Delphi HP Pump Diagnosis

0

1 2006 INVITATIONAL TRAINING

ACTYONACTYON

Service TrainingService Training

Engine : D20DT / D27DT Engine : D20DT / D27DT

Subject : Subject : HP Pump DiagnosisHP Pump Diagnosis

Date : March .13 . 2006Date : March .13 . 2006

Instructor : Brian ChoInstructor : Brian Cho

1


I. HP Pump Overview

II. Cases & Improvements

III. Diagnostics by DTCs

IV. Diagnostics by Symptoms

V. Fuel System Check Tips

Contents

2


◈ HP Pump Structure

ⅠⅠ. . HP Pump OverviewHP Pump Overview

Fuel Inlet Port

Venturi Return

High Pressure Regulator

Low PressureRegulator Fuel Temp’ Sensor

IMV(Inlet Metering Valve)

Fuel Outlet Port(To Common Rail)

1

2 3

4

5

1. Transfer Pump & Housing

2. Drive shaft & Driven Cam

3. Roller & Shoe

4. Fuel Temp’ Sensor

5. Inlet Metering Valve

3


ⅠⅠ. . HP Pump Overview

◈ Components by Function

HP Pump Overview

Component Function Symptom when malfunctioning Parts supply

Transfer PumpDriven by 4 vanes, 6bar low pressure generation transfer to Hydraulic head

Starting problem or poor acceleration due to insufficient high pressure generation

HP Pump ASSY (P/N: 6650700101)

Hydraulic Head2 couples of Shoe&Roller, High pressure generation over 250bar accumulation in C.R

Starting problem or poor acceleration due to insufficient fuel injection

HP Pump ASSY

IMV (Inlet Metering Valve)

High pressure regulator controlled by ECU

Knocking, engine stall or engine vibration

HP Pump ASSY(Preparing IMV

supply)

Fuel Temp’ Sensor

Sensing the fuel temperature transferred to hydraulic head,Reduction of fuel injection amount at hot condition(↑90℃)

Poor acceleration due to insufficient injection can be occurred.

HP Pump ASSY

High/Low PressureRegulator

Regulating HP Pump internal high/low pressure to secure stable supply

Security mechanism, rare possibility of malfunction HP Pump ASSY

Venturi-ReturnReturn port, joining 2 flows one for lubrication and the other for back leak from injectors

Can be used to identify metal chips caused from roller abrasion after taking it off

HP Pump ASSY

4


ⅠⅠ. HP Pump Overview. HP Pump Overview

◈ High Pressure Generation

■ L/P Circuit: L/P system functions supplying sufficient fuel to hydraulic head▶ Fuel Tank ▶ Priming Pump▶ Fuel Filter ▶ Transfer Pump▶ Inlet Metering Valve

■ H/P Circuit: H/P system functions generating and

accumulating fuel that injectors need. ▶ H/P Pump ▶ Common Rail▶ H/P Pipes ▶ Injectors

■ Common Fault Patterns▶ Insufficient fuel supply to transfer

pump due to air inflow.▶ Abrasion of HP Pump▶ IMV related troubles ▶ Injector related troublesH/PH/P

L/PL/P

ReturnReturnFuel TankFuel Tank

Priming PumpPriming Pump

IMVIMV

InjectorInjector

Common RailCommon Rail

Fuel FilterFuel Filter

VenturiVenturi

H/P PumpH/P Pump

Supply PumpSupply PumpSuction ValveSuction Valve

L/P Regulator(6bar)L/P Regulator(6bar)

Transfer PumpTransfer Pump

H/P LimiterH/P Limiter

5


ⅠⅠ. HP Pump Overview. HP Pump Overview

■ IMV Function

▶ Rail pressure control by regulating

fuel amount transferring to the

hydraulic head

▶ Improves injection efficiency

■ In case of no electric power

▶ Max Quantity to the hydraulic head

▶ As current increases, quantity

decreases (Normal Open Type)

◈ Inlet Metering Valve _ Fuel Pressure Regulator

ECU· Eng RPM

· APS Signal

· RPS SignalIMV Control

Current ControlInput

Required Quantityand Rail Pressure calculation

Current vs Quantity

Current (mA)

