| : | Dec 17, 2007 |
: Do NOT carry out any work on the fuel system with the engine
running. The fuel pressure within the system can be as high as 1600 bar
(23,206 lb/in²). Failure to follow this instruction may result in personal
injury. |
: Eye protection must be worn at all times when working on or near any
fuel related components. Failure to follow this instruction may result in
personal injury. |
: This procedure involves fuel handling. Be prepared for fuel spillage at
all times and always observe fuel handling precautions. Failure to follow
this instruction may result in personal injury.
|
: After carrying out repairs, the fuel system must be checked visually for
leaks. This should be done after the engine has been run, but with the
engine switched OFF. Failure to follow this instruction may result
in personal injury. |
: If taken internally, DO NOT induce vomiting. Seek immediate
medical attention. Failure to follow this instruction may result in
personal injury. |
: If fuel contacts the eyes, flush the eyes with cold water or eyewash
solution and seek medical attention. Failure to follow this instruction
may result in personal injury. |
: Wash hands thoroughly after handling, as prolonged contact may cause
irritation. Should irritation develop, seek medical attention. Failure to
follow this instruction may result in personal injury.
|
: Before disconnecting any part of the system, it is imperative that all
dust, dirt and debris is removed from around components to prevent ingress
of foreign matter into the fuel system. Failure to follow this instruction
may result in damage to the vehicle. |
: The fuel pipes between the injectors and the rail must be discarded
after each use, and new pipes installed. Failure to follow this
instruction may result in damage to the vehicle.
|
: It is essential 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. |
: Make sure that the workshop area in which the vehicle is being worked on
is as clean and dust-free as possible. Areas in which work on clutches,
brakes or where welding or machining are carried out are not suitable in
view of the risk of contamination to the fuel system. Failure to follow
this instruction may result in damage to the vehicle.
|
: Make sure that any protective clothing worn is clean and made from
lint-free non-flocking material. Failure to follow this instruction may
result in damage to the vehicle. |
: Make sure that any protective gloves worn are new and are of the
non-powdered latex type. Failure to follow this instruction may result in
damage to the vehicle. |
: Make sure that clean, non-plated tools are used. Clean tools using a new
brush that will not lose it's bristles and fresh cleaning fluid prior to
starting work on the vehicle. Failure to follow this instruction may
result in damage to the vehicle. |
: Use a steel-topped work bench and cover it with clean, lint-free,
non-flocking material. Failure to follow this instruction may result in
damage to the vehicle. |
| Mechanical | Electrical |
|---|---|
|
|
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Make sure that all DTCs are cleared following rectification. |
| Symptom | Possible causes | Action |
|---|---|---|
| Engine cranks, but does not start |
|
Check that the inertia switch has not tripped. Check the fuel level/condition. Check the fuel pump module operation, check the low pressure fuel system for leaks/damage. Check the intake air system for leaks. Check the fuel filter, check the FVCV and FPCV. Check the fuel injection pump. Check the CKP sensor. Refer to the relevant section of the workshop manual. Refer to the warranty policy and procedures manual if a module is suspect. |
| Difficult to start |
|
Check the glow plug circuits. Check the fuel level/condition. Check the fuel pump module operation, check the low pressure fuel system for leaks/damage. Check the intake air system for leaks. Check the fuel filter, check the FVCV and FPCV. Check the EGR valves. Refer to the relevant section of the workshop manual. |
| Rough idle |
|
Check the fuel level/condition. Check the low pressure fuel system for leaks/damage. Check the intake air system for leaks. Check the fuel filter, check the FVCV and FPCV. Check the EGR valves. Refer to the relevant section of the workshop manual. |
| Lack of power when accelerating |
|
Check the intake air system. Check for a blockage/restriction in the exhaust system, install new components as necessary. Check the fuel pressure. Check the EGR valves. Check the turbocharger condition and actuator operation. Refer to the relevant section of the workshop manual. |
| Engine stops/stalls |
|
Check the fuel level/condition. Check the fuel pump module operation, check the fuel system for leaks/damage. Check the intake air system for leaks. Check the FVCV and FPCV. Check the EGR valves. |
| Engine judders |
|
Check the fuel level/condition. Check the fuel system for leaks/damage. Check the intake air system for leaks. Check the FVCV and FPCV. Check the fuel injection pump. Refer to the relevant section of the workshop manual. |
| Excessive fuel consumption |
|
Check the fuel system for leaks/damage. Check the FVCV and FPCV. Check for injector DTCs. Check the EGR valves. Refer to the relevant section of the workshop manual. |
| 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). |
| For a full list of ECM DTCs, refer to section 303-14 - Electronic Engine Controls in the workshop manual. |
| DTC | Description | Possible causes | Action |
|---|---|---|---|
| P008700 | Fuel Rail/System Pressure - Too Low |
|
Refer to the electrical guides and check the FRP sensor circuits. For FRP sensor tests, refer to the relevant workshop manual section. Check the low pressure fuel lines for damage or restrictions. Check the fuel pressure. Check the low pressure fuel pump module circuits and operation. Check for fuel rail and high pressure fuel line leaks. Check for VCV and PCV DTCs and rectify as necessary. |
| P008800 | Fuel Rail/System Pressure - Too High |
|
Check the FRP sensor circuits, check the FPCV. Refer to the relevant section of the workshop manual. Check the fuel pump module circuits. Refer to the electrical guides. |
| P062700 | Fuel Pump A Control Circuit / Open |
|
Check the fuel pump and circuits. Refer to the electrical guides. Activate the relay and listen for an audible 'click'. Refer to the relevant workshop manual section. Repair/renew as necessary. Clear the DTCs and test for normal operation. |
| P062800 | Fuel Pump A Control Circuit Low |
|
Refer to the electrical guides and check the fuel pump circuits. Activate the relay and listen for an audible 'click'. Repair/renew as necessary. Clear the DTCs and test for normal operation. |
| P062900 | Fuel Pump A Control Circuit High |
|
Refer to the electrical guides and check the fuel pump circuits. Activate the relay and listen for an audible 'click'. Repair/renew as necessary. Clear the DTCs and test for normal operation. |
| P226900 | Water in Fuel Condition |
|
Drain the water from the fuel filter. Clear the DTC and retest. If the DTC resets, check the sensor circuit. Refer to the electrical guides. If no fault is found in the circuits, install a new sensor. |
| P228800 | Injector Control Pressure Too High |
|
Check the fuel pressure, refer to the relevant section of the workshop manual. Check the fuel pump module circuits and the FPCV circuits. Refer to the electrical guides. For FPCV and fuel injection pump, refer to the relevant workshop manual section. |
| P229000 | Injector Control Pressure Too Low |
|
Check the fuel pressure. Check the fuel lines for leaks/damage. Check for a blocked/restricted fuel filter. Check the fuel pump module circuits. Refer to the electrical guides. Check the FPCV circuits. Check the fuel injection pump. Refer to the relevant workshop manual section. |
| P229200 | Injector Control Pressure Erratic |
|
Check the fuel pressure, refer to the relevant section of the workshop manual. Check the fuel pump module circuits and the FPCV circuits. Refer to the electrical guides. For FPCV and fuel injection pump, refer to the relevant workshop manual section. |