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FUEL SYSTEM2.

5L DIESEL ENGINE
TABLE OF CONTENTS
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FUEL DELIVERY SYSTEM 2. 5L DIESEL
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FUEL INJECTION SYSTEM 2. 5L DIESEL
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FUEL DELIVERY SYSTEM2.5L DIESEL ENGINE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FUEL SYSTEM PRESSURE WARNING . . . . . . . . . 2
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FUEL TANK MODULE . . . . . . . . . . . . . . . . . . . . . . 2
FUEL GAUGE SENDING UNIT. . . . . . . . . . . . . . . . 2
FUEL FILTER/WATER SEPARATOR . . . . . . . . . . . . 2
FUEL SHUTDOWN SOLENOID . . . . . . . . . . . . . . . 3
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . 3
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL TUBES/LINES/HOSES AND CLAMPS
LOW-PRESSURE TYPE . . . . . . . . . . . . . . . . . . . 4
QUICK-CONNECT FITTINGSLOW
PRESSURE TYPE. . . . . . . . . . . . . . . . . . . . . . . . 5
HIGH-PRESSURE FUEL LINES . . . . . . . . . . . . . . . 5
FUEL DRAIN TUBES . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL HEATER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL HEATER RELAY . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 6
VISUAL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . 6
AIR IN FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 9
FUEL HEATER RELAY TEST . . . . . . . . . . . . . . . . . 9
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . . 10
FUEL INJECTOR / NEEDLE MOVEMENT
SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL INJECTION PUMP TEST. . . . . . . . . . . . . . . 10
FUEL SUPPLY RESTRICTIONS . . . . . . . . . . . . . . 11
FUEL SHUTDOWN SOLENOID TEST . . . . . . . . . . 11
HIGH-PRESSURE FUEL LINE LEAK TEST . . . . . . 11
SERVICE PROCEDURES
AIR BLEED PROCEDURES . . . . . . . . . . . . . . . . . 12
FUEL INJECTION PUMP TIMING . . . . . . . . . . . . . 13
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . 13
FUEL DRAIN TUBES . . . . . . . . . . . . . . . . . . . . . . 14
FUEL FILTER/WATER SEPARATOR . . . . . . . . . . . 14
FUEL HEATER. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FUEL HEATER RELAY . . . . . . . . . . . . . . . . . . . . . 15
FUEL LEVEL SENSOR. . . . . . . . . . . . . . . . . . . . . 15
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . 15
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . 19
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FUEL RESERVOIR MODULE . . . . . . . . . . . . . . . . 21
HIGH-PRESSURE LINES . . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS
FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . . . . 22
IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
FUEL INJECTOR FIRING SEQUENCE . . . . . . . . . 22
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . 22
DESCRIPTION AND OPERATION
INTRODUCTION
DESCRIPTION
Thi s Fuel Del i very secti on wi l l cover components
not control l ed by the PCM. For components con-
trol l ed by the PCM, refer to the Fuel I njecti on Sys-
tem2.5L Di esel Engi ne secti on of thi s group.
The fuel heater rel ay, fuel heater and fuel gauge
are not operated by the PCM. These components are
control l ed by the i gni ti on (key) swi tch. Al l other fuel
system el ectri cal components necessary to operate
the engi ne are control l ed or regul ated by the PCM.
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 1
FUEL SYSTEM PRESSURE WARNING
DESCRIPTION
WARNING: HIGHPRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 45,000 KPA (6526 PSI).
USE EXTREME CAUTION WHEN INSPECTING FOR
HIGHPRESSURE FUEL LEAKS. INSPECT FOR
HIGHPRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD (Fig. 1). HIGH FUEL INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
FUEL TANK
DESCRIPTION
The fuel tank and tank mounti ng used wi th the
di esel powered engi ne i s the same as used wi th gas-
ol i ne powered model s, al though the fuel tank modul e
i s di fferent.
The fuel tank contai ns the fuel tank modul e and
one rol l over val ve. Two fuel l i nes are routed to the
fuel tank modul e. One l i ne i s used for fuel suppl y to
the fuel fi l ter/water separator. The other i s used to
return excess fuel back to the fuel tank.
The fuel tank modul e contai ns the fuel gauge el ec-
tri cal sendi ng uni t. An electric fuel pump is not
used with the diesel engine.
FUEL TANK MODULE
DESCRIPTION
An el ectri c fuel pump i s not attached to the fuel
tank modul e for di esel powered engi nes. Fuel i s
drawn by the fuel i njecti on pump.
The fuel tank modul e i s i nstal l ed i n the top of the
fuel tank. The fuel tank modul e contai ns the fol l ow-
i ng components:
Fuel reservoi r
El ectri c fuel gauge sendi ng uni t
Fuel suppl y l i ne connecti on
Fuel return l i ne connecti on
Wi re harness
Fuel i nl et fi l ter (Strai ner)
FUEL GAUGE SENDING UNIT
DESCRIPTION
The fuel gauge sendi ng uni t i s attached to the si de
of the fuel pump modul e. The sendi ng uni t consi sts of
a fl oat, an arm, and a vari abl e resi stor (track). The
track i s used to send an el ectri cal si gnal used for fuel
gauge operati on.
As the fuel l evel i ncreases, the fl oat and arm move
up. Thi s decreases the sendi ng uni t resi stance, caus-
i ng the PCM to send a si gnal to the fuel gauge on the
i nstrument panel to read ful l . As the fuel l evel
decreases, the fl oat and arm move down. Thi s
i ncreases the sendi ng uni t resi stance, causi ng the
PCM to send a si gnal to the fuel gauge on the i nstru-
ment panel to move toward empty.
FUEL FILTER/WATER SEPARATOR
DESCRIPTION
The fuel fi l ter/water separator assembl y i s l ocated
i n the engi ne compartment near the strut tower (Fi g.
2).
The combi nati on fuel fi l ter/water separator pro-
tects the fuel i njecti on pump by hel pi ng to remove
water and contami nants from the fuel . Moi sture col -
l ects at the bottom of the fi l ter/separator i n a pl asti c
bowl .
The fuel fi l ter/water separator assembl y contai ns
the fuel fi l ter, fuel heater el ement, and water drai n
val ve.
For i nformati on on the fuel heater, refer to Fuel
Heater i n thi s group.
Refer to the mai ntenance schedul es i n Group 0 i n
thi s manual for the recommended fuel fi l ter repl ace-
ment i nterval s.
For peri odi c drai ni ng of water from the bowl , refer
to Fuel Fi l ter/Water Separator Removal /I nstal l ati on
i n thi s group.
Fig. 1 Typical Fuel Pressure Test at Injection Pump
1 FITTING
2 HIGH PRESSURE LINE
3 CARDBOARD
14 - 2 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
DESCRIPTION AND OPERATION (Continued)
FUEL SHUTDOWN SOLENOID
DESCRIPTION
The fuel shutdown solenoid is controlled and
operated by the ECM.
The fuel shutdown (shut-off) sol enoi d i s used to
el ectri cal l y shut off the di esel fuel suppl y to the hi gh-
pressure fuel i njecti on pump. The sol enoi d i s
mounted to the rear of the i njecti on pump.
The sol enoi d control s starti ng and stoppi ng of the
engi ne regardl ess of the posi ti on of the accel erator
pedal . When the i gni ti on (key) swi tch i s OFF, the
sol enoi d i s shut off and fuel fl ow i s not al l owed to the
fuel i njecti on pump. When the key i s pl aced i n the
ON or START posi ti ons, fuel suppl y i s al l owed at the
i njecti on pump.
FUEL INJECTION PUMP
DESCRIPTION
The fuel i njecti on pump i s a mechani cal di stri bu-
tortype, Bosch VP36 seri es (Fi g. 3). A gear on the
end of the i njecti on pump shaft meshes wi th the
dri ve gear at the front of engi ne. The pump i s
mechani cal l y ti med to the engi ne. The ECM regu-
l ates the ti mi ng of the i njecti on pump.
The i njecti on pump contai ns the fuel shutdown
sol enoi d, fuel temperature sensor, control sl eeve sen-
sor, fuel quanti ty actuator and the fuel ti mi ng sol e-
noi d (Fi g. 3).
I n the el ectroni cal l y control l ed i njecti on pump, the
pump pl unger works the same as the pump pl unger
i n a mechani cal l y control l ed i njecti on pump, but the
amount of fuel and the ti me the fuel i s i njected i s
control l ed by the vehi cl es ECM, i nstead of by a
mechani cal governor assembl y. A sol enoi d control l ed
by the ECM i s used i n pl ace of the mechani cal gov-
ernor assembl y, and i t moves a control sl eeve i nsi de
the pump that regul ates the amount of fuel bei ng
i njected. There i s no mechani cal connecti on between
the accel erator pedal and the el ectroni cal l y control l ed
i njecti on pump. I nstead, a sensor connected to the
accel erator pedal sends a si gnal to the ECM that rep-
resents the actual posi ti on of the accel erator pedal .
The ECM uses thi s i nput, al ong wi th i nput from
other sensors to move the control sl eeve to del i ver
the appropri ate amount of fuel . Thi s system i s known
as Dri ve-By-Wi re
The actual ti me that the fuel i s del i vered i s very
i mportant to the di esel combusti on process. The ECM
moni tors outputs from the engi ne speed sensor (fl y-
wheel posi ti on i n degrees), and the fuel i njector sen-
sor (mechani cal movement wi thi n the #1 cyl i nder
fuel i njector). Outputs from the Accel erator Pedal
Posi ti on sensor, engi ne speed sensor (engi ne rpm)
and engi ne cool ant temperature sensor are al so used.
The ECM wi l l then compare i ts set val ues to these
outputs to el ectri cal l y adjust the fuel ti mi ng (amount
of advance) wi thi n the i njecti on pump. Thi s i s
referred to as Cl osed Loop operati on. The ECM
moni tors fuel ti mi ng by compari ng i ts set val ue to
when the i njector #1 opens. I f the val ue i s greater
than a preset val ue a faul t wi l l be set.
Fig. 2 Fuel Filter/Water Separator Location
Fig. 3 Fuel Injection Pump
1 FUEL INJECTION PUMP ASSEMBLY
2 FUEL RETURN LINE
3 FUEL SUPPLY LINE
4 FUEL INJECTION PUMP 10WAY CONNECTOR
5 TIMING SOLENOID
6 OVERFLOW VALVE
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 3
DESCRIPTION AND OPERATION (Continued)
Actual el ectri c fuel ti mi ng (amount of advance) i s
accompl i shed by the fuel ti mi ng sol enoi d mounted to
the bottom of the i njecti on pump (Fi g. 3). Fuel ti mi ng
wi l l be adjusted by the ECM, whi ch control s the fuel
ti mi ng sol enoi d.
An overfl ow val ve i s attached i nto the fuel return
l i ne at the rear of the fuel i njecti on pump (Fi g. 3).
Thi s val ve serves two purposes. One i s to ensure that
a certai n amount of resi dual pressure i s mai ntai ned
wi thi n the pump when the engi ne i s swi tched off.
Thi s wi l l prevent the fuel ti mi ng mechani sm wi thi n
the i njecti on pump from returni ng to i ts zero posi -
ti on. The other purpose i s to al l ow excess fuel to be
returned to the fuel tank through the fuel return
l i ne. The pressure val ues wi thi n thi s val ve are preset
and can not be adjusted.
The fuel i njecti on pump suppl i es hi ghpressure
fuel of approxi matel y 45,000 kPa (6526 psi ) to each
i njector i n preci se metered amounts at the correct
ti me.
For mechani cal i njecti on pump ti mi ng, refer to
Fuel I njecti on Pump Ti mi ng i n the Servi ce Proce-
dures secti on of thi s group.
FUEL INJECTORS
DESCRIPTION
The fuel i njectors have control l ed i nternal l eakage
whi ch col l s the i njectors. Fuel drai n tubes (Fi g. 4) are
used to route thi s fuel back to the overfl ow val ve at
the rear of the i njecti on pump. Thi s excess fuel i s
then returned to the fuel tank through the fuel
return l i ne.
The i njectors are connected to the fuel i njecti on
pump by the hi gh pressure fuel l i nes. A separate
i njector i s used for each of the four cyl i nders. An
i njector contai ni ng a sensor (Fi g. 5) i s used on the
number one cyl i nder i njector. Thi s i njector i s cal l ed
i nstrumented i njector #1 or needl e movement sensor.
I t i s used to tel l the ECM when the #1 i njectors
i nternal spri ng-l oaded val ve seat has been forced
open by pressuri zed fuel bei ng del i vered to the cyl i n-
der, whi ch i s at the end of i ts compressi on stroke.
When the i nstrumented i njectors val ve seat i s force
open, i t sends a smal l vol tage spi ke pul se to the
ECM. Thi s tel l s the ECM that the #1 cyl i nder i njec-
tor i s fi ri ng. I t i s not used wi th the other three i njec-
tors.
Fuel enters the i njector at the fuel i nl et (top of
i njector) and i s routed to the needl e val ve bore. When
fuel pressure ri ses to approxi matel y 15,00015,800
kPa (21752291 psi ), the needl e val ve spri ng tensi on
i s overcome. The needl e val ve ri ses and fuel fl ows
through the spray hol es i n the nozzl e ti p i nto the
combusti on chamber. The pressure requi red to l i ft
the needl e val ve i s the i njector openi ng pressure set-
ti ng. Thi s i s referred to as the pop-off pressure set-
ti ng.
Fuel pressure i n the i njector ci rcui t decreases after
i njecti on. The i njector needl e val ve i s i mmedi atel y
cl osed by the needl e val ve spri ng and fuel fl ow i nto
the combusti on chamber i s stopped. Exhaust gases
are prevented from enteri ng the i njector nozzl e by
the needl e val ve.
A copper washer (gasket) i s used at the base of
each i njector (Fi g. 5) to prevent combusti on gases
from escapi ng.
Fuel i njector fi ri ng sequence i s 1342.
FUEL TUBES/LINES/HOSES AND CLAMPS
LOW-PRESSURE TYPE
DESCRIPTION
Al so refer to the proceedi ng secti on on Qui ckCon-
nect Fi tti ngs.
Fig. 4 Fuel Injectors and Drain Tubes
Fig. 5 Fuel Injector Sensor
1 NEEDLE MOVEMENT SENSOR
2 FUEL INJECTOR (NUMBER 1 CYLINDER ONLY)
3 COPPER WASHER
4 SENSOR CONNECTOR
14 - 4 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
DESCRIPTION AND OPERATION (Continued)
I nspect al l hose connecti ons such as cl amps, cou-
pl i ngs and fi tti ngs to make sure they are secure and
l eaks are not present. The component shoul d be
repl aced i mmedi atel y i f there i s any evi dence of deg-
radati on that coul d resul t i n fai l ure.
Never attempt to repai r a pl asti c fuel l i ne/tube or a
qui ckconnect fi tti ng. Repl ace compl ete l i ne/tube as
necessary.
Avoi d contact of any fuel tubes/hoses wi th other
vehi cl e components that coul d cause abrasi ons or
scuffi ng. Be sure that the fuel l i nes/tubes are prop-
erl y routed to prevent pi nchi ng and to avoi d heat
sources.