Quantity (l/hr)

6


ⅡⅡ. . Trouble Cases / Quality ImprovementsTrouble Cases / Quality Improvements

◈ HP Pump related Trouble Cases / Quality ImprovementsHP Pump related Trouble Cases / Quality Improvements

Model Type Symptom Cause Action Remark

Rexton/Rodius Quality HP Pump Flange Bolt

Broken & Fuel LeakInsufficient absorption of engine vibration by clamp rubber bush

Replaced flange bolt & clamp rubber bush

Refer to work procedure

Rexton/Rodius Quality Hard start, Poor

acceleration, StallIMV stuck, Transfer pump spring damaged, etc. Improved quality Refer to HP Pump

Improvement

Case

Case

Case

Case

Rodius/Kyron Case

Intermittent Eng Check Lamp ON, Engine stall

P1253 displayed, Foreign material blocked the fuel sender in fuel tank.

Removed the foreign materials

Refer to P1253 diagnosis

Rexton Case HP Pump housing leak

Hydraulic head seal assembled pinched Replaced HP Pump -

Case

Replaced HP Pump & Fuel Filter, etc.

Secured the connector

Rexton Engine stall while driving IMV internally Stuck Replaced IMV (or HP

Pump)Refer to IMV

Cleaning

RextonEngine noise,Engine oil leak

One of the HP Pump Sprocket fixing bolts unscrewed caused timing chain & pump damaged

Replaced Timing chain, HP Pump and Timing Case

-

Rexton Impossible to start Unsecured water sensor in fuel filter caused air infiltration Secured water sensor Refer to hard

start

RextonImpossible to start,Poor acceleration

HP Pump internal abrasion caused metal chips in fuel line

Refer to Metal chip repair

Rexton Engine stall while driving IMV connector unsecured Refer to IMV

Open circuit

7



◈ Repair procedure for HP Pump Flange bolt damage QualityQuality

▶ Repair Procedure1.Before starting the work, Ensure the Cleanliness around the Flange & Fuel pipe nut by washing and blowing

completely.2.Remove the Fuel pipe Brkt & HP Pipe, and replace with new clamp rubber bush & flange bolts.3.Follow the tightening procedure as below for the flange bolts (Apply torques on Nut A,B by turns evenly)

a. Apply 10 Nm on both Nuts temporarilyb. Apply 15 Nm ± 3 Nm on both Nutsc. Apply 20 Nm ± 3 Nm on both Nutsd. Apply 25 Nm ± 3 Nm on both Nuts

- Tighten the pump side nut first- Tightening Torque : 40±4Nm

Flange Bolts(2 pcs)

HP Pipe Tightening Torque: 40 ±4Nm

Nut B

Nut A

•Replace new rubber bush•Mounting bracket tightening torque: 8.9 ±0.9Nm

8



QualityQuality◈ HP Pump Quality Improvements

▶ Improvement Details1.TRANSFER PUMP SPRING CRACK [A]1) Improved spring wire drawing process and changed inspection system2) Changed the number of spring pitch and the shape of vane (Step Taper)

2.ROLLER&SHOE SCUFFING [B]1) Necessary to improve the quality of fuel

3. IMV VALVE STUCK [C]- Strengthen engineering spec and crimping condition in assembly line- Strengthen sampling inspection

▶ Quality Issues

1.Vane spring broken due to an interference [A]2.Vane spring broken due to a crack [A]3.Roller & Shoe Scuffing [B]4.IMV Sleeve deformed due to an excessive clamping

pressure [C]

9


ⅢⅢ. . HP Pump related Diagnostics by DTC

◈ HP Pump related DTCs

HP Pump related Diagnostics by DTC

DTC Description Probable CausesEngine Check Lamp

Fail-safe

P0182Fuel temp’ sensor shorted to ground

Fuel temp’ signal line shorted to ground or sensor faulty

X

X

O

P0253IMV drive line shorted to ground

IMV drive line shorted to ground or IMV faulty

OIncreases to 1500rpm, engine stalls 1 minute later and not allow to restart

P1191 High pressure delayToo much delay of high pressure generation while cranking. IMV faulty or low pressure line abnormal

O Hard start

P0255 IMV drive line open IMV drive line open or IMV faulty OIncreases to 1500rpm, engine stalls 1 minute later and not allow to restart

P1252 IMV pressure too highRail pressure much higher than ECU calculation, IMV faulty or RPS faulty

XTime delay engine stop(1 minute), MDP adaptation suspended

P1253P1256

P1258

Rail pressure minimum control error

Rail pressure much less than ECU calculation, low pressure line abnormal or excessive back leak.

