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ACTYON Service Training

Engine : D20DT / D27DT Subject : HP Pump Diagnosis Date : March .13 . 2006 Instructor : Brian Cho
1 2006 INVITATIONAL TRAINING

Contents
I. II. III. HP Pump Overview Cases & Improvements Diagnostics by DTCs

IV. Diagnostics by Symptoms V. Fuel System Check Tips

2006 INVITATIONAL TRAINING

. HP Pump Overview
HP Pump Structure
Low Pressure Regulator Fuel Temp Sensor

Fuel Inlet Port

IMV (Inlet Metering Valve)

Venturi Return Fuel Outlet Port High Pressure Regulator (To Common Rail)

4 1 2 3 5

1. 2. 3. 4. 5.

Transfer Pump & Housing Drive shaft & Driven Cam Roller & Shoe Fuel Temp Sensor Inlet Metering Valve

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. HP Pump Overview
Components by Function
Component Function
Driven by 4 vanes, 6bar low pressure generation transfer to Hydraulic head 2 couples of Shoe&Roller, High pressure generation over 250bar accumulation in C.R High pressure regulator controlled by ECU Sensing the fuel temperature transferred to hydraulic head, Reduction of fuel injection amount at hot condition(90) Regulating HP Pump internal high/low pressure to secure stable supply Return port, joining 2 flows one for lubrication and the other for back leak from injectors

Symptom when malfunctioning

Starting problem or poor acceleration due to insufficient high pressure generation Starting problem or poor acceleration due to insufficient fuel injection Knocking, engine stall or engine vibration

Parts supply
HP Pump ASSY
(P/N: 6650700101)

Transfer Pump

Hydraulic Head IMV (Inlet Metering Valve)

HP Pump ASSY HP Pump ASSY (Preparing IMV supply)

Fuel Temp Sensor

Poor acceleration due to insufficient injection can be occurred.

HP Pump ASSY

High/Low Pressure Regulator Venturi-Return

Security mechanism, rare possibility of malfunction Can be used to identify metal chips caused from roller abrasion after taking it off

HP Pump ASSY

HP Pump ASSY

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. HP Pump Overview
High Pressure Generation
L/P Regulator(6bar) IMV H/P Limiter

L/P Circuit
: L/P system functions supplying sufficient fuel to hydraulic head Fuel Tank Priming Pump Fuel Filter Transfer Pump Inlet Metering Valve

Transfer Pump

H/P Pump

H/P Circuit
Supply Pump Suction Valve

Venturi Common Rail

: H/P system functions generating and accumulating fuel that injectors need. H/P Pump Common Rail H/P Pipes Injectors

Common Fault Patterns

Injector Fuel Filter Priming Pump

H/P L/P Fuel Tank Return

Insufficient fuel supply to transfer pump due to air inflow. Abrasion of HP Pump IMV related troubles Injector related troubles

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. HP Pump Overview
Inlet Metering Valve _ Fuel Pressure Regulator
Current vs Quantity
Eng RPM APS Signal RPS Signal
Required Quantity and Rail Pressure calculation

Input

IMV Control

Quantity (l/hr)

ECU

Current Control

Current (mA) IMV Function Rail pressure control by regulating fuel amount transferring to the hydraulic head Improves injection efficiency In case of no electric power Max Quantity to the hydraulic head As current increases, quantity decreases (Normal Open Type)

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. Trouble Cases / Quality Improvements

HP Pump related Trouble Cases / Quality Improvements
Model
Rexton/ Rodius Rexton/ Rodius Rexton

Type

Symptom HP Pump Flange Bolt Broken & Fuel Leak Hard start, Poor acceleration, Stall Impossible to start, Poor acceleration Engine stall while driving Engine stall while driving Impossible to start Intermittent Eng Check Lamp ON, Engine stall HP Pump housing leak Engine noise, Engine oil leak

Cause Insufficient absorption of engine vibration by clamp rubber bush IMV stuck, Transfer pump spring damaged, etc. HP Pump internal abrasion caused metal chips in fuel line IMV connector unsecured IMV internally Stuck Unsecured water sensor in fuel filter caused air infiltration P1253 displayed, Foreign material blocked the fuel sender in fuel tank. Hydraulic head seal assembled pinched One of the HP Pump Sprocket fixing bolts unscrewed caused timing chain & pump damaged