The l i nes/tubes/hoses are of a speci al constructi on.
I f i t i s necessary to repl ace these l i nes/tubes/hoses,
use onl y ori gi nal equi pment type.
The hose cl amps used to secure the rubber hoses
are of a speci al rol l ed edge constructi on. Thi s con-
structi on i s used to prevent the edge of the cl amp
from cutti ng i nto the hose. Onl y these rol l ed edge
type cl amps may be used i n thi s system. Al l other
types of cl amps may cut i nto the hoses and cause
fuel l eaks.
Where a rubber hose i s joi ned to a metal tube
(staked), do not attempt to repai r. Repl ace enti re
l i ne/tube assembl y.
Use new ori gi nal equi pment type hose cl amps.
Ti ghten hose cl amps to 2 Nm (20 i n. l bs.) torque.
QUICK-CONNECT FITTINGS LOW PRESSURE
TYPE
DESCRIPTION
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components. These are: a
si ngl e-tab type, a two-tab type or a pl asti c retai ner
ri ng type (Fi g. 6). Refer to Qui ck-Connect Fi tti ngs i n
the Removal /I nstal l ati on secti on for more i nforma-
ti on.
CAUTION: The interior components (o-rings, spac-
ers) of quick-connect fitting are not serviced sepa-
rately, but new pull tabs are available for some
types. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
HIGH-PRESSURE FUEL LINES
DESCRIPTION
CAUTION: The highpressure fuel lines must be
held securely in place in their holders. The lines
cannot contact each other or other components. Do
not attempt to weld highpressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of highpressure
fuel line is necessary.
Hi ghpressure fuel l i nes del i ver fuel under pres-
sure of up to approxi matel y 45,000 kPa (6526 PSI )
from the i njecti on pump to the fuel i njectors. The
l i nes expand and contract from the hi ghpressure
fuel pul ses generated duri ng the i njecti on process. Al l
hi ghpressure fuel l i nes are of the same l ength and
i nsi de di ameter. Correct hi ghpressure fuel l i ne
usage and i nstal l ati on i s cri ti cal to smooth engi ne
operati on.
WARNING: USE EXTREME CAUTION WHEN
INSPECTING FOR HIGHPRESSURE FUEL LEAKS.
INSPECT FOR HIGHPRESSURE FUEL LEAKS WITH
A SHEET OF CARDBOARD. HIGH FUEL INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
Fig. 6 Plastic Retainer Ring-Type Fitting
1 FUEL TUBE
2 QUICK CONNECT FITTING
3 PUSH
4 PLASTIC RETAINER
5 PUSH
6 PUSH
7 PUSH
8 PUSH
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 5
DESCRIPTION AND OPERATION (Continued)
FUEL DRAIN TUBES
DESCRIPTION
These rubber tubes are l owpressure type. Some
fuel i s conti nual l y bei ng returned to the fuel i njecti on
pump. Duri ng i njecti on, a smal l amount of fuel fl ows
past the i njector needl e and i s not i njected i nto the
combusti on chamber. Thi s cool s and l ubri cates the
i njectors. Thi s fuel fl ows through the fuel drai n tubes
(Fi g. 7) and back to the tee banjo fi tti ng, whi ch i s
connected to the same l i ne as the overfl ow val ve. The
overfl ow val ve i s cal i brated to open at a preset pres-
sure. Excess fuel not requi red by the pump to mai n-
tai n the mi ni mum pump cavi ty pressure i s then
returned through the overfl ow val ve and on to the
fuel tank through the fuel return l i ne.
FUEL HEATER
DESCRIPTION
The fuel heater i s used to prevent di esel fuel from
waxi ng and pl uggi ng the fuel fi l ter duri ng col d
weather operati on. The fuel heater i s l ocated i n the
bottom pl asti c bowl of the fuel fi l ter/water separator
(Fi g. 8).
The el ement i nsi de the heater assembl y i s made of
a Posi ti ve Temperature Coeffi ci ent (PTC) materi al ,
and has power appl i ed to i t by the fuel heater rel ay
anyti me the i gni ti on key i s i n the on posi ti on. PTC
materi al has a hi gh resi stance to current fl ow when
i ts temperature i s hi gh, whi ch means that i t wi l l not
generate heat when the temperature i s above a cer-
tai n val ue. When the temperature i s bel ow 7C (45
F), the resi stance of the PTC el ement i s l owered, and
al l ows current to fl ow through the fuel heater el e-
ment warmi ng the fuel . When the temperature i s
above 29C (85 F), the PTC el ements resi stance
ri ses, and current fl ow through the heater el ement
stops.
Vol tage to operate the fuel heater i s suppl i ed from
the i gni ti on (key) swi tch and through the fuel heater
rel ay. Refer to the fol l owi ng Fuel Heater Rel ay for
addi ti onal i nformati on. The fuel heater and fuel
heater relay are not controlled by the Power-
train Control Module (PCM).
FUEL HEATER RELAY
DESCRIPTION
Vol tage to operate the fuel heater i s suppl i ed from
the i gni ti on (key) swi tch through the fuel heater
rel ay. The PCM or ECM is not used to control
this relay.
The fuel heater rel ay i s l ocated i n the PDC. The
PDC i s l ocated next to the battery i n the engi ne com-
partment. For the l ocati on of the rel ay wi thi n the
PDC, refer to l abel on PDC cover.
DIAGNOSIS AND TESTING
GENERAL INFORMATION
Thi s secti on of the group wi l l cover a general di ag-
nosi s of di esel engi ne fuel system components.
Diagnostic Trouble Codes: Refer to On-Board
Di agnosti cs i n Group 25, Emi ssi on Control System
for a l i st of Di agnosti c Troubl e Codes (DTCs) for cer-
tai n fuel system components.
VISUAL INSPECTION
A vi sual i nspecti on for l oose, di sconnected, or i ncor-
rectl y routed wi res and hoses shoul d be made before
attempti ng to di agnose or servi ce the di esel fuel
i njecti on system. A vi sual check wi l l hel p fi nd these
condi ti ons. I t al so saves unnecessary test and di ag-
nosti c ti me. A thorough vi sual i nspecti on of the fuel
i njecti on system i ncl udes the fol l owi ng checks:
Fig. 7 Fuel Drain Tubes
Fig. 8 Fuel Heater Temperature Sensor and Element
Location
1 TERMINAL 2
2 FUEL HEATER
3 TERMINAL 1
14 - 6 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
DESCRIPTION AND OPERATION (Continued)
(1) Be sure that the battery connecti ons are ti ght
and not corroded.
(2) Be sure that the 60 way connector i s ful l y
engaged wi th the PCM (Fi g. 9).
(3) Be sure that the 68 way connector i s ful l y
engaged wi th the MSA (Fi g. 10)
(4) Veri fy that the el ectri cal connecti ons for the
ASD rel ay are cl ean and free of corrosi on. Thi s rel ay
i s l ocated i n the PDC. For the l ocati on of the rel ay
wi thi n the PDC, refer to l abel on PDC cover.
(5) Veri fy that the el ectri cal connecti ons for the
fuel heater rel ay are cl ean and free of corrosi on. Thi s
rel ay i s l ocated i n the PDC. For the l ocati on of the
rel ay wi thi n the PDC, refer to l abel on PDC cover.
(6) Be sure the el ectri cal connectors at the ends of
the gl ow pl ugs (Fi g. 11) are ti ght and free of corro-
si on.
(7) Be sure that the el ectri cal connecti ons at the
gl ow pl ug rel ay are ti ght and not corroded. The gl ow
pl ug rel ay i s l ocated i n the engi ne compartment on
the l efti nner fender (Fi g. 12).
(8) I nspect the starter motor and starter sol enoi d
connecti ons for ti ghtness and corrosi on.
(9) Veri fy that the Fuel I njecti on Pump el ectri cal
connector i s fi rml y connected. I nspect the connector
for corrosi on or damaged wi res. The sol enoi d i s
mounted to the rear of the i njecti on pump (Fi g. 13).
(10) Veri fy that the fuel heater el ectri cal connector
i s fi rml y attached to the fi l ter bowl at the bottom of
the fuel fi l ter/water separator. I nspect the connector
for corrosi on or damaged wi res.
(11) Veri fy that the el ectri cal pi gtai l connector
(sensor connector) (Fi g. 14) for the fuel i njector sen-
sor i s fi rml y connected to the engi ne wi ri ng harness.
I nspect the connector for corrosi on or damaged wi res.
Thi s sensor i s used on the #1 cyl i nder i njector onl y.
(12) I nspect for exhaust system restri cti ons such
as pi nched exhaust pi pes or a col l apsed or pl ugged
muffl er.
(13) Veri fy that the harness connector i s fi rml y
connected to the vehi cl e speed sensor (Fi g. 15).
Fig. 9 PCM LocationTypical
1 PCM HARNESS CONNECTOR C1
2 PCM HARNESS CONNECTOR C2
3 PCM HARNESS CONNECTOR C3
4 POWERTRAIN CONTROL MODULE (PCM)
Fig. 10 ECM LocationLHD
1 ECM HARNESS CONNECTOR C1
2 ENGINE CONTROL MODULE (ECM)
3 ECM HARNESS CONNECTOR C2
4 ACCELERATOR PEDAL POSITION SENSOR
Fig. 11 Glow Plug Connector
1 GLOW PLUG ELECTRICAL CONNECTOR
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 7
DIAGNOSIS AND TESTING (Continued)
(14) Veri fy turbocharger wastegate operati on.
Refer to Group 11, Exhaust System and I ntake Man-
i fol d Group for i nformati on.
(15) Veri fy that the harness connector i s fi rml y
connected to the engi ne cool ant temperature sensor.
The sensor i s l ocated on the si de of cyl i nder head
near the rear of fuel i njecti on pump (Fi g. 16).
(16) Check for ai r i n the fuel system. Refer to the
Ai r Bl eed Procedure.
(17) I nspect al l fuel suppl y and return l i nes for
si gns of l eakage.
Fig. 12 Glow Plug Relay Location
1 MOUNTING BOLT
2 GLOW PLUG RELAY
3 ELECTRICAL CONNECTOR
Fig. 13 Fuel Shutdown Solenoid Location
1 FUEL INJECTION PUMP ASSEMBLY
2 FUEL RETURN LINE
3 FUEL SUPPLY LINE
4 FUEL INJECTION PUMP 10WAY CONNECTOR
5 TIMING SOLENOID
6 OVERFLOW VALVE
Fig. 14 Fuel Injector Sensor
1 NEEDLE MOVEMENT SENSOR
2 FUEL INJECTOR (NUMBER 1 CYLINDER ONLY)
3 COPPER WASHER
4 SENSOR CONNECTOR
Fig. 15 Vehicle Speed Sensor4 Wheel Drive
1 4WD TRANSFER CASE EXTENSION
2 VEHICLE SPEED SENSOR
3 SENSOR ELECTRICAL CONNECTOR
14 - 8 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
DIAGNOSIS AND TESTING (Continued)
(18) Be sure that the ground connecti ons are ti ght
and free of corrosi on. Refer to Group 8, Wi ri ng for
l ocati ons of ground connecti ons.
(19) I nspect the ai r cl eaner el ement (fi l ter) for
restri cti ons.
(20) Be sure that the turbocharger output hose i s
properl y connected to the charge ai r cool er (i nter-
cool er) i nl et tube. Veri fy that the charge ai r cool er
output hose i s properl y connected to the cool er and
the i ntake mani fol d. Refer to Group 11, Exhaust Sys-
tem and I ntake Mani fol d for i nformati on.
(21) Be sure that the vacuum hoses to the vacuum
pump are connected and not l eaki ng. The vacuum
pump i s l ocated i n the front of engi ne (i nternal ) and
i s dri ven from the crankshaft gear (Fi g. 17). Di scon-
nect the hose and check for mi ni mum vacuum from
the pump. Refer to Group 5, Brake System for spec-
i fi cati ons and procedures.
(22) Be sure that the accessory dri ve bel t i s not
damaged or sl i ppi ng.
(23) Veri fy there i s a good connecti on at the engi ne
speed sensor. Refer to the Fuel I njecti on System i n
thi s secti on for l ocati on of the engi ne speed sensor
l ocati on.
(24) Veri fy there i s a good connecti on at the Boost
Pressure Sensor, whi ch i s a part of the ai r i ntake
assembl y.
AIR IN FUEL SYSTEM
Ai r wi l l enter the fuel system whenever the fuel
suppl y l i nes, fuel fi l ter/water separator, fuel fi l ter
bowl , i njecti on pump, hi ghpressure l i nes or i njectors
are removed or di sconnected. Ai r wi l l al so enter the
fuel system whenever the fuel tank has been run
empty.
Ai r trapped i n the fuel system can resul t i n hard
starti ng, a rough runni ng engi ne, engi ne mi sfi re, l ow
power, excessi ve smoke and fuel knock. After servi ce
i s performed, ai r must be bl ed from the system
before starti ng the engi ne.
I nspect the fuel system from the fuel tank to the
i njectors for l oose connecti ons. Leaki ng fuel i s an
i ndi cator of l oose connecti ons or defecti ve seal s. Ai r
can al so enter the fuel system between the fuel tank
and the i njecti on pump. I nspect the fuel tank and
fuel l i nes for damage that mi ght al l ow ai r i nto the
system.
For ai r bl eedi ng, refer to Ai r Bl eed Procedure i n
the Servi ce Procedures secti on of thi s group.
FUEL HEATER RELAY TEST
The fuel heater rel ay i s l ocated i n the Power Di s-
tri buti on Center (PDC). Refer to Rel aysOperati on/
Fig. 16 Engine Coolant Temperature Sensor
Location
1 PCM ENGINE COOLANT TEMPERATURE (ECT) SENSOR
2 ECM ENGINE COOLANT TEMPERATURE (ECT) SENSOR
3 ECM ECT SENSOR HARNESS CONNECTOR
4 PCM ECT SENSOR HARNESS CONNECTOR
Fig. 17 Vaccum Pump at Front of Engine
1 VACUUM PUMP
2 CAMSHAFT
3 INJECTION PUMP
4 TIMING MARKS
5 OIL PUMP
6 CRANKSHAFT
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 9
DIAGNOSIS AND TESTING (Continued)
Testi ng i n Fuel I ngecti on System secti on of thi s
group for test procedures.
FUEL INJECTOR TEST
The fuel i njecti on nozzel s, l ocated i n the engi ne
cyl i nder head, spray fuel under hi gh pressure i nto
the i ndi vi dual combusti on chambers. Pressuri zed
fuel , del i vered by the fuel i njecti on pump, unseats a
spri ng-l oaded needl e val ve i nsi de the i njector, and
the fuel i s atomi zed as i t escapes through the i njector
openi ng i nto the engi nes combusti on chamber. I f the
fuel i njector does not operate properl y, the engi ne
may mi sfi re, or cause other dri veabi l i ty probl ems.
A l eak i n the i njecti on pumptoi njector hi ghpres-
sure fuel l i ne can cause many of the same symptoms
as a mal functi oni ng i njector. I nspect for a l eak i n the
hi ghpressure l i nes before checki ng for a mal func-
ti oni ng fuel i njector.
