FFH/PTC SYSTEM

Table of Contents

FUEL FIRED HEATER (FFH) SYSTEM 10A-3

Components locator 1 OA-3

System layout 1 OA-4

Trouble diagnosis 1 OA-13

Removal and installation 10A-25

POSITIVE TEMPERATURE COEFFICIENT (PTC) SYSTEM

.................................................................................... 10A-30

Components locator 1 OA-30

COMPONENTS 10A-31

Characteristics of PTC 1 OA-31

Circuit diagram 10A-32

REMOVAL AND INSTALLATION 10A-33

FFHlPTC SYSTEM REXTON 8M· 2004.4

10A-3

FFH SYSTEMI.

I FUEL FIRED HEATER (FFH) SYSTEM

In fuel fired heater system equipped vehicle (D27DT engine equipped), when the ambient temperature and coolant temperature is low, the burner installed in engine cooling system increases the temperature of coolant that flows into heater by firing diesel fuel for a certain period of time.

The D27DT engine equipped vehicle has the Positive Temperature Coefficient (PTC) system as a basic equipment. FFH is operated by the coolant temperature and ambient temperature while PTC is operated by the coolant temperature intake air temperature.

FFH system consists of independent fuel lines and fuel pump, coolant circuit and coolant circulation pump, electrical glow plug and exhaust system. It also provides the diagnostic function.

FFH system cannot be operated or stopped by driver's intention. The FFH system is automatically operated by the coolant temperature and the ambient temperature.

The FFH system operates up to more 2 minutes to burn the residual fuel inside the system when stopping the engine during its operation. Therefore, a certain period of FFH operation after stopping the engine is not a malfunction.

COMPONENTS LOCATOR

FFH assembly

Fuel pump

Y220_10AOOl

FFHlPTC SYSTEM REXTON 8M· 2004.4

10A-4

SYSTEM LAYOUT

10

I

6

13

1. FFH assembly

2. Water pump and bracket assembly

3. FFH No.1 bracket assembly

4. FFH No.2 bracket assembly

5. Silencer and pipe assembly

6. Fuel pump assembly

7. Fuel pump bracket assembly

8. Temperature sensor assembly

9. Intake hose

10. Fuel pipe No.1

11. Fuel pipe No.2

12. Pump outlet hose

13. FFH inlet/outlet hose assembly

FFHlPTC SYSTEM REXTON 8M • 2004.4

7

Y220_10A002

10A-5

• Exploded V· lew

~~HIPTC SYSTEM

TON SM-2004.4

10A-6

1. Jacket

2. Jacket cover

3. Combustion air fan

4. Combustion chamber

5. Combustion chamber with flame tube

6. Heat exchanger

7. Controller

8. Seal (between combustion chamber and combustion air fan)

9. O-ring

10. Glow plug with cable

11. Seal (between combustion chamber and heat

exchanger)

