Land Rover Discovery: Fuel Tank and Lines - Ingenium i4 2.0l Diesel Diagnosis and Testing
PRINCIPLE OF OPERATION
For a detailed description of the fuel tank and lines system and operation,
refer to the relevant Description and Operation section of the workshop
manual. REFER to: (310-01B Fuel Tank and Lines - INGENIUM I4 2.0L Diesel)
Fuel Tank and Lines (Description and Operation),
Specifications (Specifications),
Fuel Pump and Sensor Unit (Removal and Installation).
INSPECTION AND VERIFICATION
WARNINGS:
CAUTIONS:
NOTES:
- Check and rectify basic faults before beginning diagnostic routines
involving pinpoint tests.
- When measuring fuel sender resistance values with a multimeter, it
is critical to use the correct multimeter setting. The multimeter
should not be on the 'Auto' setting and must be set to 'Manual'.
This will help prevent incorrect diagnosis and unnecessary
replacement of fuel senders. If the multimeter range is set at 'Auto'
then, during a sweep of the sender from 50 Ohms to 998 Ohms,
the multimeter has to change its measurement range. For
approximately 1 second, during the range switch over point, the
multimeter display indicates an open circuit. This can lead to a
misdiagnosis
of a fuel sender fault.
- Verify the customer concern
- Visually inspect for obvious signs of damage and system integrity
Visual Inspection
- If an obvious cause for an observed or reported concern is found,
correct the cause (if possible) before proceeding to the next step
- If the cause is not visually evident, verify the symptom and refer to
the
Symptom Chart, alternatively check for Diagnostic Trouble Codes
(DTCs) and proceed to the DTC Index
SYMPTOM CHART
SYMPTOM:
Fuel gauge
reading too low
POSSIBLE CAUSES:
- Instrument Cluster (IC) is not
configured correctly
- Fuel pump module flange
electrical connector short
circuit to ground due to
frayed, melted
wires/connectors or corroded
connector pins
- Fuel level sensor short circuit
to ground, low resistance
- Fuel level sensor float arm broken or bent
Fuel level sensor failure
ACTION:
SYMPTOM:
Fuel gauge
reading too
high
POSSIBLE CAUSES:
- Instrument Cluster (IC) is not
configured correctly
- Fuel pump module flange
electrical connectors short
circuit to power due to melted
wires/connectors or corroded
connector pins
- Corroded electrical harness
connections between low
pressure fuel pump and
Central Junction Box (CJB)
- Corroded electrical harness
connections between Body
Control Module (BCM) and
Engine Control Module (ECM)
or Instrument Cluster (IC)
- Fuel level sensor circuit short
to ground
- Fuel level sensor failure
- Fuel level sensor float arm
jammed in the up position
ACTION:
SYMPTOM:
Fuel gauge
intermittent or
inconsistent
POSSIBLE CAUSES:
- Fuel level sensor poor ground
connection, open circuit to
power, high resistance
- Fuel pump module electrical
connector open circuit to
power due to frayed, melted
wires/connectors or corroded
connector pins
- Fuel pump module flange pins
not projecting sufficiently to
ensure electrical contact
- Harness electrical connectors
not correctly located,
disconnected, damaged or
pins backed out
ACTION:
SYMPTOM:
Engine cranks
but will not
start or
malfunction indicator lamp
illuminated
POSSIBLE CAUSES:
- Fuel tank empty
- Fuel tank active side empty
- Passive suction pipe disconnected from the fuel
pump module passive jet
connection or kinked suction
tube line
- Fuel filter restricted/blocked
- Passive side jet pump blocked
- Engine mounted fuel filter
connector wear/leak
- Open circuit between low
pressure fuel pump module
and low pressure fuel pump
- Short circuit between low
pressure fuel pump module
and low pressure fuel pump
- Low pressure fuel pump
blockage due to debris