WARNING: THE INJECTION PUMP SUPPLIES HIGH-
PRESSURE FUEL OF UP TO APPROXIMATELY
45,000 KPA (6526 PSI) TO EACH INDIVIDUAL INJEC-
TOR THROUGH THE HIGHPRESSURE LINES. FUEL
UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE THE SKIN AND CAUSE PERSONAL INJURY.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING. AVOID CONTACT WITH FUEL
SPRAY WHEN BLEEDING HIGHPRESSURE FUEL
LINES.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
To determi ne whi ch fuel i njector i s mal functi oni ng,
run the engi ne and l oosen the hi ghpressure fuel l i ne
nut at the i njector (Fi g. 18). Li sten for a change i n
engi ne speed. I f engi ne speed drops, the i njector was
operati ng normal l y. I f engi ne speed remai ns the
same, the i njector may be mal functi oni ng. After test-
i ng, ti ghten the l i ne nut to 19 Nm (14 ft. l bs.)
torque. Test al l i njectors i n the same manner one at
a ti me.
Once an i njector has been found to be mal functi on-
i ng, remove i t from the engi ne and test i t. Refer to
the Removal /I nstal l ati on secti on of thi s group for pro-
cedures.
After the i njector has been removed, i nstal l i t to a
benchmount i njector tester. Refer to operati ng
i nstructi ons suppl i ed wi th tester for procedures.
The openi ng pressure or pop pressure shoul d be
15,00015,800 kPa (21752291 psi ). I f the fuel i njec-
tor needl e val ve i s openi ng (poppi ng) to earl y or to
l ate, repl ace the i njector.
FUEL INJECTOR / NEEDLE MOVEMENT
SENSOR TEST
The needl e movement sensor i s used onl y on the
number1 cyl i nder fuel i njector (Fi g. 19). I t i s not
used on the i njectors for cyl i nders number 2, 3, or 4.
Testi ng the needl e movement sensor requi res the
use of a DRB Scan tool . Refer to the Powertrai n
Di agnosti c Procedures manual for addi ti onal i nfor-
mati on.
FUEL INJECTION PUMP TEST
The injection pump is not to be serviced or
the warranty may be voided. If the injection
pump requires service, the complete assembly
must be replaced.
I ncorrect i njecti on pump ti mi ng (mechani cal or
el ectri cal ) can cause poor performance, excessi ve
smoke and emi ssi ons and poor fuel economy.
A defecti ve fuel i njecti on pump, defecti ve fuel ti m-
i ng sol enoi d or mi sadjusted mechani cal pump ti mi ng
can cause starti ng probl ems or prevent the engi ne
from revvi ng up. I t can al so cause:
Engi ne surge at i dl e
Rough i dl e (warm engi ne)
Low power
Excessi ve fuel consumpti on
Poor performance
Low power
Fig. 18 Typical Inspection of Fuel Injector
1 FUEL INJECTOR
2 LINE FITTING
3 HIGH-PRESSURE FUEL LINE
4 FUEL DRAIN TUBES
14 - 10 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
DIAGNOSIS AND TESTING (Continued)
Bl ack smoke from the exhaust
Bl ue or whi te fog l i ke exhaust
I ncorrect i dl e or maxi mum speed
The el ectroni cal l y control l ed fuel pump has no
mechani cal governor l i ke ol der mechani cal l y con-
trol l ed fuel pumps. Do not remove the top cover of
the fuel pump, or the screws fasteni ng the wi ri ng
pi gtai l to the si de of the pump. The warranty of
the injection pump and the engine may be void
if those seals have been removed or tampered
with.
FUEL SUPPLY RESTRICTIONS
LOWPRESSURE LINES
Restri cted or Pl ugged suppl y l i nes or fuel fi l ter can
cause a ti mi ng faul t that wi l l cause the ECM to oper-
ate the engi ne i n a Li mp Home mode. See the
i ntroducti on of the Fuel I njecti on System i n thi s
group for more i nformati on on the Li mp Home mode.
Fuel suppl y l i ne restri cti ons can cause starti ng prob-
l ems and prevent the engi ne from revvi ng up. The
starti ng probl ems i ncl ude; l ow power and bl ue or
whi te fog l i ke exhaust. Test al l fuel suppl y l i nes for
restri cti ons or bl ockage. Fl ush or repl ace as neces-
sary. Bl eed the fuel system of ai r once a fuel suppl y
l i ne has been repl aced. Refer to the Ai r Bl eed Proce-
dure secti on of thi s group for procedures.
HIGHPRESSURE LINES
Restri cted (ki nked or bent) hi ghpressure l i nes can
cause starti ng probl ems, poor engi ne performance
and bl ack smoke from exhaust.
Exami ne al l hi ghpressure l i nes for any damage.
Each radi us on each hi ghpressure l i ne must be
smooth and free of any bends or ki nks.
Repl ace damaged, restri cted or l eaki ng hi ghpres-
sure fuel l i nes wi th the correct repl acement l i ne.
CAUTION: The highpressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld highpressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of highpressure
fuel line is necessary.
FUEL SHUTDOWN SOLENOID TEST
Refer to 2000 XJ 2.5L Di esel Powertrai n Di agnos-
ti c Manual for the Fuel Shutdown Sol enoi d test.
HIGH-PRESSURE FUEL LINE LEAK TEST
Hi ghpressure fuel l i ne l eaks can cause starti ng
probl ems and poor engi ne performance.
WARNING: DUE TO EXTREME FUEL PRESSURES
OF UP TO 45,000 KPA (6526 PSI), USE EXTREME
CAUTION WHEN INSPECTING FOR HIGHPRES-
SURE FUEL LEAKS. DO NOT GET YOUR HAND, OR
ANY PART OF YOUR BODY NEAR A SUSPECTED
LEAK. INSPECT FOR HIGHPRESSURE FUEL
LEAKS WITH A SHEET OF CARDBOARD. HIGH
FUEL INJECTION PRESSURE CAN CAUSE PER-
SONAL INJURY IF CONTACT IS MADE WITH THE
SKIN.
Start the engi ne. Move the cardboard over the
hi ghpressure fuel l i nes and check for fuel spray onto
the cardboard (Fi g. 20). I f a hi ghpressure l i ne con-
necti on i s l eaki ng, bl eed the system and ti ghten the
connecti on. Refer to the Ai r Bl eed Procedure i n thi s
group for procedures. Repl ace damaged, restri cted or
l eaki ng hi ghpressure fuel l i nes wi th the correct
repl acement l i ne.
CAUTION: The highpressure fuel lines must be
clamped securely in the holders. The lines cannot
contact each other or other components. Do not
attempt to weld highpressure fuel lines or to repair
lines that are damaged. Only use the recommended
lines when replacement of highpressure fuel line
is necessary.
Fig. 19 Needle Movement Sensor Location
1 NEEDLE MOVEMENT SENSOR
2 FUEL INJECTOR (NUMBER 1 CYLINDER ONLY)
3 COPPER WASHER
4 SENSOR CONNECTOR
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 11
DIAGNOSIS AND TESTING (Continued)
SERVICE PROCEDURES
AIR BLEED PROCEDURES
AIR BLEEDING AT FUEL FILTER
A certai n amount of ai r may become trapped i n the
fuel system when fuel system components are ser-
vi ced or repl aced. Bl eed the system as needed after
fuel system servi ce accordi ng to the fol l owi ng proce-
dures.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
Some ai r enters the fuel system when the fuel fi l -
ter or i njecti on pump suppl y l i ne i s changed. Thi s
smal l amount of ai r i s vented automati cal l y from the
i njecti on pump through the fuel drai n mani fol d tubes
i f the fi l ter was changed accordi ng to i nstructi ons.
Ensure the the fuel fi l ter/water separator i s ful l of
fuel
I t may be necessary to manual l y bl eed the system
i f:
The bowl of the fuel fi l ter/water separator i s not
parti al l y fi l l ed before i nstal l ati on of a new fi l ter
The i njecti on pump i s repl aced
Hi ghpressure fuel l i ne connecti ons are l oosened
or l i nes repl aced
I ni ti al engi ne startup or startup after an
extended peri od of no engi ne operati on
Runni ng fuel tank empty
FUEL INJECTION PUMP BLEEDING
(1) I f the fuel i njecti on pump has been repl aced,
ai r shoul d be bl ed at the overfl ow val ve before
attempti ng to start engi ne.
(a) Loosen the overfl ow val ve (Fi g. 21) at the
rear of the i njecti on pump.
(b) Pl ace a towel bel ow the val ve.
WARNING: WHEN CRANKING THE ENGINE TO
BLEED AIR FROM THE INJECTION PUMP, THE
ENGINE MAY START. PLACE THE TRANSMISSION
IN NEUTRAL OR PARK AND SET PARKING BRAKE
BEFORE ENGAGING THE STARTER MOTOR.
CAUTION: Do not engage the starter motor for
more than 30 seconds at a time. Allow 2 minutes
between cranking intervals.
(2) Crank the engi ne for 30 seconds at a ti me to
al l ow ai r trapped i n the i njecti on pump to vent out
the fuel i njector drai n tubes. Conti nue thi s procedure
unti l the engi ne starts. Observe the previ ous WARN-
I NG and CAUTI ON.
(3) Ti ghten overfl ow val ve.
Fig. 20 Typical Fuel Pressure Test at Injection Pump
1 FITTING
2 HIGH PRESSURE LINE
3 CARDBOARD
Fig. 21 Overflow Valve
1 FUEL INJECTION PUMP ASSEMBLY
2 FUEL RETURN LINE
3 FUEL SUPPLY LINE
4 FUEL INJECTION PUMP 10WAY CONNECTOR
5 TIMING SOLENOID
6 OVERFLOW VALVE
14 - 12 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
DIAGNOSIS AND TESTING (Continued)
HIGHPRESSURE FUEL LINE BLEEDING
WARNING: THE INJECTION PUMP SUPPLIES HIGH-
PRESSURE FUEL OF APPROXIMATELY 45,000 KPA
(6,526 PSI) TO EACH INDIVIDUAL INJECTOR
THROUGH THE HIGHPRESSURE LINES. FUEL
UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE THE SKIN AND CAUSE PERSONAL INJURY.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING AND AVOID CONTACT WITH
FUEL SPRAY WHEN BLEEDING HIGHPRESSURE
FUEL LINES.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
Bl eed ai r from one i njector at ti me.
(1) Loosen the hi ghpressure fuel l i ne fi tti ng at
the i njector (Fi g. 22).
(2) Crank the engi ne unti l al l ai r has been bl ed
from the l i ne. Do not operate the starter motor
for longer than 30 seconds. Wait 2 minutes
between cranking intervals.
(3) Start the engi ne and bl eed one i njector at a
ti me unti l the engi ne runs smoothl y.
FUEL INJECTION PUMP TIMING
Refer to the Fuel I njecti on Pump Removal and
I nstal l ati on procedure i n Servi ce Procedures l ater i n
thi s Group.
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL
REMOVAL
(1) Di sconnect el ectri cal connector.
(2) Remove accel erator pedal mounti ng bracket
nuts. Remove accel erator pedal assembl y.
INSTALLATION
(1) Pl ace accel erator pedal assembl y over studs
protrudi ng from fl oor pan. Ti ghten mounti ng nuts to
5 Nm (46 i n. l bs.) torque.
(2) Connect el ectri cal connector.
(3) Before starti ng the engi ne, operate the accel er-
ator pedal to check for any bi ndi ng.
Fig. 22 Bleeding HighPressure Fuel LineTypical
1 FUEL INJECTOR
2 LINE FITTING
3 HIGH-PRESSURE FUEL LINE
4 FUEL DRAIN TUBES
Fig. 23 Accelerator Pedal Mounting-Typical
1 PEDAL POSITION SENSOR
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 13
SERVICE PROCEDURES (Continued)
FUEL DRAIN TUBES
The fuel drai n tubes (Fi g. 24) are l owpressure
type.
Pul l each tube from the i njector for removal . Push
on for i nstal l ati on. Cl amps are not requi red for these
tubes.
FUEL FILTER/WATER SEPARATOR
The fuel fi l ter/water separator i s l ocated i n the
engi ne compartment on the l eft si de near the shock
tower. (Fi g. 25).
The fuel fi l ter/water separator assembl y contai ns
the fuel fi l ter, fuel heater el ement, and fuel drai n
val ve (Fi g. 25).
DRAINING WATER FROM FILTER BOWL
Moi sture (water) col l ects at the bottom of the fi l ter/
separator i n a pl asti c bowl . Water enteri ng the fuel
i njecti on pump can cause seri ous damage to the
pump. Note that the bulb will be illuminated for
approximately 2 seconds each time the key is
initially placed in the ON position. This is done
for a bulb check.
WARNING: DO NOT ATTEMPT TO DRAIN WATER
FROM THE FILTER/SEPARATOR WITH THE ENGINE
HOT.
(1) The bottom of the fi l ter/separator bowl i s
equi pped wi th a drai n val ve (Fi g. 25). The drai n
val ve i s equi pped wi th a fi tti ng. Attach a pi ece of
rubber hose to thi s fi tti ng. Thi s hose i s to be used as
a drai n hose.
(2) Pl ace a drai n pan under the drai n hose.
(3) Open the vent val ve at top of fuel fi l ter/water
separator.
(4) Wi th the engi ne not runni ng, open the drai n
val ve by unscrewi ng the val ve (drain valve has
right hand threads) from the fi l ter/separator bowl .
To gai n access to thi s fi tti ng, the two fi l terto
mounti ng bracket nuts (Fi g. 25) may have to be l oos-
ened a few turns.
(5) Hol d the drai n open unti l cl ean fuel exi ts the
drai n.
(6) After drai ni ng, cl ose drai n val ve.
(7) Remove rubber drai n hose.
(8) Di spose of mi xture i n drai n pan accordi ng to
appl i cabl e l ocal or federal regul ati ons.
FUEL FILTER REMOVAL
(1) Drai n al l fuel and/or water from fuel fi l ter/wa-
ter separator assembl y. Refer to the previ ous Drai n-
i ng Water From Fi l ter Bowl .
(2) Unpl ug the el ectri cal connectors at bottom of
pl asti c bowl .
(3) Remove pl asti c bowl from bottom of fuel fi l ter
(unscrews).
(4) Remove fuel fi l ter from bottom of fi l ter base
(unscrews).
FUEL FILTER INSTALLATION
(1) Cl ean bottom of fuel fi l ter base.
(2) Appl y cl ean di esel fuel to new fuel fi l ter gasket.
(3) I nstal l and ti ghten fi l ter to fi l ter base. The bev-
el ed part of the rubber gasket shoul d be faci ng up
towards the fi l ter base.
(4) Cl ean the i nsi de of bowl wi th a soap and water
mi xture before i nstal l ati on. Careful l y cl ean any resi -
due between the two metal probes at the top of the
wateri nfuel sensor. Do not use chemi cal cl eaners
as damage to the pl asti c bowl may resul t.
(5) I nstal l fi l ter bowl to bottom of fi l ter.
(6) I nstal l the el ectri cal connectors at bottom of
bowl .
(7) Ti ghten the fi l tertomounti ng bracket nuts
(Fi g. 25) to 28 Nm (250 i n. l bs.) torque.
