KIA CRT

CRT-3500
3500
Common Rail Injector Tester
User’ss Manual
User

“PIEZO”, “S” & “R” Engine Delphi “A2” “U2” Engine

Contents
1. PRODUCT COMPOSITION

2. INJECTION TEST
2 - 1.
1 Injection
I j ti Comparison
C i Test
T t ( Low
L Pressure
P Mode
M d )
2 - 2. Injection Comparison Test ( Low & High Pressure Mode )
2 - 3. Test & Diagnostic

3. HIGH PRESSURE & BACK LEAK TEST

3 - 1. High Pressure Test for each system
3 - 2. High Pressure Test for each system
3 - 3. Cleaning procedure of injector
3 - 4. Injector Back Leak Test (Dynamic)

4. DIAGNOSTIC / REPAIR / INJECTOR CLEAN & ASSEMBLY & TIPS

4 - 1. Diagnostic & Repair procedure of CRDi system
4 - 2. Cleaning procedure of injector
4 - 3. Injector assembly (Nozzle area)
4 - 4.
4 Injector assembly (Nozzle area)
4 - 5. Tips for Injector assembly (Nozzle area)

5. TECHNICAL INFORMAITON

6. PIEZO INJECTOR
5 - 1. PIEZO Injector Test
5 - 2. PIEZO Injector Low Fuel Test
5 - 3. PIEZO Injector Return Measurement
5 - 4.. PIEZO
O Injector
jecto BACK
C LEAK Test est
5 - 5. Measurement Test of injected-fuel-quantity
5 - 6. Diagnosis Method of injected-fuel-quantity Measurement
 1. CRT-3500 Composition

8 17 26 27
1 1. CASE 21. RPS adapter Connector
2. HP CONTROLLER (Combination) (for Bosch)
3. INJECTOR TEST TUBE ASSY 22. RPS Adapter Connector
18 4. PIPE type A (for DELPHI OLD)
9 5. PIPE type B 23. RPS Adapter Connector
28 6. PIPE type C (for DELPHI NEW)
2 7 DUMMY INJECTOR
7. 24 Back Leak Test bottle
24.
19 7-2. ADAPTER (for Dummy Injector) 25. Low pressure gauge
29 8. COMPRESSION GAUGE Connection tube
10 9. I/CONTROL WIRE KIT (BOSCH) 26. Low pressure gauge
10. I/CONTROL WIRE KIT (DELPHI) 27. Vacuum Gauge
30 11. B/ LEAK CONNECTOR SET 28. Connection Adapter
21
12. DUMMY RESISTER (PRV) 29. Fuel Filter Plug
3 13 DUMMY RESISTER (HP Sensor)
13. (for DELPHI)
11
14. DUST CAP (for Injector ) 30. Connection Adapter
31
15. BLOCK HOSE (Injector return line) with Hose
22 16. SPARE PARTS KIT 31. DUMMY INJECTOR (L))
12
17. RAIL PLUG (12mm) 32. I/CONTROL WIRE KIT(PIEZO)
4 18. RAIL PLUG (14mm) 33. Delphi Connector
32
13 19. USERS MANUAL 34. Delphi Dummy Injector
5 23

6 14 15

24 33
7 Warning :
T avoid
To id internal
i t l damage
d
of controller by surge
voltage do not connect the
25 34
16 connector of controller
7-2 with power supplied.

This new Injector Tester has developed in addition to in order to improve diagnostic efficiency
and accuracy for vehicles equipped with Common Rail System.
1

Enables Injection Quantity Comparison Test under Low and High fuel pressure conditions, which
it was not possible with Hi-scan/GDS/G-Scan
Also Cylinder compression and Rail pressure regulator test are additionally available.
1
 2-1 INJECTION COMPARISON TEST ( LOW PRESSURE MODE )
Test Method : Automatic Affected vehicle : All Model ( including EURO-Ⅳ)

1) LOW PRESSURE MODE TEST 5 LOW PRESSURE MODE TEST

2 3 1. Remove the injectors from engine
1 2. Block the return line of injectors
3. Install the test pipes in the rail (4ea)
and Install Test Tubes in injectors.
4.
4 Install the Back Leak bottle in the Injectors
5. Install the injector control wire.
6. Crank the engine until the injection amount level of 1
5 or 2 test tubes are close to 5.