O Hard start, Engine stall, Lack of power

P1254 P1257 P1259

Rail pressure maximum control error

Rail pressure much higher than ECU calculation, IMV faulty or RPS faulty

OTime delay engine stop(1 minute), MDP adaptation suspended

ECU reckons fuel temp’ as 95℃ and reduces engine max power

P0183Fuel temp’ sensor shorted to battery

Fuel temp’ signal line open or sensor faulty

ECU reckons fuel temp’ as 95℃ and reduces engine max power

P0251IMV drive line shorted to battery

IMV drive line shorted to battery or IMV faulty

Increases to 1500rpm, engine stalls 1 minute later and not allow to restart

10


◈ Diagnosis by DTC_P0182_ Fuel temp’ sensor shorted to ground- Detecting Condition : ECU #109 terminal (Sensor #1) below 0.5V

DTCDTC

ⅢⅢ. HP Pump related Diagnostics by DTC. HP Pump related Diagnostics by DTC

■ Diagnostic procedure : In case of current trouble (duplicable )

a. Measure the sensor resistance after disconnecting sensor connector 3 : must be at least above 100Ω

d. ECU faulty, replace it

NoYesSensor internally shorted , replace it

c. Conduct a continuity test between sensor and ECU after disconnecting each connector.1.Check between #109 and body2.Check between #109 and #110: must not be in continuity

Non-continuity

In order to know if continuity exists in between 1 and 2 or 3 and 2, disconnect the C115 and perform continuity test again.

Continuity

•When checking connector, inspect if itcontains moisture in it.

ECU

1

2

3

Fuel temp’ sensor circuit

•In case of intermittent trouble, mostly caused by shorted wire, needs to check wiring harness from sensor to ECU

b. Measure the voltage at #1 terminal(connector3) after disconnecting when IG ON : must be approx. 5v

Yes Not current trouble, Check if the 5v dropswhen shaking each connector and wire between sensor and ECU

No

11



◈ Diagnostics by DTC_P0183_ Fuel temp’ sensor open- Detecting Condition : ECU #109 terminal (Sensor #1) above 4.5V

DTCDTC

■ Diagnostic procedure : In case of current trouble (duplicable)

a. Measure the sensor resistance after disconnecting sensor connector 3 : must be below 75kΩ

d. Check the voltage at #109 terminal with connecting connector1,must be approx.5v

YesSensor Internally open, replace it

No

c. Check the voltage at #19 terminal after disconnecting connector 2 when IG ON,must be approx.5v

NoYes

※. When checking connectors, see if wiresare damaged in between connectors.

• In case of intermittent trouble, mostly caused by open wire, needs to check if connectors 1,2 and 3 have poor connection.

b. Check the voltage at #1 terminal after disconnecting sensor connector 3 whenIG ON. Must be approx.5v

Yes#1 terminal loosen or pulled out

ECU

1

2

3

Fuel temp’ sensor circuit

No

#19 terminal loosen or pulled out

No

ECU faulty if #109 terminal is normal.

12



◈ Diagnostics by DTC_P0251_IMV Drive Circuit Shorted to B+

- Detecting Condition : ECU #87 terminal(IMV #2) above 12V – Shorted to B+DTCDTC

CasesCases

■ Diagnostic procedure : In case of current trouble (duplicable)

c. If the DTC keeps displaying,ECU internally shorted, replace it.

Yes

IMV internally shorted, replace it

No

2VDisconnect C115 and check the voltage atECU #87 terminal, if the 12v continues to be checked, find shorted area in between 2 and 1.

