 jet pumps t o maint ain fuel in t he fuel deli very pot.
The HP s ys tem features a Bos ch Generati on 3 common rail inject ion s ys tem.For addit ional informat ion, refer t o: Fuel Chargi ng and Cont rol s (303-04B Fuel Charging and Cont rols - TD4 2.2L Di esel ,Des cript ion and Operat ion).
FUEL TANK CONSTRUCTION

Int ernal mounti ng bracketFuel deli very module and cross over tube2 MAPPS t ype fuel s ender unit sBreat her valve.
Internal Mounting Bracket
The int ernal mount ing bracket i s molded i nto t he t ank cas ing and provi des the locat ion for the breather val ve, andcros sover tube as s embly.
Fuel Delivery Module
ItemPart NumberDescription
1-In-t ank pump supply to jet pump
2-Fuel s upply t o engine fuel fil ter3-In-t ank pump
4-In-t ank pump supply to jet pump
5-Jet pump (us able s ide of t ank)6-Inl et from us able s ide of t ank
7-Return fuel from engi ne fuel fi lt er
8-Cros s over t ube (from unus able si de of tank)9-Jet pump (unus abl e s ide of t ank)
The fuel deli very module i s located in t he RH s i de of the t ank, and i s s ecured to the bot tom of the t ank wit h a weldedbayonet-t ype lock ri ng. The t op flange of the fuel del ivery module ass embly provides t he int ernal and ext ernal interface fort he tank elect rical and fuel connecti ons . The flange is formed wit h a 6-pin ext ernal el ect ri cal connector t hat is connect ed tot he 2 MAPPS fuel l evel s ens ors , and t he in-tank pump.

The fuel deli very module flange i s s eal ed to the t ank wit h an O-ring and s ecured wi th a locki ng ring.
The lower part of t he fuel deli very module forms the fuel del ivery pot , and provides the locat ion for the in-t ank pump andt he 2 jet pumps . The delivery pot provi des a cons t ant res ervoir of fuel for t he engine drawn fuel supply. The engine fuels uppl y and ret urn l ines are immers ed in the del ivery pot .
The delivery pot is mai ntained full by t he 2 jet pumps . The i n-t ank pump draws fuel from wit hin the fuel deli very pot andforces the fuel t hrough t he 2 jet pumps . The flow of fuel t hrough each jet pump creat es a venturi effect t hat draws fuelfrom bot h s ides of t he fuel tank i nto the fuel deli very pot. Surpl us fuel entering the fuel deli very pot overflows into theus abl e s ide of t he fuel t ank.
A valve i s l ocated in t he l ower (usabl e tank s i de) jet pump s uppl y ori fi ce. The valve i s open when the i n-t ank pump isenergized and t he lower jet pump is s upplying fuel i nto the fuel del ivery pot . The val ve wil l cl os e when the i n-t ank pump isde-energized t o prevent fuel drai ni ng from the fuel del ivery pot .
The in-tank pump is energized by t he fuel pump relay l ocat ed in the Cent ral Juncti on Box (CJB). The Engine Cont rol Module(ECM) energi zes the fuel pump relay at al l ti mes when t he ignit ion i s in power modes 4 (Acces s ory) t o 9 (Engi ne crank).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).
A modi fi ed fuel delivery modul e i s ins tal led for col d climat e market vehicl es that feat ure a fuel fi red boos ter heater andauxi li ary fuel pump. The modified fuel del ivery modul e incorporat es a s eparate fuel supply line that connects t o anauxi li ary fuel pump, mounted on the ext erior RH si de of the tank. An addi ti onal fuel l ine connects the auxil iary fuel pumpt o the fuel fi red boos ter heat er.For addit ional informat ion, refer t o: Fuel Fired Boost er Heat er (412-02B Auxi liary Cli mate Cont rol , Des cri pti on andOperat ion).
Fuel Sender Units
The 2 MAPPS fuel s ender uni ts are located on eit her s ide of t he s addl e s haped tank, and connect t o t he int ernal elect ricalconnecti ons on the fuel del ivery modul e fl ange. Each s ens or provides an elect rical signal t o t he CJB t hat i s proport ionatet o the fuel level i n each s ide of t he tank.
The act ual fuel level i n t he t ank i s calculated by the CJB and t rans mit t ed via t he medium s peed Cont roll er Area Net work(CAN) bus t o t he ins t rument clus ter.
A warning l amp is incorporat ed in t he i ns t rument clus ter and wi ll il lumi nat e when t he fuel l evel is at, or below apredetermined l evel . On vehi cles wi th a high-l ine i nst rument clus ter, a mes s age is di spl ayed and a chi me i s s ounded t oinform the driver to refuel .
For addit ional informat ion, refer t o:
Ins trument Clus ter (413-01 Ins t rument Clus t er, Descripti on and Operat ion),Informat ion and Mes s age Cent er (413-08 Informati on and Mes sage Cent er, Descripti on and Operat ion).
Fuel Tank Breather Valve
The breat her valve i s located i n t he fuel t ank and is connected to the fuel deli very module fl ange vi a an i nt ernal breatherhose. The breat her valve al lows ai r to es cape and ent er the fuel tank t o compens at e for t he changing vol ume wit hin thet ank.
FUEL TANK FILLER