Action Replaced flange bolt & clamp rubber bush Improved quality Replaced HP Pump & Fuel Filter, etc. Secured the connector Replaced IMV (or HP Pump) Secured water sensor Removed the foreign materials Replaced HP Pump Replaced Timing chain, HP Pump and Timing Case

Remark Refer to work procedure Refer to HP Pump Improvement Refer to Metal chip repair Refer to IMV Open circuit Refer to IMV Cleaning Refer to hard start Refer to P1253 diagnosis -

Quality

Quality

Case

Rexton

Case

Rexton

Case

Rexton

Case

Rodius/ Kyron

Case

Rexton

Case

Rexton

Case

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. Trouble Cases / Quality Improvements

Repair procedure for HP Pump Flange bolt damage

7
Quality Quality

Nut B
HP Pipe Tightening Torque : 40 4Nm Replace new rubber bush Mounting bracket tightening torque : 8.9 0.9Nm

Nut A Flange Bolts(2 pcs) Repair Procedure

1.Before starting the work, Ensure the Cleanliness around the Flange & Fuel pipe nut by washing and blowing completely. 2.Remove the Fuel pipe Brkt & HP Pipe, and replace with new clamp rubber bush & flange bolts. 3.Follow the tightening procedure as below for the flange bolts (Apply torques on Nut A,B by turns evenly) a. Apply 10 Nm on both Nuts temporarily b. Apply 15 Nm 3 Nm on both Nuts c. Apply 20 Nm 3 Nm on both Nuts d. Apply 25 Nm 3 Nm on both Nuts - Tighten the pump side nut first - Tightening Torque : 404Nm

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. Trouble Cases / Quality Improvements

HP Pump Quality Improvements
Quality Issues
1.Vane spring broken due to an interference [A] 2.Vane spring broken due to a crack [A] 3.Roller & Shoe Scuffing [B] 4.IMV Sleeve deformed due to an excessive clamping pressure [C]

8
Quality Quality

Improvement Details 1.TRANSFER PUMP SPRING CRACK [A] 1) Improved spring wire drawing process and changed inspection system 2) Changed the number of spring pitch and the shape of vane (Step Taper) 2.ROLLER&SHOE SCUFFING [B] 1) Necessary to improve the quality of fuel 3. IMV VALVE STUCK [C] - Strengthen engineering spec and crimping condition in assembly line - Strengthen sampling inspection

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. HP Pump related Diagnostics by DTC

HP Pump related DTCs
DTC Description
Fuel temp sensor shorted to ground Fuel temp sensor shorted to battery IMV drive line shorted to battery IMV drive line shorted to ground IMV drive line open

Probable Causes
Fuel temp signal line shorted to ground or sensor faulty Fuel temp signal line open or sensor faulty IMV drive line shorted to battery or IMV faulty IMV drive line shorted to ground or IMV faulty IMV drive line open or IMV faulty Too much delay of high pressure generation while cranking. IMV faulty or low pressure line abnormal Rail pressure much higher than ECU calculation, IMV faulty or RPS faulty Rail pressure much less than ECU calculation, low pressure line abnormal or excessive back leak.

Engine Check Lamp

X

Fail-safe
ECU reckons fuel temp as 95 and reduces engine max power ECU reckons fuel temp as 95 and reduces engine max power Increases to 1500rpm, engine stalls 1 minute later and not allow to restart Increases to 1500rpm, engine stalls 1 minute later and not allow to restart Increases to 1500rpm, engine stalls 1 minute later and not allow to restart Hard start

P0182 P0183 P0251 P0253 P0255 P1191 P1252 P1253 P1256 P1258 P1254 P1257 P1259

High pressure delay

IMV pressure too high

Time delay engine stop(1 minute), MDP adaptation suspended

Rail pressure minimum control error

Hard start, Engine stall, Lack of power

Rail pressure maximum control error

Rail pressure much higher than ECU calculation, IMV faulty or RPS faulty

Time delay engine stop(1 minute), MDP adaptation suspended

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. HP Pump related Diagnostics by DTC

Diagnosis by DTC_P0182_ Fuel temp sensor shorted to ground
- Detecting Condition : ECU #109 terminal (Sensor #1) below 0.5V
Diagnostic procedure : In case of current trouble (duplicable )
a. Measure the sensor resistance after
disconnecting sensor connector 3 : must be at least above 100 In case of intermittent trouble, mostly caused by shorted wire, needs to check wiring harness from sensor to ECU

10
DTC DTC

ECU

Yes

No
Sensor internally shorted , replace it

b. Measure the voltage at #1 terminal

(connector3) after disconnecting when IG ON : must be approx. 5v

No

Yes

Not current trouble, Check if the 5v drops when shaking each connector and wire between sensor and ECU

c. Conduct a continuity test between sensor and ECU after disconnecting

each connector. 1.Check between #109 and body 2.Check between #109 and #110 In order to know if continuity exists in between 1 and 2 or 3 and 2, disconnect the C115 and perform continuity test again.

