PUBLISHED: 18-JUN-2019

2023.0 DISCOVERY SPORT (LC), 303-04C

F U E L C H A R G I N G A N D CO N T R O LS -
INGENIUM I4 2.0L PETROL (G2360239)

D E S C R I P T I O N A N D O P E R AT I O N

COMPONENT LOCATION

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 ITEM DESCRIPTION

1 Low Pressure (LP) fuel pipe

2 High Pressure (HP) fuel line

3 HP fuel pump

4 Fuel rail

5 Fuel injector (quantity 4)

6 Fuel Rail Pressure and Temperature (FRPT) sensor

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 OVERVIEW

The Ingenium I4 2.0L Petrol engine is equipped with a High Pressure (HP) Direct Injection (DI)
system, controlled by the Powertrain Control Module (PCM). The HP fuel pump delivers a uniform
level of pressure to the shared fuel rail, which serves all 4 fuel injectors. Pressure is controllable, to
the optimum level for smooth operation, up to 200 bar (2,900 psi). The Low Pressure (LP) fuel from
the pump in the fuel tank is pressurized by the HP fuel pump and supplied to the fuel injectors via
the fuel rail. The PCM controls the fuel injectors and HP fuel pump to inject the required volume of
fuel into the combustion chambers.

The fuel charging and controls system consists of:

LP fuel pipe

HP fuel line

HP fuel pump

Fuel rail

Fuel Rail Pressure and Temperature (FRPT) sensor

The 4 fuel injectors.

The LP fuel system is covered in 'Fuel Tank and Lines' section.

For additional information, refer to: Fuel Tank and Lines (310-01A Fuel Tank and Lines - INGENIUM
I4 2.0L Diesel AJ21, Description and Operation).

DESCRIPTION

HIGH PRESSURE FUEL PUMP

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 ITEM DESCRIPTION

1 High Pressure (HP) fuel pump

2 Fuel metering valve connector

3 Low Pressure (LP) fuel inlet

4 Exhaust camshaft - Fuel pump lobes

5 Tappet

6 HP fuel outlet to fuel rail

The High Pressure (HP) fuel pump is located on the top of the engine. The HP fuel pump is attached
to the camshaft carrier with 2 bolts and sealed with an O-ring seal.

The HP fuel pump is a single cylinder pump which meters the fuel pressure according to demand
requirements for correct fuel injection. The delivery rate of the fuel pump is adjustable by means of
the fuel metering valve. The fuel metering valve is controlled by the Powertrain Control Module
(PCM) with a Pulse Width Modulation (PWM) signal.

The HP fuel pump is mechanically driven by the exhaust camshaft via a tappet. The tappet is

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 operated by a 4 lobe cam on the exhaust camshaft. A spring installed on the outside of the plunger
to hold tight the plunger and the tappet and remain in contact with the camshaft. During the
downward stroke of the pump piston, fuel is delivered to the cylinder at a pressure supplied by the
fuel tank mounted Low Pressure (LP) fuel pump. On the upward stroke of the piston the fuel in the
cylinder is compressed. If the pressure from the pump exceeds the pressure in the fuel rail the fuel is
delivered into the fuel rail via a single HP fuel line.

The cylinder and low pressure fuel supply are connected via the fuel metering valve. If the fuel
pressure in the fuel rail is sufficient, the PCM opens the metering valve during the compression
stroke of the piston. The fuel is then directed from the cylinder back into the low pressure supply.

The HP fuel pump comprises a check valve, which is located between the pump plunger and the HP
fuel pump outlet connection. The check valve maintains the desired fuel pressure in the HP side of
the fuel system. The delivered fuel quantity depends on the engine demand, controlled by the
actuation of the fuel metering valve.

FUEL INJECTORS

ITEM DESCRIPTION

1 O-ring seal

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 2 Support disc

3 Electrical connector

4 Injector solenoid

5 Combustion seal ring

6 Injector nozzle

The 4 High Pressure (HP) fuel injectors spray fuel from the fuel rail directly into the combustion
chambers. The fuel injectors are installed close to the center of the combustion chambers, between
the inlet valves and next to the spark plug. On each fuel injector, an O-ring seal and support disc
seals the head of the fuel injector in the fuel rail. A Teflon™ combustion seal ring seals the nozzle of
the fuel injector in the cylinder head.

Each fuel injector contains a solenoid operated needle valve, which opens when the solenoid
winding is energized. While the needle valve is open, fuel is sprayed into the combustion chamber.
There are 6 holes around the tip of the nozzle through which the fuel is sprayed. There are 2 holes
which direct the fuel below the spark plug. The other 4 holes direct fuel evenly around the remainder
of the combustion chamber.

The solenoid winding is connected to a power supply and a ground from the Powertrain Control
Module (PCM), which operates the fuel injectors with a 2 stage power supply. Initially the PCM
supplies the fuel injectors with 65V, then once the boost current reaches 11.5A the power supply is
switched to startup battery voltage. When the fuel injector is opened, the PCM controls the current
flow at approximately 3.1A. The PCM meters the amount of fuel injected into the combustion
chambers by adjusting the time that the solenoid winding is energized.