prot ect ion t ray is s ecured wit h i ntegral cli ps on the ins ide of t he tray t o s tuds along t he underfl oor.
CAUTION: The fuel l ine quick-fit t ype connect or is a new des ign connector i ns t alled to the TD4 vehicle. Duringmaint enance procedures t he quick-fi t t ype connect or must be releas ed and connected correct ly to prevent fuel l eakage.Us e t he correct met hod det ailed in t he rel evant s ect ion of t he Servi ce Repair Manual (SRP) t o rel eas e and connect t heconnector. Incorrect operati on of the qui ck-fi t type connector wi ll res ult in damage t o t he connector and caus e fuelleakage.
The quick-fit t ype fuel connect or is not a s elf s eali ng connector, and will not prevent fuel fl ow when dis connected.
The fuel s uppl y and ret urn lines are connected at each end wit h a qui ck-fi t type connect or. The connector is nots elf-s eal ing and will not prevent fuel fl ow when t he fuel li ne is separat ed.
FUEL FILTER ASSEMBLY
ItemPart NumberDescription
1-Fuel t emperat ure s ensor
2-Fuel s upply t o HP pump3-W at er drain screw
4-Fuel fil ter cani s ter
5-Fuel canis ter cras h s hiel d6-W at er drain poi nt
7-Fuel s upply from tank
8-Fuel return to tank9-Fuel return from HP fuel s ys t em
The fuel filt er cani st er is l ocat ed at the front RH si de of the engi ne compartment , and mount ed wi thi n an engine s upport

bracket . A cras h s hiel d is ins tal led t o prot ect t he filt er cani st er in the event of a front al impact. The fil ter cani s ter ismanufactured from heat res is t ant and flame-proof durable pl ast ic, and cont ains a paper t ype fil ter element .
The fuel t emperature s ens or is incorporated wit hin t he fuel s uppl y li ne connecti on on t he fuel fi lt er canis t er. The s ens orprovides t he ECM wi th a s ignal vol tage t hat is proporti onal t o the act ual fuel t emperat ure. The s ignal i s us ed by the ECMin conjuncti on wi th ot her vehicle s ens ors , t o cal cul ate the actual fuel pres s ure requi red i n t he HP fuel rail .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).
A bl eed screw and drai n point are locat ed on t he fi lt er canis t er. The bleed s crew allows wat er cont ent in t he fuel t o bedrai ned off during servi ce int ervals .
Fuel Filter Pre-Heat Function
The fuel filt er feat ures a fuel pre-heat functi on that operates when the return fuel t emperature is bel ow 10°C (50°F). Thepre-heat funct ion reci rculat es a quant it y of ret urn fuel from t he HP fuel s ys tem through the fil ter cani s ter t o prevent fuelwaxing, and improve the engine performance during cold runni ng.
ItemPart NumberDescriptionA-Ret urn fuel t emperat ure l es s t han 10°C (50°F)
B-Ret urn fuel t emperat ure great er than 20°C (68°F)
1-Fuel return t o t ank2-Fuel return pas sage out let
3-Fuel return pas sage by-pas s port
4-Fuel fil ter head5-Fuel return from HP fuel s yst em
6-W ax-type t hermos tat ic valve (by-pas s open)

