Diagnostics and testing 2.7L (Discovery 3)

Inspection and verification

CAUTION: DO NOT perform any repairs to the fuel system while the engine is running. Fuel pressure in the system can reach 1600 bar. Failure to follow this instruction may result in injury.

WARNING: Be sure to wear eye protection when working with or in the immediate vicinity of any fuel-related elements. Failure to follow these instructions may result in personal injury.

CAUTION: This procedure involves handling fuel. Always be prepared for possible fuel splashing and follow safe fuel handling practices. Failure to follow this instruction may result in personal injury.

CAUTION: When repairs are completed, visually inspect the fuel system for leaks. This should be done after the engine has been running but with the engine off. Failure to follow this instruction could result in injury.

CAUTION: If swallowed, DO NOT induce vomiting. Seek immediate medical attention. Failure to follow this instruction may result in injury.

WARNING: If fuel gets into your eyes, rinse with cold water or an eye wash solution and seek medical attention. Failure to follow this instruction may result in injury.

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CAUTION: Wash hands thoroughly after handling as prolonged contact may cause irritation. If irritation occurs, seek medical attention. Failure to follow this instruction may result in injury.

CAUTION: Before disconnecting any fuel system component, be sure to remove all dust and dirt from around the components to prevent dirt from entering the fuel system. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: Fuel lines between the injectors and the fuel rail must be discarded after each use and new lines installed. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: Therefore, absolute cleanliness is required when working with these components. Open holes or lines must always be plugged using appropriate plugs. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: Clean and free as much dust as possible from the workshop area where the vehicle is being worked on. Areas where clutches, brakes, welding or machining are being carried out are not suitable due to the risk of fuel system contamination. Failure to follow this instruction may result in vehicle damage.

CAUTION: All protective clothing used must be clean and made of lint-free fabric. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: Make sure that the protective gloves used are new, made of latex and not powdered with talc. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: Use only clean, non-galvanized tools. Clean tools before working on the vehicle using a new, non-shedding brush and fresh cleaning solution. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: Use a workbench with a steel tabletop, which should be covered with a clean, lint-free cloth. Failure to follow this instruction may result in damage to the vehicle.

1. Ensure that the customer's complaint is justified.



2. Visually inspect for obvious mechanical and electrical problems.

Mechanical factors	Electrical factors
Fuel level Fuel contamination Fuel supply line(s) Fuel return line(s) High pressure fuel supply line(s) Fuel tank filler pipe Fuel leak(s) Fuel tank Fuel tank filler cap Fuel filter Push-to-connect fittings Fuel manifold High pressure fuel pump Exhaust Gas Recirculation (EGR) System	Charging and battery status Fuse(es) fuse(es) Inertia Fuel Switch (IFS) Fuel Pump Module Relay Fuel pump module Electrical connector(s) Damaged or corroded wiring harness Fuel Volume Control Valve (FVCV) Fuel Pressure Control Valve (FPCV) Engine Control Module (ECM)

3. If an obvious cause for the problem you identified or the customer described is found, resolve it before moving on to further action. (if possible).

4. Use the approved diagnostic system or scan tool to retrieve all diagnostic trouble codes (DTCs) before referring to the symptom chart or DTC index.

Clear all DTCs after troubleshooting.

