Frelander 2. Manual — part 293
Item
Part Number
Description
1
-
Intake air filling tract
2
-
Intake manifold
3
-
Cylinder head swirl port
4
-
Cylinder head filling port
The TD4 cylinder head and intake manifold are designed to optimize levels of swirl across the engines speed range, and
provide a high volume of air into the cylinders. The intake manifold is designed with a lower row of 4 helical swirl ports,
and an upper row of 4 filling ports with port-deactivation device. The 8 ports are sealed to the cylinder head and structural
camshaft cover mating ports with a shaped sealing ring. The helical swirl port is configured to create optimum swirl for
efficient combustion; while the filling port is provided to supply high volumes of air without disturbing in-cylinder swirl. The
intake manifold port de-activation device is controlled by the ECM.
For additional information, refer to: Electronic Engine Controls - 2.2L Diesel (303-14 Electronic Engine Controls - 2.2L
Diesel, Description and Operation).
Each cylinder is supplied air through the helical swirl port, and when activated, through the filling port. The helical swirl
port is always open and directs air from the intake manifold lower port at a tangent into the combustion chamber. The
filling port is normally closed, and is only opened during certain engine operating conditions by the ECM. When opened the
filling port directs air from the intake manifold upper port, and through the curved intake tracts into the combustion
chamber. The intake tracts are cast with the structural camshaft cover, and join the intake manifold upper filling ports to
the cylinder head machined filling ports.
At low engine loads gas flow is so low that the filling port is closed off. This has the effect of raising gas velocity through
the helical port and increasing in-cylinder swirl to the optimum rate. To avoid the risk of the high gas flow creating
excessive swirl, the ECM opens the filling port under high gas-flow conditions to maintain consistent optimum swirl across
the engines operating range.
Intake Manifold Port De-Activation
Item
Part Number
Description
1
-
Solenoid-operated valve
2
-
Intake manifold helical swirl port
3
-
Vacuum-operated actuator
4
-
Intake manifold filling port
5
-
Butterfly valve (4 off)
Port de-activation is operated by 4-butterfly valves connected on a common shaft within the intake manifold. Each
butterfly valve is housed within a corresponding intake manifold upper filling port. The common shaft is connected to a
vacuum-operated actuator, and is operated by a solenoid valve under the control of the ECM. The vacuum required for port
de-activation is supplied from the engine mounted vacuum pump.
For additional information, refer to:
Engine
(303-01B Engine - TD4 2.2L Diesel, Description and Operation),
Electronic Engine Controls - 2.2L Diesel (303-14 Electronic Engine Controls - 2.2L Diesel, Description and Operation).
Port de-activation (opening of the filling ports) only occurs when the coolant temperature is greater than 10°C, and under
the following conditions:
Engine speed is greater than 1,800 rpm.
Engine load is greater than 15%.
Intake Air Distribution and Filtering - TD4 2.2L Diesel - Intake Air
Distribution and Filtering
Diagnosis and Testing
Principles of Operation
For a detailed description of the intake air distribution and filtering system, refer to the relevant Description and Operation
section in the workshop manual.
REFER to:
Intake Air Distribution and Filtering
(303-12B Intake Air Distribution and Filtering - TD4 2.2L Diesel, Description
and Operation).
Inspection and Verification
CAUTION: 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.
1. Verify the customer concern.
1.
2. Visually inspect for obvious signs of mechanical or electrical damage.
2.
Visual Inspection
Mechanical
Electrical
Hoses and ducts (damage/connections)
Air cleaner element
(contaminated/blocked)
Restricted air intake
Seals and gaskets
Mass Air Flow (MAF) sensor
Secondary Air Injection (AIR) Manifold Absolute Pressure (MAP)
sensor
Throttle body
Harness (security/damage)
Connections (security/damage)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step
3.
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.
4.
Symptom Chart
Symptom
Possible Cause
Action
Vehicle does not start/hard
starting/poor performance
Restricted/blocked air intake
Restricted/blocked air cleaner
element
Ensure the air intake system is free
from blockage and is correctly installed
Install a new air cleaner element as
necessary.
REFER to: Air Cleaner Element (303-12,
Removal and Installation).
Excessive intake noise
Intake pipe disconnected/damaged
after the air cleaner
Air cleaner assembly incorrectly
assembled/damaged
Check for correct installation and
integrity of air intake system
Check for correct installation and
integrity of the air cleaner assembly.