12V

a. Measure the IMV resistance after disconnecting the connector 3 : must be above 4Ω

•In case of intermittent trouble, mostly caused by shorted wire, needs to check wiring harness from IMV to ECU by tracing.

b. Check the voltage at #87 terminal after disconnecting connector 3 when IG ON,must be approx 2v.

Disconnect C115 and check the voltage atIMV #2 terminal, if the 12v continues to be checked, find shorted area in between 2 and 3.

12V

•When checking connector, inspect if itcontains moisture in it.

1

2

3

IMV Circuit

C115

ECU

7.5A IMV FUSE(F64)

13



◈ Diagnostics by DTC_P0253_IMV Drive Circuit Shorted to Ground

- Detecting Condition : ECU #87 terminal(IMV #2) below 1V – Shorted to bodyDTCDTC

CasesCases

■ Diagnostic procedure : In case of current trouble (duplicable case)

YesBelow 1v

b. Disconnect the C115 and measure the voltage at #87 :must be approx. 2.3V

Shorted in between the connector 2↔3,Correct the shorted area

a. Measure the voltage at #2 terminal after disconnecting the connector 3 : must be approx 2.3V( IG ON)


Not current trouble, Check if the 2.3v dropswhen shaking each connector and wire between IMV and ECU

1

2

3

IMV Circuit

C115

ECU

7.5A IMV FUSE(F64)

YesBelow 1v

Continuity

Non-continuity

d. ECU internally shorted. Replace it

c. Disconnect the C115 and connector 1, and conduct the continuity test between #87 and body. must not be in continuity

Shorted in between the connector 2↔1,Correct the shorted area

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c. Measure the voltage at #1 terminalafter disconnecting the IMV connector 3 :must be 12V when IG ON

Above 12V

•#87 terminal in ECU connector 1 is in poor contact (loosened or pulled out)

approx 2.3V

b. Conduct the continuity test between#87 and #2 after disconnecting the connector 1 and 3 :must be in continuity

#32 terminal poor contact in C115

1

2

3

IMV drive circuit

C115

ECU

7.5A IMV FUSE(F64)

d. IMV Internally open or IMV #2 poor contact

Non-continuityContinuity

0V12V

◈ Diagnostics by DTC_P0255_IMV Drive Circuit Open

- Detecting Condition : ECU #87 terminal(IMV #2) approx.2.3V – Open circuit

■ Diagnostic procedure : In case of current trouble _ Check IMV Fuse(7.5A) first

a. Measure the voltage at #87 terminalwhen IG ON : must be Below 11.5V


CasesCases

DTCDTC

Open circuit between connector 3 and fuse box.Check if the terminal is loose in fuse box or C115 #14

• If #87 terminal is OK, it’s not current trouble.needs to check connector 2,3 and fuse box

Below 11.5V

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a. Perform HP Pump Cranking Pressure Test

c. Conduct Injector Static Back Leak Test

Above 200bar

• No current trouble in HP line. If the DTC stores at every cranking with normal starting. faulty ECU can besuspected.

Below 200bar

b-1. Perform Low Pressure Line Visual Check

•Low pressure line checks : - Check for water sensor tightening in fuel filter- Check for tiny hole in low pressure hoses (by applying high pressure air)-Check for clogging of fuel sender inlet pipe by foreign matters.

d. HP Pump malfunction- Pump abrasion or IMV stuck open

• Replace the corresponding injector even after performing Injector Cleaning Mode

Air InflowNormal

Excessive back leakNormal

e. Conduct IMV Cleaning Mode • Replace the IMV or HP Pump if the insufficient pressure continues

Below 200bar

◈ Diagnostics by DTC_P1191_Delay of High Pressure

- Detecting Condition : High Pressurizing too late while cranking– HP Pump or low pressure line is faulty CasesCases

DTCDTC

■ Diagnostic procedure : In case of current trouble causing a poor start.