12. Upper bush for fuel pipe

13. Lower bush for fuel pipe

14. Flame sensor

15. Bush for flame sensor (graphite)

16. Control and overheating sensor with cable

17. O-ring

18. Surface sensor with cable

19. Controller connector - 14-pin connector (waterproof)

20. Pressure spring for surface sensor

21. Pressure spring for control and overheating sensor

22. O-ring

23. Coolant hose (inlet)

24. Coolant hose (outlet)

25. Tooth ring (2x)

26. Cable harness cover

27. Rubber seal

28. O-ring

29. Screw (M4 x 55 TORXl2x)

30. Screw (M4 x 16 TORXl2x)

31. Screw (M4 x 12 TORXl2x)

32. Screw (M4 x 16 TORXl4x)

33. Screw (M4 x 44 TORXl4x)

34. Controller cable harness

35. Insulation washer

FFHlPTC SYSTEM REXTON 8M • 2004.4

10A-7

.Specifications

Heater D 5 S-H
Heating medium Coolant
Control of the heat flow Large (full load) Small (small load)
Heat flow 5000W 2300W
Fuel consumption per hour .0.62. .0.27.
Mean electric power consumption in operation 35W 11 W
at start 100 W
after-running 12 W
Rated voltage 12 V
Operating range
• Lower voltage limit: An undervoltage protection 10 V
device in the controller switches the heaters off at
approx. 10 volt.
• Upper voltage limit: An overvoltage protection
device in the controller switches the heaters off at 15 V
approx. 15 volt.
Tolerable operating pressure up to 2.5 bar overpressure
Minimum water flow through the heater 200 Uh
Fuel From main fuel tank
Tolerable ambient temperature operation -40°C - BO°C
storage -40°C - 105°C (2h for 125°C)
Weight approx. 2.3 kg
(without coolant and mounted parts) FFHlPTC SYSTEM REXTON 8M· 2004.4

10A-8

• FFH Operating Process

FFH (Fuel Fired Heater) is operated according to the ambient temperature and coolant temperature.

Initial and Repeat Operating Conditions of FFH

Initial Operating Conditions of FFH:

Ambient temperature: below 5°C Coolant temperature: below 75°C

Repeat Operating Conditions of FFH:

Coolant temperature: below 75°C

When the difference between the ambient temperature at initial operation and current ambient temperature is over 3°C (to reduce the hysteresis with the temperature difference when operating FFH), FFH is operated again. For example, if the initial operating temperature was 4°C, the ambient temperature at repeat operation should be below 1°C and the coolant temperature should be below 75°C.

FFH Operations According to the Changes of Coolant Temperature

HI

LO

OFF

80'C±3'C

81'C±3'C

8S'C±3'C

Y220_10A004

Above graph shows the FFH control process while the FFH is operating. The control element is coolant as shown in the graph.

The FFH is operated in HI mode (high output: approx. 5000 W) until the coolant temperature reaches at 80°C and starts to be operated in LO mode (low output: approx. 2300 W) from 81°C.

When the coolant temperature reaches at approx. 85°C, FFH stops its operation until the operating conditions will be met again.

FFHlPTC SYSTEM REXTON 8M • 2004.4

10A-9

.Coolant Circulating Route

I I Water pump
Fan Engine [h_
- ...
-
r- ~ t; _::': ...
~ ~
-CJ
0 1-
- ~ t
'=.t-I )1

I WI L-~'
=: ,
~
Blower fan
t Heating system ~ He
... ater module

Y220_10AOOS

.Connecting the Coolant Circuit

The heater is connected to the coolant circuit in the coolant feed pipe from the vehicle engine to the heat exchanger.

Notice

FFHlPTC SYSTEM REXTON SM· 2004.4

1 OA-1 0

.Circuit Diagram

Clister "A4"

r.

3o------------------------------------~---------------------------------30 BAT+

31--~G3~0~1~~G1~0~5------------------------------------------------------_'G~1~0531 IGNol

3 C903

B

Ef23 20A

.....

111c217

'~ 1=

3 C217

Y

ALT D+

B

Y220_10A006

1C109

IBW

Ambient Temp.

Sensor f"' .... "' .... "' .... t

1~.A' t2

Water Pump

("'''''''''''''.''

~ t

1~ t2

, M»;.;=.....--..., , .

................... r

The FFH has various sensors in FFH unit, and the FFH unit is connected to the water pump, the fuel circulation pump and the ambient temperature sensor (switch) that provides important signals for the initial and repeat operations.

For diagnosis, remove the FFH system connector and install the scan tool. Currently, the K-Line that is connected to the diagnostic connector is not available.

12 C219

FFHlPTC SYSTEM REXTON 8M . 2004.4

G

BW

1 9 4 1 6 2 1 Cl15

L- ~----------~

... rrrrr"'".".".""rrrrrrrrr ...... rrrrrrrrrrrrrr .. r rrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrri

· ,

· ,

· ,

I I FFH Controller I I

t 114 13 12 11 10 9 B 7 6 5 4 3 2 1 1 ~

· ,

· ,

· ,

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· ,

t Br B R R L L W Br Br L ~

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t - -- ~

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t _ + - ~

t r- - t-- t-- I-----' t-- '

'8urner~ ~

I M l£21. lrzj. lro l£21. ~

• "L.....J,

t + Over Heating Temp. G~g A;;y ~

t Sensor Sensor Sensor ~

· ,

· , ..... "''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''"'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''',.

