Frelander 2. Manual - part 201

Engine - TD4 2.2L Diesel - Engine

Diagnosis and Testing

Principle of Operation

For a detailed description of the 2.2L Diesel engine, refer to the relevant Description and Operation section in the
workshop manual.
REFER to:

Engine

(303-01B Engine - 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.

• NOTE: If the control module or a 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 programme is in operation, prior
to the installation of a new module/component.

1. Verify the customer concern. Concerns have been separated into Leaks and Noise Vibration and Harshness

(NVH) for ease of use.

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

Visual Inspection

Mechanical

Intake air system leaks/damage
Fuel leaks
Coolant level
Coolant leaks.
REFER to:

Engine Cooling

(303-03B Engine Cooling - TD4 2.2L Diesel, Diagnosis and Testing).

Oil level
Oil leaks
Visibly damaged or worn parts
Loose or missing nuts or bolts

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 concern is not visually evident, verify the symptom and refer to the Symptom Chart.

Symptom Charts

Symptom Chart, Leaks

Symptom

Possible Cause

Action

External coolant leaks

Damaged hose(s)
Damaged expansion
tank
Damaged radiator
Leaking
seals/gaskets
Cracked/damaged
casings

For cooling system checks.
REFER to:

Engine Cooling

(303-03B Engine Cooling - TD4

2.2L Diesel, Diagnosis and Testing).

Internal coolant leaks. Note: This
may be indicated by the
production of white smoke from
the exhaust

Leaking
seals/gaskets
Cracked/damaged
casings

Check for cross contamination of cooling system and
engine oil. Check for exhaust gases being emitted
through header tank. For additional cooling system
checks.
REFER to:

Engine Cooling

(303-03B Engine Cooling - TD4

2.2L Diesel, Diagnosis and Testing).

Engine overheats

Insufficient coolant
Insufficient engine
oil
Cooling system
pressure cap fault
Thermostat not
opening
Coolant pump failure
Cooling fan failure

Check for correct coolant/engine oil levels. For cooling
system checks.
REFER to:

Engine Cooling

(303-03B Engine Cooling - TD4

2.2L Diesel, Diagnosis and Testing).

Engine takes too long to reach
operating temperature

Thermostat stuck
open

For cooling system checks.
REFER to:

Engine Cooling

(303-03B Engine Cooling - TD4

2.2L Diesel, Diagnosis and Testing).

External oil leaks

Gaskets
Seals
Hoses
Oil filter
Oil cooler
Damaged/Cracked

Clean and confirm the area of the leak. Visually check the
condition of oil carrying components. Check the crankcase
ventilation system.
REFER to:

Engine Emission Control

(303-08B Engine

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

Symptom

Possible Cause

Action

casings
Crankcase
ventilation system
Piston ring blow-by

Carry out a compression test, GO to Pinpoint Test

Internal oil leaks (leaks into coolant
or combustion chamber) Note: This
may be indicated by the
production of blue smoke from the
exhaust

Gaskets
Seals
Hoses
Damaged/Cracked
casings
W orn valve guides
W orn cylinder
bores/pistons
Broken piston rings

Check for traces of oil in the coolant. Check for evidence
of oil in the combustion chambers (deposits on the glow
plugs, etc). Confirm oil consumption and vehicle usage
with the owner/driver. Carry out an oil consumption test,
GO to Pinpoint Test

• NOTE: As the checks suggested here are open to interpretation, they should be used as a guide only. Descriptions of
noises, etc, are in general terms, so depend on a degree of experience on the part of the technician.

Symptom Chart, NVH

Symptom

Possible Cause

Action

Rattle/ticking from top of
engine

Valve gear noise
Camshaft bearing noise
Camshaft chain noise
Tensioner noise
Vacuum pump noise
High pressure fuel pump
noise
Injector leaking

Check the engine oil level and pressure, GO to Pinpoint Test

. Check the function of the hydraulic tappets and condition

of camshaft lobes and bearings. Check the camshaft chains
and tensioners, vacuum pump and high pressure fuel pump.
Carry out injector leak test

Squeaking/Creaking/Squeal
from front of engine

Accessory drive belt
Accessory drive belt
tensioner
Driven components on
accessory drive belt

Check the accessory drive belt and driven components.
REFER to:

Accessory Drive

(303-05B Accessory Drive - TD4

2.2L Diesel, Diagnosis and Testing).