•In case of intermittent trouble, mostly caused by air inflow or restricted low pressure line by foreign matters.

b-2. Check if there is

P1253P1256P1258

P1253P1256P1258

Metal Chip in the Venturi-Return. If found, follow the instruction

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a. Read #28.Inlet Metering Valve Duty valueat idle from Scan-100 Data List

c. Replace IMV or HP Pump

Above 35%

b-1. Perform IMV Cleaning Mode

• Finish after deleting the DTC

•In case of intermittent trouble, mostly caused by IMV open stuck or RPS poor contact.Checking connector 1,2,3 signal wire’s poor contact or shorted to REF wire is necessary

31~33%

Trouble solved

Trouble continues

Above 35%

1

2

3

RPS Circuit

ECU

C115b-2. Check if #09. Rail Pressure value while stall testfrom Scan-100 Data List is similar as other cars. Nevertheless, if engine power is poor, RPS or RPS signal wire faulty is suspected.

• RPS resistance check • RPS signal wire resistance check- After disconnecting connector 3 and1, must be less than 1Ω


◈ Diagnostics by DTC_P1252,1254,1257,1259_ Rail Pressure Too High

- Detecting Condition : Excessive Rail Pressure while driving– IMV or Rail Pressure Sensor is faulty

■ Diagnostic procedure : In case of current trouble _ Analyze

DTCDTC

Freeze Frame first

• No current trouble in HP line. If the DTC stores at every driving with normal starting. faulty ECU can be suspected.

17



◈ Diagnostics by DTC_P1253,1256,1258 _ Rail Pressure Too Low

- Detecting Condition : Rail pressure lower than target while driving– Insufficient generation of H/Pressure or H/Pressure Leak

DTCDTC

CasesCases

■ Diagnostic procedure : In case of current trouble causing a poor start or poor power,Check for fuel quality first.

a. Perform HP Pump Max & Cranking •In case of intermittent trouble, mostly caused by air inflow or restricted low pressure line by foreign matters.Pressure Test

Cranking Pressure Below 200bar b-2. Check if there is Metal Chip

d. Conduct Injector Cleaning Mode

• P1191-Refer to the “Delay of High Pressure”

Max Pressure Above 1050bar

•No current trouble in fuel system- Possible to exist an intermittently restricted low pressure line by foreign matters- Possible to exist an air inflow in low pressure line, etc.

e. Replace the corresponding injector(s) •Finish after deleting the DTC

ExcessiveBack Leak

Trouble Solved

Normal

in the Venturi-Return. If found, follow the instruction

Max Pressure Below 1050bar / Poor Start

b-1. Conduct Injector Dynamic Back Leak Test

Trouble Remains

18


a. Perform HP Pump Cranking Pressure Test

c. Conduct Injector Static Back Leak Test

Above 200bar

• The cause of poor starting is not HP Pump related system,Needs to check the other items that affect startability.

Below 200bar

•If possible to start, perform Injector Cleaning Mode - Replace the corresponding injector(s) if excessive backleak continues even after cleaning.

•If impossible to start, replace the corresponding injector(s)

Excessive Air InflowNormal

Excessive Back LeakNormal

e. Conduct IMV Cleaning Mode •Replace HP Pump or IMV if trouble continues

Below 200bar

ⅣⅣ. HP Pump related Diagnostics by Symptom. HP Pump related Diagnostics by Symptom

◈ Diagnostics by Symptom _ Poor Starting

- Preceding Works : First check items that affect startability such as Battery, Glow system, Immobilizer, CKP,CMP and ECT, etc.


b-2. Check if there is

CasesCases

Metal Chip in the Venturi-Return. If found, follow the instruction

b-1. Perform Low Pressure Line Visual Check

•Low pressure line checks : - Check for water sensor tightening in fuel filter- Check for tiny hole in low pressure hoses (by applying high pressure air)- Check for clogging of fuel sender inlet pipe by foreign matters.

d. HP Pump malfunction- Pump abrasion or IMV stuck open

■ Diagnostic procedure : In case of current trouble causing a poor start

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a. Check if ECU stores any rail pressure related DTCs using Scan-100

Exist • Repair referring to HP Pump related Diagnostics by DTC• Analyze

Not existFreeze Frame Data

•If trouble continues, replace HP Pump.

b. Perform Injector Dynamic Back Leak Test

NormalBack Leak

Excessive Back Leak

e. Perform IMV Cleaning Mode


d. Accelerate after disconnecting HFM sensor connector

Normal Acceleration Poor Acceleration •Replace HFM with new one


◈ Diagnostics by Symptom _ Poor Power/Poor Acceleration while driving

- Preceding Works : First check items that affect engine power and acceleration such as fuel/oil condition, filters, turbo system and EGR, etc.

