Defender. Manual — part 115
1
-
High-pressure line
2
-
Leak-off pipe
3
-
Fuel injection line
4
-
Fuel injector
5
-
Pressure limiting valve
6
-
Fuel rail
7
-
Volume Control Valve (VCV)
8
-
Fuel pressure sensor
9
-
Fuel temperature sensor
10
-
High-pressure fuel pump
11
-
Fuel return
OVERVIEW
The 2.4 liter diesel engine is equipped with a high-pressure common rail fuel injection system. With this fuel injection
process, a high-pressure fuel pump delivers a uniform level of pressure to a shared fuel rail (also known as a common
rail), which serves all 4 fuel injectors. Pressure is controlled to the optimum level for smooth operation, up to a pressure
of 1600 bar.
The system supports a pre-injection (pilot) phase, which reduces combustion noise and mechanical load.
Fuel injection pressure is generated independently of engine speed and fuel injection events. The fuel injection timing
and volume are calculated by the Engine Control Module (ECM), which then energizes the appropriate solenoid actuated
injector.
The common rail fuel injection system has the following features:
High fuel injection pressures of up to 1600 bar for greater atomisation of fuel (increasing performance and
lowering emissions)
Variable injection to optimise combustion in all engine operating conditions
Low tolerances and high precision throughout the life of the system
The fuel system is divided into 2 sub systems:
Low-pressure system
High-pressure system
The LP system features the following components:
Transfer pump (located in the high-pressure pump)
Fuel filter
Fuel cooler
The HP system features the following components:
High-pressure fuel pump
Fuel rail
High-pressure fuel pipes
Injectors
LOW-PRESSURE SYSTEM
Transfer Pump
The transfer pump is integral to the high-pressure fuel pump and is used to draw fuel from the fuel tank via the fuel
filter (for more information refer to the high-pressure fuel pump section).
The suction pressure of the transfer pump is -30 to -20 Kpa.
Fuel Filter
The canister type fuel filter is located forward of the Right Hand (RH) rear wheel and is protected against damage by a
steel plate.
For additional information, refer to:
Fuel Tank and Lines - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma
(310-01
Fuel Tank and Lines - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma, Description and Operation).
Fuel Cooler
The water cooled fuel cooler is located behind the Left Hand (LH) front wheel. The cooler has a coolant system
connection to aid heat transfer.
For additional information, refer to:
Fuel Tank and Lines - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma
(310-01
Fuel Tank and Lines - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma, Description and Operation).
HIGH-PRESSURE SYSTEM
Item
Part Number
Description
A
-
Fuel return from high-pressure pump
B
-
High-pressure line
C
-
Fuel injection line
D
-
Leak-off pipe
E
-
Fuel return to fuel tank
F
-
Fuel supply
1
-
High-pressure pump
2
-
Fuel rail
3
-
Fuel injector
4
-
Pressure limiting valve
5
-
T-piece
6
-
Fuel cooler
7
-
Fuel tank
8
-
Filling level sensor unit
9
-
Fuel filter
The fuel is drawn from the fuel tank via the fuel filter by means of the transfer pump integrated in the high-pressure
pump. The high-pressure pump pressurizes the fuel and forces it into the fuel rail. The fuel pressure required for any
given situation is available for the fuel injectors for each injection process. Fuel leaking from the injectors and/or
returning fuel from the high-pressure pump are fed back to the fuel tank.
High-Pressure fuel Pump
Item
Part Number
Description
1
-
Volume Control Valve (VCV)
2
-
Fuel temperature sensor
The high-pressure fuel pump provides the interface between the low and the high-pressure systems. Its function is to
provide sufficient pressurized fuel under all operating conditions and for the entire service life of the vehicle.
The fuel pump is located under the intake manifold and is driven by the timing chain at the front of the engine. The
pump includes a transfer pump, a high-pressure pump, a VCV and a fuel temperature sensor.
The high-pressure pump receives fuel at transfer pressure from the transfer pump and increases the fuel pressure. The
high-pressure fuel is then transferred from the high-pressure pump to the fuel rail.
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