Defender. Manual — part 117
2. 8 amps
3. 4 amps
At the beginning of an injection process, the solenoid valve is actuated with a higher pick-up current so that it opens
quickly. After a short period of time, the pick-up current is reduced to a low holding current.
To ensure optimum fuel metering, the ECM must be informed of a change of injector through the input of a 16-digit
identification number. Inside the hydraulic servo system there are various restrictions with extremely small diameters,
which have specific manufacturing tolerances. These manufacturing tolerances are given as part of the identification
number, which is located on the housing of the fuel injector.
Item
Part Number
Description
1
-
Solenoid valve
2
-
16-digit identification number
3
-
Connection for leak-off pipe
• NOTE: If the identification numbers are not entered correctly with the approved Land Rover diagnostic equipment, the
following faults may occur:
Increased black smoke formation
Irregular idling
Increased combustion noise
Furthermore, once new ECM software has been loaded with the approved Land Rover diagnostic equipment, the fuel
injectors must also be configured.
The ECM detects injector faults based on the power consumption of the solenoid valves. In the event of a fuel injector
failure, any of the following symptoms may be observed:
Engine misfire
Idle faults
Reduced engine performance
Reduced fuel economy
Difficult cold start
Difficult hot start
Increased smoke emissions
Fuel Charging and Controls - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma - Fuel Charging and Controls
Diagnosis and Testing
Overview
This section covers the fuel system from the fuel filter to the fuel injectors, and includes the fuel rail and pump.
For information on the operation of the systems:
REFER to:
Fuel Charging and Controls
(303-04A Fuel Charging and Controls - 2.4L Duratorq-TDCi HPCR (103kW/140PS)
- Puma, Description and Operation) /
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).
Inspection and Verification
WARNING: Make sure that all suitable safety precautions are observed when carrying out any work on the fuel
system. failure to observe this warning may result in personal injury.
CAUTION: Make sure that absolute cleanliness is observed when working with these components. Always install
blanking plugs to any open orifices or lines. failure to follow this instruction may result in damage to the vehicle.
1. 1. Verify the customer concern.
2. 2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart
Mechanical
Electrical
Low/contaminated fuel
Fuel supply/return line(s)
Fuel tank and filler pipe
Fuel leak(s)
Fuel filler cap
Fuel filter
Push connect fittings
Fuel pressure limiting valve
Fuel rail
Fuel injection pump
Exhaust gas recirculation (EGR) system
Fuses
Glow plug indicator
Inertia fuel shutoff (IFS) switch
Sensor(s)
Engine control module (ECM)
Fuel suction control valve
Fuel rail pressure sensor
Fuel temperature sensor
Fuel injector(s)
EGR system
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
Possible causes
Action
Engine
cranks, but
does not
start
Inertia fuel shutoff
(IFS) switch
Low/contaminated
fuel
Air leakage
Low-pressure fuel
system fault
Blocked fuel filter
Fuel suction control
valve
blocked/contaminated
Fuel injection pump
fault
Crankshaft position
(CKP) sensor
Check that the IFS has not tripped. Check the main ECM relay and circuits,
refer to the electrical guides. Check the fuel level and condition. Draw off
approximately 1 ltr (2.11 pints) of fuel and allow to stand for 1 minute.
Check to make sure there is no separation of the fuel indicating water or
other liquid in the fuel. Check the intake air system for leaks. Check the low-
pressure fuel system for leaks/damage. Check the fuel filter, check for DTCs
indicating a fuel injection pump fault. Check the fuel injection pump:
REFER to:
Fuel Injection Pump
(303-04A Fuel Charging and Controls - 2.4L
Duratorq-TDCi HPCR (103kW/140PS) - Puma, Removal and Installation).
Check the CKP sensor circuits. Refer to the electrical guides. Install a new
CKP sensor if necessary.
REFER to:
Crankshaft Position (CKP) Sensor
(303-14 Electronic Engine
Controls - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma, Removal and
Installation).
Difficult to
start
Glow plug system
fault (very cold
conditions)
Low/contaminated
fuel
Check the glow plug circuits. Refer to the electrical guides. Check the fuel
fuel
Air leakage
Low-pressure fuel
system fault
Blocked fuel filter
Fuel suction control
valve
blocked/contaminated
Exhaust gas
recirculation (EGR)
valve(s) fault
level/condition. Draw off approximately 1 ltr (2.11 pints) of fuel and allow to
stand for 1 minute. Check to make sure there is no separation of the fuel
indicating water or other liquid in the fuel. Check the intake air system for
leaks. Check the low-pressure fuel system for leaks/damage. Check the fuel
filter, check for DTCs indicating a fuel suction control valve fault. For EGR
valve checks:
REFER to:
Engine Emission Control
(303-08 Engine Emission Control - 2.4L
Duratorq-TDCi HPCR (103kW/140PS) - Puma, Diagnosis and Testing).
Rough idle
Intake air system
fault
Low/contaminated
fuel
Low-pressure fuel
system fault
Blocked fuel filter
Fuel suction control
valve
blocked/contaminated
Exhaust gas
recirculation (EGR)
valve(s) fault
Check the intake air system for leaks. Check the fuel level/condition. Draw off
approximately 1 ltr (2.11 pints) of fuel and allow to stand for 1 minute.
Check to make sure there is no separation of the fuel indicating water or
other liquid in the fuel. Check the low-pressure fuel system for leaks/damage.
Check the fuel filter, check for DTCs indicating a fuel suction control valve
fault. For EGR valve checks:
REFER to:
Engine Emission Control
(303-08 Engine Emission Control - 2.4L
Duratorq-TDCi HPCR (103kW/140PS) - Puma, Diagnosis and Testing).
