axle
Member Since: 28 Oct 2007
Location: Perth Perth the end of the Earth
Posts: 2964
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Here goes ;housing.
Installation
1. With assistance, install the heater and evaporator core
housing.
2. Install the in-vehicle crossbeam.
For additional information, refer to: In-Vehicle Crossbeam (501-12 Instrument Panel and Console, Removal and Installation).
Auxiliary Heating - Torque Specifications
Auxiliary Heating - Auxiliary Heater
Description and Operation
COMPONENT LOCATION
Published: 11-May-2011


Description

Nm

lb-ft


Fuel fired booster heater exhaust bracket bolt


10

7


Fuel fired booster heater




10



7


Item
Part Number
Description
1
-
Fuel Fired Booster Heater (FFBH) fuel pipe tank connection
2
-
FFBH receiver (where fitted)

3
-
Changeover valve (where fitted)
4
-
FFBH fuel pump
5
-
FFBH unit
OVERVIEW
The system consists of a FFBH unit and a FFBH fuel pump. On vehicles with the remote operation feature, the system also includes a changeover valve, a FFBH receiver and a remote handset.
Fuel for the FFBH system is taken from the vehicle fuel tank, through a line attached to the fuel tank top flange assembly, and supplied via the FFBH fuel pump to the FFBH unit. In the FFBH unit, the fuel delivered by the FFBH fuel pump is burned and the resultant heat output is used to heat the engine coolant.
Where fitted, the changeover valve allows the heater coolant circuit to be isolated from the engine coolant circuit during parked heating.
A control module integrated into the FFBH unit controls the operation of the FFBH unit and the FFBH fuel pump. The automatic temperature control (ATC) module controls the changeover valve. System operation is initiated by:
The instrument cluster, via the ATC module, for parked heating selections made on the Touch Screen Display (TSD).
For additional information, refer to: Audio System (415-01A Audio Unit, Description and Operation). The remote handset, via the Television (TV) system antenna and antenna amplifier, and the FFBH
receiver, for remote activation of parked heating.
The ATC module, for additional heating while the engine is running.
FFBH FUEL PUMP
The FFBH fuel pump regulates the fuel supply to the FFBH unit. The FFBH fuel pump is installed at the right- hand (RH) rear of the fuel tank, in a rubber mounting attached to the rear subframe. The pump is a self priming, solenoid operated plunger pump. The control module in the FFBH unit outputs a pulse width modulation (PWM) signal to control the operation of the pump. When the pump is de-energized, it provides a positive shut-off of the fuel supply to the FFBH unit.
Sectioned View of FFBH Fuel Pump

Item Part Number
1 -
2   -   Plunger
Description
Solenoid coil
3 -
4 -
5 -
6   -   Spring
7   -   Piston
8   -   Bush
Filter insert
Fuel line connector O-ring seal
9 -
10 -
Fuel line connector
Non return valve
The solenoid coil of the FFBH fuel pump is installed around a housing which contains a plunger and piston. The
piston locates in a bush, and a spring is installed on the piston between the bush and the plunger. A filter insert and a fuel line connector are installed in the inlet end of the housing. A non return valve and a fuel line connector are installed in the fuel outlet end of the housing.
While the solenoid coil is de-energized, the spring holds the piston and plunger in the 'closed' position at the inlet end of the housing. An O-ring seal on the plunger provides a fuel tight seal between the plunger and the filter insert, preventing any flow through the pump. When the solenoid coil is energized, the piston and plunger move towards the outlet end of the housing, until the plunger contacts the bush; fuel is then drawn in through the inlet connection and filter. The initial movement of the piston also closes transverse drillings in the bush and isolates the pumping chamber at the outlet end of the housing. Subsequent movement of the piston then forces fuel from the pumping chamber through the non return valve and into the line to the FFBH unit. When the solenoid de-energizes, the spring moves the piston and plunger back towards the closed position. As the piston and plunger move towards the closed position, fuel flows past the plunger and through the annular gaps and transverse holes in the bush to replenish the pumping chamber.
FFBH UNIT
The FFBH unit is installed in the passenger side rear of the engine compartment, below the battery. It is connected in series with the coolant supply to the heater assembly. Two electrical connectors on the FFBH unit connect it to the vehicle wiring.
FFBH Unit Components
Item Part Number
1 -
2 -
3 -
4 -
5 -
6 -
7 -
Description
Coolant outlet hose
Electrical connectors Air inlet filter Mounting bracket Exhaust pipe
Fuel supply line Coolant inlet hose

