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Common Rail Diagnostics With Frank Massey

The document discusses common rail diagnostic procedures. It describes diagnosing issues on two vehicles, a Nissan Pathfinder that wouldn't start due to an EGR valve stuck open, and a Renault Laguna that had poor starting due to a leaking fuel injector. It emphasizes the importance of using a scope to check rail pressure and current flow during diagnostics.

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Edidjo Darwin
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289 views1 page

Common Rail Diagnostics With Frank Massey

The document discusses common rail diagnostic procedures. It describes diagnosing issues on two vehicles, a Nissan Pathfinder that wouldn't start due to an EGR valve stuck open, and a Renault Laguna that had poor starting due to a leaking fuel injector. It emphasizes the importance of using a scope to check rail pressure and current flow during diagnostics.

Uploaded by

Edidjo Darwin
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Tech Tips

Common Rail
Diagnostics
Frank Massey, Autoinform

The efficient and complete combustion of an oil based fuel is fraught with problems. Its pretty much certain
that additives, rather than thermal emission control, will dominate the current and near future diesel
development. Autoinforms Frank Massey describes the basics of his common rail diagnostic procedures.

iezo injectors have revolutionised the fuel


delivery process, in both petrol and diesel
systems, however cost and in-service problems
are directing manufacturers to abandon there
use. Improvements in power delivery and
emissions, coupled with ever smaller petrol
power plants, producing remarkable economy
per mile, must surely lead to the demise in
small to medium diesel powered vehicles.
This has directed our attention to the next
generation of training programmes in 2015
towards subjects covering, twin charge , direct
petrol injection and lean burn technologies. The
CRD systems will however concentrate our
efforts for the foreseeable future.
A recent repair illustrates what can be a
difficult situation if not diagnosed and handled
effectively. A Nissan Pathfinder was presented
to us for diagnosis and repair. The vehicle
would not start, and when cranked, it did
however for a couple of seconds give the
impression it would start. The vehicle employed
a DENSO CR system, a system in which we
have considerable experience.
The first step of course is serial evaluation,
a hard DTC for EGR linear position error was
the only indication of a problem. The next
check was the generation of correct rail
pressure, this as always, involves the evaluation
using our Picoscope. The two vital parameters
of common rail functionality are pressure
against time, and to measure that you need a
scope. The rail pressure sensor default value is 1
volt KOEO (key on engine off). During cranking
the voltage reached 2.5 volts in less than 1
second, confirming excellent hydraulic
functionality. Next, once again focusing on
electronic functionality , I monitored the current
path through the injector circuits, no problems
here with 18 amps and no loss of injector
triggering events. Given that correct fuel is
delivered at the correct time and pressure, then
all thats required for a diesel to run is a
mechanically efficient engine. In an attempt to
confirm this, I decided to inject easy start into
the air intake. It didnt run, in fact pressure was
diverting back out of the inlet tract! This
suggested the possibility of a blocked exhaust
or a, valve timing error.

52

>>

February 2015

AUTOBIZ

We conducted a
little research and
discovered a recall
relating to valve timing
issues. Unsure how to
continue at this point,
and considering cost
implications , we
advised our customer.
We were considering
dropping the exhaust
just before the
catalyst, anticipating a
blocked exhaust as the
most likely cause.
However despite not
starting, there was
some pressure coming
out of the exhaust
pipe.
To assist the
escape of possible back pressure, the EGR
circuit was removed, and it was discovered that
the EGR valve was completely off its seat in the
fully open position. Surely this would not
prevent starting?
Given the DTC and evidence in hand, we
advised replacing the EGR valve. The next issue
was cost. The EGR valve was very expensive.
Replacing the valve was straight forward
enough, the vehicle started and ran normally so
all ended well. I must say I was surprised such a
fault created a no start condition, and added as
a consequence of this experience another layer
in our evaluation process. I am often quoted as
saying common rail diagnosis is straight
forward, upon reflection, I think its time to
concede otherwise.
Another recent experience involves a 2002
Laguna 1.9 CR with high mileage , but in
reasonably original condition. Suffering from
very poor crank start problems, otherwise
drivability was not bad.
Lots of DTCs, probably man made, a
couple of spare parts in the glove box,
including a can of easy start, here we go again!
Rail pressure on a Bosch volume
controlled system should reach 1.6v very
quickly, with start capability anything over 1

volt from the rail pressure sensor.1.3 volts


represents approx. 300bar pressure. Injection
can commence around 120 bar, so what was
the problem?
The Pico trace demonstrated a very slow
rise time and a voltage value just under 1 volt,
with a nominal value of 0.5v, suggesting a low
pressure priming, pressure generation or
leakage problem. Once started the pressure
was fine except the control duty cycle of the
volume regulation valve was excessive, more
open than normal. I checked the rail safety
valve for leakage, then conducted a injector
back leakage test. The No 2 (French 3) injector
was leaking very badly. Given the cost of good
replacement injectors, the owner declined the
repair.
This brings me full circle to my
introduction and technology changes. Unless
cars are regularly maintained to correct
specifications with quality parts, they will cost
more to repair or become scrap value
prematurely. We, as repairers, have to invest
ever more money into capital resources and
keep abreast of vehicle development, invest in
training and
software platforms.

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