- Low pressure fuel pump
electrical control module
inoperative
- Fuel pump inoperative
- Fuel supply pipe
detached/restricted/blocked
- In-tank fuel pipes detached
from low pressure fuel pump
or flange
- Fuel inlet filter blockage (Intank)
ACTION:
SYMPTOM:
Engine
Malfunction,
Stalls or Cut off
POSSIBLE CAUSES:
- Fuel tank empty
- Fuel tank active side empty
- Passive suction pipe
disconnected from the fuel
pump module passive jet
connection or kinked suction
tube line
- Engine mounted fuel filter
restricted/blocked
- Engine mounted fuel filter
connector wear/leak
- Passive side jet pump blocked
Open circuit between low
pressure fuel pump module
and low pressure fuel pump
- Short circuit between low
pressure fuel pump module
and low pressure fuel pump
- Low pressure fuel pump
blockage due to debris
- Low pressure fuel pump, Fuel
Pump Driver Module (FPDM)
inoperative
- Fuel pump pressure relief valve
jammed open or leaking
- Fuel pump module pressure
regulating valve jammed open
or leaking
- Debris blocking engine High
Pressure (HP) fuel pump inlet
- Fuel pump check valve leaking
- Fuel pump inoperative
- Fuel supply pipe
detached/restricted/blocked
- In-tank fuel supply pipes
detached from low pressure
fuel pump or flange
- Fuel inlet filter blockage (Intank)
ACTION:
SYMPTOM:
Engine misses
under load
POSSIBLE CAUSES:
- Fuel tank empty
- Fuel pump pressure relief valve
jammed open or leaking
- Fuel pump module pressure
regulating valve jammed open
or leaking
- Debris blocking engine High
Pressure (HP) fuel pump inlet
- Engine mounted Fuel filter
restricted/blocked
- Fuel supply pipe
detached/restricted/blocked
ACTION:
GO to Pinpoint Test D.
SYMPTOM:
Engine doesn't
rev up
POSSIBLE CAUSES:
- Engine mounted fuel filter
restricted/blocked
- Fuel supply pipe
detached/restricted/blocked
- In-tank fuel filter
restricted/blocked
- Fuel pump pressure relief valve
jammed open or leaking
- Fuel pump module pressure
regulating valve jammed open
or leaking
- Debris blocking engine High
Pressure (HP) fuel pump inlet
ACTION:
SYMPTOM:
Low pressure
fuel pump
noise during
idle and normal
driving
conditions
POSSIBLE CAUSES:
ACTION:
- Noise from the low pressure fuel
pump is normal and will reduce
considerably after 15 miles (24
kilometers) of use
SYMPTOM:
Water in fuel
above allowed
threshold
POSSIBLE CAUSES:
- Water in fuel
- Water in fuel sensor circuit
short circuit to ground, short
circuit to power, open circuit,
high resistance
- Water in fuel sensor failure
ACTION:
SYMPTOM:
Fuel leak from
fuel tank
POSSIBLE CAUSES:
- Fuel supply pipe detached
from fuel pump flange
- Fuel pump cover locking ring
and O-ring seal not fitted
properly
- Leak from vapour/breather
pipe connection incorrectly
installed within the fuel pump
module
ACTION:
- Check fuel delivery line and fuel
return line for any leakage due
to de-latching or pipe damage
- Check if the fuel pump locking
ring and O-ring seal is fitted
properly
PINPOINT TESTS
NOTE:
Two ohmmeters are required for this test.
NOTE:
If the measurement range of the ohmmeter is set to 'automatic', the
ohmmeter will briefly display 'open circuit' when the range changes.
This does not indicate a fault with the component. To prevent
incorrect diagnosis, always set the measurement range to 'manual'.
NOTE:
This test should be carried out by turning the ignition ON.
WARNING:
This procedure involves fuel handling. Be prepared for fuel spillage
at
all times and always observe fuel handling precautions. Failure to
follow these instructions may result in personal injury
NOTE:
This procedure involves disconnection of fuel lines. Place suitable
absorbent material around the fuel line to be disconnected, to absorb
any spillage when connecting the fuel pressure gauge.