NOTE :
Rail pressure will be maintained 250~300bar
automatically by vehicle’s ECU.
ECU Therefore you don’t need to use HP controller during
the test.

2 4 5
Loosen Flushing Install Test tubes
Tighten

Tighten IG on or Cranking

R
Remove i j
injectors andd install
i ll the
h dummy
d injectors
i j instead.
i d ※ All the pipes must be cleaned before installed Flushing : Crank the engine and let the fuel leaks
( Clean it with an air gun ) from the fitting area for flushing purpose.
Block the fuel return line of injectors to prevent fuel
leaking.

2
 2-2 INJECTION COMPARISON TEST (LOW & HIGH PRESSURE MODE )
Test Method : Manual (PRV Controller) / Affected vehicle : All model Exempt EURO-Ⅳ/Ⅴ model

1) LOW & HIGH PRESSURE MODE TEST LOW PRESSURE MODE TEST

1) Disconnect the PRV’s & rail pressure sensor’s

connector from the rail
2) Install ① Dummy Resister and ② Rail Pressure
Sensor Dummy in each wiring connectors.
3)) Connect HP controller’s leads to the ③ ③PRV & ④ rail
2 pressure sensor.
5) Connect HP controller’s ⑤ power cable to battery.
5 4) Crank the engine until the injection amount level
of 1 or 2 test tubes are close to target level.
(5 scale in LOW, 8 scale in HIGH)
2
3 4 NOTE :
- Rail pressure can be adjusted from 100 to 1000bar by
1 pressure adjust knob.
EC - From Euro-4(09MY) model you must use rail pressure
sensor dummy otherwise injector will not work while
U
cranking.

High Pressure
Gauge
Mode
Select S/W

holding screw

Low High Pressure adjust Knob

TEST PROCEDURE Push to drain and

1) Select MAX HIGH mode and crank engine for 2-3seconds. Pull to close

2) Crank engine and adjust the rail pressure in Low and High mode while OPEN CLOSE
engine
g cranking. g - LOW = 300 ~ 350 bar
- HIGH = 800 ~ 1000 bar
3) Drain the fuel from the test tube.
Drain Valve
NOTE: Battery must be fully charged before test 4) Perform test in each mode: LOW & HIGH.
NOTE : Perform the test more than 2 times to get accurate data.
3
 2-3 Test & Diagnostic

LOW PRESSURE MODE JUDGMENT T & Judgment

Test J d
Crank the engine until the highest level of one or more test tubes are close to targeted
level . ( LOW : 5th / HIGH : 8th scale )
Target
Judgment will automatically be made once you fill out measured values CRDi diagnosis
5 scale
check sheet in GDS ((Global Diagnosis
g System)
y )

1.5 5 6 0 For user who has no GDS

HIGH PRESSURE MODE JUDGEMENT Crank the engine until the injection amount of 2nd largest fuel amount injector is
close to target level. (5 scale when low pressure mode, 8 scale when high pressure
mode)
d )
Target
8 scale
Measure the other injector’s injection amount and judge as below.
LOW PRESSURE MODE : 1.5 ㎣ ( 1.5 scale ) or higher is normal
HIGH PRESSURE MODE : 5 ㎣ ( 5 scale) or higher is normal

10 4 3 11 NOTE : It is recommended to use CRDi diagnosis program in GDS for your

convenient and accurate diagnosis.

Compression Test
Select the correct groove according to engine type when you
4
install dummy injector.
3 2
Quick coupling on dummy injector will help you to perform
1 cylinder compression test easily and quickly.
Judgments
Green : Normal condition (25~35)
Yellow : Gray zone ( insufficient pressure)
Red : Abnormal
Please refer shop manual for each vehicle