Fig. 24 Fuel Injectors and Drain Tubes
Fig. 25 Fuel Filter/Water Separator Location
14 - 14 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
FUEL HEATER
I f the fuel heater el ement needs repl acement, the
pl asti c fi l ter bowl assembl y must be repl aced. Refer
to Fuel Fi l ter/Water Separator for i nformati on.
FUEL HEATER RELAY
The fuel heater rel ay i s l ocated i n the PDC. For
the l ocati on of the rel ay wi thi n the PDC (Fi g. 26),
refer to l abel on PDC cover.
FUEL LEVEL SENSOR
The fuel l evel sensor i s l ocated on the si de of the
fuel pump modul e. (Fi g. 27)
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on
(3) Remove el ectri cal wi re connector at sendi ng
uni t termi nal s.
(4) Press on rel ease tab (Fi g. 28) to remove send-
i ng uni t from pump modul e.
FUEL INJECTION PUMP
REMOVAL
(1) Di sconnect the negati ve battery cabl e.
(2) Thoroughl y cl ean the area around the i njecti on
pump and fuel l i nes of al l di rt, grease and other con-
tami nants. Due to the close internal tolerances
of the injection pump, this step must be per-
formed before removing pump.
(3) Remove the engi ne accessory dri ve bel t. Refer
to Group 7, Cool i ng System for procedures.
(4) Remove the generator assembl y.
(5) Remove the rubber fuel return and suppl y
hoses from the metal l i nes at the pump (Fi g. 29).
(6) Remove the el ectri cal connector at engi ne cool -
ant temperature sensor.
(7) Di sconnect the Fuel I njecti on Pump el ectri cal
connector at fuel pump. (Fi g. 29).
Fig. 26 Power Distribution Center (PDC) Location
Fig. 27 Fuel Level Sensor
1 FUEL GAUGE FLOAT
2 FUEL GAUGE SENDING UNIT
3 PIGTAIL WIRING HARNESS
Fig. 28 Fuel Level Sensor Release Tab
1 ELECTRICAL CONNECTOR
2 FUEL LEVEL SENSOR
3 RELEASE TAB
4 FUEL RESERVOIR MODULE
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 15
REMOVAL AND INSTALLATION (Continued)
(8) Di sconnect the mai n engi ne wi ri ng harness
from the gl ow pl ugs.
(9) Di sconnect the four hi ghpressure fuel l i nes
from the fuel i njecti on pump. Al so di sconnect fuel
l i nes at the fuel i njectors. For procedures, refer to
Hi ghPressure Fuel Li nes i n thi s group. Pl ace a rag
beneath the fi tti ngs to catch excess fuel .
(10) Remove the pl ug from ti mi ng gear cover.
(11) The Top Dead Center (TDC) compressi on fi ri ng
stroke for the #1 cyl i nder can be determi ned as fol l ows:
(a) Usi ng a socket attached to the front of the
crankshaft, rotate the engi ne cl ockwi se unti l spe-
ci al al i gnment tool VM# 1043 can be i nserted
through the hol e i n the bottom of the cl utch hous-
i ng, stoppi ng the fl ywheel rotati on. Thi s posi ti on i s
TDC or 180 away from TDC. Engine must be at
TDC #1 compression firing stroke.
(b) To veri fy that you are at #1 TDC Compressi on.
Remove the oi l fi l l cap from the cyl i nder head cover
and the al i gnment tool from the cl utch housi ng.
(c) Rotate the crankshaft one-quarter turn cl ock-
wi se and counter-cl ockwi se whi l e observi ng the rocker
arm through the oi l fi l l cap hol e. I f the rocker arm
moves you are not at #1 TDC Compressi on.
(d) I f #1 TDC Compressi on was found conti nue,
i f not rotate the crankshaft one revol uti on unti l the
al i gnment tool can be re-i nstal l ed i n the fl ywheel .
You are now at TDC for the #1 cyl i nder compres-
si on fi ri ng stroke. Mark the damper and ti mi ng
cover for reference to TDC. Remove the al i gnment
tool from the cl utch housi ng.
(12) Remove access pl ug and pl ug washer at rear
of pump (Fi g. 30). Thread speci al di al i ndi cator and
adapter tool VM.1011 (Fi g. 31) i nto thi s openi ng.
Hand ti ghten onl y.
Fig. 29 Fuel Injection Pump
1 FUEL INJECTION PUMP ASSEMBLY
2 FUEL RETURN LINE
3 FUEL SUPPLY LINE
4 FUEL INJECTION PUMP 10WAY CONNECTOR
5 FUEL TIMING SOLENOID
Fig. 30 Access Plug at Rear of Pump
1 ACCESS PLUG
2 WASHER
Fig. 31 Installing Dial Indicator and Special Adapter
Tools
1 DIAL INDICATOR TOOL
2 ADAPTER TOOL VM1011
14 - 16 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
(13) Sl i ghtl y rotate the engi ne i n a counter-cl ock-
wi se di recti on unti l the di al gauge i ndi cator stops
movi ng (20-25 before TDC).
(14) Remove i njecti on pump dri ve gear nut (Fi g.
32).
(15) A speci al 3pi ece gear removal tool set
VM.1003 (Fi g. 33) must be used to remove the i njec-
ti on pump dri ve gear from the pump shaft.
(a) Thread the adapter (Fi g. 34) i nto the ti mi ng
cover.
(b) Thread the gear pul l er i nto the i njecti on
pump dri ve gear (Fi g. 34). Thi s tool i s al so used to
hol d the gear i n synchroni zati on duri ng pump
removal .
(c) Remove the three i njecti on pumptogear
cover mounti ng nuts (Fi g. 35). CAUTION: This
step must be done to prevent injection pump
damage.
(d) I nstal l the dri ve bol t i nto the gear pul l er
(Fi g. 34). Ti ghten the dri ve bol t to press (remove)
the dri ve gear from i njecti on pump shaft whi l e
dri vi ng i njecti on pump rearward from ti mi ng gear
cover mounti ng studs.
(16) Remove pump from engi ne. Do not rotate
engine while gear puller is installed. Engine
damage will occur.
INSTALLATION/ADJUSTING PUMP TIMING
(1) Cl ean the mati ng surfaces of i njecti on pump
and ti mi ng gear cover.
(2) I nstal l a new i njecti on pumptoti mi ng gear
cover gasket.
(3) Remove the gear removi ng bol t (dri ve bol t)
from gear pul l er. CAUTION: Do not remove the
special gear puller or timing cover adapter
tools from timing cover at this time. Gear mis-
alignment will result.
Fig. 32 Removing Pump Drive Gear Nut
1 TIMING GEAR COVER
2 INJECTION PUMP GEAR
3 PUMP GEAR NUT
Fig. 33 Pump Gear Tools
1 DRIVE BOLT
2 TIMING COVER ADAPTER
3 GEAR PULLER
Fig. 34 Installing Pump Drive Gear Removal Tools
1 ADAPTER
2 DRIVE BOLT
3 GEAR PULLER
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 17
REMOVAL AND INSTALLATION (Continued)
(4) Pl ace the key way on the pump shaft to the 11
ocl ock posi ti on as vi ewed from the front of pump.
I nstal l the pump i nto the rear of ti mi ng gear cover
whi l e al i gni ng key way on pump shaft i nto pump
gear.
(5) I nstal l and snug the 3 i njecti on pump mount-
i ng nuts. Thi s i s not the fi nal ti ghteni ng sequence.
(6) Remove the speci al gear pul l er and adapter
tool s from ti mi ng gear cover.
(7) I nstal l the i njecti on pump dri ve gear nut.
Ti ghten nut to 88 Nm (65 ft. l bs.) torque.
(8) Remove the access pl ug and pl ug washer at
rear of pump (Fi g. 36). Thread speci al di al i ndi cator
adapter tool VM.1011 (Fi g. 37) i nto thi s openi ng.
Hand ti ghten onl y.
(9) Attach speci al di al i ndi cator tool VM.1013 i nto
the adapter tool (Fi g. 37)
(10) Usi ng a socket attached to the front of the
crankshaft, rotate the engi ne i n a counter-cl ockwi se
di recti on unti l the di al gage i ndi cator stops movi ng
(2025 before TDC).
(11) Set the di al i ndi cator to 0mm. Be sure the ti p
of the di al i ndi cator i s touchi ng the ti p i nsi de the
adapter tool .
(12) Rotate the engi ne cl ockwi se unti l speci al
al i gnment tool VM#1043 can be i nserted through the
hol e i n the bottom of the cl utch housi ng, stoppi ng the
fl ywheel rotati on. Thi s posi ti on i s #1Cyl i nder TDC
Compressi on. Engine must be at TDC #1 com-
pression firing stroke.
(13) The gauge readi ng shoul d be at 0.55 mm
(with new gears installed specification should
be 0.590.60mm). I f not, the pump must be rotated
for adjustment:
(a) Loosen the three i njecti on pump mounti ng
nuts at the mounti ng fl anges. These fl anges are
equi pped wi th sl otted hol es. The sl otted hol es are
used to rotate and posi ti on the i njecti on pump for
fuel ti mi ng. Loosen the three nuts just enough to
rotate the pump.
Fig. 35 Injection Pump Mounting Nuts
1 MOUNTING FLANGE
2 SLOTTED HOLES (3)
3 PUMP MOUNTING NUTS (3)
Fig. 36 Access Plug at Rear of Pump
1 ACCESS PLUG
2 WASHER
Fig. 37 Installing Dial Indicator and Special Adapter
Tools
1 DIAL INDICATOR TOOL
2 ADAPTER TOOL VM1011
14 - 18 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
(b) Rotate the pump unti l 0.55 mm i s i ndi cated
on the di al i ndi cator gauge. I f whi l e rotati ng the
pump the 0.55 mm speci fi cati on i s passed do not
attempt to rotate the pump i n the opposi te di rec-
ti on. You must rotate the pump back bel ow the
0.25 mm speci fi cati on and start the procedure over
from the start of the TDC procedure. Thi s wi l l pre-
vent a fal se readi ng due to gear backl ash.
(c) Ti ghten the three pump mounti ng nuts to 30
Nm (22 ft. l bs.) torque.
(d) Recheck the di al i ndi cator after ti ghteni ng
the pump mounti ng nuts. Gauge shoul d sti l l be
readi ng 0.55 mm.
(14) Remove di al i ndi cator and adapter tool s.
(15) I nstal l access pl ug and washer to rear of
i njecti on pump.
(16) I nstal l pl ug at ti mi ng gear cover.
(17) I nstal l and connect the four hi ghpressure
fuel l i nes to the fuel i njecti on pump. Al so connect
fuel l i nes at the fuel i njectors. For procedures, refer
to Hi ghPressure Fuel Li nes i n thi s group.
(18) I nstal l el ectri cal connector at engi ne cool ant
temperature sensor.
(19) Connect el ectri cal connector at fuel shutdown
sol enoi d.
(20) Connect the mai n engi ne wi ri ng harness to
the gl ow pl ugs.
(21) Connect the fuel ti mi ng sol enoi d pi gtai l har-
ness to the engi ne wi ri ng harness.
(22) Connect the overfl ow val ve/banjo fi tti ng (fuel
return l i ne assembl y). Repl ace copper gaskets before
i nstal l i ng.
(23) Connect the rubber fuel return and suppl y
hoses to metal l i nes at pump. Ti ghten hose cl amps to
2 Nm (20 i n. l bs.) torque.
(24) I nstal l generator assembl y.
(25) I nstal l engi ne accessory dri ve bel t. Refer to
Group 7, Cool i ng System for procedures.
(26) I nstal l negati ve battery cabl e to battery.
(27) Start the engi ne and bri ng to normal operat-
i ng temperature.
(28) Check for fuel l eaks.
FUEL INJECTORS
Four fuel i njectors are used on each engi ne. Of
these four, two di fferent types are used. The fuel
i njector used on cyl i nder number one i s equi pped
wi th a fuel i njector sensor (Fi g. 38). The other three
fuel i njectors are i denti cal . Do not place the fuel
injector equipped with the fuel injector sensor
into any other location except the cylinder
number one position.
REMOVAL
(1) Di sconnect negati ve battery cabl e at battery.
(2) Thoroughl y cl ean the area around the i njector
wi th compressed ai r.
(3) Remove the fuel drai n hoses (tubes) at each
i njector (Fi g. 39) bei ng servi ced. Each of these hoses
i s sl i pfi t to the fi tti ng on i njector.
Fig. 38 Fuel Injector Sensor #1 Cylinder
1 NEEDLE MOVEMENT SENSOR
2 FUEL INJECTOR (NUMBER 1 CYLINDER ONLY)
3 COPPER WASHER
4 SENSOR CONNECTOR
Fig. 39 Fuel InjectorTypical
1 FUEL INJECTOR
2 LINE FITTING
3 HIGH-PRESSURE FUEL LINE
4 FUEL DRAIN TUBES
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 19
REMOVAL AND INSTALLATION (Continued)
(4) Remove the hi ghpressure fuel l i ne at i njector
bei ng removed. Refer to Hi ghPressure Fuel Li nes i n
thi s group for procedures.
(5) Remove the i njector usi ng speci al socket tool
number VM.1012A. When removi ng cyl i nder number
one i njector, thread the wi ri ng harness through the
access hol e on the speci al socket (Fi g. 40).
(6) Remove and di scard the copper washer (seal ) at
bottom of i njector (Fi g. 38).
INSTALLATION
(1) Cl ean the i njector threads i n cyl i nder head.
(2) I nstal l new copper washer (seal ) to i njector.
(3) I nstal l i njector to engi ne. Ti ghten to 70 Nm
(52 ft. l bs.) torque.
(4) I nstal l hi ghpressure fuel l i nes. Refer to Hi gh
Pressure Fuel Li nes i n thi s group for procedures.
(5) I nstal l fuel drai n hoses (tubes) to each i njector.
Do not use cl amps at fuel drai n hoses.
(6) Connect negati ve battery cabl e to battery.
(7) Bl eed the ai r from the hi ghpressure l i nes. Refer
to the Ai r Bl eed Procedure secti on of thi s group.
FUEL TANK
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) I nsert fuel si phon hose i nto fuel fi l l er neck and
push i t i nto the tank.
(3) Drai n fuel tank dry i nto hol di ng tank or a
properl y l abel ed diesel safety contai ner.
(4) Rai se vehi cl e on hoi st.
(5) Di sconnect both the fuel fi l l and fuel vent rub-
ber hoses at the fuel tank.
(6) Di sconnect fuel suppl y and return l i nes from
the steel suppl y l i ne (Fi g. 41).
The fuel reservoir module electrical connec-
tor has a retainer that locks it in place.
(7) Sl i de el ectri cal connector l ock to unl ock.
(8) Push down on connector retai ner (Fi g. 43) and
pul l connector off modul e.
Fig. 40 Wiring Harness Through Socket
1 FUEL INJECTOR
2 WIRING HARNESS (NUMBER 1 CYLINDER ONLY)
3 SPECIAL SOCKET
4 FUEL INJECTOR SENSOR (NUMBER 1 CYLINDER ONLY)
Fig. 41 Fuel Tank Connections at Front of Tank
1 FUEL SUPPLY LINE CONNECTION
2 FUEL PUMP MODULE CONNECTOR
3 FRONT OF FUEL TANK
4 EVAP CANISTER VENT LINE CONNECTION
Fig. 42 Fuel Fill/Vent Hose Index Marks
1 FUEL TANK
2 CLAMP INDEX MARKS
3 TANK INDEX TANGS
4 HOSE INDEX MARKS
5 FUEL FILL HOSE
6 CLAMP INDEX MARKS
7 CLAMPS
8 FUEL VENT HOSE
14 - 20 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
(9) Use a transmi ssi on jack to support fuel tank.
