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Kia crt 3500 user manual eng

This document provides instructions for using the KIA CRT-3500 Common Rail Injector Tester. It describes the components included with the tester and outlines various tests that can be performed to diagnose issues with common rail diesel engines, including low and high pressure injection comparison tests, high pressure tests, injector back leak tests, cleaning and assembly procedures for injectors, and more. The summaries provided give an overview of the testing capabilities and procedures covered in the user manual.

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KIA CRT-3500 Common Rail Injector Tester User’s Manual “PIEZO”, “S” & “R” Engine Delphi “A2” “U2” Engine
Contents 1. PRODUCT COMPOSITION 2. INJECTION TEST 2 - 1. Injection Comparison Test ( Low Pressure Mode ) 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. 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 Injector BACK LEAK Test 5 - 5. Measurement Test of injected-fuel-quantity 5 - 6. Diagnosis Method of injected-fuel-quantity Measurement
1 5 4 6 14 3 10 1 13 16 12 9 7 11 21 22 23 24 25 26 27 28 29 30 17 This new Injector Tester has developed in addition to in order to improve diagnostic efficiency and accuracy for vehicles equipped with Common Rail System. 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. Warning : To avoid internal damage of controller by surge voltage do not connect the connector of controller with power supplied. 1. CRT-3500 Composition 7-2 8 2 15 1 19 18 31 32 33 34 1. CASE 2. HP CONTROLLER (Combination) 3. INJECTOR TEST TUBE ASSY 4. PIPE type A 5. PIPE type B 6. PIPE type C 7. DUMMY INJECTOR 7-2. ADAPTER (for DUMMY INJECTOR) 8. COMPRESSION GAUGE 9. I/CONTROL WIRE KIT (BOSCH) 10. I/CONTROL WIRE KIT (DELPHI) 11. B/ LEAK CONNECTOR SET 12. DUMMY RESISTER (PRV) 13. DUMMY RESISTER (HP Sensor) 14. DUST CAP (for Injector ) 15. BLOCK HOSE (Injector return line) 16. SPARE PARTS KIT 17. RAIL PLUG (12mm) 18. RAIL PLUG (14mm) 19. USERS MANUAL 21. RPS adapter Connector (for Bosch) 22. RPS Adapter Connector (for DELPHI OLD) 23. RPS Adapter Connector (for DELPHI NEW) 24. Back Leak Test bottle 25. Low pressure gauge Connection tube 26. Low pressure gauge 27. Vacuum Gauge 28. Connection Adapter 29. Fuel Filter Plug (for DELPHI) 30. Connection Adapter with Hose 31. DUMMY INJECTOR (L)) 32. I/CONTROL WIRE KIT(PIEZO) 33. Delphi Connector 34. Delphi Dummy Injector
1) LOW PRESSURE MODE TEST LOW PRESSURE MODE TEST 1. Remove the injectors from engine 2. Block the return line of injectors 3. Install the test pipes in the rail (4ea) and Install Test Tubes in injectors. 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 or 2 test tubes are close to 5. NOTE : Rail pressure will be maintained 250~300bar automatically by vehicle’s ECU. Therefore you don’t need to use HP controller during the test. 2-1 INJECTION COMPARISON TEST ( LOW PRESSURE MODE ) Test Method : Automatic Affected vehicle : All Model ( including EURO-Ⅳ) ECU 1 2 2 3 5 5 54 ※ All the pipes must be cleaned before installed . ( Clean it with an air gun ) Tighten Loosen Flushing Tighten IG on or Cranking Install Test tubes Flushing : Crank the engine and let the fuel leaks from the fitting area for flushing purpose. Remove injectors and install the dummy injectors instead. Block the fuel return line of injectors to prevent fuel leaking. 2
1) LOW & HIGH PRESSURE MODE TEST ECU 2-2 INJECTION COMPARISON TEST (LOW & HIGH PRESSURE MODE ) Test Method : Manual (PRV Controller) / Affected vehicle : All model Exempt EURO-Ⅳ/Ⅴ model Mode Select S/W Pressure adjust KnobLow High High Pressure Gauge OPEN CLOSE Drain Valve Push to drain and Pull to close 1 2 3 4 2 holding screw TEST PROCEDURE 1) Select MAX HIGH mode and crank engine for 2-3seconds. 2) Crank engine and adjust the rail pressure in Low and High mode while engine cranking. - LOW = 300 ~ 350 bar - HIGH = 800 ~ 1000 bar 3) Drain the fuel from the test tube. 4) Perform test in each mode: LOW & HIGH. NOTE : Perform the test more than 2 times to get accurate data. 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 ③PRV & ④ rail pressure sensor. 5) Connect HP controller’s ⑤ power cable to battery. 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) NOTE : - Rail pressure can be adjusted from 100 to 1000bar by pressure adjust knob. - From Euro-4(09MY) model you must use rail pressure sensor dummy otherwise injector will not work while cranking. NOTE: Battery must be fully charged before test 5 3
