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Frelander 2. Manual - part 293

Item

Part Number

Description

Intake air filling tract

Intake manifold

Cylinder head swirl port

Cylinder head filling port

The TD4 cylinder head and intake manifold are designed to optimize levels of swirl across the engines speed range, and
provide a high volume of air into the cylinders. The intake manifold is designed with a lower row of 4 helical swirl ports,
and an upper row of 4 filling ports with port-deactivation device. The 8 ports are sealed to the cylinder head and structural
camshaft cover mating ports with a shaped sealing ring. The helical swirl port is configured to create optimum swirl for
efficient combustion; while the filling port is provided to supply high volumes of air without disturbing in-cylinder swirl. The
intake manifold port de-activation device is controlled by the ECM.
For additional information, refer to: Electronic Engine Controls - 2.2L Diesel (303-14 Electronic Engine Controls - 2.2L
Diesel, Description and Operation).

Each cylinder is supplied air through the helical swirl port, and when activated, through the filling port. The helical swirl
port is always open and directs air from the intake manifold lower port at a tangent into the combustion chamber. The
filling port is normally closed, and is only opened during certain engine operating conditions by the ECM. When opened the
filling port directs air from the intake manifold upper port, and through the curved intake tracts into the combustion
chamber. The intake tracts are cast with the structural camshaft cover, and join the intake manifold upper filling ports to
the cylinder head machined filling ports.

At low engine loads gas flow is so low that the filling port is closed off. This has the effect of raising gas velocity through
the helical port and increasing in-cylinder swirl to the optimum rate. To avoid the risk of the high gas flow creating
excessive swirl, the ECM opens the filling port under high gas-flow conditions to maintain consistent optimum swirl across
the engines operating range.

Intake Manifold Port De-Activation

Item

Part Number

Description

Solenoid-operated valve

Intake manifold helical swirl port

Vacuum-operated actuator

Intake manifold filling port

Butterfly valve (4 off)

Port de-activation is operated by 4-butterfly valves connected on a common shaft within the intake manifold. Each
butterfly valve is housed within a corresponding intake manifold upper filling port. The common shaft is connected to a
vacuum-operated actuator, and is operated by a solenoid valve under the control of the ECM. The vacuum required for port
de-activation is supplied from the engine mounted vacuum pump.

For additional information, refer to:

Engine

(303-01B Engine - TD4 2.2L Diesel, Description and Operation),

Electronic Engine Controls - 2.2L Diesel (303-14 Electronic Engine Controls - 2.2L Diesel, Description and Operation).

Port de-activation (opening of the filling ports) only occurs when the coolant temperature is greater than 10°C, and under
the following conditions:

Engine speed is greater than 1,800 rpm.
Engine load is greater than 15%.

Intake Air Distribution and Filtering - TD4 2.2L Diesel - Intake Air
Distribution and Filtering

Diagnosis and Testing

Principles of Operation

For a detailed description of the intake air distribution and filtering system, refer to the relevant Description and Operation
section in the workshop manual.
REFER to:

Intake Air Distribution and Filtering

(303-12B Intake Air Distribution and Filtering - 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

Hoses and ducts (damage/connections)
Air cleaner element
(contaminated/blocked)
Restricted air intake
Seals and gaskets

Mass Air Flow (MAF) sensor
Secondary Air Injection (AIR) Manifold Absolute Pressure (MAP)
sensor
Throttle body
Harness (security/damage)
Connections (security/damage)

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

Vehicle does not start/hard
starting/poor performance

Restricted/blocked air intake
Restricted/blocked air cleaner
element

Ensure the air intake system is free
from blockage and is correctly installed
Install a new air cleaner element as
necessary.
REFER to: Air Cleaner Element (303-12,
Removal and Installation).

Excessive intake noise

Intake pipe disconnected/damaged
after the air cleaner
Air cleaner assembly incorrectly
assembled/damaged

Check for correct installation and
integrity of air intake system
Check for correct installation and
integrity of the air cleaner assembly.
REFER to: Air Cleaner Element (303-12,
Removal and Installation).

DTC Index

• 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.

• 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 additional
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. W hen 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.

DTC

Description

Possible Causes

Action

P006900 MAP - Barometric Pressure

Correlation

Boost pressure sensor circuit - short to
ground, power, open circuit
Barometric pressure sensor failure

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

DTC

Description

Possible Causes

Action

system

P007200 Ambient Air Temperature

Sensor Circuit Low

Ambient air temperature sensor circuit -
short to ground, open circuit