Defender. Manual — part 137
Item
Part Number
Description
1
-
Cylinder head cover
2
-
Gas transfer pipe
3
-
Air intake tube
4
-
Oil separator
OVERVIEW
The crankcase ventilation system on the engine manages the positive pressure built up during running. In order to
prevent excessive oil loss/consumption the separator ensures that all gasses emitted from the crankcase during engine
running are separated from any oil particles.
Crankcase gas enters the oil separator unit located in the engine cam cover due to the pressure differential between the
crank case and the air induction duct. The oil separator removes oil from the crankcase gasses. The crank case pressure
is released into the air induction system via the Crank Case Vent Tube. The separated oil drains from the separator to
the oil pan via the engines internal oil galleries.
Engine Emission Control - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma - Engine Emission Control
Diagnosis and Testing
Overview
For information on description and operation:
REFER to:
Engine Emission Control
(303-08 Engine Emission Control - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma, Description and Operation).
Inspection and Verification
1. 1. Verify the customer concern.
2. 2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart
Mechanical
Electrical
Engine breather hoses
Oil separator
Exhaust gas recirculation (EGR) pipes (check for cracks)
EGR valve
EGR cooler(s)
Fuse(s)
Wiring harness
Loose or corroded electrical connector(s)
EGR valve
Engine control module (ECM)
3. 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. 4. Use the approved diagnostic system or a scan tool to retrieve any diagnostic trouble codes (DTCs) before
moving onto the symptom chart or DTC index.
Make sure that all DTCs are cleared following rectification.
Symptom Chart
Symptom
(specific)
Possible cause
Action
Difficult to
start
Exhaust gas recirculation
(EGR) valve stuck open
Check the EGR valve and circuits. Refer to the electrical guides.
Check the mechanical condition of the EGR valve. Rectify as
necessary.
Poor/Erratic
idle
Lack of power
when
accelerating
Engine
stops/stalls
Exhaust gas recirculation
(EGR) valve stuck open
Breather system
disconnected/restricted/blocked
Check the EGR valve and circuits. Refer to the electrical guides.
Check the mechanical condition of the EGR valve. Check the
engine breather system. Check the oil separator.
REFER to:
Engine Emission Control
(303-08 Engine Emission
Control - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma,
Description and Operation).
Check for DTCs indicating an EGR valve, throttle or sensor fault.
Rectify as necessary.
Excessive fuel
consumption
Exhaust gas recirculation
(EGR) valve stuck open
EGR not operating
Breather system
restricted/blocked
Excessive
black smoke
Excessive
emissions
Excessive
blow-by
Breather system
restricted/blocked
Check the engine breather hoses. Check the oil separator.
REFER to:
Engine Emission Control
(303-08 Engine Emission
Control - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma,
Description and Operation).
Rectify as necessary.
Engine oil
leaks
Breather system
restricted/blocked
Check the engine breather hoses. Check the oil separator.
REFER to:
Engine Emission Control
(303-08 Engine Emission
Control - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma,
Description and Operation).
Rectify as necessary.
DTC Index
• NOTE: If a control module or 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 program is in operation,
before the replacement of a component.
• NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the
scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 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 an up-to-date calibration certificate. When 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.
• NOTE: For a full list of engine control module (ECM) DTCs:
REFER to:
Electronic Engine Controls
(303-14 Electronic Engine Controls - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma, Diagnosis and Testing).
DTC
Description
Possible cause
Action
P006A00 Manifold absolute pressure
(MAP) sensor - mass or
volume air flow correlation
• NOTE: The MAP
sensor is part of the
manifold absolute
pressure temperature
(MAPT) sensor
Restricted air
intake path
Exhaust gas
recirculation
(EGR) valve
stuck open
Turbocharger
fault
MAP sensor fault
Mass air flow
(MAF) sensor
fault
Check the intake air path for restrictions. Rectify as
necessary. Check for DTCs indicating an EGR,
turbocharger, MAPT or MAF sensor fault. Rectify as
necessary. Clear the DTCs and check for normal
operation.