Adapter for
new (A-ENG)
Injectors
4
 3-1 HIGH PRESSURE TEST for each system

Purpose of this test is to check the High pressure pump

pump’ss and the rail
High pressure test with Injectors ( Step 2-1)
pressure sensor’s performance.
TEST PROCEDURE
- Install the back leak bottle and hose to injectors
- Remove the wiring connectors from all Injectors.
- Install the HP controller and set the mode switch to Highg pposition.
- Install ① PRV Dummy Resister and ② Rail Pressure Sensor Dummy in
each wiring connectors.
1
- Crank the engine and measure the rail pressure and injector back
leak amount.
SERVICE SPEC
Hi h pressure : Above
High Ab 700 bar
b ( withith normall Back
B k Leak
L k)
2
Back Leak : Less than 3 times than minimum amount injector
CHECK POINT (if test is failed )
- Fuel Leak (rail plug or pipes connection)
- PRV (leakage or damaged)
- Fuel
F l li
line
BOSCH EURO- 3 SYTEM (With PRV type) - HP pump (leakage or damaged)

High pressure test without Injectors ( Step 2-2) Purpose of this test is to confirm the High pressure pump performance or to
reconfirm high pressure pump performance when measured value of pressure
was lower
l than
h 700bar
700b during
d i Step
S 2-1.
21
High pressure sensor Avoid injector back leak completely by blocking rail outlet.

Test Procedure

- Remove the Injector pipes from the rail.

- Block the rail outlet using rail plug.
- Install the HP controller and set the mode switch to High position
- Crank the engine and measure the rail pressure.
SERVICE SPEC : Above 900 bar
If measured pressure from Step2-1was below 700bar and measured pressure
High pressure Pump
from Step2-2 was over 1000bar, the high pressure pump is in good condition.
The low pressure (below 700bar) might be read due to too much injector back
leak.
BOSCH EURO- 3 SYTEM (With PRV type)
5
 3-2 HIGH PRESSURE TEST for each system

High pressure test without Injectors ( Step 2-3)

Test Procedure
High pressure sensor
- Remove
R th
the injector
i j t pipes
i from
f the
th rail
il
- Block the rail outlet using rail plug.
- Install the HP controller and set mode switch to High position.
- Crank the engine and measure rail pressure.
SERVICE SPEC
BOSCH : Above 900 bar
DELPHI SYSTEM : 1000 bar
NOTE :

High pressure pump If measured rail pressure value was out of specification
check following items.
BOSCH EURO- 2 SYTEM (Without PRV type)
- Low pressure pump (or suction pump) and its strainer
(Including fuel tank)
High pressure test without Injectors ( Step 2-4) - High pressure pump and IMV (Inlet Metering Valve)

If th
the vehicle
hi l problem
bl iis still
till persisted
i t d while
hil rail
il pressure value
l isi in
i
specification check whether the fuel pump was contaminated or damaged.
High pressure sensor

High pressure pump

DELPHI SYSTEM (Without PRV type)

6
 3-3 HIGH PRESSURE TEST for each system

Electric pump type (Bosch Type II) Pressure Gauge Electric pump type (BOSCH Type Ⅱ)

ⓐ ⓐ Low Pressure Gauge EURO-Ⅲ model

ⓒ Test Tube Assay
ⓓ Connection Adapter CASE
PRESSURE
JUDGMENT
(bar)
ⓔ Connection Adapter with Hose
ⓕ Hose Clamp
ⓔ
1 1.5~3.5 kg/㎠ System normal
ⓒ F l Filter
Fuel Filt (or
( fuel
f l line
li / strainer
t i or etc
t )
ⓕ
2 0 ~1.5 kg/㎠
ⓓ clogging

3 no pressure Abnormal function of fuel pump

EURO-Ⅳ model

PRESSURE
CASE (bar)
JUDGMENT

1 2.5 ~ 5 kg/㎠ System normal

Fuel pump Filter or fuel line clogging (pump in
(Electric) 2 0.5~2.0 kg/㎠
g
good condition))

3 no pressure Abnormal function of fuel pump

Internal suction pump type (Delphi)
ⓑ
b

ⓓⓓ ⓖ ⓖ Internal suction pump type ( Delphi)

g d CASE VACUUM JUDGMENT

1 10~20 cmHg System normal (good condition)

Filter or fuel line clogging (pump in good

2 20~60 cmHg
condition)

Air leak in to the system or Suction pump

3 0~10 cmHg
damage

7 3
 3-4 INJECTOR BACK LEAK TEST( DYNAMIC)

INJECTOR BACK LEAK TEST (DYNAMIC)