LOW PRESSURE MODE JUDGMENT Target 5 scale HIGH PRESSURE MODE JUDGEMENT Target 8 scale 1.5 5 6 0 10 114 3 Test & Judgment Crank the engine until the highest level of one or more test tubes are close to targeted level . ( LOW : 5th / HIGH : 8th scale ) Judgment will automatically be made once you fill out measured values CRDi diagnosis check sheet in GDS (Global Diagnosis System) 2-3 Test & Diagnostic Select the correct groove according to engine type when you install dummy injector. Quick coupling on dummy injector will help you to perform 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 Compression Test 1 23 4 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) 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 NOTE : It is recommended to use CRDi diagnosis program in GDS for your convenient and accurate diagnosis. For user who has no GDS 4 Adapter for new (A-ENG) Injectors
BOSCH EURO- 3 SYTEM (With PRV type) High pressure test with Injectors ( Step 2-1) Purpose of this test is to check the High pressure pump’s and the rail 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 High position. - Install ① PRV Dummy Resister and ② Rail Pressure Sensor Dummy in each wiring connectors. - Crank the engine and measure the rail pressure and injector back leak amount. SERVICE SPEC High pressure : Above 700 bar ( with normal Back Leak ) 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 line - HP pump (leakage or damaged) High pressure sensor High pressure Pump 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 than 700bar during Step 2-1. 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 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) 3-1 HIGH PRESSURE TEST for each system High pressure test without Injectors ( Step 2-2) 5 1 2
High pressure sensor High pressure pump High pressure sensor High pressure pump Test Procedure - Remove the injector pipes from the rail - 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 : If measured rail pressure value was out of specification check following items. - Low pressure pump (or suction pump) and its strainer (Including fuel tank) - High pressure pump and IMV (Inlet Metering Valve) If the vehicle problem is still persisted while rail pressure value is in specification check whether the fuel pump was contaminated or damaged. 3-2 HIGH PRESSURE TEST for each system DELPHI SYSTEM (Without PRV type) High pressure test without Injectors ( Step 2-3) High pressure test without Injectors ( Step 2-4) BOSCH EURO- 2 SYTEM (Without PRV type) 6
Fuel pump (Electric) ⓕ ⓐ Low Pressure Gauge ⓒ Test Tube Assay ⓓ Connection Adapter ⓔ Connection Adapter with Hose ⓕ Hose Clamp ⓔ ⓓ ⓐ ⓒ Pressure GaugeElectric pump type (Bosch Type II) Internal suction pump type (Delphi) ⓒ ⓖ ⓓⓓ ⓑ Electric pump type (BOSCH Type Ⅱ) EURO-Ⅲ model CASE PRESSURE (bar) JUDGMENT 1 1.5~3.5 kg/㎠ System normal 2 0 ~1.5 kg/㎠ Fuel Filter (or fuel line / strainer or etc ) clogging 3 no pressure Abnormal function of fuel pump EURO-Ⅳ model CASE PRESSURE (bar) JUDGMENT 1 2.5 ~ 5 kg/㎠ System normal 2 0.5~2.0 kg/㎠ Filter or fuel line clogging (pump in good condition) 3 no pressure Abnormal function of fuel pump Internal suction pump type ( Delphi) CASE VACUUM JUDGMENT 1 10~20 cmHg System normal (good condition) 2 20~60 cmHg Filter or fuel line clogging (pump in good condition) 3 0~10 cmHg Air leak in to the system or Suction pump damage ⓖ 37 3-3 HIGH PRESSURE TEST for each system
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. 30sec / 3000rpm stopStart 1min 30sec / 3000rpm Stop Idle acceleration Start 2min Normal condition ＃2 Injector abnormal 1 2 3 4 Service Limit 25cc 1 2 3 4 Abnormal injector DELPHI Replace the injector which indicates exceeds 25cc. 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 58 3-4 INJECTOR BACK LEAK TEST( DYNAMIC) 1 2 3 4
Injector / EGR / TC problem - Engine Vibration - Hesitation / jerking - Smoke emitting Classify the symptoms FinishTest Diagnosis by CRT-1000 Finish NG Enter OK * Injector repairs : Repair injector (replacing internal parts) if it is not recovered after cleaning. * Replace injector assembly when the internal parts are not available. 4-1. Diagnostic & Repair procedure of CRDi system Repair or replace the part related to problem. OK Check the function of EGR & VGT / WGT system NG Repair or Replace Fuel line or pump problem - Engine stall - Hard start or impossible to start - Fuel pump noise - DTC set ( related with pressure line ) OK Cleaning Test NG Replace Injector 9