Table of signs of malfunction

Sign of malfunction	Possible reasons	Action
The engine turns over but does not start	Inertia Fuel Switch (IFS) Low fuel level/contamination Fuel pump module malfunction Low pressure in the fuel system Air leak Fuel filter clogged Blocked/contaminated fuel volume control valve (FVCV) Clogged/contaminated fuel pressure valve (FPCV) High pressure fuel pump malfunction Crankshaft Position Sensor (CKP) ECM failure	Check if the inertia switch is activated. Check the fuel level/condition. Check the operation of the fuel pump module, check the low pressure circuit of the fuel system for leaks/ damage. Check the air intake system for leaks. Check the fuel filter, check the FVCV and FPCV. Check the high-pressure fuel pump. Check the TFR sensor. Refer to the corresponding section in the service station manual. If you have any doubts about the functionality of the module, please refer to the manual on warranty service policies and procedures.
Difficulty starting	Malfunction of the glow plug system (very low temperature conditions) Low fuel level/contamination Fuel pump module malfunction Low pressure in the fuel system Air leak Fuel filter clogged Blocked/contaminated fuel volume control valve (FVCV) Clogged/contaminated fuel pressure valve (FPCV) Exhaust Gas Recirculation (EGR) Valve Malfunction	Check glow plug circuits. Check fuel level/condition. Check fuel pump module operation, check low pressure fuel system circuit for leaks/damage. Check air intake system for leaks. Check fuel filter, check FVCV and FPCV. Check EGR valves. Refer to the appropriate section in the workshop manual.
Rough idle operation	Low fuel level/contamination Low pressure in the fuel system Air leak Fuel filter clogged Blocked/contaminated fuel volume control valve (FVCV) Clogged/contaminated fuel pressure valve (FPCV) Exhaust Gas Recirculation (EGR) Valve Malfunction	Check the fuel level/condition. Check the fuel system low pressure circuit for leaks/ damage. Check the air intake system for leaks. Check the fuel filter, check the FVCV and FPCV. Check the EGR valves. Refer to the corresponding section in the service station manual.
Loss of power when accelerating	Air intake system malfunction Blocked catalytic converter Low fuel pressure Exhaust Gas Recirculation (EGR) Valve Malfunction Turbocharger failure	Check the air intake system. Check the exhaust system for leaks or blockages. Install new components if necessary. Check the fuel system pressure. Check the EGR valves. Check the condition of the turbocharger and the operation of the actuator. Refer to the relevant section in the service station manual.
Engine stops/stalls	Low fuel level/contamination Fuel pump module malfunction Low pressure in the fuel system High pressure fuel leak Air leak Blocked/contaminated fuel volume control valve (FVCV) Clogged/contaminated fuel pressure valve (FPCV) Exhaust Gas Recirculation (EGR) Valve Malfunction	Check fuel level/condition. Check fuel pump module operation, check fuel system for leaks/damage. Check air intake system for leaks. Check FVCV and FPCV. Check EGR valves.
Engine jerking	Low fuel level/contamination Low pressure in the fuel system High pressure fuel leak Air leak Blocked/contaminated fuel volume control valve (FVCV) Clogged/contaminated fuel pressure valve (FPCV) High pressure fuel pump malfunction	Check the fuel level/condition. Check the fuel system for leaks/ damage. Check the air intake system for leaks. Check FVCV and FPCV. Check the high-pressure fuel pump. Refer to the corresponding section in the service station manual.
Increased fuel consumption	Low pressure in the fuel system High pressure fuel leak Leak in fuel temperature sensor Blocked/contaminated fuel volume control valve (FVCV) Clogged/contaminated fuel pressure valve (FPCV) Fuel injector malfunction Exhaust Gas Recirculation (EGR) Valve Malfunction	Check the fuel system for leaks/damage. Check the FVCV and FPCV. Check for injector related DTCs. Check the EGR valves. Refer to the appropriate section in the workshop manual.

DTC Index

NOTE: Generic scan tools cannot read the codes listed or can only read 5-digit codes. Match the 5 digits from the scan tool with the first 5 digits of the listed 7-digit code to identify the fault. (the last 2 digits provide additional information readable by a manufacturer approved diagnostic system).

NOTE: For a complete listing of ECM DTCs, refer to Section 303-14, Electronic Engine Control System, in the service manual.

