Frelander 2. Manual — part 251
Fuel Charging and Controls - TD4 2.2L Diesel - Fuel Charging and Controls
Diagnosis and Testing
Principles of Operation
For a detailed description of the fuel charging and controls, refer to the relevant Description and Operation section in the
workshop manual.
REFER to:
Fuel Charging and Controls
(303-04B Fuel Charging and Controls - TD4 2.2L Diesel, Description and Operation) /
Turbocharger
(303-04C Fuel Charging and Controls - Turbocharger - 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
Fuel level
Fuel leaks
Damaged fuel lines
Damaged push connect fittings
Fuel contamination/grade/quality
Throttle body
Fuses
Loose or corroded electrical connectors
Harnesses
Sensor(s)
Engine Control Module (ECM)
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
Engine cranks but
does not start
Fuel level
Contaminated fuel
Fuel system
leaking/blocked
Air intake system
Electronic engine
controls
Check fuel level and for contamination. Check fuel and air intake
system integrity. Check for DTCs and refer to the relevant DTC Index
Difficult to start
Fuel level
Contaminated fuel
Fuel system
leaking/blocked
Air intake system
Electronic engine
controls
Check fuel level and for contamination. Check fuel and air intake
system integrity. Check for DTCs and refer to the relevant DTC Index
Rough idle
Low/contaminated fuel
Fuel system
leaking/blocked
Electronic engine
controls
Check fuel level/condition. Check integrity of fuel and engine control
systems. Check for DTCs and refer to relevant DTC Index.
Lack of power under
acceleration
Contaminated fuel
Air intake system
Blocked
exhaust/catalytic
converter
Turbocharger fault
Fuel system
Electronic engine
controls
Low engine
compressions
Check for fuel contamination. Check for DTCs and refer to relevant
DTC Index. Check integrity of air intake, exhaust, turbocharger, and
engine control systems
Engine stops/stalls
Low/contaminated fuel
Fuel system
Air intake system
Electronic engine
controls
Check for fuel contamination. Check for DTCs and refer to the relevant
DTC Index. Check integrity of fuel, air intake, and engine systems
DTC Index
• NOTE: If the control module/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 extra
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 a current 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 that involve pinpoint tests.
• 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 Cause
Action
P004513 Turbo charger/Supercharger
Boost Control A Circuit /
Open
Turbo charger actuator
power stage output 2
circuit - open load
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P004518 Turbo charger/Supercharger
Boost Control A Circuit /
Open
Power stage temperature
dependant current
limitation
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P004519 Turbo charger/Supercharger
Boost Control A Circuit /
Open
Turbo charger actuator
power stage output 1
circuit - over current
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P004619 Turbo charger/Supercharger
Boost Control A Circuit
Range/Performance
Power stage excess
temperature
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P004711 Turbo charger/Supercharger
Boost Control A Circuit Low
Turbo charger actuator
power stage output 1
circuit - short to ground
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P004714 Turbo charger/Supercharger
Boost Control A Circuit Low
Turbo charger actuator
power stage output 2
circuit - short to ground
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P004718 Turbo charger/Supercharger
Boost Control A Circuit Low
Power stage current
limitation
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P004800 Turbo charger/Supercharger
Boost Control A Circuit High
Actuator power stage
error
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P004812 Turbo charger/Supercharger
Boost Control A Circuit High
Turbo charger actuator
power stage output 1
circuit - short to power
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P004815 Turbo charger/Supercharger
Boost Control A Circuit High
Turbo charger actuator
power stage output 2
circuit - short to power
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P008821 Fuel Rail/System Pressure -
Too High
Pressure control valve
circuit - short to power
Pressure control valve
stuck closed
Check for pressure control valve DTCs and refer to
relevant DTC Index
P008822 Fuel Rail/System Pressure -
Too High
Leaking fuel system
Volume control valve