: must not be in continuity

Non-continuity

Continuity

d. ECU faulty, replace it

When checking connector, inspect if it contains moisture in it.

Fuel temp sensor circuit

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. HP Pump related Diagnostics by DTC

Diagnostics by DTC_P0183_ Fuel temp sensor open
- Detecting Condition : ECU #109 terminal (Sensor #1) above 4.5V
Diagnostic procedure : In case of current trouble (duplicable)
a. Measure the sensor resistance after disconnecting sensor connector 3 : must be below 75k In case of intermittent trouble, mostly caused by open wire, needs to check if connectors 1,2 and 3 have poor connection.

11
DTC DTC

ECU

Yes

No Sensor Internally open, replace it

b. Check the voltage at #1 terminal after disconnecting sensor connector 3 when IG ON. Must be approx.5v

No

Yes

#1 terminal loosen or pulled out

c. Check the voltage at #19 terminal after disconnecting connector 2 when IG ON, must be approx.5v

Yes No
d. Check the voltage at #109 terminal with connecting connector1,must be approx.5v

#19 terminal loosen or pulled out

No
. When checking connectors, see if wires are damaged in between connectors. Fuel temp sensor circuit

ECU faulty if #109 terminal is normal.

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. HP Pump related Diagnostics by DTC

Diagnostics by DTC_P0251_IMV Drive Circuit Shorted to B+
- Detecting Condition : ECU #87 terminal(IMV #2) above 12V Shorted to B+
Diagnostic procedure : In case of current trouble (duplicable)
a. Measure the IMV resistance after disconnecting the connector 3 : must be above 4 In case of intermittent trouble, mostly caused by shorted wire, needs to check wiring harness from IMV to ECU by tracing.

12
DTC DTC Cases Cases

ECU

1
Yes No
7.5A IMV FUSE (F64)

b. Check the voltage at #87 terminal after disconnecting connector 3 when IG ON, must be approx 2v.

IMV internally shorted, replace it

2
Disconnect C115 and check the voltage at IMV #2 terminal, if the 12v continues to be checked, find shorted area in between 2 and 3. Disconnect C115 and check the voltage at ECU #87 terminal, if the 12v continues to be checked, find shorted area in between 2 and 1.

C115

12V

2V 12V

c. If the DTC keeps displaying, ECU internally shorted, replace it.

When checking connector, inspect if it contains moisture in it.

IMV Circuit

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. HP Pump related Diagnostics by DTC

Diagnostics by DTC_P0253_IMV Drive Circuit Shorted to Ground
- Detecting Condition : ECU #87 terminal(IMV #2) below 1V Shorted to body
Diagnostic procedure : In case of current trouble (duplicable case)
a. Measure the voltage at #2 terminal after disconnecting the connector 3 : must be approx 2.3V( IG ON) In case of intermittent trouble, mostly caused by shorted wire, needs to check wiring harness from IMV to ECU by tracing.

13
DTC DTC Cases Cases

ECU

1
Below 1v

Yes
7.5A IMV FUSE (F64)

Not current trouble, Check if the 2.3v drops

b. Disconnect the C115 and measure the voltage at #87 : when shaking each connector and wire between IMV and ECU

must be approx. 2.3V

C115

Below 1v

Yes

Shorted in between the connector 23,

Correct the shorted area

c. Disconnect the C115 and connector 1, and conduct the continuity test between #87 and body. must not be in continuity

Continuity

Non-continuity
d. ECU internally shorted. Replace it

Shorted in between the connector 21,

Correct the shorted area

IMV Circuit

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. HP Pump related Diagnostics by DTC

Diagnostics by DTC_P0255_IMV Drive Circuit Open
- Detecting Condition : ECU #87 terminal(IMV #2) approx.2.3V Open circuit
Diagnostic procedure : In case of current trouble _ Check IMV Fuse(7.5A) first
a. Measure the voltage at #87 terminal when IG ON : must be Below 11.5V In case of intermittent trouble, mostly caused by shorted wire, needs to check wiring harness from IMV to ECU by tracing.