NOTE:
This procedure involves disconnection of fuel lines. Place suitable
absorbent material around the fuel line to be disconnected, to absorb
any spillage when connecting the fuel pressure gauge.
MIS - FUELLING ISSUES / ACCIDENTALLY FILLING THE FUEL TANK WITH GASOLINE
INSTEAD OF DIESEL
NOTES:
- The customer MUST be informed prior to vehicle hand-over of the
consequences of adding gasoline to the fuel tank instead of diesel.
- The cost of this repair work is not Jaguar Land Rover's
responsibility. If the customer does not have all of the appropriate
work carried out, warranty may be refused on all affected
components.
- If the customer refuses the advised repair or wants a lower level
repair than advised, the vehicle must be added to the Restricted
Warranty Register.
- Vehicle mis-fuelling will not result in a formal warranty restriction
if
the approved repair has been completed.
- The symptom charts below describe the four possible scenarios of a
customer incorrectly fuelling a diesel engine vehicle with gasoline. When
customers report a mis-fuel, allow them to fully explain
exactly what took place before advising the necessary repair.
- The procedures listed below are for guidance only. The relevant
sections of TOPIx must be referred to for all detailed procedures
and replacement of parts.
- Purge operation of the low pressure fuel pumps on the following
vehicle lines is activated when the drivers door is opened: Jaguar
XE, Jaguar XF, Jaguar F-Pace. For all other vehicle lines, the purge
operation of the low pressure fuel pumps is activated when the
ignition is switched on.
Mis-fuelling Procedure 1
Mis-fuelling Procedure 2
Mis-fuelling Procedure 3
Mis-fuelling Procedure 4
FUEL GAUGE , RESISTANCE , VOLTAGE AND FUEL TANK LEVEL COMPARISON CHART
Use the chart to determine fuel tank fuel volume versus fuel gauge reading
to determine the fuel level symptom and fault.
NOTES:
- The vehicle must be parked on a level surface to obtain an accurate
fuel level gauge reading.
- The actual values may vary, according to the quantity of fuel in the
left and right sides of the fuel tank.
- An accurate fuel level gauge reading requires 3 to 5 minutes for
levels to stabilise.
Volume, Resistance and Voltage Values
DTC INDEX
For a list of Diagnostic Trouble Codes (DTCs) that could be logged on this
vehicle, please refer to Section 100-00. Diagnostic Trouble Code (DTC Index
- INGENIUM I4 2.0L Diesel, DTC: Engine Control Module (ECM) B10A2-07
to P034B-76
Fuel Tank and Lines - Ingenium i4 2.0l Diesel Specifications
Capacity
General Specifications
Torque Specifications
READ NEXT:
WARNINGS:
Place the vehicle in a well ventilated, quarantined area and
arrange
' No Smoking/Petrol Fumes' signs about the vehicle.
Do not carry or operate cellular phones when working on or near
COMPONENT LOCATION
Clutch pedal
Brake/clutch reservoir
Brake fluid level sensor
High pressure clutch line
Clutch master cylinder
Clutch pedal position sensor
Low pressure hose connector
Low
SEE MORE:
REMOVAL
NOTE:
Some variation in the illustrations may occur, but the essential
information is always correct.
Some components shown removed for clarity.
Disconnect the battery ground cable.
Refer to: Specifications (414-01 Battery, Mounting and Cables,
Specifications).
WARNING:
Make sure to su
COMPONENT LOCATION
Rear Junction Box (RJB)
Quiescent Current Control Module (QCCM)
Battery Monitoring System (BMS) control module
Primary battery
Gateway Module (GWM)
Central Junction Box (CJB)
Voltage Quality Module (VQM) - vehicles with auto stop/start system only
Starter motor or Tande