circuit - short to ground,
open circuit
Volume control valve
stuck open
Check for fuel leaks. Refer to electrical circuit
diagrams and check volume control valve circuit for
short to ground, open circuit. Install a new high
pressure fuel pump as required
P008824 Fuel Rail/System Pressure -
Too High
Leaking fuel system
Pressure control valve
stuck
Pressure control valve
circuit - short to ground,
power, open circuit
Check for fuel leaks. Refer to electrical circuit
diagrams and check pressure control valve circuit
for short to ground, power, open circuit. Install a
new pressure control valve as required
P008827 Fuel Rail/System Pressure -
Too High
Leak in high pressure
section
Injector nozzle stuck
open/worn
Worn high pressure
pump, filter blocked
Leaking pressure control
valve
Check for fuel leaks in high and low pressure
systems, check for additional DTCs and refer to
DTC Index
DTC
Description
Possible Cause
Action
Low pressure section
pressure low (leak in
system, pump output
low)
P009B00 Fuel Pressure Relief Control
Circuit/Open
Pressure control valve
control circuit - open load
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P009C00 Fuel Pressure Relief Control
Circuit Low
Pressure control valve
control circuit - short to
ground
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P009D00 Fuel Pressure Relief Control
Circuit High
Pressure control valve
control circuit - short to
power
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P009E00 Fuel Pressure Relief Control
Performance/Stuck Off
Pressure control valve
power stage excess
temperature
Refer to electrical circuit diagrams and check
pressure control valve circuit for high resistance, if
no fault identified install new ECM. Refer to the
new module/component installation note at the
top of the DTC Index
P00AF75 Turbo charger/Supercharger
Boost Control A Module
Performance
Variable Gate Turbo
charger sensor circuit -
short to ground, power,
open circuit
Variable Gate Turbo
charger sensor failure
Refer to electrical circuit diagrams and check
variable gate Turbo charger sensor circuit for short
to ground, power, open circuit. Install a new Turbo
charger as required
P018200 Fuel Temperature Sensor A
Circuit Low
Fuel temperature sensor
voltage below lower limit
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P018300 Fuel Temperature Sensor A
Circuit High
Fuel temperature sensor
voltage above upper limit
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P023422 Turbo charger/Supercharger
A Over boost Condition
Boost pressure control
deviation below lower
limit at full load
Check for turbo charger related DTCs and refer to
the relevant DTC Index
P023700 Turbo charger/Supercharger
Boost Sensor A Circuit Low
Boost pressure sensor
circuit - short to ground,
open circuit
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P023800 Turbo charger/Supercharger
Boost Sensor A Circuit High
Boost pressure sensor
circuit - short to power
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P025100 Injection Pump Fuel Metering
Control A
Fuel metering unit control
circuit - open load
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P02CC21 Cylinder 1 Fuel Injector
Offset Learning at Min Limit
Injector energising time
calibration during overrun
- time below lower limit
Install a new injector
P02CD22 Cylinder 1 Fuel Injector
Offset Learning at Max Limit
Injector energising time
calibration during overrun
- time above upper limit
Install a new injector
P02CE21 Cylinder 2 Fuel Injector
Offset Learning at Min Limit
Injector energising time
calibration during overrun
- time below lower limit
Install a new injector
P02CF22 Cylinder 2 Fuel Injector
Offset Learning at Max Limit
Injector energising time
calibration during overrun
- time above upper limit
Install a new injector
P02D021 Cylinder 3 Fuel Injector
Offset Learning at Min Limit
Injector energising time
calibration during overrun
- time below lower limit
Install a new injector
P02D122 Cylinder 3 Fuel Injector
Offset Learning at Max Limit
Injector energising time
calibration during overrun
- time above upper limit
Install a new injector
P02D221 Cylinder 4 Fuel Injector
Offset Learning at Min Limit
Injector energising time
calibration during overrun
- time below lower limit
Install a new injector
P02D322 Cylinder 4 Fuel Injector
Offset Learning at Max Limit
Injector energising time
calibration during overrun
- time above upper limit
Install a new injector
P02E013 Diesel Intake Air Flow