1) Remove the return hose from each injector and Install injector return hose adapter
visible tubes flasks and injector return hose plug
referring to Injector back leak test (STATIC) in previous page.
2) Conduct the high pressure leak test referring to following explanation.
BOSCH Type Ⅰ,Ⅱ,Ⅲ : D3EA(1.5D-ENG), D4EA(2.0D-ENG), D4FA(U-ENG), D4CB(2.5A-ENG)
3) Start engine → 3 minutes at idle → accelerate engine up to 2500 rpm and keep the 2500rpm for
2 minutes →Stop Engine after 2 minutes
4) When the test is completed, measure the amount of fuel in each flask
5) Judgments
BOSCH Type Ⅰ,Ⅱ,Ⅲ
Replace the injector which is shown more 3 times than the minimum value.
Normal condition ＃22 Injector abnormal

30sec / 3000rpm

Start 1min stop

1 2 3 4 1 2 3 4

DELPHI : J3 (2.9L)
3) Connect the Hi-Scan and select the 'High Pressure Leak Test' mode.
4) Conduct the 'High Pressure Leak Test' until the Hi-Scan finish the test automatically.
or manually : Start engine → 2minutes at idle → 3 times acceleration →Stop Engine
5) For the accuracy of the test, perform the test more than twice and select
the largest amount as a measured value.
※ The flasks should be empty before the 2nd test started.
6) Judgments
2min
Start Stop
DELPHI Idle
Replace the injector which indicates exceeds 25cc. acceleration

Service Limit 25cc

Abnormal
1 2 3 4 injector

8 5
 4-1. Diagnostic & Repair procedure of CRDi system

Cl if the
Classify h symptoms Check the function of
EGR & VGT / WGT system
Injector / EGR / TC problem NG
Repair or Replace
- Engine Vibration
- Hesitation / jerking
- Smoke emitting
OK

Test Cleaning Test Finish

OK

NG
Replace Injector

Diagnosis by CRT-1000
Fuel line or pump problem Finish
- Engine
E i stall t ll
- Hard start or impossible to start OK
NG
- Fuel pump noise
- DTC set
( related with pressure line )

Enter

Repair or replace the part

related to problem.

* Injector repairs : Repair injector (replacing internal parts) if it is not recovered after cleaning.
* Replace injector assembly when the internal parts are not available.
9
 4-2. Cleaning procedure of injector

Repairing injector must be done in a clean and dust free Do not interchangeg internal pparts of injectors
j as it will influence
environment to prevent injector contamination. on its calibration. Use only original parts to maintain the proper
performance.

Cl i
Cleaning Note : Do not use brush
Disassembled while rinse to avoid
Start Soaking
contamination

( more than 5 minutes)

Washing Rinse

Kerosene or Diesel Clean Diesel

Thinner
※ Caution: Thinner and its evaporated gas is harmful to people.
Bottle cap must be closed while soaking.

End
Performance test Assembling
byy Injector
j Tester Inspection
(T id
(To identify
tif th
the parts
t that
th t needd
to replace)

10
 4-3. Injector assembly (Nozzle area)

Should be moving freely

Spindle should be inserted into nozzle holder freely( without any
resistance).

Spindle

1)Type #1 (33800-27900) Direction

Shim Spring Guide Shim Spindle Nozzle holder Cap Nut

Pin

Assembling
2) Type #2 (33800-27000)

NOTE :
Cap nutt mustt be
C b tighten
ti ht by
b Torque
T wrench.h
Required parts for thinner
Over torque will cause to have lack of injection amount while insufficient torque will
soaking.
cause to have fuel leaking or abnormal function.

Tightening Torque : 45N-m

Repairing injector must be done in a clean and dust free environment to prevent injector
contamination.

Thinner More than 5min Diesel

11
 4-4. Injector assembly (Nozzle area)

3) T
Type #3 (DELPHI) Should be moving freely
Control valve should be inserted into valve body
freely ( without any resistance).
Repairing injector must be done in a clean and dust free
environment to prevent injector contamination.
Control
Valve Valve body
The purpose of the control valve on the Delphi
injector is to control injection amount. It might
cause incorrect injection amount and excessive
back leak if the valve has stuck.