B

10A-11

• Control and Safety Mode

Heater operations and safety mode * If the fuel pump

1. If the fuel pump fails to ignite within 90 seconds after fuel pumping starts, the start procedure is repeated as described. If after a further 90 seconds fuel pumping the fuel pump still fails to ignite, the heater is switched off in fault mode.

The controller is locked after a certain number of failed starts.

2. If the flame does out by itself during operation, firstly a new start is activated. If the fuel pump fails to ignite within 90 seconds after fuel pumping has started again, the heater is switched off.

3. If the heater is overheated (lack of water, poorly vented cooling circuit), the overheating sensor triggers, the fuel supply is interrupted and the heater is switched off.

4. The heater is switched off if the lower or upper voltage limit is reached .

• Technical Data - Water Pump

5. The fuel pump does not start when the glow plug is defect or electrical lead to the dosing pump is interrupted.

6. The fan motor speed is monitored continuously.

If the fan motor does not start up, the heater is switched off in fault mode after 120 seconds.

7. It is possible to diagnose the system by connecting the diagnostic device to controller. For details, refer to the "Diagnosis Procedures" section.

[Emergency shutdown]

If an emergency shutdown -EMERGENCY OFF- is necessary during operation, proceed as follows;

• Pull the fuse (Ef23: 20A) out.

• Disconnect the heater from the battery.

Rated voltage

12 V

Operating voltage

9 V - 15 V

Power consumption

16 W

Pumping capacity (0.1 bar)

8001/h

Operating temperature

Weight

0.28 kg

.Characteristic Curve of Water Pump (12 V)

10.20

0.15

~ oIL _.
oIL
~ .. .........
...
... 2'°1

1.5

::1

250 500 750 1000 1250

1-----Q(IIH)------1

- I max ••• .6..pmin

Y220_10A007

FFHlPTC SYSTEM REXTON 8M· 2004.4

10A-12

.Function Diagram

HYDRONIC on Control stage large Control stage HYDRONIC off
small Afterrunning on
Cl
:::l 9.BV
"C. ~
.! ~ .. . . · .................... · ....... ~ · .....
(!l
~qE. . . . . . . . . . . . . . . . . . . . . . · ........
C ~ ~ /
~ ~ ..
~~L. ~If
.... . ....... . . . . . . · .................... · . · .....
c.
E ~qE.
:::l . . . .. . ... . . . . . . . . · ...... . . · .....
Il. ~~
Cl
c
'iii ~~L. . . . . . . . . · .................... . · .....
0 I
c
o 510172025~0 8~ 85 - 20-
time sec 40 110 -51- -120- t Vehicle fan on Water pump on

t Frame detection

t Vehicle fan off

Y220_10Aooa

.Sectional Drawing according to the Temperatures

'C

1 00 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

80

Y220_10A009

off

60

40

Vehicle fan ON

--.; - - - - - - - - - - - - - - - - - - - - - - - - - - - - - --

20 Ia~g~ ~ -_0. ~e!Ji~~ f~n_ O_F~ _

30

large 5.0KW smal2.3KW

time

FFHlPTC SYSTEM REXTON 8M - 2004.4

10A-13

TROUBLE DIAGNOSIS

.When Faults Occur, First Check ...

• Faulty wiring?

(short circuits, interruptions)

• Visual check for

- corroded contacts

- defect fuses

- damaged electrical leads, links and connections

- damaged exhaust and combustion air guidance

• Check battery voltage

Battery voltage < 10 volt: the undervoltage protection has triggered

• Check fuel supply

Check Voltage Supply Ubatt (terminal 30) Disconnect the 1 O-pin connector and measure the voltage present in connector between chamber 1 and chamber 2.

For deviations in the battery voltage, check the fuses, supply lines, ground connection and plus point on battery for loss of voltage (corrosion / interruption).