REFER to: Air Cleaner Element (303-12,
Removal and Installation).
DTC Index
• NOTE: If the control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the
Warranty Policy and Procedures manual (section B1.2), or determine if any prior approval programme is in operation, prior
to the installation of a new module/component.
• NOTE: Generic scan tools may not read the codes listed, or may read only five digit codes. Match the five digits from the
scan tool to the first five digits of the seven digit code listed to identify the fault (the last two digits give additional
information read by the manufacturer approved diagnostic system).
• NOTE: When performing voltage or resistance tests, always use a digital multimeter (DMM) accurate to three decimal
places, and with an up-to-date calibration certificate. W hen testing resistance always take the resistance of the DMM
leads into account.
• NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
• NOTE: Inspect connectors for signs of water ingress, and pins for damage and/or corrosion.
• NOTE: If DTCs are recorded and, after performing the pinpoint tests, a fault is not present, an intermittent concern may
be the cause. Always check for loose connections and corroded terminals.
DTC
Description
Possible Causes
Action
P006900 MAP - Barometric Pressure
Correlation
Boost pressure sensor circuit - short to
ground, power, open circuit
Barometric pressure sensor failure
Carry out the pinpoint tests
associated with this DTC using the
manufacturer approved diagnostic
DTC
Description
Possible Causes
Action
system
P007200 Ambient Air Temperature
Sensor Circuit Low
Ambient air temperature sensor circuit -
short to ground, open circuit
Carry out the pinpoint tests
associated with this DTC using the
manufacturer approved diagnostic
system
P007300 Ambient Air Temperature
Sensor Circuit High
Ambient air temperature sensor circuit -
short to power
Carry out the pinpoint tests
associated with this DTC using the
manufacturer approved diagnostic
system
P009700 Intake Air Temperature
Sensor 2 Circuit Low
Intake air temperature sensor voltage
below lower limit
Carry out the pinpoint tests
associated with this DTC using the
manufacturer approved diagnostic
system
P009800 Intake Air Temperature
Sensor 2 Circuit High
Intake air temperature sensor voltage
above upper limit
Carry out the pinpoint tests
associated with this DTC using the
manufacturer approved diagnostic
system
P010000 Mass or Volume Air Flow A
Circuit
MAF Sensor signal circuit - short to
ground, power, open circuit
Carry out the pinpoint tests
associated with this DTC using the
manufacturer approved diagnostic
system
P010221 Mass or Volume Air Flow A
Circuit Low
Air flow PWM raw signal above upper
limit
Carry out the pinpoint tests
associated with this DTC using the
manufacturer approved diagnostic
system
P010226 Mass or Volume Air Flow A
Circuit Low
Air flow PWM corrected signal above
upper limit
Carry out the pinpoint tests
associated with this DTC using the
manufacturer approved diagnostic
system
P010322 Mass or Volume Air Flow A
Circuit High
Air flow PWM raw signal above upper
limit
Carry out the pinpoint tests
associated with this DTC using the
manufacturer approved diagnostic
system
P010327 Mass or Volume Air Flow A
Circuit High
Air flow PWM corrected signal above
upper limit
Carry out the pinpoint tests
associated with this DTC using the
manufacturer approved diagnostic
system
P011200 Intake Air Temperature
Sensor 1 Circuit Low
Intake air temperature sensor 1 circuit -
short to ground
Carry out the pinpoint tests
associated with this DTC using the
manufacturer approved diagnostic
system
P110222 Mass Air Flow Sensor in
Range But Lower Than
Expected
Air Mass (measured) is too low (not
plausible) with calculated reference air
mass during overrun: ratio of
calculated/actual too high
Carry out the pinpoint tests
associated with this DTC using the
manufacturer approved diagnostic
system
P110321 Mass Air Flow Sensor in
Range But Higher Than
Expected
Air Mass (measured) is too high (not
plausible) with calculated reference air
mass during overrun: ratio of
calculated/actual too low
Carry out the pinpoint tests
associated with this DTC using the
manufacturer approved diagnostic
system
P222700 Barometric Pressure Circuit
Range/Performance
Atmospheric Pressure Sensor defective
Install a new module, refer to the
new module/component installation
note at the top of the DTC Index.
REFER to: Powertrain Control Module
(PCM) (303-14, Removal and
Installation).
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