Remove bol ts from fuel tank straps.
(10) Lower tank sl i ghtl y. Careful l y remove fi l l er
hose from tank.
(11) Lower the fuel tank. Remove cl amp and
remove fuel fi l l er tube vent hose. Remove fuel tank
from vehi cl e.
INSTALLATION
(1) Posi ti on fuel tank on transmi ssi on jack. Con-
nect fuel fi l l er tube vent hose and repl ace cl amp.
(2) Rai se tank i nto posi ti on and careful l y work
fi l l er tube i nto tank. A l i ght coati ng of cl ean engi ne
oi l on the tube end may be used to ai d assembl y.
(3) Feed fi l l er vent l i ne thorough frame rai l . Care-
ful not to cross l i nes.
(4) Ti ghten strap bol ts to 9 Nm (80 i n. l bs.).
Remove transmi ssi on jack.
CAUTION: Ensure straps are not twisted or bent
before or after tightening strap nuts.
(5) Connect modul e el ectri cal connector. Pl ace
retai ner i n l ocked posi ti on.
(6) Lubri cate the fuel suppl y and return l i nes wi th
cl ean 30 wei ght engi ne oi l , i nstal l the qui ck connect
fuel fi tti ng. Refer to Tube/Fi tti ng Assembl y i n the
Fuel Del i very secti on of thi s Group.
(7) Attach fi l l er l i ne to fi l l er tube. Pul l on connec-
tor to make sure of connecti on.
(8) Fi l l fuel tank, repl ace cap, and connect battery
negati ve cabl e.
FUEL RESERVOIR MODULE
REMOVAL
WARNING: THE FUEL RESERVOIR OF THE FUEL
MODULE DOES NOT EMPTY OUT WHEN THE TANK
IS DRAINED. THE FUEL IN THE RESERVOIR WILL
SPILL OUT WHEN THE MODULE IS REMOVED.
(1) Di sconnect negati ve cabl e from battery.
(2) Drai n fuel tank dry i nto hol di ng tank or a
properl y l abel ed diesel safety contai ner.
(3) Rai se vehi cl e on hoi st.
(4) Use a transmi ssi on jack to support the fuel
tank. Remove bol ts from fuel tank straps. Lower
tank sl i ghtl y.
(5) Cl ean area around fuel reservoi r modul e and
tank to keep di rt and forei gn materi al out of tank.
(6) Di sconnect fuel l i nes from fuel modul e by
depressi ng qui ck connect retai ners wi th thumb and
fore fi nger.
(7) Sl i de modul e el ectri cal connector l ock to
unl ock.
(8) Push down on connector retai ner and pul l con-
nector off modul e.
(9) Usi ng Speci al Tool 6856, remove pl asti c l ocknut
countercl ockwi se to rel ease pump modul e (Fi g. 44).
(10) Careful l y remove modul e and o-ri ng from tank.
(11) Di scard ol d o-ri ng.
INSTALLATION
(1) Thoroughl y cl ean l ocknut threads and mati ng
ful e tank threads. Use a soap/water sol uti on. Do Not
use carburetor cleaner to clean threads.
(2) Appl y cl ean water to the o-ri ng seal and pl ace
on the mati ng fuel tank threads.
Fig. 43 Module Connector Retainer and Lock
1 PUSH DOWN ON RETAINER
2 CONNECTOR LOCK
Fig. 44 Fuel Reservoir Module Lock Nut Removal
1 SPECIAL TOOL 6856
2 LOCKNUT
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 21
REMOVAL AND INSTALLATION (Continued)
(3) Wi pe seal area of tank cl ean and pl ace a new
o-ri ng seal i n posi ti on on pump.
(4) Posi ti on fuel reservoi r modul e i n tank wi th l ocknut.
(5) Ti ghten l ocknut to 75 Nm (55 ft. l bs.).
(6) Connect fuel l i nes.
(7) Pl ug i n el ectri cal connector. Sl i de connector
l ock i nto posi ti on.
(8) Rai se fuel tank, i nstal l bol ts i nto fuel tank
straps and ti ghten.
(9) Lower vehi cl e on hoi st.
(10) Connect negati ve cabl e from battery.
(11) Fi l l fuel tank. Check for l eaks.
(12) I nstal l fuel fi l l er cap.
HIGH-PRESSURE LINES
Al l hi ghpressure fuel l i nes are of the same l ength and
i nsi de di ameter. Correct hi ghpressure fuel l i ne usage
and i nstal l ati on i s cri ti cal to smooth engi ne operati on.
CAUTION: The highpressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld highpressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of highpressure
fuel line is necessary.
REMOVAL
(1) Di sconnect negati ve battery cabl e from battery.
(2) Remove the necessary cl amps hol di ng the l i nes
to the engi ne.
(3) Cl ean the area around each fuel l i ne connec-
ti on. Di sconnect each l i ne at the top of each fuel
i njector (Fi g. 45).
(4) Di sconnect each hi ghpressure l i ne fi tti ng at
each fuel i njecti on pump del i very val ve.
(5) Very careful l y remove each l i ne from the engi ne.
Note the posi ti on (fi ri ng order) of each l i ne whi l e remov-
i ng. Do not bend the line while removing.
CAUTION: Be sure that the highpressure fuel lines
are installed in the same order that they were
removed. Prevent the injection pump delivery valve
holders from turning when removing or installing
highpressure lines from injection pump.
INSTALLATION
(1) Careful l y posi ti on each hi ghpressure fuel l i ne
to the fuel i njector and fuel i njecti on pump del i very
val ve hol der i n the correct fi ri ng order. Al so posi ti on
each l i ne i n the correct l i ne hol der.
(2) Loosel y i nstal l the l i ne cl amp/hol der bol ts.
(3) Ti ghten each l i ne at the del i very val ve to 19
Nm (168 i n. l bs.) torque.
(4) Ti ghten each l i ne at the fuel i njector to 19 Nm
(168 i n. l bs.) torque.
Be sure the lines are not contacting each
other or any other component.
(5) Bl eed ai r from the fuel system. Refer to the Ai r
Bl eed Procedure secti on of thi s group.
SPECIFICATIONS
FUEL TANK CAPACITY
75 Liters (20.0 Gals.)
Nomi nal refi l l capaci ti es are shown. A vari ati on
may be observed from vehi cl e to vehi cl e due to man-
ufacturi ng tol erances, ambi ent temperatures and
refi l l procedures.
IDLE SPEED
750 RPM 25 RPM wi th engi ne at normal oper-
ati ng temperature.
FUEL INJECTOR FIRING SEQUENCE
1342
FUEL SYSTEM PRESSURE
Peak Injection Pressure/Fuel Injection Pump
Operating Pressure: 40,00045,000 kPa (5801
6526 psi ).
Opening Pressure of Fuel Injector: 16,500
17,300 kPa (23932509 psi ).
Fig. 45 Fuel Lines at Fuel Injectors
1 FUEL INJECTOR
2 LINE FITTING
3 HIGH-PRESSURE FUEL LINE
4 FUEL DRAIN TUBES
14 - 22 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
FUEL INJ ECTION SYSTEM2.5L DIESEL ENGINE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . 23
POWERTRAIN CONTROL MODULE (PCM) . . . . . 24
BOOST PRESSURE SENSOR . . . . . . . . . . . . . . . 25
VEHICLE THEFT ALARM . . . . . . . . . . . . . . . . . . . 25
BATTERY VOLTAGEPCM INPUT. . . . . . . . . . . . 25
SENSOR RETURNECM/PCM INPUT
(ANALOG GROUND) . . . . . . . . . . . . . . . . . . . . . 26
IGNITION CIRCUIT SENSEECM/PCM INPUT . . 26
IGNITION CIRCUIT SENSEPCM INPUT . . . . . . 26
POWER GROUND . . . . . . . . . . . . . . . . . . . . . . . . 26
NEEDLE MOVEMENT OR INTRUMENTED
FIRST INJECTORECM INPUT . . . . . . . . . . . . 26
FUEL INJECTOR SENSORGROUND. . . . . . . . . 26
ENGINE COOLANT TEMPERATURE
SENSORECM/PCM INPUT. . . . . . . . . . . . . . . 26
ENGINE SPEED SENSORECM INPUT . . . . . . . 26
AIR CONDITIONING (A/C) CONTROLSECM
INPUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
BRAKE SWITCHECM INPUT. . . . . . . . . . . . . . . 28
DATA LINK CONNECTORPCM AND ECM
INPUT AND OUTPUT . . . . . . . . . . . . . . . . . . . . 28
VEHICLE SPEED SENSORECM INPUT . . . . . . 28
SPEED CONTROLECM INPUT . . . . . . . . . . . . . 28
ASD RELAYECM INPUT . . . . . . . . . . . . . . . . . . 29
FIVE VOLT POWERECM/PCM OUTPUT . . . . . . 29
ENGINE COOLANT GAUGEPCM OUTPUT . . . . 29
ENGINE OIL PRESSURE GAUGEPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
GLOW PLUG LAMPPCM OUTPUT . . . . . . . . . . 29
SPEED CONTROLPCM OUTPUTS . . . . . . . . . . 29
AIR CONDITIONING RELAYECM OUTPUT . . . . 29
TIMING SOLENOIDECM OUTPUT . . . . . . . . . . 29
TACHOMETERPCM OUTPUT . . . . . . . . . . . . . . 30
GLOW PLUG RELAYECM OUTPUT . . . . . . . . . 30
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ELECTRIC VACUUM MODULATOR (EVM)
ECM OUTPUT. . . . . . . . . . . . . . . . . . . . . . . . . . 31
DIAGNOSIS AND TESTING
DIESEL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . 31
ASD RELAY TEST . . . . . . . . . . . . . . . . . . . . . . . . 31
ENGINE SPEED SENSOR TEST . . . . . . . . . . . . . 31
ENGINE COOLANT TEMPERATURE SENSOR
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
GLOW PLUG TEST . . . . . . . . . . . . . . . . . . . . . . . 31
GLOW PLUG RELAY TEST . . . . . . . . . . . . . . . . . 33
RELAYSOPERATION/TESTING. . . . . . . . . . . . . 34
BOOST / PRESSURE SENSOR . . . . . . . . . . . . . . 34
VEHICLE SPEED SENSOR TEST. . . . . . . . . . . . . 35
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . 35
REMOVAL AND INSTALLATION
ASD RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
A/C CLUTCH RELAY . . . . . . . . . . . . . . . . . . . . . . 35
ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . 35
ENGINE COOLANT TEMPERATURE SENSOR. . . 35
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
GLOW PLUG RELAY . . . . . . . . . . . . . . . . . . . . . . 36
POWERTRAIN CONTROL MODULE (PCM) . . . . . 36
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . 37
SPECIFICATIONS
GLOW PLUG CURRENT DRAW. . . . . . . . . . . . . . 38
TORQUE CHART2.5L DIESEL. . . . . . . . . . . . . . 38
DESCRIPTION AND OPERATION
FUEL INJECTION SYSTEM
DESCRIPTION
Thi s secti on wi l l cover components ei ther regul ated
or control l ed by the ECM control l er and the Power-
trai n Control Modul e (PCM). The fuel heater rel ay
and fuel heater are not operated by the ECM control -
l er or the PCM. These components are control l ed by
the i gni ti on (key) swi tch. Al l other fuel system el ec-
tri cal components necessary to operate the engi ne
are control l ed or regul ated by the ECM control l er,
whi ch i nterfaces wi th the PCM. Refer to the fol l ow-
i ng descri pti on for more i nformati on.
Certai n fuel system component fai l ures may cause
a no start, or prevent the engi ne from runni ng. I t i s
i mportant to know that the ECM has a feature
where, i f possi bl e, i t wi l l i gnore the fai l ed sensor, set
a code rel ated to the sensor, and operate the engi ne
i n a Li mp Home mode. When the ECM i s operati ng
i n a Li mp Home mode, the Check Engi ne Lamp on
the i nstrument panel may be constantl y i l l umi nated,
and the engi ne wi l l most l i kel y have a noti ceabl e l oss
of performance. An exampl e of thi s woul d be an
Accel erator Pedal Posi ti on Sensor fai l ure, and i n that
si tuati on, the engi ne woul d run at a constant 1100
RPM, regardl ess of the actual posi ti on of the pedal .
Thi s i s the most extreme of the three Li mp Home
modes.
When the Check Engi ne Lamp i s i l l umi nated con-
stantl y wi th the key on and the engi ne runni ng, i t
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 23
usual l y i ndi cates a probl em has been detected some-
where wi thi n the fuel system. The DRBI I I scan tool
i s the best method for communi cati ng wi th the ECM
and PCM to di agnose faul ts wi thi n the system.
POWERTRAIN CONTROL MODULE (PCM)
DESCRIPTION
On LHD vehi cl es, the ECM i s mounted behi nd the
l ower I nstrument Panel to the ri ght of the accel era-
tor pedal (Fi g. 1). On RHD vehi cl es, the ECM i s
mounted behi nd the l ower I nstrument Panel to the
l eft of the cl utch pedal . The Powertrai n Control Mod-
ul e (PCM) i s mounted i n the engi ne compartment.
(Fi g. 2).
The ECM Control l er i s a preprogrammed, di gi tal
computer. I t wi l l ei ther di rectl y operate or parti al l y
regul ate the:
Speed Control
Speed Control l amp
Fuel Ti mi ng Sol enoi d
Check Engi ne Li ght
Gl ow Pl ug Rel ay
Gl ow Pl ugs
Gl ow Pl ug Lamp
ASD Rel ay
Ai r Condi ti oni ng
Tachometer
El ectri c Vacuum Modul ator (EVM)
The ECM can adapt i ts programmi ng to meet
changi ng operati ng condi ti ons.
The ECM recei ves i nput si gnal s from vari ous
swi tches and sensors. Based on these i nputs, the
ECM regul ates vari ous engi ne and vehi cl e operati ons
through di fferent system components. These compo-
nents are referred to as ECM Outputs. The sensors
and swi tches that provi de i nputs to the ECM are
consi dered ECM Inputs.