Check Key-ON signal (D+)

Disconnect the 1 O-pin connector and measure the voltage present in connector 1 between chamber 6 and chamber 2.

Notice

.Controller Lock

• The controller is locked when the following faults occur:

Overheating

• If FFH overheats 10 times in succession, error code

015 appears and the controller is locked.

Too many start attempts

If FFH performs 10 start attempts in vain, error code 050 appears and the controller is locked.

.Cancel the Controller Lock

Canceling the controller lock depends on the corresponding testing equipment and is described in Diagnosis Instrument section.

.Testing Equipment

The electronic controller of FFH can save up to 5 errors. The errors can be read and displayed from the controller using one of the following items of equipment. In addition, the controller lock can be cancelled.

Diagnosis instrument

After connecting the diagnosis instrument, the function or error is shown numerically in the display. For connection and handling of the diagnosis instrument, refer to next section. An adapter cable is necessary to connect up the diagnosis instrument.

" /

-dl R-

, ....

Y220_10A010

FFHlPTC SYSTEM REXTON 8M· 2004.4

10A-14

.Fault Diagnosis with the Diagnosis Instrument

Self- Diagnosis

Y220_10A011

1. Fuel fired heater

2. Adapter cable

3. Diagnosis instrument

Diagnosis Instrument

6
~,
, ,-
-dJ R-
, "
~l~r-I-rr~
1 2 3 4 5
Y220 10A012 1. Delete Fauit Memory Button

2. Delete Fauit Memory Button)

3. Switch Heater On/Off Request Diagnosis Button)

4. Fault Backwards Button, AF, F1 - F5

5. Fault Forwards Button, AF, F1 - F5

6. Display

FFHlPTC SYSTEM REXTON 8M - 2004.4

10A-15

How to use diagnosis instrument

The electronic controller of HYDRONIC can save up to 5 faults, which can be read and displayed with the diagnosis instrument. The current fault is shown as " AF" and a 2-digit number and always written in memory place F1. Previous faults are transferred to memory places F2 to F5, and the contents of memory place F5 are overwritten.

Connecting up the diagnosis instrument

• Disconnect the a-pole connector from the HYDRONIC cable harness and connect the adapter cable.

• Then connect the diagnosis instrument to the adapter cable.

The display shows:

" 1 LI/

-d ,'1-

,. '"

Querying the fault memory

• Press the button D on the diagnosis unit to switch on HYDRONIC.

The display shows:

-, /

-_._ -..!~l

",. ':l11

• After a seconds, the display shows:

[ RF:DDlliJ [ RF:6l! lliJ

I I

no error

current fault

Fault diagnosis not possible

Possible causes:

• adapter cable not connected properly

• controller defect or not capable of diagnosis (not a universal controller)

Display of fault memory F1 - F5 or F5 - F1

• Press the buttons '.' or ".' once or several times to show the individual fault memories in decreasing or

increasing order.

The display shows:

e.g. fault memory 2 / error code 1 0

F 2: ID lli Only those fault memories occupied by a fault are shown

Delete fault memory

• Eliminate cause of fault.

• Press both buttons "L" at the same time until the display shows:

" / -_._ -..!!l

;,. '1l1

• Once the fault memories are deleted, the last current fault is shown. The current fault is not reset to 00 until the next restart of HYDRONIC, insofar as no other current fault has occurred.

The display shows:

HYDRONIC no faults

Controller lock

• Overheating

If HYDRONIC overheats 10 times in succession, fault 012, AF 015 appears in the display, i.e. the controller is locked.

• Too many start attempts

If HYDRONIC performs 10 start attempts in vain, fault 052, AF 050 appears in the display, i.e. the controller is locked.

Canceling the controller lock

• Delete the fault memory as described and switch off HYDRONIC with button "D".

• The controller lock is cancelled and the diagnosis finished.

