Land Rover Discovery: Fuel Charging and Controls - Ingenium i4 2.0l Diesel / Diagnosis and Testing

PRINCIPLES OF OPERATION

For a detailed description of the Fuel Charging and Controls system, refer to the relevant Description and Operation section in the workshop manual.

REFER to: Fuel Charging and Controls (303-04C Fuel Charging and Controls - INGENIUM I4 2.0L Diesel, Description and Operation).

INSPECTION AND VERIFICATION

WARNINGS:

• Do NOT carry out any work on the fuel system with the engine running. The fuel pressure within the system can be as high as 1600 bar (23,206 lb/in²). Failure to follow this instruction may result in personal injury.
• Eye protection must be worn at all times when working on or near any fuel related components. Failure to follow this instruction may result in personal injury.
• This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow this instruction may result in personal injury.
• After making repairs, the fuel system must be checked visually for leaks. Failure to follow this instruction may result in personal injury.
• If fuel is taken internally, do not induce vomiting. Seek immediate medical attention. Failure to follow this instruction may result in personal injury. If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek medical attention. Failure to follow this instruction may result in personal injury.
• Wash hands thoroughly after handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention.

  Failure to follow this instruction may result in personal injury.

CAUTIONS:

• Before disconnecting any part of the fuel system, it is imperative that all dust, dirt and debris is removed from around components to prevent ingress of foreign matter. Failure to follow this instruction may result in damage to the vehicle.
• It is essential that absolute cleanliness is observed when working with fuel system components. Always install blanking plugs to any open orifices or lines. Failure to follow this instruction may result in damage to the vehicle.
• The fuel pipes between the injectors and the rail must be discarded after each use, and new pipes installed. Failure to follow this instruction may result in damage to the vehicle.
• Make sure that the workshop area in which the vehicle is being worked on is as clean and dust-free as possible. Areas in which work on clutches, brakes or where welding or machining are carried out are not suitable in view of the risk of contamination to the fuel system. Failure to follow this instruction may result in damage to the vehicle.
• Make sure that any protective clothing worn is clean and made from lint-free non-flocking material. Failure to follow this instruction may result in damage to the vehicle.
• Make sure that any protective gloves worn are new and are of the non-powdered latex type. Failure to follow this instruction may result in damage to the vehicle.
• Make sure that clean, non-plated tools are used. Clean tools using a new brush that will not lose its bristles and fresh cleaning fluid prior to starting work on the vehicle. Failure to follow this instruction may result in damage to the vehicle.
• Use a steel-topped work bench and cover it with clean, lint-free, non-flocking material. Failure to follow this instruction may result in damage to the vehicle.
• Diagnosis by substitution from a donor vehicle is NOT acceptable.

  Substitution of control modules does not guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or the donor vehicle.

NOTES:

• If a control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the Warranty Policy and Procedures manual, or determine if any prior approval programme is in operation, prior to the installation of a new module/component.
• When performing voltage or resistance tests, always use a digital multimeter accurate to three decimal places, and with an up-todate calibration certificate. When testing resistance always take the resistance of the digital multimeter leads into account.
• Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

1. Verify the customer concern
2. Visually inspect for obvious signs of damage and system integrity

Visual Inspection

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for Diagnostic Trouble Codes (DTCs) and refer to the DTC Index
5. Check DDW for open campaigns. Refer to the corresponding bulletins and SSMs which may be valid for the specific customer complaint and carry out the recommendations as required

SYMPTOM CHART

SYMPTOM:

Engine cranks, but does not start

POSSIBLE CAUSES:

• Engine system fault
• Intake pipe disconnected/damaged after the air cleaner
• Fuel level low
• Fuel contaminated
• Low pressure fuel system restricted/leaking/damaged
• Fuel filter restricted/leaking/damaged
• Fuel volume control valve blocked/contaminated
• Fuel pressure control valve blocked/contaminated
• High pressure fuel pump internal failure

ACTION:

• Using the Jaguar Land Rover approved diagnostic equipment, check the powertrain control module for related DTCs and refer to the relevant DTC index
• Check the intake system for correct installation and damage. Rectify as necessary
• Check the fuel level. Rectify as necessary
• Check the fuel for contamination.