Control Circuit/Open
Throttle motor control
circuit - open circuit
Refer to electrical circuit diagrams and check
throttle control circuit for open circuit
DTC
Description
Possible Cause
Action
P02E100 Diesel Intake Air Flow
Control Performance
Throttle valve stuck
during after run learning
routine
Error in driver IC (CJ230
power stage) for Throttle
Valve Actuator
Clear the DTC and re-test. If the DTC remains,
install a new ECM. Refer to the new
module/component installation note at the top of
the DTC Index
P02E119 Diesel Intake Air Flow
Control Performance
Throttle motor control
circuit - short circuit
overload error
Refer to electrical circuit diagrams and check
throttle control circuit for short circuit fault
P02E14B Diesel Intake Air Flow
Control Performance
Excess Temperature in
CJ230 power stage for
Throttle Valve Actuator
Clear the DTC and re-test. If the DTC remains,
install a new ECM. Refer to the new
module/component installation note at the top of
the DTC Index
P02E211 Diesel Intake Air Flow
Control Circuit Low
Throttle motor control
circuit - short to ground
Refer to electrical circuit diagrams and check
throttle control circuit for short to ground
P02E214 Diesel Intake Air Flow
Control Circuit Low
Throttle motor control
circuit - short to ground
Refer to electrical circuit diagrams and check
throttle control circuit for short to ground
P02E312 Diesel Intake Air Flow
Control Circuit High
Throttle motor control
circuit - short to power
Refer to electrical circuit diagrams and check
throttle control circuit for short to power
P02E315 Diesel Intake Air Flow
Control Circuit High
Throttle motor control
circuit - short to power
Refer to electrical circuit diagrams and check
throttle control circuit for short to power
P02E471 Diesel Intake Air Flow
Control Stuck Open
Throttle valve stuck
during normal engine
running - attempt to
unstick valve
unsuccessful
Check/clear throttle valve from obstruction/sticking
P02E571 Diesel Intake Air Flow
Control Stuck Closed
Throttle valve stuck
closed during normal
engine running - attempt
to unstick valve
unsuccessful
Check/clear throttle valve from obstruction/sticking
P02E728 Diesel Intake Air Flow
Position Sensor
Range/Performance
Throttle valve open or
closed position offset
difference with first
learning too large
Throttle valve open or
closed position offset
difference with previous
learning too large
Check/clear throttle valve from
obstruction/sticking, clear DTC and re-test. If the
DTC remains, install a new throttle body
P02E800 Diesel Intake Air Flow
Position Sensor Circuit Low
Throttle position sensor
circuit - short to ground,
open circuit
Refer to electrical circuit diagrams and check
throttle position sensor circuit for short to ground,
open circuit
P02E872 Diesel Intake Air Flow
Position Sensor Circuit Low
Throttle valve position
deviation - valve stuck
open
Check/clear throttle valve from obstruction/sticking
P02E900 Diesel Intake Air Flow
Position Sensor Circuit High
Throttle position sensor
circuit - short to power
Refer to electrical circuit diagrams and check
throttle position sensor circuit for short to power
P02E973 Diesel Intake Air Flow
Position Sensor Circuit High
Throttle valve position
deviation - valve stuck
closed
Check/clear throttle valve from obstruction/sticking
P031300 Misfire Detected With Low
Fuel
Low fuel - misfire induced
by ECM to warn driver
before shut off
Carry out the pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system
P062B00 Internal Control Module Fuel
Injector Control Performance
Overrun Monitor - injector
energising times too long
during overrun
Redundant shut off path
error
Install a new ECM, refer to the new
module/component installation note at the top of
the DTC Index.
REFER to: Powertrain Control Module (PCM)
(303-14 Electronic Engine Controls - 2.2L Diesel,
Removal and Installation).
P062B16 Internal Control Module Fuel
Injector Control Performance
Redundant shut off path
voltage too low
Install a new ECM, refer to the new
module/component installation note at the top of
the DTC Index.
REFER to: Powertrain Control Module (PCM)
(303-14 Electronic Engine Controls - 2.2L Diesel,
Removal and Installation).
P062B17 Internal Control Module Fuel
Injector Control Performance
Redundant shut off path
voltage too high
Install a new ECM, refer to the new
module/component installation note at the top of
the DTC Index.
REFER to: Powertrain Control Module (PCM)
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