Disassembled Cleaning Inspection (To identify the parts that need to replace) AssemblingPerformance test by Injector Tester Start End 4-2. Cleaning procedure of injector Clean Diesel Repairing injector must be done in a clean and dust free environment to prevent injector contamination. Soaking ( more than 5 minutes) Washing Rinse Note : Do not use brush while rinse to avoid contamination Do not interchange internal parts of injectors as it will influence on its calibration. Use only original parts to maintain the proper performance. Thinner ※ Caution: Thinner and its evaporated gas is harmful to people. Bottle cap must be closed while soaking. Kerosene or Diesel 10
Tightening Torque : 45N-m NOTE : Cap nut must be tighten by Torque wrench. Over torque will cause to have lack of injection amount while insufficient torque will cause to have fuel leaking or abnormal function. 1)Type #1 (33800-27900) 2) Type #2 (33800-27000) Direction Shim Spring Guide Pin Nozzle holder Cap NutShim 4-3. Injector assembly (Nozzle area) Spindle should be inserted into nozzle holder freely( without any resistance). Spindle Should be moving freely Spindle Thinner Required parts for thinner soaking. More than 5min Repairing injector must be done in a clean and dust free environment to prevent injector contamination. Diesel Assembling 11
3) Type #3 (DELPHI) 4-4. Injector assembly (Nozzle area) Valve body Return Spring Control Valve Shim 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. Control Valve Valve body Return spring NozzleSpindle Cap nut Free movement are required Thinner Required parts for thinner soaking More than 5min Tightening Torque : 45N-m 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. Repairing injector must be done in a clean and dust free environment to prevent injector contamination. Should be moving freely Control valve should be inserted into valve body freely ( without any resistance). 12
4-5. Tips for Injector assembly (Nozzle area) 3. While cleaning the injector in cleaning fluid it must be checked for free movement of the spindle in nozzle holder. It must be gently moved until there is no resistance to movement. Free movements are required 4. When you Inserts the spindle to the nozzle holder, change the direction of scratched mark to the opposite direction of supply hole 2. Change the direction of spindle 1. Remove the spindle from the nozzle holder 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. Scratched mark Spindle with C2 coating Change the direction Scratched mark Fuel supply hole Cleaning procedure of nozzle Try to in and out the spindle for the cleaning 13
5. Technical Information Injector TestDefected Injector no classification and re-labeling Process for Re-manufacturing Injectors Repair Delivery Production Injector labeling Data input Fitting the injector Code readout Engine manufacture Data record Vehicle manufacture ECU programming with IMA data ECU Injector Manufacture Class 1 2 3 Injector Test and classifications Process for Manufacturing Injectors Compensation of 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. But Incase of re-manufactured injectors( for in-use car service), it is almost impossible to classify 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. Thus using an unclassified repaired injector will not influence engine performance or emission level in significant ways . 14
1) Set-up Method 6-1 PIEZO Injector Test ECU 1 2 6 5 7 Tighten Open Nut Clean Re-tighten Engine Cranking 3 9 8 4 15 ※ Piezo Injector is not an previous Solenoid Type. Piezo injector making satisfy method of the high 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. Piezo injector is high reply and power, it is also less exhaust. ■ Set-up 1. Detached Injector Back Leak Line and attached as left picture by Tube. 2. Set-up the dummy resister ※ Why? : If control valve of Rail is detached, ECU order to stop the fuel pump by disconnect the line. 3. Set-up the back Leak test bottle. 4. Detached the injectors form engine and set up the dummy injectors. 5. Cleaning the nozzle at end of Injector by sinner 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. Keep ignition (engine) on until injected fuel. 2. If not to injected fuel, please check the leaking fuel in any parts. Test Tube - Detached injectors and set up the dummy injectors. - Set up the tube and plastic holder on the injector return hole ※ After low pressure supply by Piezo injector, please check any fuel leaking - Set up the pipe and tube and back leak test bottle. - Before the set up those, please clean all connections between pipes and injectors Dust cleaning method : - Not to open nut between injector and connection, and littlebit injected some fuel , then dust will be leaked more.