■ Diagnostic procedure : In case of current trouble causing a poor power


c-2. Check if there exists Metal Chip in the Venturi-Return. If found, follow the instruction.

c-3. If excessive back leak continues even after Injector Cleaning Mode, replace the corresponding Injector(s)

c-1. Perform Low Pressure Line Visual Check


20



◈ Diagnostics by Symptom _ Engine Stall / Rough Idle

- Preceding Works : First check items that affect engine stall and rough idle such as fuel condition, filters, power supply/ground and sensors’ data, etc.

■ Diagnostic procedure : In case of current trouble causing engine stall or rough idle

a. Check if ECU stores any rail pressure related DTCs using Scan-100

Exist• Repair referring to HP Pump related Diagnostics by DTC• Analyze Freeze Frame Data

Not exist

b. Perform Injector Dynamic Back Leak Test

•If trouble continues, replace HP Pump.

NormalBack Leak

Excessive Back Leak

•In case of intermittent trouble, mostly caused by air inflow or restricted low pressure line by foreign matters or poor contact of power supply line to ECU or sensors/actuators.

c-2. Check if there exists Metal Chip in the Venturi-Return. If found, follow the instruction.

c-3. If excessive back leak continues even after Injector Cleaning Mode, replace the corresponding Injector(s)

c-1. Perform Low Pressure Line Visual Check



e. Perform IMV Cleaning Mode

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Test Procedure

1. Engine warm up (above 60℃)

2. No DTCs detected related to Battery Voltage,

Injector, IMV and RPS

3. Install the back leak tester and keep idling

for 2 minutes after starting

4. Perform Scan-100 Fuel Leak Detection

- Engine runs up to 3500rpm 4 times by itself

5. Read the graduations on each flask

6. Replace the corresponding Injector(s) if back

leaked amount is above 38㎖.

7. Input C2I data after replacing

◈ Injector Dynamic Back-Leak Test

■ Purpose : In order to judge whether injectors are working well by measuring the Back-leak amount under loads, if an injector(s) has an excessive back leak, it can result in droppinghigh pressure in common rail and this leads to poor acceleration or engine stall.

Poor PowerPoor Power Metal ChipMetal Chip

ⅤⅤ. Fuel System Check Tips(1). Fuel System Check Tips(1)

P1253,1256,1258P1253,1256,1258Engine StallEngine Stall

22


■ Scan-100 Fuel Leak Detection function : If not satisfied with “3. Test Condition” , “5.Test Failure” will be displayed. During performing the test, engine rpm repeats Idle ↔ 3500 4 times spontaneously. ECU calculates rail pressure change rate and display the result.

No Leak Detected


◈ Injector Dynamic Back-Leak Test

23



◈ Injector Static Back-Leak Test

■ Purpose : In order to judge whether injectors are working well by measuring the Back-leak amount while cranking, if an injector(s) has an excessive back leak, it can result in droppinghigh pressure in common rail and this leads to poor or hard start.

1. Remove each returning hose from injectors and connect the testeras shown in the figure

2. Disconnect IMV connector and Injectors’ connectors3. Crank the engine 2 times for 5 seconds each4. Measure the back leaked length in the tube5. Replace injector(s) if the length exceeds 20cm

Below 20cm

P1191P1191

Poor StartingPoor Starting

Metal ChipMetal Chip

24



◈ HP Pump Max Pressure Test

■ Purpose : In order to judge whether HP Pump generates its Max pressure, if out of spec,poor starting or poor acceleration can be occurred.

■ Test Procedure : Disconnect IMV connector or fuse, Crank for 5 seconds and see if maxpressure reaches up to 1050bar.