Free movement are required Tightening Torque : 45N-m

Shim Spindle Nozzle

Control Valve Return spring Cap nut
Return Spring
Valve body

Required parts for thinner soaking

NOTE
When you test injector after cleaning operate injector
more than 3~4 times in high pressure mode of HP
controller for bed-in and flushing.
g

Thinner More than 5min

12
 4-5. Tips for Injector assembly (Nozzle area)

Cleaning procedure of nozzle 33. While cleaning the injector in cleaning fluid it must be
2. Change the direction of spindle checked for free movement of the spindle in nozzle holder.
1. Remove the spindle from the
It must be gently moved until there is no resistance to
nozzle holder
movement.

Free movements are required

Try to in and out the spindle for
the cleaning

Scratched mark
Spindle with C2 coating

Fuel supply hole Scratched mark

4. When you Inserts the spindle to the nozzle holder, change the direction
Change the direction of scratched mark to the opposite direction of supply hole

Most scratched marks on spindle of nozzle are due to wearing.

The damaged spindle causes friction increase and produce low or over injection
Normally , you must replace the damaged nozzle assembly or change to new injector.
But it is possible to fix the injector without replacing the parts by using the above method.
Usually(100%) scratch marks match with the fuel supply hole, therefore if you change the direction of
scratched area, you may save the parts without technical problem.
By using the CIT- 2000 or 3000, you can get the right results.

13
 5. Technical Information

Compensation of injected-fuel-quantity
injected fuel quantity
New functions are added to common-rail systems to enhance the high precision of the fuel-injection system further, and ensure them for the service life of
the vehicle. With injector delivery compensation (IMA), a mass of measuring data is detected for each injector during the injector manufacturing process.
The data is then affixed to the injector in the form of a data-matrix code. This data is transferred to the ECU during vehicle production. While the engine is
running, these values are used to compensate for deviation in metering and switching response.
j
But Incase of re-manufactured injectors( ( for in-use car service),
), it is almost impossible
p to classify
y control and label due to technical limitation as remarked
as below.
- Mechanical wearing and increasing tolerance (even rest of all injectors) - There is no space for re-labeling on injector head
- Different regulation between new car and in-use car (no required) - Cost saving
- According to mileage of vehicle tolerance of all injectors are increased simultaneously (most of them out of control range).
The Injector Delivery Compensation system offers solutions to above situation
situation. Thus using an unclassified repaired injector will not influence engine
performance or emission level in significant ways .
Process for Manufacturing Injectors
Injector Manufacture Injector Test and classifications Injector labeling Data input

Production

Class 1 2 3

Engine manufacture V hi l manufacture

Vehicle f t
Code readout
Fitting Data record
ECU programming with IMA data
the
injector

ECU

Process for Re-manufacturing Injectors

no classification and re-labeling
Defected Repair Injector Test
I j t
Injector Delivery

14
 6-1 PIEZO Injector Test

※ Piezo Injector is not an previous Solenoid Type. Piezo injector making satisfy method of the high
1) Set-up Method exhaust, power and precision.
※ Previous Solenoid Valve needs an oil pressure coupler to help limited movement of Piezo injector
and there is a system to maintain the oil pressure coupler for the safety maintain of it.
1 Piezo injector is high reply and power, it is also less exhaust.
6
■ Set-up
11. D
Detached
t h d IInjector
j t B Backk Leak
L k Line
Li andd attached
tt h d as left
l ft picture
i t by
b Tube.
T b
3 2. Set-up the dummy resister
5 9 ※ Why? : If control valve of Rail is detached, ECU order to stop the fuel pump by
disconnect the line.
2
3. Set-up the back Leak test bottle.
4. Detached the injectors form engine and set up the dummy injectors.
8 5 Cleaning the nozzle at end of Injector by sinner
5.
ECU 6. Attached the test pipe and injector on the rail.
7. Connecting the injector drive line and the back leak measurement kit as left picture.
8. Tighten pipe connection to stand up test tubes.
9. Check all connection are right to connect included injector pipes
■ Test
1. Keepp ignition
g (engine)
( g ) on until injected
j fuel.
2. If not to injected fuel, please check the leaking fuel in any parts.