The display shows:

FFHlPTC SYSTEM REXTON 8M· 2004.4

10A-16

.Trouble Code

Trouble Trouble Description Remedies
Code
0 No faults
10 Shutdown for overvoltage • Measure battery voltage (must be < 15.9 V)
• Check alternator
11 Shutdown for undervoltage • Measure battery voltage (must be > 10.2 V under load)
• Check alternator
• Check lead
12 Overheating (software threshold) Temperature at overheating sensor> 125°C
• Check cooling system:
• Check the temperature sensor and overheating sensor, replace
if necessary
14 Overheating (difference evaluation) Difference in temperature values between surface sensor and con-
trol overheating sensor is too large. (Prerequisite for this trouble
code display is that the heater is in operation and the water tem-
perature at the overheating sensor has reached min. BO°C)
• Check cooling system
• Check the temperature sensor and overheating sensor, replace
if necessary
15 Overheating (operating block) The controller is locked.
• Delete the fault memory to release the controller
• Check cooling system
• Check the temperature sensor and overheating sensor, replace
if necessary
16 Difference evaluation 2 If the surface sensor has a far higher temperature value than the con-
trol overheating sensor, then the system proceeds with a fault shutdown.
17 Overheating (hardware, device) Temperature at control overheating sensor> 125°C
• Check cooling system
• Check the temperature sensor and overheating sensor,replace
if necessary
20 Glow plug interruption • Check cable harness for this component for damage and
through current and replace component if necessary
• Check plug-in connection, replace component if necessary
21 Overload, short-circuit or ground • Check cable harness for this component for damage, replace
contact, glow plug output component if necessary
22 Glow plug output defect • Check cable harness for this component for damage, replace
component if necessary FFHlPTC SYSTEM REXTON 8M • 2004.4

10A-17

Trouble
Code Trouble Description Remedies
30 Speed of combustion fan motor out- Fan wheel or combustion air fan motor blocked (frozen,
side tolerable range contaminated, stiff, cable harness scrapes on shaft end, ... )
• Eliminate blockage
• Measure speed of combustion air fan motor:
- dismantle combustion air fan
- check with 8.2 V + 0.2 V, to do so, unclip the cable 0.752
black from chamber 13 of the 14-pin connector and the
cable 0.752 brown from chamber 14. Apply marking (white
paint) to the fan wheel and measure speed with contactless
speed meter.
If the measured speed is outside a range of 8,800 rpm to
10,400 rpm, then replace the combustion fan. If the mea-
sured speed is within a range of 8800 rpm to 10400 rpm,
then replace the controller.
31 Burner motor interruption • Check cable harness for this component for damage and
through current
• Check plug-in connection, replace component if necessary
32 Overload, short-circuit or ground • Fan wheel or combustion air fan motor blocked
contact, burner motor (contaminated, stiff)
• Check cable harness of this component for damage, if neces-
sary replace component
34 Burner motor output defect • Check whether the lead to this component has a short-circuit
to GND, if not, check component for ground contact, if neces-
sary replace controller
47 Overload, short-circuit or ground • Check cable harness to the external component for damage
contact, fuel pump and through current and replace external component if neces-
sary
48 Fuel pump interruption • Check cable harness to the external component for damage
and through current
• Check plug-in connection, replace external component if
necessary
49 Fuel pump output defect • Check whether lead to this component has short-circuit to
+Ub, if not, check component for ground contact, replace
controller if necessary
50 Operating block because too many Too many start attempts, the controller is locked
start attempts in vain (10 start • Delete the fault memory to release the controller
attempts, also one start repeat for • Check fuel quantity and fuel supply
every start attempt)
51 Time exceeded for cold blowing • During start (no flame formed yet), the flame sensor reports
temperature value too high for too long
• Check exhaust and combustion air
• Check flame sensor FFHlPTC SYSTEM REXTON 8M· 2004.4

