SHOP MANUAL
Engine
Ch 1 page 214
H5 – Verification of a faulty injector
1. Remove the high pressure pipe to the injector which has been identified in H1.
2. Plug the outlet of the identified injector at the outlet port on the fuel accumulator using tool 99 019. If the out-
let port of cylinder 1 has to be plugged, see the instructions in TI 03-08 01 28.
3. Start the engine and repeat H1. This system should be able to maintain pressure.
H6 – Checking for internal leaks
Wear protective goggles.There is a risk
of fuel spraying from the high pressure
connections when pressurised.
The accumulator may be under high pressure.
Reduce the pressure using SDP3 before starting work.
A tool must be made to determine whether the fuel system is leaking. A pressure regulator, a shut-off valve, two
hose couplings, hose clamps, hose and Tema quick release coupling 1100N for connection to the test
connection are required. Assemble the parts as illustrated on the next page. It is vital that all couplings and
connections are tight.
1. Detach and remove all high pressure pipes between the accumulator and the high pressure connections.
2. Connect the tool to the test connection on the return fuel manifold and open the test connection.
Important !
Open the fuel filler cap so that the pressure does not deform the tank.
3. Pressurise the return fuel manifold. Slowly increase the pressure. Listen for a bubbling noise in the tank. The
bubbling noise indicates at what pressure the overflow valve opens. The pressure should be higher than 0.5 bar.
Then pressurise the manifold to max. 3 bar.
4. Listen for return leakage in the injectors by blocking one high pressure connection at a time and quickly re-
moving the obstacle. If there is internal leakage in the injector, a hissing sound will be heard.
5. Renew the injector or injectors with internal leakage as described above. When renewing an injector, the
tuning code of the new injector must be programmed to the correct cylinder using SDP3 and basic setting of
injector adaptation must be performed.
Remember that several injectors can sometimes be faulty at the same
time. Therefore if a faulty injector cannot be veried, plug it and repeat
step H1. If no other faulty injector can be veried, continue troubleshoot-
ing as described in H6.
NOTE
To Next Page
Loading...