W hine/Slap/Growl from
front of engine

Accessory drive belt
Accessory drive belt
tensioner
Driven components on
accessory drive belt
Timing belt noise
Timing belt tensioner
noise

Check the accessory drive belt and driven components.
REFER to:

Accessory Drive

(303-05B Accessory Drive - TD4

2.2L Diesel, Diagnosis and Testing).
Check the timing belt and tensioners for noise/damage

Knock from lower half of
engine (often worse with a
cold engine)

Engine oil level/pressure
low
Piston slap
Piston pin noise
Connecting rod bearing
noise

Check the engine oil level and pressure, GO to Pinpoint Test

. Check for debris in the engine oil, check condition of

engine components

Knock/Rumble from lower
half of engine (often worse
on overrun)

Engine oil level/pressure
low
Main bearing noise

Check the engine oil level and pressure, GO to Pinpoint Test

. Check for debris in the engine oil, check condition of

engine components

W hine/Whistle

Intake air system leaks
Damaged turbocharger
(when noise emanating
from rear of engine)

Check for loose/damaged intake air system components.
Check for excessive turbocharger shaft float Note: a small
amount of turbocharger shaft float is normal/acceptable.
Check for general damage to turbocharger

Misfire/Rough running

Electronic engine controls
Fuel charging and
controls
Intake air system leaks
Exhaust gas recirculation
(EGR) system
Burnt/sticking valves
Worn valve guides
Worn cylinder
bores/pistons
Broken piston rings
Damaged/Cracked casings

For electronic engine controls.
REFER to:

Electronic Engine Controls

(303-14B Electronic

Engine Controls - TD4 2.2L Diesel, Diagnosis and Testing).
For fuel charging and controls systems tests.
REFER to:

Fuel Charging and Controls

(303-04B Fuel Charging

and Controls - TD4 2.2L Diesel, Diagnosis and Testing).
Check intake air system for damage/leaks. For EGR system
tests.
REFER to:

Engine Emission Control

(303-08B Engine Emission

Control - TD4 2.2L Diesel, Diagnosis and Testing).
Check for damaged engine components. Carry out a
compression test, GO to Pinpoint Test

Pinpoint Tests

• NOTE: Where reference is made to 'suitable equipment', this refers to standard workshop equipment. Refer to the
operating instructions for your own equipment when performing any tests.

PINPOINT TEST A : CHECK THE CYLINDER COMPRESSIONS

WARNING: Only compression testers able to read the higher compression pressures found in diesel engines should

be used. Failure to follow this instruction may result in personal injury.

2
3
4
5
6

7
8
9

10
11

2
3

1
2
3
4
5
6

7
8

• NOTE: W here possible, compression testing should be carried out on an engine at normal operating temperature.

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

A1: CARRY OUT A DRY CYLINDER COMPRESSION TEST

Make sure the parking brake is applied and that the selector lever is in neutral (or park for vehicles
with automatic transmission).
Set the ignition status to OFF.
Remove the starter relay.
Disconnect the starter motor solenoid connector.
Connect a suitable remote starter device to the starter motor solenoid.
Remove the glow plugs.
REFER to:

Glow Plugs

(303-07B Glow Plug System, Removal and Installation).

Install suitable adaptor in place of the glow plug in the first cylinder to be tested.
Connect a suitable compression tester to the adaptor. See warning above.
Using the remote starter device, crank the engine a minimum of five revolutions.
Record the compression figure and the number of revolutions taken to reach it.
Repeat steps 7 - 10 above for the remaining cylinders, cranking the engine for a similar number of
revolutions each time.
Compare the compression figures across all the cylinders.