ECM Inputs are:
Ai r Condi ti oni ng Sel ecti on
Theft Al arm
ASD Rel ay
Control Sl eeve Posi ti on Sensor
Fuel Temperature Sensor
Mass Ai r Fl ow Sensor
Accel erator Pedal Posi ti on Sensor
Engi ne Cool ant Temperature Sensor
Low I dl e Posi ti on Swi tch
5 Vol t Suppl y
Vehi cl e Speed Sensor
Engi ne Speed/Crank Posi ti on Sensor (rpm)
Needl e Movement Sensor
Starter Si gnal
Brake Swi tch
Speed Control Swi tch
Power Ground
I gni ti on (key) Swi tch Sense
ECM Outputs:
After i nputs are recei ved by the ECM and PCM,
certai n sensors, swi tches and components are con-
trol l ed or regul ated by the ECM and PCM. These are
consi dered ECM Outputs. These outputs are for:
A/C Cl utch Rel ay (for A/C cl utch operati on)
Fig. 1 ECM LocationLHD
1 ECM HARNESS CONNECTOR C1
2 ENGINE CONTROL MODULE (ECM)
3 ECM HARNESS CONNECTOR C2
4 ACCELERATOR PEDAL POSITION SENSOR
Fig. 2 PCM LocationLHD
1 PCM HARNESS CONNECTOR C1
2 PCM HARNESS CONNECTOR C2
3 PCM HARNESS CONNECTOR C3
4 POWERTRAIN CONTROL MODULE (PCM)
14 - 24 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
DESCRIPTION AND OPERATION (Continued)
Speed Control Lamp
ASD Rel ay
5 Vol ts Suppl y
Fuel Quanti ty Actuator
Fuel Ti mi ng Sol enoi d
Fuel Shutdown Sol enoi d
Gl ow Pl ug Lamp
Check Engi ne Lamp (On/Off si gnal )
El ectri c Vacuum Modul ator (EVM)
Gl ow Pl ug Rel ay
Tachometer
The PCM sends and reci eves si gnal s to and from
the ECM control l er. PCM inputs are:
Power Gound
5 Vol ts Suppl y
Vehi cl e Speed Sensor
Water-I n-Fuel Sensor
Cool ant Temperature Sensor
Low Cool ant Sensor
Sensor Return
Fuel Level Sensor
Oi l Pressure Sensor
Tachometer Si gnal
Gl ow Pl ug Lamp
Check Engi ne Lamp (On/Off si gnal )
Brake On/Off Swi tch
Battery Vol tage
ASD Rel ay
PCM Outputs:
A/C On Si gnal
Vehi cl e Theft Al arm Ok to Run si gnal
Body Control Modul e CCD Bus (+)
Body Control Modul e CCD Bus ()
Scan Tool Data Li nk Reci eve
Scan Tool Data Li nk Transmi t
Low Cool ant Lamp
Generator Control
BOOST PRESSURE SENSOR
DESCRIPTION
The Boost Pressure Sensor i s mounted to the top of
the i ntake mani fol d (Fi g. 3). I t i s a sensor that mea-
sures both mani fol d vacuum and turbo boost, and i t
al so contai ns an i ntegrated i ntake ai r temperature
sensor. The Boost Pressure Sensor takes the pl ace of
the Mass Ai r Fl ow (MAF). I n the I ntake Ai r Temper-
ature Sensor component, there i s a cerami c el ement
that changes i ts resi stance based on temperature.
The cerami c el ement i s part of an el ectroni c ci rcui t
connected to the PCM, and has a vol tage appl i ed to
i t. The cerami c el ement i s exposed to the ai r i nsi de
the i ntake. Thi s ai r has a cool i ng effect on the
cerami c el ement, and i ts resi stance changes. Thi s
causes the vol tage fl owi ng through the i ntake ai r
temperature ci rcui t to vary. The vol tage si gnal pro-
duced by the I ntake Ai r Temperature Sensor changes
i nversel y to the temperature, and i s measured by the
PCM. As a general rul e, when the temperature of the
ai r i n the i ntake i s hi gh, the vol tage si gnal produced
by the I ntake Ai r Temperature Sensor i s l ow. The
component of the Boost Pressure Sensor that mea-
sures mani fol d vacuum and turbo boost produces a
vol tage si gnal that i s proporti onal to the pressure i n
the i ntake mani fol d. When the i ntake mani fol d pres-
sure i s l ow, the vol tage i s l ow, and when the pressure
i s hi gh, the vol tage i s hi gh. The PCM uses the vol t-
age si gnal s from the Boost Pressure Sensor, and the
I ntake Ai r Temperature Sensor to determi ne the
amount of ai r fl owi ng through the i ntake mani fol d.
VEHICLE THEFT ALARM
DESCRIPTION
The PCM can l earn i f the vehi cl e has a Vehi cl e
Theft Al arm (VTA) system. Once i t detects the vehi -
cl e havi ng VTA, the controller can ONLY BE
USED ON VEHICLES WITH VTA.
I f the PCM i s put i t on a vehi cl e wi thout VTA the
Gl ow Pl ug Lamp wi l l start to bl i nk and the vehi cl e
wi l l not start.
The PCM cannot be fl ashed to remove the VTA.
BATTERY VOLTAGE PCM INPUT
DESCRIPTION
The battery vol tage i nput provi des power to the
PCM. I t al so i nforms the PCM what vol tage l evel i s
bei ng suppl i ed by the generator once the vehi cl e i s
runni ng.
Fig. 3 Boost Pressure Sensor Location
1 BOOST PRESSURE SENSOR HARNESS CONNECTOR
2 BOOST PRESSURE SENSOR
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 25
DESCRIPTION AND OPERATION (Continued)
The battery i nput al so provi des the vol tage that i s
needed to keep the PCM memory al i ve. The memory
stores Di agnosti c Troubl e Code (DTC) messages.
Troubl e codes wi l l sti l l be stored even i f the battary
vol tage i s l ost.
SENSOR RETURN ECM/PCM INPUT (ANALOG
GROUND)
DESCRIPTION
Sensor Return provi des a l ow noi se Anal og ground
reference for al l system sensors.
IGNITION CIRCUIT SENSE ECM/PCM INPUT
DESCRIPTION
The i gni ti on ci rcui t sense i nput si gnal s the ECM
and PCM that the i gni ti on (key) swi tch has been
turned to the ON posi ti on. Thi s si gnal i ni ti ates the
gl ow pl ug control routi ne to begi n the preheat
cycl e.
IGNITION CIRCUIT SENSE PCM INPUT
The i gni ti on ci rcui t sense i nput si gnal s the PCM
that the i gni ti on (key) swi tch has been turned to the
ON posi ti on. Thi s si gnal i ni ti ates the gl ow pl ug con-
trol routi ne to begi n the preheat cycl e.
POWER GROUND
DESCRIPTION
Provi des a common ground for power devi ces (sol e-
noi d and rel ay devi ces).
NEEDLE MOVEMENT OR INTRUMENTED FIRST
INJECTOR ECM INPUT
DESCRIPTION
Thi s i nput from the ECM suppl i es a constant 30
mA el ectri cal current source for the fi rst i njector sen-
sor. I t wi l l vary the vol tage to thi s sensor when i t
senses a mechani cal movement wi thi n the i njector
needl e (pi ntl e) of the number1 cyl i nder fuel i njector.
When thi s vol tage has been determi ned by the ECM,
i t wi l l then control an output to the fuel ti mi ng sol e-
noi d (the fuel ti mi ng sol enoi d i s l ocated on the fuel
i njecti on pump). Al so refer to Fuel I njecti on Pump for
addi ti onal i nformati on.
The fi rst i njector sensor i s a magneti c (i nducti ve)
type.
The fi rst i njector sensor i s used onl y on the fuel
i njector for the number1 cyl i nder (Fi g. 4). I t i s not
used on the i njectors for cyl i nders number 2, 3, or 4.
FUEL INJECTOR SENSOR GROUND
DESCRIPTION
Provi des a l ow noi se ground for the fuel i njector
sensor onl y.
ENGINE COOLANT TEMPERATURE SENSOR
ECM/PCM INPUT
DESCRIPTION
The 05 vol t i nput from thi s sensor tel l s the ECM
and PCM the temperature of the engi ne cool ant.
Based on the vol tage recei ved at the ECM, i t wi l l
then determi ne operati on of the fuel ti mi ng sol enoi d,
gl ow pl ug rel ay, el ectri cal vacuum modul ator (emi s-
si on component) and generator (chargi ng system).
The sensor i s l ocated on the si de of the #3 cyl i nder
head near the rear of fuel i njecti on pump (Fi g. 5).
ENGINE SPEED SENSOR ECM INPUT
DESCRIPTION
The engi ne speed sensor i s mounted to the trans-
mi ssi on bel l housi ng at the l eft/rear si de of the engi ne
bl ock (Fi g. 6).
The engi ne speed sensor produces i ts own output
si gnal . I f thi s si gnal i s not recei ved, the ECM wi l l not
al l ow the engi ne to start.
The engi ne speed sensor i nput i s used i n conjunc-
ti on wi th the fi rst i njector sensor to establ i sh fuel
i njecti on pump ti mi ng.
Fig. 4 Fuel Injector Sensor
1 NEEDLE MOVEMENT SENSOR
2 FUEL INJECTOR (NUMBER 1 CYLINDER ONLY)
3 COPPER WASHER
4 SENSOR CONNECTOR
14 - 26 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
DESCRIPTION AND OPERATION (Continued)
The fl ywheel has four notches at i ts outer edge
(Fi g. 7). Each notch i s spaced equal l y every 90. The
notches cause a pul se to be generated when they
pass under the speed sensor (Fi g. 7). These pul ses
are the i nput to the ECM. The i nput from thi s sensor
determi nes crankshaft posi ti on (i n degrees) by moni -
tori ng the notches.
The sensor al so generates an rpm si gnal to the
ECM. Thi s si gnal i s used as an i nput for the control
of the generator fi el d, vehi cl e speed control , and
i nstrument panel mounted tachometer.
I f the engi ne speed sensor shoul d fai l , the system
i s unabl e to compensate for the probl em and the car
wi l l stop.
AIR CONDITIONING (A/C) CONTROLS ECM
INPUTS
DESCRIPTION
The A/C control system i nformati on appl i es to fac-
tory i nstal l ed ai r condi ti oni ng uni ts.
A/C REQUEST SIGNAL: When ei ther the A/C or
Defrost mode has been sel ected and the A/C l ow and
hi ghpressure swi tches are cl osed, an i nput si gnal i s
sent to the ECM. The ECM uses thi s i nput to cycl e
the A/C compressor through the A/C rel ay.
I f the A/C l ow or hi ghpressure swi tch opens, the
ECM wi l l not recei ve an A/C request si gnal . The
PCM wi l l then remove the ground from the A/C rel ay.
Thi s wi l l deacti vate the A/C compressor cl utch. Al so,
i f the engi ne cool ant reaches a temperature outsi de
normal of i ts normal range, or i t overheats, the ECM
wi l l deacti vate the A/C cl utch.
Fig. 5 Engine Coolant Temperature Sensor Location
1 PCM ENGINE COOLANT TEMPERATURE (ECT) SENSOR
2 ECM ENGINE COOLANT TEMPERATURE (ECT) SENSOR
3 ECM ECT SENSOR HARNESS CONNECTOR
4 PCM ECT SENSOR HARNESS CONNECTOR
Fig. 6 Engine Speed Sensor Location
1 ENGINE SPEED SENSOR
2 GROMMET
3 MOUNTING BOLT(S)
4 LEFT REAR OF ENGINE
5 TRANSMISSION
Fig. 7 Speed Sensor Operation
1 ENGINE SPEED SENSOR
2 FLYWHEEL
3 NOTCHES
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 27
DESCRIPTION AND OPERATION (Continued)
BRAKE SWITCH ECM INPUT
DESCRIPTION
When the brake l i ght swi tch i s acti vated, the ECM
recei ves an i nput i ndi cati ng that the brakes are
bei ng appl i ed. After recei vi ng thi s i nput, the ECM i s
used to control the speed control system. There i s a
Pri mary and a Secondary brake swi tch. The Second-
ary brake swi tch i s cl osed unti l the brake pedal i s
pressed.
DATA LINK CONNECTOR PCM AND ECM
INPUT AND OUTPUT
The 16way data l i nk connector (di agnosti c scan
tool connector) l i nks the Di agnosti c Readout Box
(DRB) scan tool wi th the PCM and ECM. The data
l i nk connector i s l ocated under the i nstrument panel
near the l eft body si de cowl panel on l eft hand dri ve
vehi cl es (Fi g. 8). And near the ri ght body si de cowl
panel on ri ght hand dri ve vehi cl es (Fi g. 9).
VEHICLE SPEED SENSOR ECM INPUT
The vehi cl e speed sensor i s l ocated i n the transfer
case extensi on housi ng (Fi g. 10). The sensor i nput i s
used by the ECM to determi ne vehi cl e speed and di s-
tance travel ed.
The speed sensor generates 8 pul ses per sensor
revol uti on. These si gnal s, i n conjuncti on wi th a
cl osed throttl e si gnal from the accel erator pedal posi -
ti on sensor, i ndi cate an i dl e decel erati on to the ECM.
When the vehi cl e i s stopped at i dl e, a rel eased pedal
si gnal i s recei ved by the ECM (but a speed sensor
si gnal i s not recei ved).
I n addi ti on to determi ni ng di stance and vehi cl e
speed, the output from the sensor i s used to control
speed control operati on.
SPEED CONTROL ECM INPUT
DESCRIPTION
The speed control system provi des fi ve separate
i nputs to the ECM: On/Off, Set, Resume/Accel , Cancel ,
and Decel .. The On/Off i nput i nforms the ECM that the
speed control system has been acti vated. The Set i nput
Fig. 8 Data Link Connector Location LHD
1 16WAY DATA LINK CONNECTOR
Fig. 9 Data Link Connector Location RHD
1 DATA LINK CONNECTOR
Fig. 10 Vehicle Speed Sensor4 Wheel Drive
1 4WD TRANSFER CASE EXTENSION
2 VEHICLE SPEED SENSOR
3 SENSOR ELECTRICAL CONNECTOR
14 - 28 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
DESCRIPTION AND OPERATION (Continued)
i nforms the ECM that a fi xed vehi cl e speed has been
sel ected. The Resume i nput i ndi cates to the ECM that
the previ ous fi xed speed i s requested.
Speed control operati on wi l l start at 50 km/h142
km/h (3585 mph). The upper range of operati on i s
not restri cted by vehi cl e speed. I nputs that effect
speed control operati on are vehi cl e speed sensor and
accel erator pedal posi ti on sensor.
Refer to Group 8H for further speed control i nfor-
mati on.
ASD RELAY ECM INPUT
DESCRIPTION
A 12 vol t si gnal at thi s i nput i ndi cates to the ECM
that the ASD rel ay has been acti vated. The ASD
rel ay i s l ocated i n the PDC. The PDC i s l ocated next
to the battery i n the engi ne compartment. For the
l ocati on of the rel ay wi thi n the PDC, refer to l abel on
PDC cover.
Thi s i nput i s used onl y to sense that the ASD rel ay
i s energi zed. I f the ECM does not see 12 vol ts (+) at
thi s i nput when the ASD rel ay shoul d be acti vated, i t
wi l l set a Di agnosti c Troubl e Code (DTC).
FIVE VOLT POWER ECM/PCM OUTPUT
DESCRIPTION
Thi s ci rcui t suppl i es approxi matel y 5 vol ts to
power the Accel erator Pedal Posi ti on Sensor, and the
Boost Pressure Sensor.
ENGINE COOLANT GAUGE PCM OUTPUT
DESCRIPTION
Refer to the I nstrument Panel and Gauges group
for addi ti onal i nformati on.
ENGINE OIL PRESSURE GAUGE PCM
OUTPUT
DESCRIPTION
Refer to the I nstrument Panel and Gauges group
for addi ti onal i nformati on.
