ICE identification
Electrical circuit
Check:
- battery charge;
- fault codes using a diagnostic tool;
- high fuel pressure reading with scan tool (parameter measurement).
Supply system
Check:
- the amount of fuel in the fuel tank - at least 15 liters;
- fuel quality (in case of doubt about the quality of the fuel, use an additional tank with a filter and fill in the fuel, the origin of which is known);
- low pressure supply circuit (see corresponding operation).
Engine operation
Check camshaft drive (belt drive).
Check all elements that can cause a drop in engine power:
- clogging of the exhaust system;
- clogged air filter.
Checking the pressure sensor on the common rail fuel injection (engine does not start)
Disconnect the high fuel pressure sensor connector.
Turn on the starter:
- engine starts - replace high fuel pressure sensor;
- engine does not start - continue checking.
Special tools for testing the high pressure circuit:
1 - substitute for the high pressure fuel rail 1613. A;
2 - a device for relieving fuel pressure 1613.B;
3 - substitute for the electromagnetic supply valve 1613.C;
4 - fuel pressure indicator 1613.D;
5 - high pressure fuel pipe 1613.E1;
6 - vessels for returning fuel from injectors 1613.R;
7 - vessel for measuring the return of the high pressure fuel pump 1613.G;
8 - diesel fuel return fitting from injectors «DELPHI» 1613.N;
9 - fitting for the return of diesel fuel from the injectors «Bosch/Siemens» 1613. J;
10 - set of plugs 1613.K.
Checking diesel injectors
Attention. Do not disconnect the rubber tubes of the fuel return fittings from the injectors.
Disconnect the fuel return fittings from the injectors.
Fit fittings of tool 9 to the diesel injectors.
Attach vessels 6 to fittings of fixture 9.
Attach the vessel kit 6 to the engine cowl.
Turn on the starter:
- engine starts - leave the engine idling for two minutes;
- the engine does not start - turn on the starter for 15 seconds.
Attention. The volume of fuel return from diesel injectors is several milliliters, the return increases with increasing wear of the diesel engine.
Replace one or more diesel injectors that have more gates than others.
Note. After replacing one or more injectors, it is necessary to check them.
If the injectors are working properly, continue checking.
Checking the high pressure fuel pump
Disconnect the camshaft position sensor connector.
Note. Before disconnecting, clean the high pressure fuel fittings (see corresponding operation).
Remove the high pressure fuel pipe connecting the high pressure pump to the common injector rail.
Depending on the type of high pressure fuel pump, connect tool 1 with tool 5 or with the previously removed fuel pipe.
Attach tool 2 vessel to tool 1.
Connect fixture 4 to fixture 1.
Click on the check button.
Tool indicator 4 shows the battery charge.
Tool pointer 4 shows last fuel pressure (within 5 seconds).
Simultaneously press the test button and turn on the starter.
When a message appears «Stop» turn off the starter on the tool indicator 4.
Tool pointer 4 indicates the maximum fuel pressure (within 5 seconds).
Tool pointer 4 shows the amount of residual fuel pressure.
Note. Tool 4 display flashes if fuel pressure is above 50 bar.
If the fuel pressure is above 300 bar: repeat the previous checks again.
If the fuel pressure is below 300 bar: continue the test.
Attention. Loosen the fuel pressure relief screw 1a before disconnecting tool 1.
Checking the Fuel Pressure Regulator
Replace the fuel pressure regulator with a new one.
Perform a high pressure pump test.
If the fuel pressure is above 300 bar: The original fuel regulator is faulty.
If the fuel pressure is below 300 bar: Replace the high pressure fuel pump.
Attention. Replace the previously removed high pressure fuel pipe.
Note. If replacing the high pressure fuel pump, install a new regulator.