SHOP MANUAL
Engine
Ch 1 page 218
H4 - Checking injectors using SDP3
1 Check cylinder balancing at idling speed using SDP3. Note if any cylinder deviates.
2 Perform a cylinder output test using SDP3. Note which cylinder deviates from the others by having a
higher output.
3 By comparing the two results with each other, a cylinder with deviations in both tests can be identified.
Continue troubleshooting on the injector for that cylinder.
H5 - Verification of a faulty injector
1 Remove the high pressure pipe to the injector which has been identified in H4.
2 Plug the outlet of the identified injector at the outlet port on the fuel accumulator using tool 99 019.
If the outlet port of cylinder 1 has to be plugged, see the instructions in TI 03-08 01 28.
3 Start the engine and run it at idling speed for at least 15 seconds.
4 Switch off the engine. Read the pressure remaining in the accumulator using SDP3. If the pressure is
more than 0 bar after 1 minute, the faulty injector has been found and must be renewed. If the faulty
injector cannot be verified, continue troubleshooting in accordance with H6.
H6 - Checking for internal leak
There is a risk of fuel splashing 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 needed. 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.
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 removing 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.
6 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.
Wear protective goggles.
Open the fuel ller cap so that the pressure does not deform the tank.
WARNING
CAUTION
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