Lack of
power when
accelerating
Intake air system
fault
Restricted exhaust
system
Low fuel pressure
Exhaust gas
recirculation (EGR)
valve(s) fault
Turbocharger
actuator fault
Check the intake air system for leakage or restriction. Check for a
blockage/restriction in the exhaust system, install new components as
necessary:
REFER to:
Catalytic Converter
(309-00 Exhaust System - 2.4L Duratorq-TDCi
HPCR (103kW/140PS) - Puma, Removal and Installation).
Check for DTCs indicating a fuel pressure fault. For EGR valve checks:
REFER to:
Engine Emission Control
(303-08 Engine Emission Control - 2.4L
Duratorq-TDCi HPCR (103kW/140PS) - Puma, Diagnosis and Testing).
For turbocharger actuator checks:
REFER to:
Turbocharger
(303-04B Fuel Charging and Controls - Turbocharger
- 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma, Removal and
Installation).
Engine
stops/stalls
Air leakage
Low/contaminated
fuel
Low-pressure fuel
system fault
High-pressure fuel
leak
Fuel suction control
valve
blocked/contaminated
Exhaust gas
recirculation (EGR)
valve fault
Check the intake air system for leaks. Check the fuel level/condition. Draw off
approximately 1 ltr (2.11 pints) of fuel and allow to stand for 1 minute.
Check to make sure there is no separation of the fuel indicating water or
other liquid in the fuel. Check the fuel system for leaks/damage. Check for
DTCs indicating a fuel suction control valve fault. For EGR valve checks:
REFER to:
Engine Emission Control
(303-08 Engine Emission Control - 2.4L
Duratorq-TDCi HPCR (103kW/140PS) - Puma, Diagnosis and Testing).
Engine
judders
Low/contaminated
fuel
Air ingress
Low-pressure fuel
system fault
Fuel suction control
valve
blocked/contaminated
High-pressure fuel
leak
Fuel injection pump
fault
Check the fuel level/condition. Draw off approximately 1 ltr (2.11 pints) of
fuel and allow to stand for 1 minute. Check to make sure there is no
separation of the fuel indicating water or other liquid in the fuel. Check the
intake air system for leaks. Check the low-pressure fuel system for
leaks/damage. Check the high-pressure fuel system for leaks. Check for DTCs
indicating a fuel suction control valve fault. Check the fuel injection pump:
REFER to:
Fuel Injection Pump
(303-04A Fuel Charging and Controls - 2.4L
Duratorq-TDCi HPCR (103kW/140PS) - Puma, Removal and Installation).
Excessive
fuel
consumption
Low-pressure fuel
system fault
Fuel suction control
valve
blocked/contaminated
Fuel temperature
sensor leak
High-pressure fuel
leak
Injector(s) fault
Check the low-pressure fuel system for leaks/damage. Check for DTCs
indicating a fuel suction control valve fault. Check the fuel temperature
sensor, fuel injection pump, etc. for leaks. Check for injector DTCs. For EGR
valve checks:
REFER to:
Engine Emission Control
(303-08 Engine Emission Control - 2.4L
Duratorq-TDCi HPCR (103kW/140PS) - Puma, Diagnosis and Testing).
Exhaust gas
recirculation (EGR)
valve(s) fault
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 causes
Action
P008807 Fuel rail/system
pressure - too high
Fuel rail
pressure sensor
to engine
control module
(ECM) wiring
(supply/signal):
short circuit to
each other
Fuel rail
pressure sensor
to ECM signal
circuit: short
circuit to power
Fuel rail
pressure sensor
fault
Fuel injection
pump circuit:
short circuit to
power
Fuel injection
pump fault
Fuel rail
pressure
limiting valve
Check for related DTCs. Rectify as necessary. Clear the DTCs and
test for normal operation. Check the fuel rail pressure sensor and
circuits. Refer to the electrical guides. The fuel rail pressure
sensor cannot be serviced separately. Install a new fuel rail if
necessary.
REFER to:
Fuel Rail
(303-04A Fuel Charging and Controls - 2.4L
Duratorq-TDCi HPCR (103kW/140PS) - Puma, Removal and
Installation).
Check the fuel suction control valve and circuits. Refer to the
electrical guides. The fuel suction control valve is not serviceable
separately. Install a new fuel injection pump if necessary.
REFER to:
Fuel Injection Pump
(303-04A Fuel Charging and
Controls - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma,
Removal and Installation).
Clear the DTCs and carry out a road test to confirm repair.
P008809 Fuel rail/system
pressure - too high
Fuel rail
pressure sensor
to engine
control module
(ECM) wiring
(supply/signal):
short circuit to
each other
Fuel rail
pressure sensor
to ECM sensor
circuit: short
circuit to power
Fuel rail
pressure sensor
fault
Fuel injection
pump circuit:
short circuit to
power
Check for related DTCs. Rectify as necessary. Clear the DTCs and
test for normal operation. Check the fuel rail pressure sensor and
circuits. Refer to the electrical guides. The fuel rail pressure
sensor cannot be serviced separately. Install a new fuel rail if
necessary.
REFER to:
Fuel Rail
(303-04A Fuel Charging and Controls - 2.4L
Duratorq-TDCi HPCR (103kW/140PS) - Puma, Removal and
Installation).
Check the fuel suction control valve and circuits. Refer to the
electrical guides. The fuel suction control valve is not serviceable
separately. Install a new fuel injection pump if necessary.
REFER to:
Fuel Injection Pump
(303-04A Fuel Charging and
Controls - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma,
Removal and Installation).
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