14
DTC DTC Cases Cases

ECU

approx 2.3V

Above 12V Below 11.5V

#87 terminal in ECU connector 1 is in poor contact (loosened or pulled out)

b. Conduct the continuity test between #87 and #2 after disconnecting the connector 1 and 3 :

7.5A IMV FUSE (F64)

must be in continuity Continuity Non-continuity

If #87 terminal is OK, its not current trouble. needs to check connector 2,3 and fuse box

C115

c. Measure the voltage at #1 terminal after disconnecting the IMV connector 3 :

#32 terminal poor contact in C115

must be 12V when IG ON 12V 0V

d. IMV Internally open or IMV #2 poor

contact

Open circuit between connector 3 and fuse box.

Check if the terminal is loose in fuse box or C115 #14

IMV drive circuit

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. HP Pump related Diagnostics by DTC

Diagnostics by DTC_P1191_Delay of High Pressure
- Detecting Condition : High Pressurizing too late while cranking
HP Pump or low pressure line is faulty Diagnostic procedure : In case of current trouble causing a poor start.
a. Perform HP Pump Cranking Pressure In case of intermittent trouble, mostly caused by air inflow or restricted low pressure line by foreign matters. b-2. Check if there is Metal Chip in the Venturi-Return. If found, follow the instruction

15
DTC DTC Cases Cases
P1253 P1253 P1256 P1256 P1258 P1258

Test Below 200bar Below 200bar Above 200bar

b-1. Perform Low Pressure Line Visual Check

No current trouble in HP line. If the DTC stores at every cranking with normal starting. faulty ECU can be suspected.

Normal

Air Inflow
Low pressure line checks : - Check for water sensor tightening in fuel filter - Check for tiny hole in low pressure hoses (by applying high pressure air) -Check for clogging of fuel sender inlet pipe by foreign matters.

c. Conduct Injector Static Back Leak Test

Normal

Excessive back leak

d. HP Pump malfunction - Pump abrasion or IMV stuck open Replace the corresponding injector even after performing

Injector Cleaning Mode

e. Conduct IMV Cleaning Mode Replace the IMV or HP Pump if the insufficient pressure continues

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. HP Pump related Diagnostics by DTC

Diagnostics by DTC_P1252,1254,1257,1259_ Rail Pressure Too High
- Detecting Condition : Excessive Rail Pressure while driving
IMV or Rail Pressure Sensor is faulty Diagnostic procedure : In case of current trouble _ Analyze Freeze Frame first
a. Read #28.Inlet Metering Valve Duty value at idle from Scan-100 Data List In case of intermittent trouble, mostly caused by IMV open stuck or RPS poor contact. Checking connector 1,2,3 signal wires poor contact or shorted to REF wire is necessary

16
DTC DTC

ECU

31~33% Above 35% Above 35%

b-1. Perform IMV Cleaning Mode No current trouble in HP line. If the DTC stores at every driving with normal starting. faulty ECU can be suspected.

b-2. Check if #09. Rail Pressure value while stall test from Scan-100 Data List is similar as other cars. Nevertheless, if engine power is poor, RPS or RPS signal wire faulty is suspected.

C115

Trouble continues

Trouble solved

RPS resistance check RPS signal wire resistance check - After disconnecting connector 3 and1, must be less than 1

c. Replace IMV or HP Pump

Finish after deleting the DTC

RPS Circuit

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. HP Pump related Diagnostics by DTC

Diagnostics by DTC_P1253,1256,1258 _ Rail Pressure Too Low
- Detecting Condition : Rail pressure lower than target while driving
Insufficient generation of H/Pressure or H/Pressure Leak Diagnostic procedure : In case of current trouble causing a poor start or poor power, Check for fuel quality first.
a. Perform HP Pump Max & Cranking

17
DTC DTC Cases Cases

Pressure Test Cranking Pressure Below 200bar Max Pressure Above 1050bar Max Pressure Below 1050bar / Poor Start

In case of intermittent trouble, mostly caused by air inflow or restricted low pressure line by foreign matters.

b-2. Check if there is Metal Chip in the Venturi-Return. If found, follow the instruction

b-1. Conduct Injector Dynamic Back Leak

Test Excessive Back Leak Normal

P1191-Refer to the Delay of High Pressure

d. Conduct Injector Cleaning Mode

No current trouble in fuel system - Possible to exist an intermittently restricted low pressure line by foreign matters - Possible to exist an air inflow in low pressure line, etc.