  Draw off approximately 1 liter (2.11 pints) of fuel and allow to stand for 1 minute. Check for separation of the fuel (indicating water or other liquid in the fuel). Rectify as necessary

• Check the low pressure fuel system for restrictions, leaks and damage. Rectify as necessary
• Check the fuel filter for restrictions, leaks and damage. Rectify as necessary
• Check the fuel volume control valve for blockages and contamination. Rectify as necessary
• Check the fuel pressure control valve for blockages and contamination.Rectify as necessary
• Check the high pressure fuel pump.

  Rectify as necessary

SYMPTOM:

Difficult to start

POSSIBLE CAUSES:

• Engine system fault Intake pipe disconnected/damaged after the air cleaner
• Fuel level low
• Fuel contaminated
• Glow plugs inoperative
• Low pressure fuel system restricted/leaking/damaged
• Fuel filter restricted/leaking/damaged
• Fuel volume control valve blocked/contaminated
• Fuel pressure control valve blocked/contaminated
• Exhaust gas recirculation system fault

ACTION:

• Using the Jaguar Land Rover approved diagnostic equipment, check the powertrain control module for related DTCs and refer to the relevant DTC index
• Check the intake system for correct installation and damage. Rectify as necessary
• Check the fuel level. Rectify as necessary
• Check the fuel for contamination.
• Draw off approximately 1 liter (2.11 pints) of fuel and allow to stand for 1 minute. Check for separation of the fuel (indicating water or other liquid in the fuel). Rectify as necessary
• Refer to the relevant section of the workshop manual and check the glow plugs. Rectify as necessary
• Check the low pressure fuel system for restrictions, leaks and damage. Rectify as necessary
• Check the fuel filter for restrictions, leaks and damage. Rectify as necessary
• Check the fuel volume control valve for blockages and contamination. Rectify as necessary
• Check the fuel pressure control valve for blockages and contamination.

  Rectify as necessary

• Refer to the relevant section of the workshop manual and check the exhaust gas recirculation system.

  Rectify as necessary

SYMPTOM:

Rough idle

POSSIBLE CAUSES:

• Engine system fault
• Fuel level low
• Fuel contaminated
• Low pressure fuel system restricted/leaking/damaged
• Fuel filter restricted/leaking/damaged
• Fuel volume control valve blocked/contaminated
• Fuel pressure control valve blocked/contaminated
• Exhaust gas recirculation system fault

ACTION:

• Using the Jaguar Land Rover approved diagnostic equipment, check the powertrain control module for related DTCs and refer to the relevant DTC index
• Check the fuel level. Rectify as necessary
• Check the fuel for contamination.

  Draw off approximately 1 liter (2.11 pints) of fuel and allow to stand for 1 minute. Check for separation of the fuel (indicating water or other liquid in the fuel). Rectify as necessary

• Check the low pressure fuel system for restrictions, leaks and damage. Rectify as necessary
• Check the fuel filter for restrictions, leaks and damage. Rectify as necessary
• Check the fuel volume control valve for blockages and contamination. Rectify as necessary
• Check the fuel pressure control valve for blockages and contamination.

  Rectify as necessary

• Refer to the relevant section of the workshop manual and check the exhaust gas recirculation system.

  Rectify as necessary

SYMPTOM:

Lack of power when accelerating

POSSIBLE CAUSES:

• Engine system fault
• Intake pipe disconnected/damaged after the air cleaner
• Intake pipe restricted/blocked
• Air filter element restricted/blocked
• Exhaust system restricted/blocked
• Low pressure fuel system restricted/leaking/damaged
• Exhaust gas recirculation system fault
• Turbocharger actuator rod detached/seized
• Turbocharger failure

ACTION:

• Using the Jaguar Land Rover approved diagnostic equipment, check the powertrain control module for related DTCs and refer to the relevant DTC index
• Check the intake system for correct installation and damage. Rectify as necessary
• Check the intake pipe for restrictions and blockages. Rectify as necessary
• Check the air filter element for restrictions and blockages. Rectify as necessary
• Check the exhaust system for restrictions and blockages. Rectify as necessary
• Check the low pressure fuel system for restrictions, leaks and damage. Rectify as necessary
• Refer to the relevant section of the workshop manual and check the exhaust gas recirculation system. Rectify as necessary
• Check the integrity of the turbocharger actuator rod. Rectify as necessary
• Check the integrity of the turbocharger. Rectify as necessary

SYMPTOM:

Engine stops/stalls

POSSIBLE CAUSES:

• Fuel level low
• Fuel contaminated
• Low pressure fuel system restricted/leaking/damaged
• High pressure fuel system leaking
• Fuel volume control valve blocked/contaminated
• Fuel pressure control valve blocked/contaminated
• Exhaust gas recirculation system fault

ACTION:

• Check the fuel level. Rectify as necessary
• Check the fuel for contamination.

  Draw off approximately 1 liter (2.11 pints) of fuel and allow to stand for 1 minute. Check for separation of the fuel (indicating water or other liquid in the fuel). Rectify as necessary

• Check the low pressure fuel system for restrictions, leaks and damage. Rectify as necessary
• Check the high pressure fuel system for leaks. Rectify as necessary
• Check the fuel volume control valve for blockages and contamination. Rectify as necessary
• Check the fuel pressure control valve for blockages and contamination.

  Rectify as necessary

• Refer to the relevant section of the workshop manual and check the exhaust gas recirculation system.

  Rectify as necessary

SYMPTOM:

Engine judders

POSSIBLE CAUSES:

• Fuel level low
• Fuel contaminated
• Low pressure fuel system restricted/leaking/damaged
• Fuel volume control valve blocked/contaminated
• Fuel pressure control valve blocked/contaminated
• High pressure fuel system leaking
• High pressure fuel pump internal failure

ACTION:

• Check the fuel level. Rectify as necessary
• Check the fuel for contamination.
• Draw off approximately 1 liter (2.11 pints) of fuel and allow to stand for 1 minute. Check for separation of the fuel (indicating water or other liquid in the fuel). Rectify as necessary
• Check the low pressure fuel system for restrictions, leaks and damage. Rectify as necessary
• Check the fuel volume control valve for blockages and contamination. Rectify as necessary
• Check the fuel pressure control valve for blockages and contamination.

  Rectify as necessary

• Check the high pressure fuel system for leaks. Rectify as necessary
• Check the high pressure fuel pump.

  Rectify as necessary

SYMPTOM:

Fuel consumption excessive

POSSIBLE CAUSES:

• Engine system fault
• Low pressure fuel system restricted/leaking/damaged
• Fuel volume control valve blocked/contaminated
• Fuel pressure control valve blocked/contaminated
• High pressure fuel system leaking
• Injector fault(s)
• Exhaust gas recirculation system fault

ACTION:

• Using the Jaguar Land Rover approved diagnostic equipment, check the powertrain control module for related DTCs and refer to the relevant DTC index
• Check the low pressure fuel system for restrictions, leaks and damage. Rectify as necessary
• Check the fuel volume control valve for blockages and contamination. Rectify as necessary
• Check the fuel pressure control valve for blockages and contamination.

  Rectify as necessary

• Check the high pressure fuel system for leaks. Rectify as necessary
• Using the Jaguar Land Rover approved diagnostic equipment, check the powertrain control module for related DTCs and refer to the relevant DTC index
• Refer to the relevant section of the workshop manual and check the exhaust gas recirculation system.

  Rectify as necessary

DTC INDEX

For a list of Diagnostic Trouble Codes (DTCs) that could be logged on this vehicle, please refer to Section 100-00. REFER to: Diagnostic Trouble Code Index - INGENIUM I4 2.0L Diesel, DTC: Engine Control Module (ECM) B10A2-07 to P034B-76 (100-00 General Information, Description and Operation).

Fuel Charging and Controls - Ingenium i4 2.0l Diesel Specifications

Torque Specifications

NOTE:

* = Refer to procedure for correct torque sequence.

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