2) Low Pressure Test 6-2 PIEZO Injector Low Fuel Test Low Pressure (bar) Measurement Judgment 3.5 ~4.5 bar Bar Normal Condition Above 4.5 bar bar Fuel Filter / Low Pressure Line Choked (Blocked) Less 2.0 bar bar Low Pressure Line Leaking / Electronic Pump damaged 1 2 3 5 Low Pressure Gauge ECU 4 Normal Pressure : 3.5 ~4.5 bar 16 ■ Set up 1. Before the Fuel filter, please fuel hose detached and connect low pressure gauge as left picture. 2. To connect hose to use fuel line. ※ For the low pressure fuel type, the fuel pressure gauge should be connect before the fuel filter. 3. Engine on (ignition on). ※ Check any fuel leaking. 4. Read the low pressure gauge. ■ 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.
3) Injector Return Measurement ■ Set up 1. Before the Fuel Filter, please fuel hose detached and connect low pressure gauge on fuel return side as left picture. ※ Some Fuel leaked from the Piezo injector side. 2. Engine on (ignition on) ※ Check any fuel leaking. 3. Read the low pressure gauge ■ 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. 6-3 PIEZO Injector Return Measurement Low Pressure (bar) Measurement Judgment 3.5 ~4.5 bar bar Normal Condition Above 4.5 bar bar Fuel Filter / Low Pressure Line Choked (Blocked) Less 2.0 bar bar Low Pressure Line Leaking / Electronic Pump damaged 1 2 3 5 Low Pressure Gauge ECU 4 Normal Pressure : 3.5 ~4.5 bar 17
4) PIEZO Injector Back Leak Test (Dynamic) ■ Outline (Dynamic Test) 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 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, than off the engine. 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-fuel-quantity, the injector should be consider to replace. 6-4 PIEZO Injector BACK LEAK Test EC U Normal Condition ＃2 Injector Abnormal 1 2 3 41 2 3 4 5) PIEZP Injector Back Leak Test (Static) ■ Outline (Static Test) This test is one of best efficiency test for the injector test. If this test testing together with fuel testing, it will be is very good test to find out faulty of injector. If we check the actual pressure test of high fuel pressure pump by the Static test, it could be check the high pressure line and measuring the injected-fuel-quantity simultaneously ■ Set up 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 pressure pump and to connect the high pressure gauge with the rail pressure sensor and battery each by each. 4. Disconnecting the connector of rail pressure valve on CRDI side. ※ 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. ▷Measuring highest measurement of high pressure gauge (above 1,000bar) ▷Measuring back leak injected-fuel-quantity of tube connected with injector return hole. (less than 5mm) ※ Piezo return quantity is almost noting compare with previous solenoid type. The solenoid type should be less than 200mm 1 2 3 4 ECU 6 6 5 18 High Pressure Gauge
6) Injected-fuel-quantity Test ECU Test Mode Selection Switch Low Pressure High Pressure High Pressure gauge Discharge Close Drain Valve Push discharge Pull Close 2 3 5 4 Fixing Bolt Test Method 1) After selected Low/High mode, cracking and control the pressure by pressure control nove - LOW pressure = 300 ~ 350 bar, - HIGH pressure = 800 ~ 1000 bar ☞ Draining injected-fuel-quantity to control pressure 2) Cracking . If arrived to second scale on the gauge , stop the cracking - Low pressure = 5 scale, - High pressure = 10scale 6  The previous CRDI Fuel Test is only test injector pressure and 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 and compare each measurement of injectors. Than it should have result of differences. Also, it can be compare injected-fuel-quantity by real pressure controller, which controlling low and high pressure. Warning : At the first engine cracking , there is possible to have a declination of injected-fuel-quantity, because of the air. 6-5 Measurement Test of injected-fuel-quantity 1 Dummy7 19 ■ Set up 1. Disconnect the pressure control valve (PRV) and rail pressure sensor 2. Block up low pressure line ① to connect dummy of rail pressure sensor ②③ 3. Connect the connector of pressure control line ④⑤. 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 control part.
Test judgment of Low pressure mode (300~350 bar) Target 5 scale Test judgment of high pressure mode (800~1000 bar) Target 8 scale 1.5 5 6 0 10 114 3 Test and Judgment : Low Mode (300~350bar) , the result of test and high pressure mode (800~1000 bar) 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, according to the performance of Diesel Vehicle or old vehicle) Cylinder Pressure Test Method Test and Judgment At the engine on , if 2nd injector reached target quantity out of 4 injectors, stop the engine. If the injector is a brand new injector or a standard injector, it should be a standard. Target injection scale : Low mode = 5 scales High mode = 8 scales Judgment and service limitation 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 ) Warning : - The injected-fuel-quantity is very important, because a injector has a good condition as closed to injected-fuel-quantity of standard injector. - It can be possible to estimate life time of the injector with the injected-fuel-quantity. It doesn’t matter 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) Piezo Injector Adapter 6-6 Diagnosis Method of injected-fuel-quantity Measurement 20

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Kia crt 3500 user manual eng

  • 1.