Open Nut Clean Re-tighten Test Tube

4 7

Tighten Engine Cranking

- Detached
D h d iinjectors
j andd set up the
h dummy
d injectors.
i j - Set up the pipe and tube and back leak test bottle.
bottle Dust cleaning method :
- Set up the tube and plastic holder on the injector - Before the set up those, please clean all connections - Not to open nut between injector and connection,
return hole between pipes and injectors and littlebit injected some fuel , then dust will be
※ After low pressure supply by Piezo injector, leaked more.
please check any fuel leaking
15
 6-2 PIEZO Injector Low Fuel Test

■ Set
2) Low Pressure 1 S t up

Low Pressure Gauge 1. Before the Fuel filter, please fuel hose detached and
Test Normal Pressure :
connect low pressure gauge as left picture.
3.5 ~4.5 bar
2. To connect hose to use fuel line.
2 ※ For the low pressure fuel type, the fuel pressure gauge
ECU 3
should be connect before the fuel filter.
3. Engine on (ignition on).
4
※ Check any fuel leaking.
4. Read the low pressure gauge.
5

■ Judgment
1. Engine Idle RPM should be maintain at normal
condition.
2. Check any fuel leaking again and again
3 Based on the belo
3. below table,
table to judge
j dge the lo
low press
pressure
re line.
line

Low Pressure
Measurement Judgment
(bar)

3.5 ~4.5 bar Bar Normal Condition

Fuel Filter / Low Pressure Line

Above 4.5 bar bar
Choked (Blocked)

Low Pressure Line Leaking

Less 2.0 bar bar
/ Electronic Pump damaged

16
 6-3 PIEZO Injector Return Measurement

1 Low Pressure Gauge

g ■ Set up
3) Injector
I j t Return
R t Measurement
M t
Normal Pressure : 1. Before the Fuel Filter, please fuel hose detached
3.5 ~4.5 bar and connect low pressure gauge on fuel return
side as left picture.
2
3 ※ Some Fuel leaked from the Piezo injector
j side.
2. Engine on (ignition on)
ECU 4
※ Check any fuel leaking.
3. Read the low pressure gauge
5
■ Judgment
1. Engine Idle RPM should be maintain at normal
condition.
2. Check any fuel leaking again and again
3. Based on the below table, to judge the low
pressure line.

Low Pressure
Measurement Judgment
(bar)

3.5 ~4.5 bar bar Normal Condition

Fuel Filter / Low Pressure Line

Above 4.5 bar bar
Choked (Blocked)

Low Pressure Line Leaking

Less 2.0 bar bar
/ Electronic Pump damaged

17
 6-4 PIEZO Injector BACK LEAK Test

■ Outline ((Dynamic
y Test))
4) PIEZO IInjector
j B k Leak
Back L k Test
T (Dynamic)
(D i ) If injector back leak too much, it will be caused engine start
fault, delay and etc. This test is very popular test nowadays.
The test is very important test to check abrasion pressure
control valve and leaking from return line of injector.

■ Set up
1. Assemble the Tube and Plastic Holder on the return hole of
injector
2. The low pressure supplied by the Piezo injector. So, block up
ECU a hole of hose by the low pressure gauge.
3. After engine start, please check the leaking fuel in any parts.
4. After 1 mints idling and than to keep the 1000rpm in 30 sec,
Normal Condition ＃22 Injector th off
than ff the
th engine.
i
Abnormal 5. For the accuracy test, please test at least 3 times again and
again.

■ Judgment
As show picture, if injected-fuel-quantity much more than 3
times to compare with base injected
injected-fuel-quantity
fuel quantity, the injector
1 2 3 4 1 2 3 4 should be consider to replace.

