SsangYong Rexton. Service manual - part 144

DI10-181

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DIAGNOSIS

DI ENG SM - 2004.4

Example of Pressure/Volume Loss in Pump

Pressure/Volume Loss in High Pressure Pump

When the required target pressure/volume cannot be delivered due to fuel supply line or pump damage

Ex.:

• Air in fuel supply line

• Excessive vacuum pressure in fuel supply line (-300 mbar)

• Burnt out or mechanically damaged pump

• Supply fuel with increased temperature ( > 65°C)

Y220_10065

Decreased pressure/volume from

pump

Pressure/volume loss

Pump capacity

Pressure/volume

build up

Pressure/volume

consumption

Fuel injection

volume

Injector back
leak volume

DI10-182

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DIAGNOSIS

DI ENG SM - 2004.4

FUEL SYSTEM PRESSURE TEST

Test Tool Kit

For High Pressure Line

For Transfer Line

Y220_10066

Y220_10067

DI10-183

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DIAGNOSIS

DI ENG SM - 2004.4

Prerequisite

1. Check the connections in fuel supply lines.

2. Check the fuel level in fuel tank.

3. Check if the air exists in fuel supply lines (air bubbles in fuel supply lines or fuel with air bubbles).

4. Check the fuel supply lines for leaks (transfer and high pressure).

5. Check if the specified fuel is used.

6. Check the fuel filter for contamination and abnormality.

Fuel System Test Process

Determine DTC

DTC Detected?

Fuel system

related DTC:

P1252, P1253,

P1254...P0251

High pressure fuel

related problem

No

No

Yes

no

Check and repair

transfer and H/P fuel

system

Check fuel filter and H/P

fuel system

Diagnose and repair

according to the de-

tected DTC

Notice

If more than one DTC have been detected, check the wiring
harness for open or short first.

Check the transfer fuel system and fuel filter before
proceeding the high pressure fuel system check in next page.

DI10-184

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DIAGNOSIS

DI ENG SM - 2004.4

FUEL SYSTEM CHECK PROCESS

Initial Check

• Transfer fuel system (air in system), specified fuel used

• Fuel leaks, fuel filter

• Diagnostic Trouble Code

• Wiring harness

• Abnormal noise from injector

No Abnormality

in Initial Check?

No

Check and repair

No

Check transfer fuel system (refer to 4-2)

Install the transparent tube between fuel
filter and priming pump. Check the trans-
fer fuel system for clogged or air bubbles.
Check if the vacuum pressure is proper.

Check the injector

back leak volume

Replace high pressure pump

Yes

Yes

No

Yes

No

Yes

Yes

Replace the injector

Enter new injector C2I data into ECU

after replacing the injector

Replace the injector

Enter new injector C2I data into ECU

after replacing the injector

Perform the initial check again.

Method 1

Method 2

Dynamic Test for Injector Back leak Volume (refer to 4-4)

(with engine running)

1. Warm up engine (coolant temp.: over 60°C), place an

empty plastic container under the return of injector, and
start engine.

2. Run the engine for 30 seconds at idle speed, perform :

fuel system pressure leakage test” with Scan-i, and
check the fuel level in container. It should be over 38 ml.

Check fuel rail pressure (refer to 4-1)

When cranking engine for 5 seconds
after disconnecting IMV connector, is
the rail pressure over 1,050 bar?

* Thoroughly clean the components

before installation

High Pressure Pump Test (refer to 4-5)

Install the closed rail into high pressure
pump at outlet port. Remove IMV connector
and crank engine for 5 seconds. Is the pres-
sure over 1,050 bar?

Static Test for Injector Back leak Volume

(refer to 4-3)

(with engine cranking but not running)

Place an empty plastic container under the return of
injector:

Remove IMV and injector connectors, crank for 5
seconds, and check the injector back leak volume.
The fuel length in tube should be over 20 cm.

No