Publi s hed: 11-May-2011
Fuel Tank and Lines - TD4 2.2L Diesel - Fuel Tank and Lines
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the fuel tank and l ines s ys t ems , refer t o t he rel evant Des cript ion and Operat ion s ecti on in the
works hop manual .
REFER to: Fuel Tank and Lines (310-01B Fuel Tank and Lines - TD4 2.2L Dies el, 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 does
not guarant ee confirmat ion of a faul t, and may als o caus e addit ional fault s i n t he v ehi cl e being t est ed and/or t he donor
vehi cl e.
1. Verify t he cus t omer concern.
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2. Vis ually ins pect for obvious s igns of mechani cal or electrical damage.
2.
Visual Inspection Mechanical Electrical
Fuel l eaks Damaged fuel l ines
Damaged push connect fit t ings
Fuel l evel
Fuel contami nati on/grade/quali ty
Damaged fuel t ank fi ller pipe cap
Damaged fuel t ank fi ller pipe Fuses
Loos e or corroded elect rical connect ors
Harnes s es
Fuel Pump Dri ver Module (FPDM)
Central Junct ion Box (CJB)
Fuel pump relay
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) before
proceeding t o t he next s t ep.
3.
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 Ch art, al ternat ively, check for
Di agnos ti c Trouble Codes (DTCs) and refer t o t he DTC Index.
4.
Symptom Chart Symptom Possible Cause Action
Engine cranks , but
does not fi re Low/contaminated fuel Intake air l eakage
Fuel sys tem leak, blocked/res tricted
El ect ronic engine controls Check for l ow/contami nat ed fuel
Check int egrit y of i nt ake air s yst em
Check fuel s yst em for leaks and
bl ockage/res t ri ct ion. Read DTCs and refer to
relevant DTC Index For electronic engine control t es ts .
REFER t o: Electroni c Engi ne Control s (303-14,
Diagnos is and Tes t ing). Di fficul t t o s tart
Gl owpl ug faul t Low/contaminated fuel
Check engi ne cool ant l evel /anti -
freeze cont ent Bat tery
Intake air s ys tem leak
El ect ronic engine controls
Injector l eak
Fuel sys tem leak, blocked/res tricted Check int egrit y of glowpl ug sys t em
Check for l ow/contami nat ed fuel
Check t he engi ne cool ant l evel and condi ti on.
REFER t o: Specificati ons (303-03B Engine Cool ing
- TD4 2.2L Di es el, Specificat ions ). Ens ure the bat tery is i n a full y charged and
servi ceable condit ion Check int ake air s yst em for leaks
For electronic engine control t es ts .
REFER t o: Electroni c Engi ne Control s (303-14,
Diagnos is and Tes t ing). Carry out i njector leak t est s , ins tal l new inject ors
as neces sary.
REFER t o: Fuel Injector (303-04B Fuel Charging
and Cont rols - TD4 2.2L Di esel , Removal and
Ins tal lati on). Check fuel s yst em for leaks and
bl ockage/res t ri ct ion. Read DTCs and refer to
relevant DTC Index Rough idl e
Intake air s ys tem leak Low/contaminated fuel
Fuel sys tem leak, blocked/res tricted
EGR val ve fault Check int ake air s yst em for leaks
Check for l ow/contami nat ed fuel
Check fuel s yst em for leaks and
bl ockage/res t ri ct ion. Read DTCs and refer to
relevant DTC Index Check EGR s ys tem for fai lure.
REFER t o: Engi ne Emis s ion Cont rol (303-08B
Engine Emis s ion Control - TD4 2.2L Di esel ,
Diagnos is and Tes t ing).