10A-18

Trouble Trouble Description Remedies
Code
52 Safety time exceeded • Check exhaust and combustion air system
• Check fuel quantity and fuel supply
• Clean or replace sieve used in fitting of fuel pump
53 Flame aborted from "power" stage Warning
54 Flame aborted from "large" stage
56 Flame aborted from "small" stage
-
Fault(because no more start attempt allowed )
• Check exhaust and combustion air system
• Check fuel quantity and fuel supply
• Check flame sensor - see trouble code 64 and 65
60 Control overheating sensor interrup- • Check cable harness to this component for damage and through
tion current
• Check plug-in connection
• Check sensor resistance value, replace component if necessary
61 Short circuit or ground contact con- • Check cable harness to this component for damage
trol overheating sensor • Check sensor resistance value, replace external component if
necessary
64 Flame sensor interruption • Check cable harness to this component for damage and
through current
• Check plug-in connection
• Check sensor resistance value, replace component if necessary
65 Short circuit flame sensor • Check cable harness to this component for damage
• Check sensor resistance value, replace external component if
necessary
71 Surface sensor interruption • Check cable harness to this component for damage and through
current
• Check plug-in connection
• Check sensor resistance value, replace component if necessary
72 Short circuit surface sensor • Check cable harness to this component for damage
• Check sensor resistance value, replace external component if
necessary
74 Overheating hardware defect, operating • Replace controller
block
87 Internal temperature sensor short-circuit • Replace controller
88 Internal temperature sensor interruption • Replace controller
89 CAN error • Check CAN interface
90 Watch dog reset • Replace controller FFHlPTC SYSTEM REXTON 8M - 2004.4

10A-19

Trouble Trouble Description Remedies
Code
91 Too many resets • Replace controller
92 ROM error • Replace controller
93 RAM error • Replace controller
94 Transistor fault occurs too frequently • Remedy short-circuit of the component to +Ub to GND, replace
- operation block controller if necessary
95 Software stack overflow • Replace controller
96 No valid process, operation lock • Replace controller
97 Resonator/quartz faulty, • Replace controller
wrong processor cycle
98 Main relay faulty • Replace controller
99 EEPROM error • Replace controller FFHlPTC SYSTEM REXTON 8M - 2004.4

10A-20

.Components and Compositions

Notice

Jacket cover

2

, ,

3

Y220_10A022

Control and overheating Sensor

2

Check control and overheating sensor

35 30


\
\
\
\
<,
~ ~ 25

20

15

10 5

20

40

60

80

100 120

Temperature (0C)

Y220_10A024

Specified I value

- The O-rings are installed between jacket cover and two coolant hoses.

- The coolant hoses should be connected to right side.

1. Jacket

2. Jacket cover

3. Cable harness cover

The Control and overheating sensor and cable harness make up one component.

1. Control and overheating sensor

2. Pressure spring

Check the control and overheating sensor with a digital multimeter. If the resistance according to the changes of flame sensor temperature is out of specified values, the flame sensor is defective.

Temperature ["C] 0 10 20 30 40 50 60 70 80 90 100 110 120
Resistance [.] 32.54 19.87 12.48 8.06 5.33 3.60 2.48 1.75 1.25 0.91 0.67 0.50 0.38
±2.2 ±1.0 ±0.5 ±0.4 ±0.3 ±0.25 ±0.17 ±0.13 ±0.1 ±0.08 ±0.06 ±0.05 ±0.04 FFHlPTC SYSTEM REXTON 8M - 2004.4

10A-21

Surface sensor

The surface sensor and cable harness make up one component.

1. Surface sensor

2. Pressure spring

Check the surface sensor with a digital multi meter. If the resistance of flame sensor is out of specified values, the flame sensor is defective.

2

Temperature ["C] 0 10 20 30 40 50 60 70 80 90 100 110 120
Resistance [.] 30.00 19.53 13.03 8.90 6.20 4.41 3.19 2.34 1.75 1.32 1.02 0.79 0.62
±0.13 ±1.6 ±1.89 ±2.2 ±2.4 ±2.9 ±3.19 ±3.6 ±3.92 ±4.4 ±4.78 ±5.3 ±5.70 The surface heater and cable harness make up one component.

