Frelander 2. Manual - part 398

W ax-type thermostatic valve (by-pass closed)

The fuel filter canister head incorporates a wax-type thermostatic valve and spring, located in the fuel return passage
between the HP fuel system and fuel tank return connections. The thermostatic valve is seated in a by-pass port that
connects the fuel return passage to the fuel filter canister chamber.

The thermostatic valve is operated by the temperature of the fuel in the fuel return passage, felt at the upper side of the
thermostatic valve; and the temperature of the supply fuel in the canister chamber, felt at the under side of the
thermostatic valve.

The quantity of return fuel recirculated through the filter canister chamber is proportional to the temperature of the return
fuel, and the position of the thermostatic valve.

Return Fuel Temperature

Percentage Return Fuel to Tank

Percentage Recirculated Fuel

Less than 10°C (50°F)

5 - 10%

90 - 95%

Greater than 20°C (68°F)

95 - 100%

0 - 5%

Fuel Temperature Less Than 10°C (50°F)

The thermostatic valve is in the contracted position and held off the by-pass port seat. The upper side of the thermostatic
valve almost closes off the fuel return passage outlet due to the position of the thermostatic valve, and the light pressure
applied by the spring.

A large proportion of returned fuel to the filter passes through the open by-pass port and is recirculated in the fuel filter
canister chamber. A small proportion of the return fuel is allowed to pass across the thermostatic valve and is directed
through the fuel return passage outlet to the fuel tank.

Fuel passing through the fuel return passage outlet also provides the lubrication for the thermostatic valve stem.

Fuel Temperature Greater Than 20°C (68°F)

The thermostatic valve expands against spring pressure to almost close off the fuel return passage by-pass port, and
opens the fuel return passage outlet.

A small proportion of return fuel to the filter passes through the partially open by-pass port and is recirculated in the fuel
filter canister chamber. A large proportion of the return fuel passes across the thermostatic valve and is directed through
the open fuel return passage outlet to the fuel tank.

Fuel Tank and Lines - TD4 2.2L Diesel - Fuel Tank and Lines

Diagnosis and Testing

Principles of Operation

For a detailed description of the fuel tank and lines systems, refer to the relevant Description and Operation section in the
workshop manual.
REFER to:

Fuel Tank and Lines

(310-01B Fuel Tank and Lines - 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.

2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection

Mechanical

Electrical

Fuel leaks
Damaged fuel lines
Damaged push connect fittings
Fuel level
Fuel contamination/grade/quality
Damaged fuel tank filler pipe cap
Damaged fuel tank filler pipe

Fuses
Loose or corroded electrical connectors
Harnesses
Fuel Pump Driver Module (FPDM)
Central Junction Box (CJB)
Fuel pump relay
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.

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.

Symptom Chart

Symptom

Possible Cause

Action

Engine cranks, but
does not fire

Low/contaminated fuel
Intake air leakage
Fuel system leak, blocked/restricted
Electronic engine controls

Check for low/contaminated fuel
Check integrity of intake air system
Check fuel system for leaks and
blockage/restriction. Read DTCs and refer to
relevant DTC Index
For electronic engine control tests.
REFER to: Electronic Engine Controls (303-14,
Diagnosis and Testing).

Difficult to start

Glowplug fault
Low/contaminated fuel
Check engine coolant level/anti-
freeze content
Battery
Intake air system leak
Electronic engine controls
Injector leak
Fuel system leak, blocked/restricted

Check integrity of glowplug system
Check for low/contaminated fuel
Check the engine coolant level and condition.
REFER to:

Specifications

(303-03B Engine Cooling

- TD4 2.2L Diesel, Specifications).
Ensure the battery is in a fully charged and
serviceable condition
Check intake air system for leaks
For electronic engine control tests.
REFER to: Electronic Engine Controls (303-14,
Diagnosis and Testing).
Carry out injector leak tests, install new injectors
as necessary.
REFER to:

Fuel Injector

(303-04B Fuel Charging

and Controls - TD4 2.2L Diesel, Removal and
Installation).
Check fuel system for leaks and
blockage/restriction. Read DTCs and refer to
relevant DTC Index

Rough idle

Intake air system leak
Low/contaminated fuel
Fuel system leak, blocked/restricted
EGR valve fault

Check intake air system for leaks
Check for low/contaminated fuel
Check fuel system for leaks and
blockage/restriction. Read DTCs and refer to
relevant DTC Index
Check EGR system for failure.
REFER to:

Engine Emission Control

(303-08B

Engine Emission Control - TD4 2.2L Diesel,
Diagnosis and Testing).