    KIA CRT-3500 Common RailInjector Tester User’s Manual “PIEZO”, “S” & “R” Engine Delphi “A2” “U2” Engine
  • 2.
    Contents 1. PRODUCT COMPOSITION 2.INJECTION TEST 2 - 1. Injection Comparison Test ( Low Pressure Mode ) 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. 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 Injector BACK LEAK Test 5 - 5. Measurement Test of injected-fuel-quantity 5 - 6. Diagnosis Method of injected-fuel-quantity Measurement
  • 3.
    1 5 4 6 14 3 10 1 13 16 12 9 7 11 21 22 23 24 25 26 27 28 29 30 17 Thisnew Injector Tester has developed in addition to in order to improve diagnostic efficiency and accuracy for vehicles equipped with Common Rail System. 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. Warning : To avoid internal damage of controller by surge voltage do not connect the connector of controller with power supplied. 1. CRT-3500 Composition 7-2 8 2 15 1 19 18 31 32 33 34 1. CASE 2. HP CONTROLLER (Combination) 3. INJECTOR TEST TUBE ASSY 4. PIPE type A 5. PIPE type B 6. PIPE type C 7. DUMMY INJECTOR 7-2. ADAPTER (for DUMMY INJECTOR) 8. COMPRESSION GAUGE 9. I/CONTROL WIRE KIT (BOSCH) 10. I/CONTROL WIRE KIT (DELPHI) 11. B/ LEAK CONNECTOR SET 12. DUMMY RESISTER (PRV) 13. DUMMY RESISTER (HP Sensor) 14. DUST CAP (for Injector ) 15. BLOCK HOSE (Injector return line) 16. SPARE PARTS KIT 17. RAIL PLUG (12mm) 18. RAIL PLUG (14mm) 19. USERS MANUAL 21. RPS adapter Connector (for Bosch) 22. RPS Adapter Connector (for DELPHI OLD) 23. RPS Adapter Connector (for DELPHI NEW) 24. Back Leak Test bottle 25. Low pressure gauge Connection tube 26. Low pressure gauge 27. Vacuum Gauge 28. Connection Adapter 29. Fuel Filter Plug (for DELPHI) 30. Connection Adapter with Hose 31. DUMMY INJECTOR (L)) 32. I/CONTROL WIRE KIT(PIEZO) 33. Delphi Connector 34. Delphi Dummy Injector
  • 4.
    1) LOW PRESSUREMODE TEST LOW PRESSURE MODE TEST 1. Remove the injectors from engine 2. Block the return line of injectors 3. Install the test pipes in the rail (4ea) and Install Test Tubes in injectors. 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 or 2 test tubes are close to 5. NOTE : Rail pressure will be maintained 250~300bar automatically by vehicle’s ECU. Therefore you don’t need to use HP controller during the test. 2-1 INJECTION COMPARISON TEST ( LOW PRESSURE MODE ) Test Method : Automatic Affected vehicle : All Model ( including EURO-Ⅳ) ECU 1 2 2 3 5 5 54 ※ All the pipes must be cleaned before installed . ( Clean it with an air gun ) Tighten Loosen Flushing Tighten IG on or Cranking Install Test tubes Flushing : Crank the engine and let the fuel leaks from the fitting area for flushing purpose. Remove injectors and install the dummy injectors instead. Block the fuel return line of injectors to prevent fuel leaking. 2
  • 5.
    1) LOW &HIGH PRESSURE MODE TEST ECU 2-2 INJECTION COMPARISON TEST (LOW & HIGH PRESSURE MODE ) Test Method : Manual (PRV Controller) / Affected vehicle : All model Exempt EURO-Ⅳ/Ⅴ model Mode Select S/W Pressure adjust KnobLow High High Pressure Gauge OPEN CLOSE Drain Valve Push to drain and Pull to close 1 2 3 4 2 holding screw TEST PROCEDURE 1) Select MAX HIGH mode and crank engine for 2-3seconds. 2) Crank engine and adjust the rail pressure in Low and High mode while engine cranking. - LOW = 300 ~ 350 bar - HIGH = 800 ~ 1000 bar 3) Drain the fuel from the test tube. 4) Perform test in each mode: LOW & HIGH. NOTE : Perform the test more than 2 times to get accurate data. 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 ③PRV & ④ rail pressure sensor. 5) Connect HP controller’s ⑤ power cable to battery. 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) NOTE : - Rail pressure can be adjusted from 100 to 1000bar by pressure adjust knob. - From Euro-4(09MY) model you must use rail pressure sensor dummy otherwise injector will not work while cranking. NOTE: Battery must be fully charged before test 5 3
  • 6.