◈ HP Pump Cranking Pressure Test

■ Purpose : In order to judge whether the cause of poor starting is due to high pressure system or others.

■ Test Procedure : Disconnect CMP (Cam Position) sensor connector or fuse, Crank for 3 seconds and see if max pressure reaches at least 200bar.

How to use Scan-100

1. Select Data List2. Select 09.Rail Pressure3. Press Line Graph button4. Press Bar button※ Check the time that the pressure

reaches 200bar

P1191P1191 P1253,1256,1258P1253,1256,1258 Poor StartingPoor Starting

25



◈ Low Pressure Line Visual Check

■ Purpose : In order to check if the cause of insufficient high pressure is due to air inflow, which may result in poor acceleration or poor starting.

Check Procedure1. Prepare a clear tube as shown in the figure.2. Connect HP Pump Inlet and Fuel Filter Outlet by using a clear tube

(Needs to modify the ends with quick connectors)3. Supply fuel to HP Pump by using the priming pump.4. Observe if air passes in the clear tube while cranking or engine idle.

* Caution : Keep the cleanliness when the tube is installed.

HP PumpInlet

Fuel FilterOutlet

PrimingPump

•Part Name: Gauge-Low Pressure

•P/Number: Y99220042B

P1191P1191

Poor AccelerationPoor Acceleration


Engine StallEngine Stall

26


◈ Injector Cleaning Mode

▶ Cleaning Procedure

Disconnect the RPS connector after the engine warm-up when idling, ECU enters into Fail-safe mode, which the rail pressure maintains

at 1800bar with pinging.

Through this process, the foreign matters on the injector control valve can be eliminated by ultra high pressure. If this cleaning mode reduces back-leak amount, but still not normal, additional conduct can be made.

Rev the engine up to 3000rpm with fully accelerating, stop the engine after repeating 10 times.

When there is excessive back-leak from injectors causing engine poor power or engine stall, follow the below sequence.


■ Purpose : In order to get rid of foreign matters, which may cause excessive back-leak from injectors. If the excessive back-leak is made by foreign matters, unnecessary replacement of injectors can be reduced by performing the cleaning mode.

Erase the DTC by using Scan-100

P1191P1191

P1253P1256P1258


Poor StartingPoor Startin

P1253P1256P1258

Engine Stall

g

Engine Stall

27


◈ IMV Cleaning Mode

▶ Cleaning Procedure

Take off IMV from HP Pump and connect IMV connector, and remove Screen Filter from IMV.

Clean the IMV piston by spraying a WD-40 or Carburetor Cleaner for 2~3 min.With this process, Foreign matters can be removed, however, IMV malfunctionitself won’t be solved such as broken spring, damaged piston, etc. Caution) Before taking off IMV, make sure to spray with cleaner and blow out the HP Pump to keep the cleanliness, not allowed to wear cotton gloves.

Turn the IG key on and drive the IMV by using Scan-100 with spraying cleaner,repeat Active/Stop for 2~3 minutes.

If rough idle or excessive rail pressure exists without IMV related DTC,Follow the below procedure.

P1252,1254,1257,1259P1252,1254,1257,1259



CasesCases


■ Purpose : In order to get rid of foreign matters from IMV, which may cause rough idle, poor starting, engine stall or excessively high rail pressure due to the stuck open/close of IMV piston. It’s recommended performing this mode before replacing the HP Pump or IMV.

Install the IMV after flushing in diesel and delete DTC P1191P1191

Engine StallEngine Stall

28



◈ IMV Cleaning ModeIMV Cleaning StepIMV Cleaning Step

1

32

29



◈ Freeze Frame Data Analysis Poor AccelerationPoor Acceleration

Engine Stall

Engine Stall

P1252

■ Purpose : ECU memorizes 8 items related with the DTC stored in ROM, thesedata give detailed information on the engine driving situation that ECU detected the DTC. P1252

▶ Data Analysis for Rail Pressure related DTC - Example : P1254_Rail Pressure Control Negative

1. In case that P1254 is detected.

2. Place the cursor to the DTC, if multiple.

3. Press the ENTER button, and Freeze Frame Data will be displayed as shownin the right figure.

4. Although “IMV Open Demand” is as lowas 19%, which is requested to make the highest pressure of HP Pump, “Rail Pressure Feedback” shows only 220bar,which is much less than target pressure.

