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Frelander 2. Manual - part 389

Vapor pipe to evaporative emission canister

Vapor purge pipe to intake manifold

Fuel delivery pipe to engine

Breather pipe

Item

Part Number

Description

Roll Over Valve (ROV)

Crossover tube assembly

Fill limit vent valve

Coarse fuel filter

Fuel gage sender units

Primary fuel filter

Fuel delivery module

Fuel filter element

OVERVIEW

The 70 liter saddle-type fuel tank is located below the rear seat and astride the driveshaft.

The fuel tank is manufactured using the latest six-layer laminated blow-molding technology providing both high mechanical
strength and complete emissions integrity. The fuel filler neck is produced from aluminum to balance high-strength with
low-weight. In the event of an accident damaging the filler neck, an inlet check valve in the tank's filler stub prevents fuel
escaping.

A single pump supplies the engine's fuel demands while also supplying the fuel to power the venturi. The rapid flow of fuel
through the venturi nozzle creates a depression which draws fuel back across the saddle into the pump side of the tank.

The fuel gage senders are sealed units which use magnetic actuation in place of electrical contacts; this prevents the

problem of chemical contamination of electrical components.

To meet on-board refueling vapor recovery (ORVR) requirements, the fuel tank and associated components are designed to
minimize fuel vapor loss during refueling. This is achieved by preventing fuel vapor from the fuel tank venting directly to
the atmosphere. Instead fuel vapor is directed into the evaporative emission (EVAP) canister where it is stored before
being purged at intervals to the engine’s intake manifold.
For additional information, refer to:

Evaporative Emissions

(303-13 Evaporative Emissions, Description and Operation).

Roll Over Valve (ROV)

The ROV is connected via pipes to a liquid vapour separator. The separator is connected via a pipe to the tank breather
outlet in the pump module flange. The ROV contains a non-return valve, which closes in the event of the vehicle
overturning, preventing liquid fuel escaping from the tank via the breather pipe.

Fuel Tank and Lines - I6 3.2L Petrol - 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

(310-01A Fuel Tank and Lines - I6 3.2L Petrol, 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: For diagnostic purposes the cylinders are divided into two banks: Bank 1 - Cylinder numbers 1, 2 and 3. Bank 2 -
Cylinders 4, 5 and 6

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

Engine breather system
disconnected/restricted
Ignition system
Fuel system
Electronic engine controls

Ensure the engine breather system is free from
restriction and is correctly installed
For ignition system tests.
REFER to:

Engine Ignition

(303-07A Engine

Ignition, Diagnosis and Testing).
For fuel system tests. Read DTCs and refer to
DTC Index in this section
For electronic engine control tests.
REFER to:

Electronic Engine Controls

(303-14A

Electronic Engine Controls - I6 3.2L Petrol,
Diagnosis and Testing).

Engine cranks and fires, but will
not start

Evaporative emissions
purge valve
Fuel pump
Spark plugs
Ignition coil failure(s)

For purge valve tests.
REFER to:

Evaporative Emissions

(303-13

Evaporative Emissions, Diagnosis and Testing).
For fuel pump tests. Check for DTCs and refer
to DTC Index in this section
For ignition system tests.
REFER to:

Engine Ignition

(303-07A Engine

Ignition, Diagnosis and Testing).

Difficult cold start

Check engine coolant
level/anti-freeze content
Battery
Electronic engine controls
Fuel pump
Evaporative emissions
purge valve

Check the engine coolant level and condition.
REFER to:

Specifications

(303-03A Engine

Cooling - I6 3.2L Petrol, Specifications).
Ensure the battery is in a fully charged and
serviceable condition
For electronic engine control tests.
REFER to:

Electronic Engine Controls

(303-14A

Electronic Engine Controls - I6 3.2L Petrol,
Diagnosis and Testing).
For fuel system tests. Read DTCs and refer to
DTC Index in this section
For purge valve tests.
REFER to:

Evaporative Emissions

(303-13

Evaporative Emissions, Diagnosis and Testing).