DTC	Description	Possible reasons	Action
P008700	Fuel rail/system pressure too low	Fuel Rail Pressure (FRP) Sensor Disconnected FRP Sensor to ECM Signal Circuit Short to Ground FRP Sensor Power Circuit: High Resistance FRP sensor failure Leak in the fuel line Reducing the capacity of the fuel line Fuel Pump Module Circuit High Resistance Fuel Pump Module Circuit Short to Ground Fuel pump module malfunction Fuel injection valve malfunction Pressure control valve malfunction	Refer to the electrical equipment manual and check the fuel manifold pressure sensor circuits. Checks of the fuel manifold pressure sensor are described in the corresponding section of the service station manual. Check the fuel system's low pressure lines for leaks/ damage. Check the fuel system pressure. Check the circuits and operation of the low-pressure fuel pump module. Check the fuel manifold and high-pressure fuel line for leaks. Check for DTC codes for the VCV and PCV valves, and correct the problem if necessary.
P008800	Fuel rail/system pressure too high	Wiring from Fuel Rail Pressure (FRP) Sensor to ECM (nutrition/perception): short circuit on each other Signal circuit between FRP sensor and ECM: short circuit to battery + FRP sensor failure Fuel Pressure Control Valve (FPCV) Malfunction Fuel Pump Module Electrical Circuit: Short to Battery Positive Fuel pump module malfunction	Check the electrical circuits of the FRP sensor and the FPCV valve. Refer to the corresponding section in the service station manual. Check the electrical circuits of the fuel pump module. Refer to the electrical equipment manual.
P062700	Fuel Pump A Control Circuit Open	Fuel Pump Module Relay Control Circuit Short to Battery Positive Fuel Pump Module Relay Malfunction	Check the fuel pump and electrical circuits. Refer to the electrical manual. Activate the relay and listen for a "click". Refer to the appropriate section of the service manual. Repair/replace as necessary. Clear DTCs and check for proper operation.
P062800	Low Voltage in Fuel Pump A Control Circuit	Fuel Pump Module Relay Control Circuit High Resistance Fuel Pump Module Relay Control Circuit Short to Ground Fuel Pump Module Relay Malfunction	Refer to the electrical manual and check the fuel pump circuits. Activate the relay and listen for a "click". Repair/replace as necessary. Clear DTCs and check for proper operation.
P062900	Fuel Pump A Control Circuit High Voltage	Fuel Pump Module Relay Control Circuit High Resistance Fuel Pump Module Relay Malfunction	Refer to the electrical manual and check the fuel pump circuits. Activate the relay and listen for a "click". Repair/replace as necessary. Clear DTCs and check for proper operation.
P226900	Presence of water in fuel	Presence of water in fuel Water in Fuel Sensor Circuit Short to Ground Water in fuel sensor malfunction	Drain the condensate from the fuel filter. Clear the DTCs and retest. If the trouble code returns, check the sensor circuit. Refer to the electrical manual. If no faults were found in the electrical circuits, install a new sensor.
P228800	Injector control pressure too high	Fuel Pressure Control Valve (FPCV) Minimum Limit Reached Injector control pressure too high FPCV electrical circuit malfunction FPCV malfunction Fuel Pump Module Electrical Circuit: Short to Battery Positive Fuel pump module malfunction High pressure fuel pump malfunction	Check fuel pressure, refer to the relevant section of the workshop manual. Check the fuel pump module and FPCV circuits. Refer to the electrical manual. High pressure fuel pump and FPCV checks are described in the relevant section of the workshop manual.
P229000	Injector control pressure too low	Fuel Pressure Control Valve (FPCV) maximum limit reached Injector control pressure too low Leak in the fuel line Reduced fuel filter/fuel system flow capacity FPCV electrical circuit malfunction FPCV malfunction Fuel Pump Module Circuit Short to Ground Fuel pump module malfunction High pressure fuel pump malfunction	Check the fuel system pressure. Check the fuel lines for leaks/ damage. Check for clogged/ reduced fuel filter capacity. Check the electrical circuits of the fuel pump module. Refer to the electrical equipment manual. Check the FMCV electrical circuits. Check the high-pressure fuel pump. See the corresponding section of the manual for service stations.
P229200	Injector control pressure fluctuations	Fuel Injector Control Pressure: Erratic FPCV electrical circuit malfunction FPCV malfunction Fuel Pump Module Circuit High Resistance, Short to Ground, Short to Battery Fuel pump module malfunction High pressure fuel pump malfunction	Check fuel pressure, refer to the relevant section of the workshop manual. Check the fuel pump module and FPCV circuits. Refer to the electrical manual. High pressure fuel pump and FPCV checks are described in the relevant section of the workshop manual.