Sectioned View of FFBH Unit
Item     Part Number    Description
1     -    Combustion air fan
2       -     Burner housing 3       -     Control module 4       -     Heat exchanger 5       -     Burner insert
6       -     Exhaust
7     -    Glow plug/flame sensor
8     -    Evaporator
9     -    Coolant inlet
10     -    Circulation pump
11       -     Fuel inlet
12       -     Coolant outlet

13
-
Air inlet
Circulation Pump
The circulation pump is installed at the coolant inlet to the FFBH unit to assist the coolant flow through the FFBH unit and the heater assembly. The pump runs continuously while the FFBH unit is in standby or active operating modes. While the FFBH unit is inactive, coolant flow is reliant on the engine coolant pump and the auxiliary coolant pump.
Combustion Air Fan
The combustion air fan regulates the flow of air into the unit to support combustion of the fuel supplied by the FFBH pump and to purge and cool the FFBH unit. A canister type filter is included in the air inlet supply line to prevent particulates entering and contaminating the FFBH unit.
Burner Housing
The burner housing contains the burner insert and also incorporates connections for the exhaust pipe, the coolant inlet from the circulation pump and the coolant outlet to the heater assembly. The exhaust pipe directs exhaust combustion gases to atmosphere through a pipe below the FFBH unit.
The burner insert incorporates the fuel combustion chamber, an evaporator and a glow plug/flame sensor. Fuel from the FFBH fuel pump is supplied to the evaporator, where it evaporates and enters the combustion chamber to mix with air from the combustion air fan. The glow plug/flame sensor provides the ignition source of the fuel:air mixture and, once combustion is established, monitors the flame.
Control Module/Heat Exchanger
The control module controls and monitors operation of the FFBH system. Ventilation of the control module is provided by an internal flow of air from the combustion air fan. The heat exchanger transfers heat generated by combustion to the coolant. A sensor in the heat exchanger provides the control module with an input of heat exchanger casing temperature, which the control module relates to coolant temperature and uses to control system operation. The temperature settings in the control module are calibrated to compensate for the difference between coolant temperature and the heat exchanger casing temperature detected by the sensor. Typically, as the coolant temperature increases, the coolant will be approximately 7 °C (12.6 °F) hotter than the temperature detected by the sensor; as the coolant temperature decreases, the coolant will be approximately 2 °C (3.6 °F) cooler than the temperature detected by the sensor.
CHANGEOVER VALVE
The changeover valve is a normally open solenoid valve installed between the supply and return sides of the heater coolant circuit. The changeover valve is located in the engine compartment on the engine bulkhead. When de-energized, the changeover valve connects the heater coolant circuit to the engine coolant circuit. When energized, the changeover valve isolates the heater coolant circuit from the engine coolant circuit.
The changeover valve is controlled by a power feed from the ATC module.
FFBH RECEIVER
The FFBH receiver translates the FFBH request radio signals, relayed from the TV antenna amplifier, into a voltage output to the FFBH unit. When a request for parked heating is received, the FFBH receiver outputs a battery power feed to the FFBH unit. When a request to switch off parked heating is received, the FFBH receiver disconnects the power feed.
The FFBH receiver has a permanent power feed from the vehicle battery and is connected to the TV antenna amplifier by a coaxial cable.
FFBH REMOTE HANDSET
Item
Part Number
Description
1
-
Antenna
2
-
Off button
3
-
On button
4
-
light emitting diode (LED)
The FFBH remote handset allows parked heating to be remotely controlled up to a minimum of 100 m (328 ft) from the vehicle. On and off buttons activate and de-activate parked heating, a red LED illuminates to indicate when parked heating is active and when the on/off signals have been received by the vehicle. The FFBH remote handset is powered by 2 serviceable 1.5 V batteries located under a cover on the rear of the handset.
CONTROL DIAGRAM
• NOTE: A = Hardwired; B = K bus; F = RF transmission; K = I bus; M = P bus; N = Medium speed controller area network (CAN) bus; P = MOST ring; T = Coaxial cable
Item
Part Number
Description
1
-
FFBH remote handset
2
-
RH side window antenna