GLOW PLUG LAMP PCM OUTPUT
DESCRIPTION
The Gl ow Pl ug l amp (mal functi on i ndi cator l amp)
i l l umi nates on the message center each ti me the i gni -
ti on (key) swi tch i s turned on. I t wi l l stay on for
about two seconds as a bul b test.
SPEED CONTROL PCM OUTPUTS
DESCRIPTION
These two ci rcui ts control the fuel quanti ty actua-
tor to regul ate vehi cl e speed. Refer to Group 8H for
Speed Control i nformati on.
AIR CONDITIONING RELAY ECM OUTPUT
DESCRIPTION
Thi s ci rcui t control s a ground si gnal for operati on
of the A/C cl utch rel ay. Al so refer to Ai r Condi ti oni ng
(A/C) Control sECM I nput for addi ti onal i nforma-
ti on.
The A/C rel ay i s l ocated i n the Power Di stri buti on
Center (PDC). The PDC i s l ocated next to the battery
i n the engi ne compartment. For the l ocati on of the
rel ay wi thi n the PDC, refer to l abel on PDC cover.
TIMING SOLENOID ECM OUTPUT
DESCRIPTION
The ti mi ng sol enoi d i s l ocated on the bottom of the
fuel i njecti on pump (Fi g. 12).
Thi s 12(+) vol t, pul se wi dth modul ated (dutycycl e)
output control s the amount of fuel ti mi ng (advance)
i n the fuel i njecti on pump. The hi gher the dutycy-
cl e, the l ower the advance. The l ower the dutycycl e,
the more advanced the fuel ti mi ng.
Fig. 11 Glow Plug Lamp Symbol
Fig. 12 Timing Solenoid
1 FUEL INJECTION PUMP ASSEMBLY
2 FUEL RETURN LINE
3 FUEL SUPPLY LINE
4 FUEL INJECTION PUMP 10WAY CONNECTOR
5 TIMING SOLENOID
6 OVERFLOW VALVE
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 29
DESCRIPTION AND OPERATION (Continued)
The dutycycl e i s determi ned by the ECM from
i nputs i t recei ves from the fuel i njector sensor and
engi ne speed sensor.
TACHOMETER PCM OUTPUT
DESCRIPTION
The PCM reci eves engi ne rpm val ues from the
ECM control l er, and then suppl i es engi ne rpm val ues
to the Body Control l er that then suppl i es the i nstru-
ment cl uster mounted tachometer (i f equi pped). Refer
to Group 8E for tachometer i nformati on.
GLOW PLUG RELAY ECM OUTPUT
DESCRIPTION
When the i gni ti on (key) swi tch i s pl aced i n the ON
posi ti on, a si gnal i s sent to the ECM rel ati ng current
engi ne cool ant temperature. Thi s si gnal i s sent from
the engi ne cool ant temperature sensor.
After recei vi ng thi s si gnal , the ECM wi l l determi ne
i f, when and for how l ong a peri od the gl ow pl ug
rel ay shoul d be acti vated. Thi s i s done before, duri ng
and after the engi ne i s started. Whenever the gl ow
pl ug rel ay i s acti vated, i t wi l l control the 12V+ 100
amp ci rcui t for the operati on of the four gl ow pl ugs.
Wi th a col d engi ne, the gl ow pl ug rel ay and gl ow
pl ugs may be acti vated for a maxi mum ti me of 200
seconds. Refer to the fol l owi ng Gl ow Pl ug Control
chart for a temperature/ti me compari son of gl ow pl ug
rel ay operati on.
I n thi s chart, PreHeat and PostHeat ti mes are
menti oned. Preheat i s the amount of ti me the gl ow
pl ug rel ay ci rcui t i s acti vated when the i gni ti on (key)
swi tch i s ON, but the engi ne has yet to be started.
Postheat i s the amount of ti me the gl ow pl ug rel ay
ci rcui t i s acti vated after the engi ne i s operati ng. The
Gl ow Pl ug l amp wi l l not be i l l umi nated duri ng the
postheat cycl e.
GLOW PLUGS
DESCRIPTION
Gl ow pl ugs are used to hel p start a col d or cool
engi ne. The pl ug wi l l heat up and gl ow to heat the
combusti on chamber of each cyl i nder. An i ndi vi dual
pl ug i s used for each cyl i nder. Each pl ug i s threaded
i nto the cyl i nder head above the fuel i njector (Fi g.
14).
Each pl ug wi l l momentari l y draw approxi matel y 25
amps of el ectri cal current duri ng the i ni ti al keyon
Fig. 13 Glow Plug Relay Location
1 MOUNTING BOLT
2 GLOW PLUG RELAY
3 ELECTRICAL CONNECTOR
GLOW PLUG CONTROL
ENGINE
COOLANT
TEMP-
ERATURE
KEY ON
WAIT-TO-
START
LAMP ON
(SECONDS)
PRE-HEAT
CYCLE
(GLOW
PLUGS
ON)
(SECONDS)
POST-
HEAT
CYCLE
(SECONDS)
-30 C 15 SEC. 45 SEC. 200 SEC.
-10 C 8 SEC. 35 SEC. 180 SEC.
+10 C 6 SEC. 25 SEC. 118 SEC.
+30 C 5 SEC. 20 SEC. 70 SEC.
+40 C 4 SEC. 16 SEC. 60 SEC.
+70 C 3 SEC. 16 SEC. 20 SEC.
Fig. 14 Glow Plug
1 GLOW PLUG
14 - 30 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
DESCRIPTION AND OPERATION (Continued)
cycl e. Thi s i s on a col d or cool engi ne. After heati ng,
the current draw wi l l drop to approxi matel y 912
amps per pl ug.
Total momentary current draw for al l four pl ugs i s
approxi matel y 100 amps on a col d engi ne droppi ng to
a total of approxi matel y 40 amps after the pl ugs are
heated.
El ectri cal operati on of the gl ow pl ugs are con-
trol l ed by the gl ow pl ug rel ay. Refer to the previ ous
Gl ow Pl ug Rel ayECM Output for addi ti onal i nfor-
mati on.
ELECTRIC VACUUM MODULATOR (EVM) ECM
OUTPUT
DESCRIPTION
Thi s ci rcui t control s operati on of the El ectri c Vac-
uum Modul ator (EVM). The EVM control s operati on
of the EGR val ve.
Refer to Group 25, Emi ssi on Control System for
i nformati on. See El ectri c Vacuum Modul ator.
DIAGNOSIS AND TESTING
DIESEL DIAGNOSTICS
The ECM control l ers perform engi ne off di agnosti c
tests, whi ch may be heard for about 60 seconds after
turni ng the key off.
ASD RELAY TEST
To perform a test of the rel ay and i ts rel ated ci r-
cui try, refer to the DRB scan tool . To test the rel ay
onl y, refer to Rel aysOperati on/Testi ng i n thi s sec-
ti on of the group.
Diagnostic Trouble Codes: Refer to On-Board
Di agnosti cs i n Group 25, Emi ssi on Control System
for a l i st of Di agnosti c Troubl e Codes (DTCs) for cer-
tai n fuel system components.
ENGINE SPEED SENSOR TEST
To perform a test of the engi ne speed sensor and
i ts rel ated ci rcui try, refer to the 3.1L Powertrai n
Di agnosti c Procedures Manual .
Diagnostic Trouble Codes: Refer to On-Board
Di agnosti cs i n Group 25, Emi ssi on Control System
for a l i st of Di agnosti c Troubl e Codes (DTCs) for cer-
tai n fuel system components.
ENGINE COOLANT TEMPERATURE SENSOR
TEST
The sensor i s l ocated on the si de of cyl i nder head
near the rear of fuel i njecti on pump (Fi g. 15).
For a l i st of Di agnosti c Troubl e Codes (DTCs) for
certai n fuel system components, refer to On-Board
Di agnosti cs i n Group 25, Emi ssi on Control System.
To test the sensor onl y, refer to the fol l owi ng:
(1) Di sconnect wi re harness connector from cool ant
temperature sensor.
(2) Test the resi stance of the sensor wi th a hi gh
i nput i mpedance (di gi tal ) vol tohmmeter. The resi s-
tance (as measured across the sensor termi nal s)
shoul d be l ess than 1340 ohms wi th the engi ne
warm. Refer to the fol l owi ng Sensor Resi stance
(OHMS) chart. Repl ace the sensor i f i t i s not wi thi n
the range of resi stance speci fi ed i n the chart.
(3) Test conti nui ty of the wi re harness. Do thi s
between the ECM wi re harness connector and the
sensor connector termi nal . Al so test conti nui ty of
wi re harness to the sensor connector termi nal . Refer
to Group 8W for wi ri ng connector and ci rcui try i nfor-
mati on. Repai r the wi re harness i f an open ci rcui t i s
i ndi cated.
(4) After tests are compl eted, connect el ectri cal
connector to sensor.
GLOW PLUG TEST
Hard starti ng or a rough i dl e after starti ng may be
caused by one or more defecti ve gl ow pl ugs. Before
testi ng the gl ow pl ugs, a test of the gl ow pl ug rel ays
shoul d be performed. Thi s wi l l ensure that 12V+ i s
avai l abl e at the pl ugs when starti ng the engi ne.
Refer to the Gl ow Pl ug Rel ay Test for i nformati on.
For accurate test resul ts, the gl ow pl ugs shoul d be
removed from the engi ne. The pl ugs must be checked
Fig. 15 Engine Coolant Temperature Sensor
Location
1 PCM ENGINE COOLANT TEMPERATURE (ECT) SENSOR
2 ECM ENGINE COOLANT TEMPERATURE (ECT) SENSOR
3 ECM ECT SENSOR HARNESS CONNECTOR
4 PCM ECT SENSOR HARNESS CONNECTOR
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 31
DESCRIPTION AND OPERATION (Continued)
when col d. Do not check the plugs if the engine
has recently been operated. If plugs are
checked when warm, incorrect amp gauge
readings will result.
Use Churchi l l Gl ow Pl ug Tester DX.900 or an
equi val ent (Fi g. 16) for the fol l owi ng tests. Thi s
tester i s equi pped wi th 4 ti mer l amps.
(1) Remove the gl ow pl ugs from the engi ne. Refer
to Gl ow Pl ug Removal /I nstal l ati on.
(2) Attach the red l ead of the tester to the 12V+
(posi ti ve) si de of the battery.
(3) Attach the bl ack l ead of the tester to the 12V
(negati ve) si de of the battery.
(4) Fi t the gl ow pl ug i nto the top of the tester and
secure i t wi th the spri ng l oaded bar (Fi g. 16).
(5) Attach the thi rd l ead wi re of the tester to the
el ectri cal termi nal at the end of the gl ow pl ug.
(6) When performi ng the test, the tester button
(Fi g. 16) shoul d be hel d conti nuousl y wi thout rel ease
for 20 seconds as i ndi cated by the 4 ti mer l amps.
Each i l l umi nated l amp represents a 5 second ti me
l apse.
(a) Press and hol d the tester button (Fi g. 16)
and note the amp gauge readi ng. The gauge read-
i ng shoul d i ndi cate a momentary, i ni ti al current
draw (surge) of approxi matel y 25 amps. After the
i ni ti al surge, the amp gauge readi ng shoul d begi n
to fal l off. The gl ow pl ug ti p shoul d start to gl ow
an orange col or after 5 seconds. I f the ti p di d not
gl ow after 5 seconds, repl ace the gl ow pl ug. Before
di scardi ng the gl ow pl ug, check the posi ti on of the
ci rcui t breaker on the bottom of the pl ug tester. I t
may have to be reset. Reset i f necessary.
(b) Conti nue to hol d the tester button whi l e
observi ng the amp gauge and the 4 ti mer l amps.
When al l 4 l amps are i l l umi nated, i ndi cati ng a 20
second ti me l apse, the amp gauge readi ng shoul d
i ndi cate a 912 amp current draw. I f not, repl ace
the gl ow pl ug. Refer to Gl ow Pl ug Removal /I nstal -
l ati on.
(7) Check each gl ow pl ug i n thi s manner usi ng one
20 second cycl e. I f the gl ow pl ug i s to be retested, i t
must fi rst be al l owed to cool to room temperature.
WARNING: THE GLOW PLUG WILL BECOME
EXTREMELY HOT (GLOWING) DURING THESE
TESTS. BURNS COULD RESULT IF IMPROPERLY
HANDLED. ALLOW THE GLOW PLUG TO COOL
BEFORE REMOVING FROM TESTER.
(8) Remove the gl ow pl ug from the tester.
SENSOR RESISTANCE (OHMS)
SENSOR RESISTANCE (OHMS)COOLANT
TEMPERATURE SENSOR/INTAKE AIR
TEMPERATURE SENSOR
TEMPERATURE RESISTANCE (OHMS)
C F MIN MAX
40 40 291,490 381,710
20 4 85,850 108,390
10 14 49,250 61,430
0 32 29,330 35,990
10 50 17,990 21,810
20 68 11,370 13,610
25 77 9,120 10,880
30 86 7,370 8,750
40 104 4,900 5,750
50 122 3,330 3,880
60 140 2,310 2,670
70 158 1,630 1,870
80 176 1,170 1,340
90 194 860 970
100 212 640 270
110 230 480 540
120 248 370 410
Fig. 16 Typical Glow Plug Tester
1 INSERT GLOW PLUG HERE
2 OBSERVATION WINDOW
3 SPRING LOADED BAR
4 TIMER LAMPS (4)
5 TEST LEADS
6 TESTER BUTTON
14 - 32 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
DIAGNOSIS AND TESTING (Continued)
GLOW PLUG RELAY TEST
The gl ow pl ug rel ay i s l ocated i n the engi ne com-
partment on the l efti nner fender (Fi g. 17).
When the i gni ti on (key) swi tch i s pl aced i n the ON
posi ti on, a si gnal i s sent to the ECM rel ati ng current
engi ne cool ant temperature. Thi s si gnal i s sent from
the engi ne cool ant temperature sensor.
After recei vi ng thi s si gnal , the ECM wi l l determi ne
i f, when and for how l ong a peri od the gl ow pl ug
rel ay shoul d be acti vated. Thi s i s done before, duri ng
and after the engi ne i s started. Whenever the gl ow
pl ug rel ay i s acti vated, i t wi l l control the 12V+ 100
amp ci rcui t for the operati on of the four gl ow pl ugs.
The Gl ow Pl ug l amp i s ti ed to thi s ci rcui t. Lamp
operati on i s al so control l ed by the ECM.
Wi th a col d engi ne, the gl ow pl ug rel ay and gl ow
pl ugs may be acti vated for a maxi mum ti me of 200
seconds. Refer to the Gl ow Pl ug Control chart for a
temperature/ti me compari son of gl ow pl ug rel ay oper-
ati on.
I n thi s chart, PreHeat and PostHeat ti mes are
menti oned. Preheat i s the amount of ti me the gl ow
pl ug rel ay ci rcui t i s acti vated when the i gni ti on (key)
swi tch i s ON, but the engi ne has yet to be started.
Postheat i s the amount of ti me the gl ow pl ug rel ay
ci rcui t i s acti vated after the engi ne i s operati ng. The
Gl ow Pl ug l amp wi l l not be i l l umi nated duri ng the
postheat cycl e.