P010029 Mass or volume air flow A
circuit - signal invalid
Restricted air
intake path
Check for leak
between mass air
flow (MAF)
sensor and
turbocharger
MAF sensor fault
Turbocharger
fault
Exhaust gas
recirculation
(EGR) valve fault
Check the intake air system for leaks, restrictions, etc.
Check for related DTCs. Rectify as necessary. Clear the
DTCs and test for normal operation.
P04031A Exhaust gas recirculation
(EGR) control circuit - circuit
resistance below threshold
EGR control
valve actuator
circuit: short
circuit to ground
EGR control
valve actuator
circuit: short
circuit to power
EGR control
valve actuator
circuit: open
circuit
EGR control
valve fault
Check the EGR control valve actuator and circuits.
Refer to the electrical guides. Install a new EGR valve
if necessary.
REFER to:
Exhaust Gas Recirculation (EGR) Valve
(303-08 Engine Emission Control - 2.4L Duratorq-TDCi
HPCR (103kW/140PS) - Puma, Removal and
Installation).
Clear the DTCs and test for normal operation.
P04031B Exhaust gas recirculation
(EGR) control circuit - circuit
resistance above threshold
EGR control
valve actuator
circuit: short
circuit to ground
EGR control
valve actuator
circuit: short
circuit to power
EGR control
valve actuator
circuit: open
circuit
EGR control
valve fault
P040311 Exhaust gas recirculation
(EGR) control circuit - circuit
short to ground
EGR control
valve actuator
circuit: short
circuit to ground
EGR control
valve fault
P040312 Exhaust gas recirculation
(EGR) control circuit - circuit
short to battery
EGR control
valve actuator
circuit: short
circuit to power
EGR control
valve fault
P040472 Exhaust gas recirculation
(EGR) control circuit
range/performance - actuator
stuck open
EGR control
valve actuator
circuit fault
EGR control
valve fault
Check the EGR control valve actuator and circuits.
Refer to the electrical guides. Install a new EGR valve
if necessary.
REFER to:
Exhaust Gas Recirculation (EGR) Valve
(303-08 Engine Emission Control - 2.4L Duratorq-TDCi
HPCR (103kW/140PS) - Puma, Removal and
Installation).
Clear the DTCs and test for normal operation.
P040473 Exhaust gas recirculation
(EGR) control circuit
range/performance - actuator
stuck closed
EGR control
valve actuator
circuit fault
EGR control
valve fault
P14022F Exhaust gas recirculation
(EGR) control valve metering
orifice restricted - signal
erratic
EGR valve
control circuit:
open circuit
EGR valve
control circuit:
short circuit to
ground
EGR valve
control circuit:
short circuit to
power
EGR valve fault
Check the EGR valve actuator and circuits. Refer to
the electrical guides. Install a new EGR valve if
necessary.
REFER to:
Exhaust Gas Recirculation (EGR) Valve
(303-08 Engine Emission Control - 2.4L Duratorq-TDCi
HPCR (103kW/140PS) - Puma, Removal and
Installation).
Clear the DTCs and test for normal operation.
P140216 Exhaust gas recirculation
(EGR) control valve - circuit
voltage below threshold
EGR valve
control circuit:
open circuit
EGR valve
control circuit:
short circuit to
ground
EGR valve fault
P140217 Exhaust gas recirculation
(EGR) control valve - circuit
voltage above threshold
EGR valve
control circuit:
short circuit to
power
EGR valve fault
P140977 Exhaust gas recirculation
(EGR) control valve vacuum
regulator solenoid circuit -
commanded position not
reachable
EGR valve
control circuit:
open circuit
EGR valve
control circuit:
short circuit to
ground
EGR valve
control circuit:
short circuit to
power
EGR valve fault
Check the EGR valve actuator and circuits. Refer to
the electrical guides. Install a new EGR valve if
necessary.
REFER to:
Exhaust Gas Recirculation (EGR) Valve
(303-08 Engine Emission Control - 2.4L Duratorq-TDCi
HPCR (103kW/140PS) - Puma, Removal and
Installation).
Clear the DTCs and test for normal operation.
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