Symptom

Possible Cause

Action

Engine
hesitates/poor
acceleration

Intake air system leak
Restricted exhaust system
Fuel system leak, blocked/restricted
EGR valve fault
Turbocharger actuator fault

Check intake air system for leaks
Check exhaust system for blockage/restriction
Check fuel system for leaks and
blockage/restriction. Read DTCs and refer to
relevant DTC Index
Check EGR system for failure.
REFER to:

Engine Emission Control

(303-08B

Engine Emission Control - TD4 2.2L Diesel,
Diagnosis and Testing).
Check for turbocharger actuator fault. Read DTCs
and refer to relevant DTC Index

Engine stops/stalls

Breather system
disconnected/restricted
Intake air system leak/restricted
Electronic engine controls
Fuel system leak, blocked/restricted
EGR valve fault

Ensure the engine breather system is free from
restriction and is correctly installed
Check intake air system for leaks/restriction
For electronic engine control tests.
REFER to:

Electronic Engine Controls

(303-14B

Electronic Engine Controls - TD4 2.2L Diesel,
Diagnosis and Testing).
Check fuel system for leaks and
blockage/restriction. Read DTCs and refer to
relevant DTC Index
Check EGR system for failure.
REFER to:

Engine Emission Control

(303-08B

Engine Emission Control - TD4 2.2L Diesel,
Diagnosis and Testing).

Excessive fuel
consumption

Fuel pressure, fuel pump, fuel lines
blocked/contaminated, leaking
Injector leak
Electronic engine controls
EGR valve fault

Check fuel lines for leakage, blockage/restriction.
For fuel pump tests, check DTCs and refer to
relevant DTC Index
Carry out fuel injector leak tests, install new
injectors as necessary.
REFER to:

Fuel Injector

(303-04B Fuel Charging

and Controls - TD4 2.2L Diesel, Removal and
Installation).
For electronic engine control tests.
REFER to: Electronic Engine Controls (303-14,
Diagnosis and Testing).
Check EGR system for failure.
REFER to:

Engine Emission Control

(303-08B

Engine Emission Control - TD4 2.2L Diesel,
Diagnosis and Testing).

DTC Index

• NOTE: If a module or component is suspect, and the vehicle remains under the Manufacturers warranty, refer to the
Warranty Policy and Procedure 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 electrical 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: 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

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

DTC

Description

Possible Cause

Action

P008827 Fuel Rail/System Pressure -

Too High

Leak in high pressure
section
Injector nozzle stuck
open/worn
W orn high pressure
pump, filter blocked
Leaking pressure
control valve
Low pressure section
pressure low (leak in
system, pump output
low)

Check for fuel leaks in high and low pressure systems,
check for additional DTCs and refer to DTC Index

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

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

P115A68 Low Fuel Level - Forced

Limited Power (event
information DTC only)

Low fuel - second
warning after cluster
warning lamp
illuminated

Check for additional related DTCs and refer to relevant
DTC Index

P115B68 Low Fuel Level - Forced

Engine Shutdown (event
information DTC only)

Low fuel - first
warning after cluster
warning lamp
illuminated
Low fuel - fuel empty,
engine shut off

Check fuel level. Check for additional related DTCs and
refer to relevant DTC Index

P226600 W ater in Fuel Sensor Circuit

Low

Fuel Filter Water In
Fuel switch short
circuit to ground

Carry out the pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system

P226700 W ater in Fuel Sensor Circuit

High

Fuel Filter Water In
Fuel switch short
circuit to battery

Carry out the pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system

P228800 Injector Control Pressure

Too High

Leaking fuel system
Fuel high pressure
pump circuit - short to
ground, open circuit
Fuel high pressure
pump failure

Check for fuel leaks. Refer to the electrical circuit
diagrams and check fuel high pressure pump circuit for
short to ground, open circuit. Install a new high
pressure pump as required

Content .. 396 397 398 399 ..