TESTING:
Di sconnect and i sol ate the el ectri cal connectors
(Fi g. 18) at al l four gl ow pl ugs. Wi th the engi ne cool
or col d, and the key i n the ON posi ti on, check for
1012 vol ts + at each el ectri cal connector. 1012 vol ts
+ shoul d be at each connector whenever the ECM i s
operati ng i n the preheat or postheat cycl es (refer
to the fol l owi ng Gl ow Pl ug Control chart). Be very
careful not to allow any of the four discon-
nected glow plug electrical connectors to con-
tact a metal surface. When the key is turned to
the ON position, approximately 100 amps at 12
volts is supplied to these connectors. I f 1012
vol ts + i s not avai l abl e at each connector, check con-
ti nui ty of wi ri ng harness di rectl y to the rel ay. I f con-
ti nui ty i s good di rectl y to the rel ay, the faul t i s ei ther
wi th the rel ay or the rel ay i nput from the ECM. To
test the rel ay onl y, refer to Rel aysOperati on/Test-
i ng i n thi s secti on of the group. I f the rel ay test i s
good, refer to the DRB scan tool .
Diagnostic Trouble Codes: Refer to On-Board
Di agnosti cs i n Group 25, Emi ssi on Control System
for a l i st of Di agnosti c Troubl e Codes (DTCs) for cer-
tai n fuel system components.
Fig. 17 Glow Plug Relay Location
1 MOUNTING BOLT
2 GLOW PLUG RELAY
3 ELECTRICAL CONNECTOR
Fig. 18 Wiring Connection at Glow Plug
1 GLOW PLUG ELECTRICAL CONNECTOR
GLOW PLUG CONTROL
ENGINE
COOLANT
TEMP-
ERATURE
KEY ON
WAIT-TO-
START
LAMP ON
(SECONDS)
PRE-HEAT
CYCLE
(GLOW
PLUGS
ON)
(SECONDS)
POST-
HEAT
CYCLE
(SECONDS)
-30 C 15 SEC. 45 SEC. 200 SEC.
-10 C 8 SEC. 35 SEC. 180 SEC.
+10 C 6 SEC. 25 SEC. 118 SEC.
+30 C 5 SEC. 20 SEC. 70 SEC.
+40 C 4 SEC. 16 SEC. 60 SEC.
+70 C 3 SEC. 16 SEC. 20 SEC.
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 33
DIAGNOSIS AND TESTING (Continued)
RELAYS OPERATION/TESTING
The following description of operation and
tests apply only to the ASD and other relays.
The termi nal s on the bottom of each rel ay are num-
bered (Fi g. 19).
OPERATION
Termi nal number 30 i s connected to battery vol t-
age. For both the ASD and other rel ays, termi nal 30
i s connected to battery vol tage at al l ti mes.
The ECM grounds the coi l si de of the rel ay
through termi nal number 85.
Termi nal number 86 suppl i es vol tage to the coi l
si de of the rel ay.
When the PCM de-energi zes the ASD and other
rel ays, termi nal number 87A connects to termi nal 30.
Thi s i s the Off posi ti on. I n the off posi ti on, vol tage i s
not suppl i ed to the rest of the ci rcui t. Termi nal 87A
i s the center termi nal on the rel ay.
When the ECM energi zes the ASD and other
rel ays, termi nal 87 connects to termi nal 30. Thi s i s
the On posi ti on. Termi nal 87 suppl i es vol tage to the
rest of the ci rcui t.
TESTING
The fol l owi ng procedure appl i es to the ASD and
other rel ays.
(1) Remove rel ay from connector before testi ng.
(2) Wi th the rel ay removed from the vehi cl e, use
an ohmmeter to check the resi stance between termi -
nal s 85 and 86. The resi stance shoul d be between 75
5 ohms.
(3) Connect the ohmmeter between termi nal s 30
and 87A. The ohmmeter shoul d show conti nui ty
between termi nal s 30 and 87A.
(4) Connect the ohmmeter between termi nal s 87
and 30. The ohmmeter shoul d not show conti nui ty at
thi s ti me.
(5) Connect one end of a jumper wi re (16 gauge or
smal l er) to rel ay termi nal 85. Connect the other end
of the jumper wi re to the ground si de of a 12 vol t
power source.
(6) Connect one end of another jumper wi re (16
gauge or smal l er) to the power si de of the 12 vol t
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
(7) Attach the other end of the jumper wi re to
rel ay termi nal 86. Thi s acti vates the rel ay. The ohm-
meter shoul d now show conti nui ty between rel ay ter-
mi nal s 87 and 30. The ohmmeter shoul d not show
conti nui ty between rel ay termi nal s 87A and 30.
(8) Di sconnect jumper wi res.
(9) Repl ace the rel ay i f i t di d not pass the conti nu-
i ty and resi stance tests. I f the rel ay passed the tests,
i t operates properl y. Check the remai nder of the ASD
and other rel ay ci rcui ts. Refer to group 8W, Wi ri ng
Di agrams.
BOOST / PRESSURE SENSOR
I f the boost pressure sensor fai l s, the PCM records
a DTC i nto memory and conti nues to operate the
Fig. 19 Glow Plug Relay Location
1 MOUNTING BOLT
2 GLOW PLUG RELAY
3 ELECTRICAL CONNECTOR
Fig. 20 Boost Pressure Sensor Location
1 BOOST PRESSURE SENSOR HARNESS CONNECTOR
2 BOOST PRESSURE SENSOR
14 - 34 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
DIAGNOSIS AND TESTING (Continued)
engi ne i n one of the three l i mp-i n modes. When the
PCM i s operati ng i n thi s mode, a l oss of power wi l l
be present, as i f the turbocharger was not operati ng.
The best method for di agnosi ng faul ts wi th the boost
pressure sensor i s wi th the DRB I I I scan tool . Diag-
nostic Trouble Codes: Refer to On-Board Di agnos-
ti cs i n Group 25, Emi ssi on Control System for a l i st
of Di agnosti c Troubl e Codes (DTCs) for certai n fuel
system components.
VEHICLE SPEED SENSOR TEST
To perform a test of the sensor and i ts rel ated ci r-
cui try, refer to DRB scan tool .
Diagnostic Trouble Codes: Refer to On-Board
Di agnosti cs i n Group 25, Emi ssi on Control System
for a l i st of Di agnosti c Troubl e Codes (DTCs) for cer-
tai n fuel system components.
DIAGNOSTIC TROUBLE CODES
For a l i st of Di agnosti c Troubl e Codes (DTCs),
refer to Group 25, Emi ssi on Control System for i nfor-
mati on. See On-Board Di agnosti cs.
REMOVAL AND INSTALLATION
ASD RELAY
The ASD rel ay i s l ocated i n the PDC. For the l oca-
ti on of the rel ay wi thi n the PDC, refer to l abel on
PDC cover.
A/C CLUTCH RELAY
The A/C cl utch rel ay i s l ocated i n the PDC. For the
l ocati on of the rel ay wi thi n the PDC, refer to l abel on
PDC cover.
ENGINE SPEED SENSOR
The engi ne speed sensor i s mounted to the trans-
mi ssi on bel l housi ng at the rear of the engi ne bl ock
(Fi g. 21).
REMOVAL
(1) Di sconnect the harness (on the sensor) from
the mai n el ectri cal harness.
(2) Remove the sensor mounti ng bol ts.
(3) Remove the sensor.
INSTALLATION
(1) I nstal l the sensor fl ush agai nst the openi ng i n
the transmi ssi on housi ng.
(2) I nstal l and ti ghten the sensor mounti ng bol t to
19 Nm (14 ft. l bs.) torque.
(3) Connect the el ectri cal connector to the sensor.
ENGINE COOLANT TEMPERATURE SENSOR
The sensor i s l ocated on the si de of cyl i nder head
near the rear of fuel i njecti on pump.
REMOVAL
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7, COOLING.
(1) Parti al l y drai n cool i ng system. Refer to Group
7, Cool i ng.
(2) Di sconnect el ectri cal connector from sensor.
(3) Remove sensor from cyl i nder head.
INSTALLATION
(1) I nstal l a new copper gasket to sensor.
(2) I nstal l sensor to cyl i nder head.
(3) Ti ghten sensor to 18 Nm (13 ft. l bs.) torque.
(4) Connect el ectri cal connector to sensor.
(5) Repl ace any l ost engi ne cool ant. Refer to Group
7, Cool i ng System.
GLOW PLUGS
The gl ow pl ugs are l ocated above each fuel i njector
(Fi g. 22). Four i ndi vi dual pl ugs are used.
REMOVAL
(1) Di sconnect the negati ve battery cabl e at the
battery.
(2) Cl ean the area around the gl ow pl ug wi th com-
pressed ai r before removal .
Fig. 21 Engine Speed Sensor
1 ENGINE SPEED SENSOR
2 GROMMET
3 MOUNTING BOLT(S)
4 LEFT REAR OF ENGINE
5 TRANSMISSION
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 35
DIAGNOSIS AND TESTING (Continued)
(3) Di sconnect el ectri cal connector (Fi g. 23) at gl ow
pl ug.
(4) Remove the gl ow pl ug (Fi g. 22) from cyl i nder
head.
INSTALLATION
(1) Appl y hi ghtemperature anti sei ze compound
to gl ow pl ug threads before i nstal l ati on
(2) I nstal l the gl ow pl ug i nto the cyl i nder head.
Ti ghten to 14 Nm (123 i n. l bs.) torque.
(3) Connect battery cabl e to battery.
GLOW PLUG RELAY
The gl ow pl ug rel ay i s l ocated i n the engi ne com-
partment on the l efti nner fender (Fi g. 24).
REMOVAL
(1) Di sconnect the negati ve battery cabl e at the
battery.
(2) Remove rel ay mounti ng bol t.
(3) Di sconnect el ectri cal connector at rel ay and
remove rel ay.
INSTALLATION
(1) Check condi ti on of el ectri cal connector for dam-
age or corrosi on. Repai r as necessary.
(2) I nstal l el ectri cal connector to rel ay.
(3) I nstal l rel ay to i nner fender.
(4) Connect battery cabl e to battery.
POWERTRAIN CONTROL MODULE (PCM)
The PCM i s mounted to a bracket mounted to the
i nner si de of the ri ght fender wel l behi nd the ai r
cl eaner assembl y. (Fi g. 25).
REMOVAL
(1) Di sconnect the negati ve battery cabl e at the
battery.
(2) Loosen the 60Way connector (Fi g. 25). The
el ectri cal connector has a sl i di ng bar whi ch moves
i nward to l ock or outward to unl ock.
(3) Remove the el ectri cal connector by pul l i ng
strai ght out.
(4) Remove PCM.
INSTALLATION
(1) After the PCM el ectri cal connector has been
separated from the PCM, i nspect the pi ns for corro-
Fig. 22 Glow Plug
1 GLOW PLUG
Fig. 23 Glow Plug Electrical Connector
1 GLOW PLUG ELECTRICAL CONNECTOR
Fig. 24 Glow Plug Relay Location
1 MOUNTING BOLT
2 GLOW PLUG RELAY
3 ELECTRICAL CONNECTOR
14 - 36 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
si on, bei ng spread apart, bent or mi sal i gned. Al so
i nspect the pi n hei ghts i n the connector. I f the pi n
hei ghts are di fferent, thi s woul d i ndi cate a pi n has
separated from the connector. Repai r as necessary.
(2) Engage 60way connector i nto PCM. Move
sl i de bar to l ock connector.
(3) Connect negati ve cabl e to battery.
VEHICLE SPEED SENSOR
The vehi cl e speed sensor i s l ocated i n the transfer
case housi ng for 4 wheel dri ve vehi cl es (Fi g. 26).
REMOVAL
(1) Rai se and support vehi cl e.
(2) Cl ean the area around the sensor before
removal .
(3) Di sconnect the el ectri cal connector from the
sensor (Fi g. 27).
(4) Remove the sensor mounti ng bol t (Fi g. 27).
(5) Pul l the sensor from the speedometer pi ni on
gear adapter for removal .
INSTALLATION
(1) I nstal l new sensor i nto speedometer gear
adapter.
(2) Ti ghten sensor mounti ng bol t. To prevent dam-
age to sensor or speedometer adapter, be sure the
sensor i s mounted fl ush to the adapter before ti ght-
eni ng.
(3) Connect el ectri cal connector to sensor.
Fig. 25 PCM Location
1 PCM HARNESS CONNECTOR C1
2 PCM HARNESS CONNECTOR C2
3 PCM HARNESS CONNECTOR C3
4 POWERTRAIN CONTROL MODULE (PCM)
Fig. 26 Vehicle Speed Sensor Location4WD
1 SENSOR ELECTRICAL CONNECTOR
2 4WD TRANSFER CASE EXTENSION
3 VEHICLE SPEED SENSOR
Fig. 27 Sensor Removal/InstallationTypical
1 ELECTRICAL CONNECTOR
2 SENSOR MOUNTING BOLT
3 O-RING
4 SPEEDOMETER PINION GEAR
5 SPEEDOMETER PINION GEAR ADAPTER
6 O-RING
7 VEHICLE SPEED SENSOR
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 37
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
GLOW PLUG CURRENT DRAW
Initial Current Draw: Approxi matel y 2225
amps per pl ug.
After 20 seconds of operation: Approxi matel y
912 amps per pl ug.
TORQUE CHART 2. 5L DIESEL
DESCRIPTION TORQUE
Accel erator Pedal Bracket Mounti ng Nuts . . 5 Nm
(46 i n. l bs.)
Banjo-Type Fi tti ngs . . . . . . . . . . 19 Nm (14 ft. l bs.)
Engi ne Cool ant Temperature Sensor . . . . . . 18 Nm
(13 ft. l bs.)
Engi ne Speed Sensor Bol ts . . . . 19 Nm (14 ft. l bs.)
Fuel Hose (Tube) Cl amps For Rubber Hose . . . 2 Nm
(20 i n. l bs.)
Fuel I njector . . . . . . . . . . . . . . . 70 Nm (52 ft. l bs.)
Fuel I njector Li ne At I njector . . 30 Nm (22 ft. l bs.)
Fuel I njector Li ne At I njector Pump . . . . . . 30 Nm
(22 ft. l bs.)
Fuel I njecti on Pump Mounti ng Nuts . . . . . . 30 Nm
(22 ft. l bs.)
Fuel I njecti on Pump Dri ve Gear . . . . . . . . . 88 Nm
(65 ft. l bs.)
Fuel Li ne Cl amp Bracket Bol ts . 24 Nm (18 ft. l bs.)
Fuel Tank Nuts . . . . . . . . . . . . 11 Nm (100 i n. l bs.)
Gl ow Pl ugs . . . . . . . . . . . . . . . 23 Nm (203 i n. l bs.)
Powertrai n Control Modul e Mounti ng Bol ts . . 1 Nm
(9 i n. l bs.)
Throttl e Posi ti on Sensor Mounti ng Bol ts . . . 7 Nm
(60 i n. l bs.)
Vehi cl e Speed Sensor Mounti ng Bol ts . . . . . . 3 Nm
(26 i n. l bs.)
14 - 38 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ

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