- Normal Spec : Approx. 32% 250bar

5. In conclusion, the cause of DTC P1254can be HP leak or poor HP generation.

30



1. Spray the cleaner and blow out in the area of Venturi-return.2. Remove the Venturi from HP Pump.3. To find metal chips, insert a magnet into the port.4. If confirmed metal chips, first clean HP pipes, fuel hoses and fuel tank by using diesel.5. Perform Injector Static Back-leak Test or Dynamic Back-leak Test after replacing HP

Pump and filter.6. Replace all injectors and common rail if back-leak amount is out of spec.

Make sure to keep cleanliness all the time.Recommend to use the above way of checking for metal chips than fuel filter checking.

Venturi-Return


CasesCases


◈ Metal Chip Treatment

■ Purpose : When metal chips are found in the Venturi-Return, follow the below process in order to prevent 2nd trouble.Metal Chips can cause engine stall or poor starting

P1253P1256P1258

P1253P1256P1258

Engine Stall

■ How to find Metal Chips : See if there are metal chips after taking off the Venturi-Return .

Metal chips presence

Engine Stall

P1191P1191

31



◈ HP Pump Components’ InformationNo Part Name Part Number -

6650700101 550,000

21,000

100

20,000

7,800

200

240,000

1,500

200

13,000

13,000

13,000

24,000

220,000

200

200

2,900

6640750329(D20DT)

6650750129(D27DT)

6679900404(D27DT)

6650700015

6650700014

4656008000

6640170021(D20DT)

6650170121(D27DT)

6650170003

6659900201

6640700033(D20)

6650700633(D27)

6640700133(D20)

6650700733(D27)

6640700333(D20)

6650700833(D27)

6640700032(D20)

6650700733(D27)

6640700195(D20)

6650700295(D27)

914020008011

914020008011

6640700181(D20)

6650700181(D27)

Fuel Pump Assy

Pump Sprocket

Sprocket Bolt

Bearing Housing

Bearing Shaft

Pump Nut

Injector

Injector Clamp

Injector Bolt

Fuel Pipe(Cyl.1)

Fuel Pipe(Cyl.1&3)

Fuel Pipe(Cyl.1)

Fuel Pipe(Cyl.2&4)

Fuel Pipe(Cyl.3)

Fuel Pipe(Cyl.5)

Fuel Pipe

Fuel Rail Assy

Housing Bolt

Fuel Rail Bolt

Fuel Return Tube

Torque (Nm)

1 -

4 -

5 20+90°

6 -

7 -

8 65±6

9 -

11 10±180 ° +20 °

12 -

15 40±4

16 40±4

17 40±4

18 40±4

23 25±2.5

24 25±2.5

25 25±2.5

26 -

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◈ Diagnostic Tool set for Fuel System _ P/Number : Y99220012B

①

②

④

③

■ Configuration by function

① Injector Back-leak tester : Tool for Injector Dynamic/Static Back-leak test.

② Close Rail (Rail Pressure Sensor) : Tool for HP Pump maxPressure check.Used with ③ Rail Pressure Tester (Substitution for Scan-100)

③ Rail Pressure Tester : Tool for HP Pump max pressure check.Used with ② Close Rail (Substitution for Scan-100)

④ Coil for IMV check : To check IMV open/short circuit.- P0253/0255

33


◈ Metal Chip Inspection through Venturi-returnMetal ChipsMetal Chips

34


◈ Remove IMV Fuse to perform Injector Dynamic Back-leak Test

Rexton

Actyon/KyronMain Relay

Vacuum Modulator

IMV

Max Pressure TestMax Pressure Test

35


◈ IMV Cleaning Mode _ Step1 IMV CleaningIMV Cleaning

36


◈ IMV Cleaning Mode _ Step 2

37


◈ IMV Cleaning Mode _ Step 3

Delphi HP Pump Diagnosis

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