Thread: High pressure pump reset/SVC relearn on 2.2 puma - options

I've got a 2.4 version so I'm not sure if this will help or not...


I recently removed my Injectors and had them tested - 3 of the 4 failed the test and they said they were over-fuelling. I didn't really notice much difference in economy but since I have a big trip planned for next year I decide to replace them.


I ended up buying 4 new injectors and installed them, then using my Nanacom I coded them in and then took the car for a drive to get the engine up to running temp, then did the pilot relearning process which was successfully completed.


I would have thought if u are having over-fuelling issues - then that would point to a issue with the injectors and not the pump as the injector governs how much fuel is injected... I realise that the Pump will very the pressure in the rail depending on load, etc but in the end the injector governs the amount of fuel injected into the cylinder (??) -- Others may know more as I'm no mechanic so take what I said with a grain of salt

The fuel delivery into the combustion chamber is controlled by both the hpfp pressure and the injector duration time.

It could be over-fuelling if the hpfp is delivering higher pressure than requested by the ECM, or if the injectors themselves are delivering more fuel because of wear/ leaking etc.

A failed/under reading rail pressure sensor could also be the cause, or a stuck pressure control valve. You would think that faults would be shown though.

I know nothing at all about these engines, the above comments are general common rail methods.

From what I've read about these engines though, as posted before me is that it's usually faulty injectors.

DazzaTD5 is your man with these.

The GAP tool will do both the learn on the suction control valve and reset the HPFP.
The exact wording is not what I have said above as I'm going just off my memory.

Typically the 2.2 will wear out the injectors anywhere from 70K on wards, there is no hard and fast point.
Also getting injectors tested is a waste of aprox $250 per injector.

Worn injectors typically make that rattle sound (actually its pre-ignition/detonation) on cold driving off, floating on throttle once warn or on hard throttle.


my obvious question is how have you determined its over fuelling?

I think you're all probably right and I should stump up for some new injectors. I guess I was hoping I could shell out a few bucks and at least try one of the plugin tools first and hope for the best. I recall you @DazzaTD5 saying in the past that resetting the HPFP periodically seemed to be good practice on these TDCIs. BTW I haven't got a GAP Tool just the BAS version which its based on, but I can't see any option in there for the 2.2 in their online manual only the 2.4 (they call L316-07) v 2.2 (which they call L316-12) and BAS themselves only mention it for the 2.4 on their instructions.

So the overfueling has persisted after replacing/upgrading the intercooler and hoses, cleaning and swapping out the MAF/MAP. Cleaning out the EGR and giving the turbo a - reasonable, I'm no expert - checkup (no whine, vanes move easy when disconnected from actuator, no play in the compressor wheel etc), along with all the regular maintenance. It manifests as a very slightly sooty exhaust (no smoke) and slow but steady decline in economy. No error codes. Oil level is perfect between changes with no drips or leaks. It has been a rock steady average of 10.3l/100km for over 9 years (had it since new) but over the last 18/24 months slowly creeping up, now around 11.5l/100km. But runs like a clock otherwise.

Thanks all

Just to follow up on this thread with regards to reset of the high pressure fuel pump, I couldnt remember the wording and have only had D4 and TDCi 2.4 models in a no TDCi 2.2

See the pics below in order.
So either the bas version of the gap tool doesnt have this and or the gap online doco's are incorrect.
and yes I reset (2.2) or calibrate (2.4) on every service

you state etc etc...

doing intercooler etc etc made no difference - I wouldnt expect it to change.
some soot in exhaust - dont see any issue there.
so over 9 years the fuel economy has dropped 1 lt / 100km

No offence... but are you kidding me?
that is not over fuelling.
over fuelling is you can see black smoke, even small amounts on hard throttle.

Tyres wearing, brake drag, fuel quality, service intervals, engine efficiency, environmental etc etc.
As your Defender is not a closed system I would say over 9 years there may well be some effects from;
Degradation, Entropy, Laws of thermodynamics ?