3 -       TV antenna amplifier
4 -       FFBH receiver
5 -       Passenger door mirror
6 -       FFBH fuel pump
7 -       Passenger door module
8 -       generic electronic module (GEM)
9 -     Driver door module
10 -     Changeover valve
11 -     Driver door mirror
12     -     TSD
13     -     IHU
14 -       ATC module
15 -       Instrument cluster
16 -       Diagnostic socket
17     -     FFBH
18 -       Fuse 59, central junction box (CJB)
PRINCIPLES OF OPERATION
The FFBH system operates in two modes:
Parked heating, to heat the passenger compartment while the vehicle is parked with the engine off. Additional heating, to boost heater performance while the engine is running.
The ATC module disables FFBH operation if battery voltage is too low:
When the engine is off the low voltage limit is 11.4 V for more than 10 seconds; the system is re-enabled if battery voltage increases to 12.2 V.
When the engine is running the low voltage limit varies with ambient temperature, from 11.1 V at -25°C (- 13°F) and below to 11.7 V at 15 °C (59 °F) and above; if battery voltage is below the limit for 2 minutes the system is disabled for the remainder of the ignition cycle.
During FFBH operation, with or without the engine running, the coolant valves of the climate control system remain de-energized and heater core temperature is directly related to the temperature of the coolant coming from the FFBH unit.
Parked Heating/Ventilation
Parked heating works in conjunction with parked ventilation. When parked heating/ventilation is selected, the vehicle interior is either heated by parked heating or cooled by parked ventilation, depending on the ambient temperature. Parked heating occurs if the ambient temperature is less than 16 °C (61 °F); parked ventilation occurs if the ambient temperature is 16 °C (61 °F) or more.
Parked heating/ventilation is controlled by direct selection on the TSD, by using the TSD to program one or two on/off cycle times in the following 24 hour period, or by using the FFBH remote handset. The direct selection and programmed time modes of operation are selected when the engine is stopped and the ignition switch is in position I. If required the key can then be removed from the ignition switch and the vehicle locked. In all operating modes, parked heating/ventilation is automatically de-activated after 30 minutes to prevent excessive drain on the battery. Parked ventilation is automatically de-activated when the ignition is switched on.
When programmed times for parked heating/ventilation are entered on the TSD, the times are stored in the memory of the instrument cluster and the climate set indicator, on the TSD, is permanently illuminated.
If the engine is started while parked heating is on:
If the engine coolant temperature is equal to or more than the heater coolant temperature, parked heating is switched off.
If the engine coolant temperature is less than the heater coolant temperature, parked heating remains on until the engine coolant temperature reaches the heater coolant temperature.

Programmed and TSD Selected Parked Heating/Ventilation
At a programmed parked heating/ventilation start time, or when parked heating/ventilation is selected on using the TSD, the instrument cluster outputs:
A parked heating/ventilation request to the TSD via the medium speed CAN bus, the Integrated Head Unit (IHU) and the Media Orientated System Transport (MOST) ring.
A parked heating/ventilation request to the ATC module and the GEM on the K bus.
The ambient and engine coolant temperatures to the ATC module and GEM on the K bus. On receipt of the messages:
The climate set indicator on the TSD panel flashes at 2 Hz to indicate that parked heating/ventilation is active.
If the ambient temperature is less than 5 °C (41 °F), the GEM activates the door mirror heaters for 3 minutes.
If parked heating is activated, the ATC module:
- Energizes the changeover valve.
- Sends a K bus message to activate the FFBH.
- Operates the blower at speed 1.
- Opens the windscreen distribution doors in the heater assembly and closes the face and footwell doors.
If parked ventilation is activated, the ATC module: - Operates the blower at speed 1.
- Opens the face level distribution doors in the heater assembly and closes the windscreen and footwell doors.
When parked heating/ventilation is selected off, or after 30 minutes has elapsed, the instrument cluster sends parked heating/ventilation off messages on the medium speed CAN bus and the K bus. On receipt of the messages:
The TSD switches off the climate set indicator. If parked heating is active, the ATC module:
- Sends a K bus message to de-activate the FFBH.
- Switches off the blower.
- Returns the distribution doors to the previous settings. - After 3 minutes, de-energizes the changeover valve.
If parked ventilation is active, the ATC module: - Switches off the blower.
- Returns the distribution doors to the previous settings.
Remotely Selected Parked Heating/Ventilation
When parked heating/ventilation is selected on with the remote handset, the request is received by the FFBH receiver via the TV antenna and TV antenna amplifier. The FFBH receiver relays the request as a hardwired signal to the FFBH control module. On receipt of the request, the FFBH control module sends the request to the ATC module and the instrument cluster on the K bus. Parked heating/ventilation then operates as detailed above.
Heater Coolant Circuit
Item
Part Number
Description
1
-
Coolant valve (manual system)
2
-
Heater core
3
-
Coolant valves (automatic system)
4
-
Auxiliary coolant pump