■ Outline (Static Test)

5) PIEZP Injector Back Leak Test (Static) This test is one of best efficiency test for the injector test. If this test testing together with fuel
High Pressure Gauge testing, it will be is very good test to find out faulty of injector. If we check the actual pressure test
of high
g fuel ppressure ppump p by
y the Static test,, it could be check the high
g ppressure line and
3
measuring the injected-fuel-quantity simultaneously
1 ■ Set up
2
1. After detached injector, please attached dummy injector
2. The low pressure supplied by the Piezo injector, So, block up a hole of hose by the low pressure
gauge.
3. After back leak kit set up, please detached a connector of oil control valve of the rail pressure sensor
and high
g ppressure ppump p and to connect the high g ppressure ggauge
g with the rail ppressure sensor and
battery each by each.
4 4. Disconnecting the connector of rail pressure valve on CRDI side.
ECU ※ To supply power less than 5 mints to protect an electronic damage of rail pressure control valve.
5. Connecting the test tube with rail pressure control valve line.
6. Switch on the high pressure gauge
▷Engine cracking 5 sec.
6
6 ▷Measuring g highest
g measurement of high g ppressure ggauge g ((above 1,000bar)
, )
▷Measuring back leak injected-fuel-quantity of tube connected with injector return hole. (less than
5 5mm)
※ Piezo return quantity is almost noting compare with previous solenoid type. The solenoid type
should be less than 200mm

18
 6-5 Measurement Test of injected-fuel-quantity

Ú The previous CRDI Fuel Test is only test injector pressure and
6) Injected-fuel-quantity
I j df l i Test
T back leak test. The important part of diagnosis is an injection test of
the injector, it is real combustion.
As shown picture, this test is a measuring injected-fuel-quantity
1 and compare each measurement of injectors. Than it should have
result of differences. Also, it can be compare injected-fuel-quantity
byy real ppressure controller,, which controllingg low and high
g
Dummy Register pressure.
7
6 ■ Set up
1. Disconnect the pressure control valve (PRV) and rail pressure
sensor
3 2. Block up low pressure line ① to connect dummy of rail pressure
5 4 sensor ②③
ECU 3. Connect the connector of pressure control line ④⑤.
2 4. After set up the tube, leaking the air.
※ For the accuracy measurement, using the actuation cracking

■ Test
1 Possible to control rail pressure from 100 to 1000 bar by the
1.
control part.

Warning : At the first engine cracking , there is possible to have a

declination of injected-fuel-quantity, because of the air. High Pressure gauge

Test Mode Selection

Switch Fixing Bolt

High Pressure Push discharge

Low
Pull Close
Pressure
Test Method Discharge Close
1) After selected Low/High mode, cracking and control the pressure by pressure control nove
- LOW pressure = 300 ~ 350 bbar, - HIGH pressure = 800 ~ 1000 bbar
☞ Draining injected-fuel-quantity to control pressure
Drain Valve
2) Cracking . If arrived to second scale on the gauge , stop the cracking
- Low pressure = 5 scale, - High pressure = 10scale
19
 6-6 Diagnosis Method of injected-fuel-quantity Measurement

Test judgment of Low pressure mode (300

(300~350
350 bar) Test and Judgment :
Low Mode (300~350bar) , the result of test and high pressure mode (800~1000 bar)
Test and Judgment
At the engine on , if 2nd injector reached target quantity out of 4 injectors, stop the engine. If the
Target injector is a brand new injector or a standard injector, it should be a standard.
5 scale Target
g injection
j scale : Low mode = 5 scales High g mode = 8 scales
Judgment and service limitation
1.5 5 6 0 Low pressure test : above 1.5 scales is normal condition (In case of standard injector is on 5 scales )
Low pressure test : above 4 scales is normal condition (In case of standard injector is on 8 scales )
Test judgment of high pressure mode (800~1000 bar)
Warning :
- The injected-fuel-quantity is very important, because a injector has a good condition as closed to
injected-fuel-quantity of standard injector.
Target - It can be possible to estimate life time of the injector with the injected-fuel-quantity. It doesn’t matter
8 scale with service limitation . Strong standard measurement is good to judgment, but it will be increased
cost. Recommending to consider the vehicle's condition and model year.
- If injected-fuel-quantity is over 30% compare with the normal condition and new injector, is a faulty
injector. (Over injected-fuel-quantity)
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10 4
3
Cylinder Pressure Test Method 1) Need to use dummy injector to prevent oil leaking at the compression and pressure test.
2) Before attach the dummy, need to check injector combined space.
3) Standard pressure is 30 ㎏/㎠ (Possible to have a difference,
difference according to the performance
of Diesel Vehicle or old vehicle)

Piezo Injector Adapter

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