Are the compression figures within 10% of each other?
Yes

Unless the compression figures are universally very low (experience will indicate this), check for
other causes for the customer complaint.

GO to A2

A2: CARRY OUT A WET CYLINDER COMPRESSION TEST

CAUTION: If engine oil is introduced into the cylinders, run the engine at 2,000 rpm for a minimum of ten minutes

after completing testing to prevent damage to the catalytic converters. Failure to follow this instruction may result in
damage to the vehicle.
• NOTE: There is a combustion chamber in the top of each piston. Make sure that the oil is not allowed to run into this
chamber.

Using a suitable oil can with a flexible spout, introduce a small amount of clean engine oil into the
cylinder just before testing, such that the oil is able to run between the piston and the cylinder bore.
Repeat steps 7 - 10 from the test above, introducing oil into each cylinder just before testing.
Compare the compression figures across all the cylinders.

Is the compression figure higher than the dry test?
Yes

A higher figure following the introduction of oil may indicate a worn or damaged cylinder bore, piston
and/or piston rings. Disassembly would be required to confirm this.

If the compression figure is unaffected by the introduction of oil, but the figure is still less than 90%
of the other cylinders, this may indicate a burnt and/or sticking valve, leaking head gasket, etc.
Disassembly would be required to confirm this.
Clear any DTCs which may have been induced by the test.

PINPOINT TEST B : OIL CONSUMPTION TEST

• NOTE: Oil consumption will vary, depending on a number of factors. New engines will normally use more oil than 'run-in'
engines, once a consumption figure has been determined contact Dealer Technical Support for further assistance.

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

B1: CHECK FOR EXCESSIVE OIL CONSUMPTION

Start the engine and allow it to run until it reaches normal operating temperature.
Make sure the vehicle is parked on a level surface and switch off.
Allow to settle for at least five minutes.
Check the oil level.
Correct the level, if necessary, and record the reading and mileage in the vehicle history.
Make sure that the owner/driver is aware that a test is being carried out, and that they should not
top-up their oil level for the duration of the test, but should check the level every 160-240 Km
(100-150 miles).
When the oil level reaches the ADD mark, the customer should bring the vehicle in to be checked.
Top-up the oil to the level at the beginning of the test and record the amount of oil needed to do
so, and the mileage covered in the course of the test.
From this, the consumption can be calculated, and a decision made as to whether or not the
consumption is considered excessive.

Is the consumption excessive for the mileage and/or use? Contact Dealer Technical Support for further
assistance.
Yes

Disassembly will be required to check the components indicated in the symptom chart.

No further action is necessary.

PINPOINT TEST C : CHECK THE ENGINE OIL PRESSURE

• NOTE: The vehicle must be driven a minimum of 6 miles (10 kilometers) prior to testing the oil pressure. Do not attempt
to attain normal engine operating temperature by allowing the engine to idle.
• NOTE: Check and, if necessary, top-up the engine oil level before beginning this test.

TEST CONDITIONS

DETAILS/RESULTS/ACTIONS

C1: CHECK FOR LOW ENGINE OIL PRESSURE

4
5

Remove the oil pressure sensor.
REFER to:

Engine Oil Pressure (EOP) Sensor

(303-14B

Electronic Engine Controls - TD4 2.2L Diesel, Removal and
Installation).
Connect the oil pressure gauge and adaptor in place of the
oil pressure sensor.

Start the engine and check for leaks at the gauge
connection.
Allow the engine to idle and monitor the oil pressure.
Raise the engine speed to 4000 rpm and monitor the oil
pressure.

Is the oil pressure approximately 1.6 bar (23 lb/in²) at idle, and
3.1 bar (45 lb/in²) at 4000 rpm?
Yes

No fault is indicated at these pressures, oil pressure is
considered normal.

Low pressure may indicate a problem with: oil pump,
filtering, clearances within the engine. Check if there are
any other indications of engine faults (noise, etc). High
pressure may indicate a blockage in the lubrication system.
If this is not resolved, high oil pressure will lead to engine
oil leaks and other failures.

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