1. Controller

2. Jacket

3. Combustion chamber housing

4. Screw

Check surface sensor

30 30 25 20 15 10

o o o 10 20 30 40 50 60 70 80 90 100110120


\
\
~
,
~
~ '-.., Y220_10A026

Specifiedl value

Controller

2

FFHlPTC SYSTEM REXTON 8M· 2004.4

10A-22

Glow plug

Y220_10A028

Combustion chamber housing

Y220_10A029

\

Flame sensor

2

3

Y220_10A030

1. Glow plug

2. Combustion chamber with flame pipe

1. Jacket

2. Combustion chamber

3. Combustion chamber housing

4. Insulation washer

5. Seal - combustion chamber / combustion air fan

6. Seal - combustion chamber / heat exchanger

1. Flame sensor

2. Graphite bush

3. Bush

FFHlPTC SYSTEM REXTON 8M • 2004.4

10A-23

Check flame sensor

3000 2750 2500 2250 2000 1750 1500 1250 1000

750 500

o 50 100 150200250300350400450500 550

v
./
V
l/
t"
l/
V Specifiedl value

Y220_10A03l

Check the surface sensor with a digital multi meter. If the resistance of flame sensor is out of specified values, the flame sensor is defective.

Temperature ["C] 0 10 20 30 50 80 90 100 130 150 200 250 300 350 400
Resistance [.] 1000 1022 1062 1097 1194 1309 1347 1385 1498 1573 1758 1941 2120 2297 2470
±10 ±10 ±11 ±11 ±12 ±13 ±14 ±15 ±17 ±20 ±24 ±28 ±32 ±36 ±40 Combustion air fan

3 ------<-0

Y220_10A032

Y220_10A033

1. Combustion chamber

2. O-ring

3. Rubber seal

4. Combustion air fan

FFHlPTC SYSTEM REXTON 8M· 2004.4

10A-24

Combustion chamber

00-:

Y220_10A034

Heat exchanger

Heat exchanger

Y220_10A036

1. Combustion chamber

2. Heat exchanger

3. Jacket

4. O-ring

5. Seal - combustion chamber / heat exchanger

1. Jacket

2. Heat exchanger

3. Combustion chamber with flame tube

4. Seal - combustion chamber / heat exchanger

5. O-ring (for heat exchanger)

1. Heat exchanger

2. Jacket

3. Stopper

4. Groove (bottom of heat exchanger)

FFHlPTC SYSTEM REXTON 8M • 2004.4

10A-25

REMOVAL AND INSTALLATION

.Preceding Work: Disconnection of negative battery cable

Notice

Fuel Pump - Removal and Installation

1. Lift up the vehicle and disconnect the fuel pump connector.

2. Remove the fuel supply hoses at both sides of fuel pump.

Notice

3. Unscrew the bracket bolt and remove the fuel pump.

4. Install in the reverse order of removal.

Tightening torque

10 ± 1.0 Nm

FFHlPTC SYSTEM REXTON 8M· 2004.4

10A-26

Ambient Temperature Switch - Removal and Installation

1. Remove the radiator grille.

2. Disconnect the ambient temperature switch connector behind the front bumper.

3. Remove the ambient temperature switch.

4. Install in the reverse order of removal.

FFHlPTC SYSTEM REXTON 8M • 2004.4

10A-27

FFH Unit - Removal and Installation

1. Open the engine hood.

2. Disconnect the FFH coolant circulation pump connector.

3. Unscrew the bracket nut for coolant circulation pump.

Tightening torque

10 ± 1.0 Nm

4. Release the clamps and remove the inlet and outlet hoses from coolant circulation pump.

Notice

FFHlPTC SYSTEM REXTON 8M· 2004.4

10A-28

5. Disconnect the FFH connector.

6. Remove the coolant outlet hose of FFH.

7. Remove the fuel supply hose.

Notice

8. Remove the FFH mounting nuts.

Installation Notice

Tightening torque

10 ± 1.0 Nm

FFHlPTC SYSTEM REXTON 8M • 2004.4

9. Remove the FFH silencer bracket bolts at both sides.

10A-29

Tightening torque

10 ± 1.0 Nm

10. Remove the FFH unit.

11. Install in the reverse order of removal.

Y220_10A052

FFHlPTC SYSTEM REXTON 8M· 2004.4