If a fuel injector fails, the engine will suffer from unstable idle speed, poor Noise, Vibration and
Harshness (NVH) and poor emissions performance. The Malfunction Indicator Lamp (MIL) in the
Instrument Cluster (IC) will also be illuminated.

FUEL RAIL

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 ITEM DESCRIPTION

1 Wiring harness - Fuel injector

2 Fuel Rail Pressure and Temperature (FRPT) sensor

3 High Pressure (HP) fuel line connection

4 Fuel rail

5 Fuel injector clamp (quantity 4)

6 Fuel injector (quantity 4)

The fuel rail is located on the top of the engine and it is attached to the cylinder head with 4 bolts.
The fuel rail also secures the 4 fuel injectors in position. An O-ring seal on each injector locates in a
bore in the fuel rail. As the fuel rail is tightened to the cylinder head the fuel injectors are retained
between the fuel rail and the cylinder head. The fuel injector clamp on each fuel injector provides
appropriate force to hold the fuel injector in position.

The fuel rail incorporates a threaded boss for connection of the High Pressure (HP) fuel line.

The fuel rail comprises a wiring harness, which provides the connection between the fuel injectors

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 and the engine wiring harness. The wiring harness is secured to the fuel rail with 3 clips.

FUEL RAIL PRESSURE AND TEMPERATURE SENSOR

The Fuel Rail Pressure and Temperature (FRPT) sensor is located at the top of the fuel rail. The FRPT
sensor is screwed into a threaded port and sealed with a mating taper in the fuel rail. The sensor is
connected directly to the Powertrain Control Module (PCM).

The FRPT sensor is a metal thin film technology type sensor. The FRPT sensor is connected with 4
wires to the PCM. The PCM supplies a 5V reference voltage to the sensor. The pressure
measurement is based on the expansion of a thin steel diaphragm which is sensed by the PCM on a
return signal wire which is proportional to the fuel pressure in the fuel rail.

The PCM compares the sensor signal voltage to stored memory values, to calculate the actual fuel
pressure present in the fuel rail. The PCM then uses the fuel rail pressure information to control the
operating position of the fuel metering valve.

The FRPT sensor contains a Negative Temperature Coefficient (NTC) resistor which allows the PCM
to determine the fuel temperature.

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 OPERATION

GENERAL

The Powertrain Control Module (PCM) controls the output from the High Pressure (HP) fuel pump to
deliver the required volume of fuel at pressures up to 200 bar (2,900 psi).

The Powertrain Control Module (PCM) compares the fuel temperature information from the Fuel Rail
Pressure and Temperature (FRPT) sensor to the data in the maps. The PCM compensate the time the
fuel injectors need to be energized to deliver the correct mass of fuel to the combustion chambers.

HIGH PRESSURE FUEL PUMP

Schematic Diagram - High Pressure Fuel Pump

ITEM DESCRIPTION

1 Pressure Relief Valve (PRV)

2 High Pressure (HP) fuel outlet connection

3 Check valve

4 Pump plunger

5 Low Pressure (LP) fuel inlet connection

6 Damper chamber

7 Fuel metering valve

In addition to the plunger, the High Pressure (HP) fuel pump contains:

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 A damper chamber

A fuel metering valve

A check valve

A Pressure Relief Valve (PRV).

The damper chamber absorbs pressure pulses from the Low Pressure (LP) fuel system. The fuel
metering valve regulates the output pressure from the HP fuel pump. The fuel metering valve is a
normally open solenoid valve controlled by the Powertrain Control Module (PCM) with a Pulse Width
Modulation (PWM) signal. During the inlet stroke of the plunger the fuel metering valve is de-
energized and fuel flows into the pumping chamber. The PCM energizes the fuel metering valve
closed during the delivery stroke of the plunger. The pressurized fuel in the pumping chamber flows
through the check valve into the fuel rail through the HP fuel line.

By changing the closing point of the fuel metering valve, the PCM can determine the volume of fuel
output during the delivery stroke and thus the fuel pressure in the fuel rail. The check valve prevents
the return of HP fuel to the pumping chamber during the inlet stroke of the plunger.

The Pressure Relief Valve (PRV) protects the HP side of the system from excessive pressure if there is
a failure of the fuel metering valve. If the HP fuel pump delivery pressure increases to 250 bar (3,626
psi), the PRV opens and returns fuel to the inlet side of the plunger.

CONTROL DIAGRAM

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 A = HARDWIRED: AL = PULSE WIDTH MODULATION (PWM).

ITEM DESCRIPTION

1 Powertrain Control Module (PCM)

2 Fuel injector (quantity 4)

3 Fuel metering valve - High Pressure (HP) fuel pump

4 Ground

5 Power supply

6 Fuel Rail Pressure and Temperature (FRPT) sensor

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