Trouble Remains

Trouble Solved

e. Replace the corresponding injector(s)

Finish after deleting the DTC

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. HP Pump related Diagnostics by Symptom

Diagnostics by Symptom _ Poor Starting
- Preceding Works : First check items that affect startability such as Battery, Glow system, Immobilizer, CKP,CMP and ECT, etc. Diagnostic procedure : In case of current trouble causing a poor start
a. Perform HP Pump Cranking Pressure Test In case of intermittent trouble, mostly caused by air inflow or restricted low pressure line by foreign matters. b-2. Check if there is Metal Chip in the Venturi-Return. If found, follow the instruction

18

Cases Cases

Below 200bar

Below 200bar Above 200bar

b-1. Perform Low Pressure Line Visual Check

The cause of poor starting is not HP Pump related system, Needs to check the other items that affect startability. Low pressure line checks : - Check for water sensor tightening in fuel filter - Check for tiny hole in low pressure hoses (by applying high pressure air) - Check for clogging of fuel sender inlet pipe by foreign matters. If possible to start, perform Injector Cleaning Mode - Replace the corresponding injector(s) if excessive back leak continues even after cleaning. If impossible to start, replace the corresponding injector(s)

Normal

Excessive Air Inflow

c. Conduct Injector Static Back Leak Test

Normal

Excessive Back Leak

d. HP Pump malfunction - Pump abrasion or IMV stuck open

e. Conduct IMV Cleaning Mode

Replace HP Pump or IMV if trouble continues

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. HP Pump related Diagnostics by Symptom

Diagnostics by Symptom _ Poor Power/Poor Acceleration while driving
- Preceding Works : First check items that affect engine power and acceleration such as fuel/oil condition, filters, turbo system and EGR, etc. Diagnostic procedure : In case of current trouble causing a poor power
a. Check if ECU stores any rail pressure related DTCs using Scan-100 In case of intermittent trouble, mostly caused by air inflow or restricted low pressure line by foreign matters. Repair referring to HP Pump related Diagnostics by DTC Analyze Freeze Frame Data

19

Not exist

Exist

b. Perform Injector Dynamic Back Leak Test c-2. Check if there exists Metal Chip in the Venturi-Return. If found, follow the instruction. c-3. If excessive back leak continues even after Injector Cleaning Mode, replace the corresponding Injector(s)

Normal Back Leak

Excessive Back Leak

c-1. Perform Low Pressure Line Visual Check

Normal

Excessive Air Inflow

d. Accelerate after disconnecting HFM

sensor connector Poor Acceleration Normal Acceleration

Low pressure line checks : - Check for water sensor tightening in fuel filter - Check for tiny hole in low pressure hoses (by applying high pressure air) - Check for clogging of fuel sender inlet pipe by foreign matters.

Replace HFM with new one

e. Perform IMV Cleaning Mode

If trouble continues, replace HP Pump.

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. HP Pump related Diagnostics by Symptom

Diagnostics by Symptom _ Engine Stall / Rough Idle
- Preceding Works : First check items that affect engine stall and rough idle such as fuel condition, filters, power supply/ground and sensors data, etc. Diagnostic procedure : In case of current trouble causing engine stall or rough idle
a. Check if ECU stores any rail pressure related DTCs using Scan-100 In case of intermittent trouble, mostly caused by air inflow or restricted low pressure line by foreign matters or poor contact of power supply line to ECU or sensors/actuators. Repair referring to HP Pump related Diagnostics by DTC Analyze Freeze Frame Data

20

Not exist

Exist

b. Perform Injector Dynamic Back Leak Test c-2. Check if there exists Metal Chip in the Venturi-Return. If found, follow the instruction. c-3. If excessive back leak continues even after Injector Cleaning Mode, replace the corresponding Injector(s)

Normal Back Leak

Excessive Back Leak

c-1. Perform Low Pressure Line Visual Check Low pressure line checks : - Check for water sensor tightening in fuel filter - Check for tiny hole in low pressure hoses (by applying high pressure air) - Check for clogging of fuel sender inlet pipe by foreign matters. If trouble continues, replace HP Pump.