    LOW PRESSURE MODEJUDGMENT Target 5 scale HIGH PRESSURE MODE JUDGEMENT Target 8 scale 1.5 5 6 0 10 114 3 Test & Judgment Crank the engine until the highest level of one or more test tubes are close to targeted level . ( LOW : 5th / HIGH : 8th scale ) Judgment will automatically be made once you fill out measured values CRDi diagnosis check sheet in GDS (Global Diagnosis System) 2-3 Test & Diagnostic Select the correct groove according to engine type when you install dummy injector. Quick coupling on dummy injector will help you to perform 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 Compression Test 1 23 4 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) 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 NOTE : It is recommended to use CRDi diagnosis program in GDS for your convenient and accurate diagnosis. For user who has no GDS 4 Adapter for new (A-ENG) Injectors
  • 7.
    BOSCH EURO- 3SYTEM (With PRV type) High pressure test with Injectors ( Step 2-1) Purpose of this test is to check the High pressure pump’s and the rail 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 High position. - Install ① PRV Dummy Resister and ② Rail Pressure Sensor Dummy in each wiring connectors. - Crank the engine and measure the rail pressure and injector back leak amount. SERVICE SPEC High pressure : Above 700 bar ( with normal Back Leak ) 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 line - HP pump (leakage or damaged) High pressure sensor High pressure Pump 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 than 700bar during Step 2-1. 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 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) 3-1 HIGH PRESSURE TEST for each system High pressure test without Injectors ( Step 2-2) 5 1 2
  • 8.
    High pressure sensor Highpressure pump High pressure sensor High pressure pump Test Procedure - Remove the injector pipes from the rail - 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 : If measured rail pressure value was out of specification check following items. - Low pressure pump (or suction pump) and its strainer (Including fuel tank) - High pressure pump and IMV (Inlet Metering Valve) If the vehicle problem is still persisted while rail pressure value is in specification check whether the fuel pump was contaminated or damaged. 3-2 HIGH PRESSURE TEST for each system DELPHI SYSTEM (Without PRV type) High pressure test without Injectors ( Step 2-3) High pressure test without Injectors ( Step 2-4) BOSCH EURO- 2 SYTEM (Without PRV type) 6
  • 9.
    Fuel pump (Electric) ⓕ ⓐ LowPressure Gauge ⓒ Test Tube Assay ⓓ Connection Adapter ⓔ Connection Adapter with Hose ⓕ Hose Clamp ⓔ ⓓ ⓐ ⓒ Pressure GaugeElectric pump type (Bosch Type II) Internal suction pump type (Delphi) ⓒ ⓖ ⓓⓓ ⓑ Electric pump type (BOSCH Type Ⅱ) EURO-Ⅲ model CASE PRESSURE (bar) JUDGMENT 1 1.5~3.5 kg/㎠ System normal 2 0 ~1.5 kg/㎠ Fuel Filter (or fuel line / strainer or etc ) clogging 3 no pressure Abnormal function of fuel pump EURO-Ⅳ model CASE PRESSURE (bar) JUDGMENT 1 2.5 ~ 5 kg/㎠ System normal 2 0.5~2.0 kg/㎠ Filter or fuel line clogging (pump in good condition) 3 no pressure Abnormal function of fuel pump Internal suction pump type ( Delphi) CASE VACUUM JUDGMENT 1 10~20 cmHg System normal (good condition) 2 20~60 cmHg Filter or fuel line clogging (pump in good condition) 3 0~10 cmHg Air leak in to the system or Suction pump damage ⓖ 37 3-3 HIGH PRESSURE TEST for each system
  • 10.
    INJECTOR BACK LEAKTEST (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. 30sec / 3000rpm stopStart 1min 30sec / 3000rpm Stop Idle acceleration Start 2min Normal condition ＃2 Injector abnormal 1 2 3 4 Service Limit 25cc 1 2 3 4 Abnormal injector DELPHI Replace the injector which indicates exceeds 25cc. 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 58 3-4 INJECTOR BACK LEAK TEST( DYNAMIC) 1 2 3 4
  • 11.
    Injector / EGR/ TC problem - Engine Vibration - Hesitation / jerking - Smoke emitting Classify the symptoms FinishTest Diagnosis by CRT-1000 Finish NG Enter OK * Injector repairs : Repair injector (replacing internal parts) if it is not recovered after cleaning. * Replace injector assembly when the internal parts are not available. 4-1. Diagnostic & Repair procedure of CRDi system Repair or replace the part related to problem. OK Check the function of EGR & VGT / WGT system NG Repair or Replace Fuel line or pump problem - Engine stall - Hard start or impossible to start - Fuel pump noise - DTC set ( related with pressure line ) OK Cleaning Test NG Replace Injector 9
  • 12.