5
-
Engine cooling system
6
-
ATC module
7
-
Changeover valve (where fitted)
8
-
FFBH unit
Additional Heating
On diesel vehicles, additional heating reduces the heater warm-up time and is also used to maintain heater performance throughout the drive cycle. On petrol vehicles, additional heating is only used to reduce the heater warm-up time at the beginning of the drive cycle, and only occurs if parked heating is already active when the engine starts.
The ATC module activates the additional heating mode when the engine is running and the following conditions coexist:
The ambient temperature is less than 8 °C (41 °F).
The engine coolant temperature is less than 75 °C (167 °F). The heater coolant temperature is less than 70 °C (158 °F). The reference temperature is 100%.
The blower is on.
To activate the additional heating mode, the ATC module energizes the auxiliary coolant pump and sends K bus messages to the FFBH unit to start/continue operation (the changeover valve remains de-energized).
The ATC module stops the FFBH and de-energizes the auxiliary coolant pump when any of the following occur: The engine stops.
The ambient temperature increases to more than 15 °C (46 °F).
The engine coolant temperature increases to more than 75 °C (167 °F). The heater coolant temperature increases to more than 70 °C (158 °F). The reference temperature decreases to less than 90%.
The blower is selected off.
FFBH Unit
Once initiated by a message from the ATC module, FFBH operation is controlled by the control module in the FFBH unit. The control module controls the FFBH unit at one of two heat output levels, 2.5 kW at part load combustion and 5 kW at full load combustion.
Start Sequence: At the beginning of the start sequence the control module energizes the glow plug function of the glow plug/flame sensor, to preheat the combustion chamber, starts the combustion air fan at slow speed and energizes the coolant circulation pump. After approximately 30 seconds, the control module energizes the FFBH fuel pump at the starting sequence speed. The fuel delivered by the FFBH fuel pump evaporates in the combustion chamber, mixes with air from the combustion air fan and is ignited by the glow plug/flame sensor. The control module then progressively increases the speed of the FFBH fuel pump and the combustion air fan. Once combustion is established the control module switches the glow plug/flame sensor from the glow plug function to the flame sensing function to monitor combustion. From the beginning of the start sequence to stable combustion takes approximately 90 seconds for a start to part load combustion and 150 seconds for a start to full load combustion.
Coolant Temperature Control: When the control module first enters the active mode, it initiates a start to full load combustion. Full load combustion continues until the heat exchanger casing temperature reaches 72 °C (162 °F), at this point the control module decreases the speed of the FFBH fuel pump and the combustion air fan to half speed, to produce part load combustion. The control module maintains part load combustion
while the heat exchanger casing temperature remains between 68 and 76 °C (154 and 169 °F). If the heat exchanger casing temperature decreases to 68 °C (154 °F), the control module switches the system to full load combustion again. If the heat exchanger casing temperature increases to 76 °C (169 °F), the control module enters a control idle phase of operation.
On entering the control idle phase, the control module immediately switches the FFBH fuel pump off, to stop combustion, and starts a timer for the combustion air fan. After a 2 minute cool down period, the control module switches the combustion air fan off and then remains in the control idle phase while the heat exchanger casing temperature remains above 71 °C (160 °F). If the heat exchanger casing temperature decreases to 71 °C (160 °F), within 15 minutes of the control module entering the control idle phase, the control module initiates a start to part load combustion. If more than 15 minutes elapse before the heat exchanger casing temperature decreases to 71 °C (160 °F), the control module initiates a start to full load combustion.
In order to limit the build up of carbon deposits on the glow plug/flame sensor, the control module also enters the control idle phase if the continuous part and/or full load combustion time exceeds 72 minutes. After the cool down period, if the heat exchanger casing is still in the temperature range that requires additional heat, the control module initiates an immediate restart to part or full load combustion as appropriate.
Shutdown: When the ATC module sends a K bus message to de-activate the FFBH operation, the control module de-energizes the FFBH fuel pump to stop combustion, but continues operation of the combustion air fan and the circulation pump to cool down the FFBH unit. The cool down time depends on the combustion load at the time the message is received.
Cool Down Times
Diagnostics: The control module monitors the FFBH system for faults. Any faults detected are stored in a volatile memory in the control module, which can be interrogated using the Land Rover approved diagnostic system. A maximum of 3 faults and associated freeze frame data can be stored at any one time. If a further fault is detected, the oldest fault is overwritten by the new fault.
The control module also incorporates an error lockout mode of operation that inhibits system operation to prevent serious faults from causing further damage to the system. In the error lockout mode, the control module immediately stops the FFBH fuel pump, and stops the combustion air fan and circulation pump after a cool down time of approximately 2 minutes. Error lockout occurs for start sequence failures and/or combustion flameouts, heat exchanger casing overheat and out of limit input voltage. The error lockout mode can be cleared using the Land Rover approved diagnostic system, or by disconnecting the battery power supply for a minimum of 10 seconds.
Start Failure/Flameout: If a start sequence fails to establish combustion, or a flameout occurs after combustion is established, the control module immediately initiates another start sequence. The start failure or flameout is also recorded by an event timer in the control module. The event timer is increased by one after each start failure or flameout, and decreased by one if a subsequent start is successful. If the event timer increases to three (over any number of drive cycles), the control module enters the error lockout mode.
Heat Exchanger Casing Overheat: To protect the system from excessive temperatures, the control module enters the error lockout mode if the heat exchanger casing temperature exceeds 105 °C (221 °F).
Out of Limit Voltage: The control module enters the error lockout mode if the battery or alternator power input is less than 10.5 ± 0.3 V for more than 20 seconds, or more than 15.5 ± 0.5 V for more than 6 seconds.
Combustion Load
Cool Down Time, Seconds
Part
100
Full
175