Symptom

Possible Cause

Action

Difficult hot start

Injector leak
Electronic engine controls
Evaporative emissions
purge valve
Fuel pump
Ignition system
Injector leak

Carry out injector leak tests, install new
injectors as necessary.
REFER to:

Fuel Injector

(303-04A Fuel Charging

and Controls - I6 3.2L Petrol, Removal and
Installation).
For electronic engine control tests.
REFER to:

Electronic Engine Controls

(303-14A

Electronic Engine Controls - I6 3.2L Petrol,
Diagnosis and Testing).
For purge valve tests.
REFER to:

Evaporative Emissions

(303-13

Evaporative Emissions, Diagnosis and Testing).
For fuel system tests. Read DTCs and refer to
DTC Index in this section
For ignition system tests.
REFER to:

Engine Ignition

(303-07A Engine

Ignition, Diagnosis and Testing).

Difficult to start after hot soak
(vehicle standing, engine off,
after engine has reached
operating temperature)

Electronic engine controls
Evaporative emissions
purge valve
Fuel pump
Ignition system

Carry out injector leak tests, install new
injectors as necessary.
REFER to:

Fuel Injector

(303-04A Fuel Charging

and Controls - I6 3.2L Petrol, Removal and
Installation).
For electronic engine control tests.
REFER to:

Electronic Engine Controls

(303-14A

Electronic Engine Controls - I6 3.2L Petrol,
Diagnosis and Testing).
For purge valve tests.
REFER to:

Evaporative Emissions

(303-13

Evaporative Emissions, Diagnosis and Testing).
For fuel system tests. Read DTCs and refer to
DTC Index in this section
For ignition system tests.
REFER to:

Engine Ignition

(303-07A Engine

Ignition, Diagnosis and Testing).

Engine stalls soon after start

Breather system
disconnected/restricted
ECM relay
Electronic engine controls
Ignition system
Air intake system
restricted
Air leakage
Fuel lines

Ensure the engine breather system is free from
restriction and is correctly installed
For ECM relay and electronic engine controls
tests.
REFER to:

Electronic Engine Controls

(303-14A

Electronic Engine Controls - I6 3.2L Petrol,
Diagnosis and Testing).
For ignition system tests.
REFER to:

Engine Ignition

(303-07A Engine

Ignition, Diagnosis and Testing).
Check for blockage in air cleaner element and
air intake system
Check for leakage in air intake system
For fuel line tests. GO to Pinpoint Test

Engine hesitates/poor
acceleration

Fuel pressure, fuel pump,
fuel lines
Injector leak
Air leakage
Electronic engine controls
Ignition system
Transmission malfunction
Restricted pedal travel
(carpet, etc)

For fuel pressure tests. GO to Pinpoint Test

For fuel line tests. GO to Pinpoint Test

For

fuel pump tests, check DTCs and refer to DTC
Index in this section
Carry out fuel injector leak tests, install new
injectors as necessary.
REFER to:

Fuel Injector

(303-04A Fuel Charging

and Controls - I6 3.2L Petrol, Removal and
Installation).
Check for leakage from air intake system
For electronic engine control tests.
REFER to:

Electronic Engine Controls

(303-14A

Electronic Engine Controls - I6 3.2L Petrol,
Diagnosis and Testing).
For ignition system tests.
REFER to:

Engine Ignition

(303-07A Engine

Ignition, Diagnosis and Testing).
For transmission system tests.
REFER to:

Diagnostics

(307-01 Automatic

Transmission/Transaxle, Diagnosis and
Testing).
Ensure accelerator pedal is free from restriction

Engine backfires

Fuel pump, fuel lines
Air leakage
Electronic engine controls
Ignition system
Sticking variable camshaft
timing (VCT) hub

For fuel pump tests. Read DTCs and refer to
DTC Index in this section. For fuel line tests.
GO to Pinpoint Test

Check for leakage from air intake system
For electronic engine control tests.
REFER to:

Electronic Engine Controls

(303-14A

Electronic Engine Controls - I6 3.2L Petrol,
Diagnosis and Testing).
For ignition system tests.
REFER to:

Engine Ignition

(303-07A Engine

Content .. 387 388 389 390 ..