    Disassembled Cleaning Inspection (To identify theparts that need to replace) AssemblingPerformance test by Injector Tester Start End 4-2. Cleaning procedure of injector Clean Diesel Repairing injector must be done in a clean and dust free environment to prevent injector contamination. Soaking ( more than 5 minutes) Washing Rinse Note : Do not use brush while rinse to avoid contamination Do not interchange internal parts of injectors as it will influence on its calibration. Use only original parts to maintain the proper performance. Thinner ※ Caution: Thinner and its evaporated gas is harmful to people. Bottle cap must be closed while soaking. Kerosene or Diesel 10
  • 13.
    Tightening Torque :45N-m NOTE : Cap nut must be tighten by Torque wrench. Over torque will cause to have lack of injection amount while insufficient torque will cause to have fuel leaking or abnormal function. 1)Type #1 (33800-27900) 2) Type #2 (33800-27000) Direction Shim Spring Guide Pin Nozzle holder Cap NutShim 4-3. Injector assembly (Nozzle area) Spindle should be inserted into nozzle holder freely( without any resistance). Spindle Should be moving freely Spindle Thinner Required parts for thinner soaking. More than 5min Repairing injector must be done in a clean and dust free environment to prevent injector contamination. Diesel Assembling 11
  • 14.
    3) Type #3(DELPHI) 4-4. Injector assembly (Nozzle area) Valve body Return Spring Control Valve Shim 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. Control Valve Valve body Return spring NozzleSpindle Cap nut Free movement are required Thinner Required parts for thinner soaking More than 5min Tightening Torque : 45N-m 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. Repairing injector must be done in a clean and dust free environment to prevent injector contamination. Should be moving freely Control valve should be inserted into valve body freely ( without any resistance). 12
  • 15.
    4-5. Tips forInjector assembly (Nozzle area) 3. While cleaning the injector in cleaning fluid it must be checked for free movement of the spindle in nozzle holder. It must be gently moved until there is no resistance to movement. Free movements are required 4. When you Inserts the spindle to the nozzle holder, change the direction of scratched mark to the opposite direction of supply hole 2. Change the direction of spindle 1. Remove the spindle from the nozzle holder 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. Scratched mark Spindle with C2 coating Change the direction Scratched mark Fuel supply hole Cleaning procedure of nozzle Try to in and out the spindle for the cleaning 13
  • 16.
    5. Technical Information InjectorTestDefected Injector no classification and re-labeling Process for Re-manufacturing Injectors Repair Delivery Production Injector labeling Data input Fitting the injector Code readout Engine manufacture Data record Vehicle manufacture ECU programming with IMA data ECU Injector Manufacture Class 1 2 3 Injector Test and classifications Process for Manufacturing Injectors Compensation of 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. But Incase of re-manufactured injectors( for in-use car service), it is almost impossible to classify 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. Thus using an unclassified repaired injector will not influence engine performance or emission level in significant ways . 14
  • 17.
    1) Set-up Method 6-1PIEZO Injector Test ECU 1 2 6 5 7 Tighten Open Nut Clean Re-tighten Engine Cranking 3 9 8 4 15 ※ Piezo Injector is not an previous Solenoid Type. Piezo injector making satisfy method of the high 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. Piezo injector is high reply and power, it is also less exhaust. ■ Set-up 1. Detached Injector Back Leak Line and attached as left picture by Tube. 2. Set-up the dummy resister ※ Why? : If control valve of Rail is detached, ECU order to stop the fuel pump by disconnect the line. 3. Set-up the back Leak test bottle. 4. Detached the injectors form engine and set up the dummy injectors. 5. Cleaning the nozzle at end of Injector by sinner 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. Keep ignition (engine) on until injected fuel. 2. If not to injected fuel, please check the leaking fuel in any parts. Test Tube - Detached injectors and set up the dummy injectors. - Set up the tube and plastic holder on the injector return hole ※ After low pressure supply by Piezo injector, please check any fuel leaking - Set up the pipe and tube and back leak test bottle. - Before the set up those, please clean all connections between pipes and injectors Dust cleaning method : - Not to open nut between injector and connection, and littlebit injected some fuel , then dust will be leaked more.
  • 18.