Auxiliary Heating - Fuel Fired Booster Heater4.2L SC V8 - AJV8
Removal and Installation
Removal
• CAUTIONS:
RHD illustration shown, LHD is similar.
Make sure that all openings are sealed. Use new blanking caps.
• NOTE: Removal steps in this procedure may contain installation details.
Disconnect the battery ground cable.
Refer to: Specifications (414-00, Specifications).
2. WARNING: Make sure to support the vehicle with axle stands.
Raise and support the vehicle.
Refer to: Fender Splash Shield (501-02, Removal and Installation).
Refer to: Cooling System Draining, Filling and Bleeding - 5.0L NA V8 - AJ133 (303-03B, General Procedures).
Refer to: Cooling System Draining, Filling and Bleeding - 5.0L SC V8 - AJ133 (303-03B, General Procedures).
Torque: 10 Nm

Torque: 10 Nm
7. CAUTION: Be prepared to collect escaping fluids.
Torque: 10 Nm
9. NOTE: Do not disassemble further if the component is removed for access only.
Torque: 10 Nm
Installation
Thats for the 3.6 TDV8 and 4.2 Supercharger the info for the TD6 and BMW 4.4 seams a bit more spread out in the service manual 2008 MY Supercharged
Rimini Red / Jet
four zone climate
remote park heater
and no ugly kid windows.
magnus satis quod turpis satis
Last edited by axle on 13th Jun 2012 7:10pm. Edited 1 time in total
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