    2) Low Pressure Test 6-2PIEZO Injector Low Fuel Test Low Pressure (bar) Measurement Judgment 3.5 ~4.5 bar Bar Normal Condition Above 4.5 bar bar Fuel Filter / Low Pressure Line Choked (Blocked) Less 2.0 bar bar Low Pressure Line Leaking / Electronic Pump damaged 1 2 3 5 Low Pressure Gauge ECU 4 Normal Pressure : 3.5 ~4.5 bar 16 ■ Set up 1. Before the Fuel filter, please fuel hose detached and connect low pressure gauge as left picture. 2. To connect hose to use fuel line. ※ For the low pressure fuel type, the fuel pressure gauge should be connect before the fuel filter. 3. Engine on (ignition on). ※ Check any fuel leaking. 4. Read the low pressure gauge. ■ 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.
  • 19.
    3) Injector ReturnMeasurement ■ Set up 1. Before the Fuel Filter, please fuel hose detached and connect low pressure gauge on fuel return side as left picture. ※ Some Fuel leaked from the Piezo injector side. 2. Engine on (ignition on) ※ Check any fuel leaking. 3. Read the low pressure gauge ■ 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. 6-3 PIEZO Injector Return Measurement Low Pressure (bar) Measurement Judgment 3.5 ~4.5 bar bar Normal Condition Above 4.5 bar bar Fuel Filter / Low Pressure Line Choked (Blocked) Less 2.0 bar bar Low Pressure Line Leaking / Electronic Pump damaged 1 2 3 5 Low Pressure Gauge ECU 4 Normal Pressure : 3.5 ~4.5 bar 17
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    4) PIEZO InjectorBack Leak Test (Dynamic) ■ Outline (Dynamic Test) 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 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, than off the engine. 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-fuel-quantity, the injector should be consider to replace. 6-4 PIEZO Injector BACK LEAK Test EC U Normal Condition ＃2 Injector Abnormal 1 2 3 41 2 3 4 5) PIEZP Injector Back Leak Test (Static) ■ Outline (Static Test) This test is one of best efficiency test for the injector test. If this test testing together with fuel testing, it will be is very good test to find out faulty of injector. If we check the actual pressure test of high fuel pressure pump by the Static test, it could be check the high pressure line and measuring the injected-fuel-quantity simultaneously ■ Set up 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 pressure pump and to connect the high pressure gauge with the rail pressure sensor and battery each by each. 4. Disconnecting the connector of rail pressure valve on CRDI side. ※ 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. ▷Measuring highest measurement of high pressure gauge (above 1,000bar) ▷Measuring back leak injected-fuel-quantity of tube connected with injector return hole. (less than 5mm) ※ Piezo return quantity is almost noting compare with previous solenoid type. The solenoid type should be less than 200mm 1 2 3 4 ECU 6 6 5 18 High Pressure Gauge
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    6) Injected-fuel-quantity Test ECU TestMode Selection Switch Low Pressure High Pressure High Pressure gauge Discharge Close Drain Valve Push discharge Pull Close 2 3 5 4 Fixing Bolt Test Method 1) After selected Low/High mode, cracking and control the pressure by pressure control nove - LOW pressure = 300 ~ 350 bar, - HIGH pressure = 800 ~ 1000 bar ☞ Draining injected-fuel-quantity to control pressure 2) Cracking . If arrived to second scale on the gauge , stop the cracking - Low pressure = 5 scale, - High pressure = 10scale 6  The previous CRDI Fuel Test is only test injector pressure and 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 and compare each measurement of injectors. Than it should have result of differences. Also, it can be compare injected-fuel-quantity by real pressure controller, which controlling low and high pressure. Warning : At the first engine cracking , there is possible to have a declination of injected-fuel-quantity, because of the air. 6-5 Measurement Test of injected-fuel-quantity 1 Dummy7 19 ■ Set up 1. Disconnect the pressure control valve (PRV) and rail pressure sensor 2. Block up low pressure line ① to connect dummy of rail pressure sensor ②③ 3. Connect the connector of pressure control line ④⑤. 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 control part.
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    Test judgment ofLow pressure mode (300~350 bar) Target 5 scale Test judgment of high pressure mode (800~1000 bar) Target 8 scale 1.5 5 6 0 10 114 3 Test and Judgment : Low Mode (300~350bar) , the result of test and high pressure mode (800~1000 bar) 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, according to the performance of Diesel Vehicle or old vehicle) Cylinder Pressure Test Method Test and Judgment At the engine on , if 2nd injector reached target quantity out of 4 injectors, stop the engine. If the injector is a brand new injector or a standard injector, it should be a standard. Target injection scale : Low mode = 5 scales High mode = 8 scales Judgment and service limitation 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 ) Warning : - The injected-fuel-quantity is very important, because a injector has a good condition as closed to injected-fuel-quantity of standard injector. - It can be possible to estimate life time of the injector with the injected-fuel-quantity. It doesn’t matter 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) Piezo Injector Adapter 6-6 Diagnosis Method of injected-fuel-quantity Measurement 20