Normal

Excessive Air Inflow

e. Perform IMV Cleaning Mode

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. Fuel System Check Tips(1)

Injector Dynamic Back-Leak Test
Purpose : In order to judge whether injectors are working well by measuring the Back-leak amount under loads, if an injector(s) has an excessive back leak, it can result in dropping high pressure in common rail and this leads to poor acceleration or engine stall. Test Procedure 1. Engine warm up (above 60)

21

2. No DTCs detected related to Battery Voltage, Injector, IMV and RPS 3. Install the back leak tester and keep idling for 2 minutes after starting 4. Perform Scan-100 Fuel Leak Detection - Engine runs up to 3500rpm 4 times by itself 5. Read the graduations on each flask 6. Replace the corresponding Injector(s) if back leaked amount is above 38. 7. Input C2I data after replacing
Engine Stall Engine Stall Poor Power Poor Power Metal Chip Metal Chip P1253,1256,1258 P1253,1256,1258

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. Fuel System Check Tips(1)

Injector Dynamic Back-Leak Test
Scan-100 Fuel Leak Detection function : If not satisfied with 3. Test Condition , 5.Test Failure will be displayed. During performing the test, engine rpm repeats Idle 3500 4 times spontaneously. ECU calculates rail pressure change rate and display the result.

22

No Leak Detected

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. Fuel System Check Tips(2)

Injector Static Back-Leak Test
Purpose : In order to judge whether injectors are working well by measuring the Back-leak amount while cranking, if an injector(s) has an excessive back leak, it can result in dropping high pressure in common rail and this leads to poor or hard start.

23

Below 20cm

1. 2. 3. 4. 5.

Remove each returning hose from injectors and connect the tester as shown in the figure Disconnect IMV connector and Injectors connectors Crank the engine 2 times for 5 seconds each Measure the back leaked length in the tube Replace injector(s) if the length exceeds 20cm P1191 P1191 Poor Starting Poor Starting Metal Chip Metal Chip

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. Fuel System Check Tips(3)

HP Pump Max Pressure Test
Purpose : In order to judge whether HP Pump generates its Max pressure, if out of spec, poor starting or poor acceleration can be occurred. Test Procedure : Disconnect IMV connector or fuse, Crank for 5 seconds and see if max pressure reaches up to 1050bar.

24

HP Pump Cranking Pressure Test

Purpose : In order to judge whether the cause of poor starting is due to high pressure system or others. Test Procedure : Disconnect CMP (Cam Position) sensor connector or fuse, Crank for 3 seconds and see if max pressure reaches at least 200bar.

How to use Scan-100 1. Select Data List 2. Select 09.Rail Pressure 3. Press Line Graph button 4. Press Bar button Check the time that the pressure reaches 200bar

P1191 P1191 1

P1253,1256,1258 P1253,1256,1258

Poor Starting Poor Starting

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. Fuel System Check Tips(4)

Low Pressure Line Visual Check

25

Purpose : In order to check if the cause of insufficient high pressure is due to air inflow, which may result in poor acceleration or poor starting.
HP Pump Inlet Priming Pump Fuel Filter Outlet

Part Name: Gauge-Low Pressure Check Procedure

1. Prepare a clear tube as shown in the figure. 2. Connect HP Pump Inlet and Fuel Filter Outlet by using a clear tube (Needs to modify the ends with quick connectors) 3. Supply fuel to HP Pump by using the priming pump. 4. Observe if air passes in the clear tube while cranking or engine idle. * Caution : Keep the cleanliness when the tube is installed.

P/Number: Y99220042B
P1191 P1191 Poor Starting Poor Starting Engine Stall Engine Stall Poor Acceleration Poor Acceleration

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. Fuel System Check Tips(5)

Injector Cleaning Mode
Purpose : In order to get rid of foreign matters, which may cause excessive back-leak from injectors. If the excessive back-leak is made by foreign matters, unnecessary replacement of injectors can be reduced by performing the cleaning mode.

26

Cleaning Procedure
When there is excessive back-leak from injectors causing engine poor power or engine stall, follow the below sequence. Disconnect the RPS connector after the engine warm-up when idling, ECU enters into Fail-safe mode, which the rail pressure maintains at 1800bar with pinging.

Rev the engine up to 3000rpm with fully accelerating, stop the engine after repeating 10 times.

P1191 P1191 P1253 P1253 P1256 P1256 P1258 P1258

Erase the DTC by using Scan-100 Through this process, the foreign matters on the injector control valve can be eliminated by ultra high pressure. If this cleaning mode reduces back-leak amount, but still not normal, additional conduct can be made. 1

Poor Starting Poor Starting Engine Stall Engine Stall

Poor Acceleration Poor Acceleration

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. Fuel System Check Tips(6)

IMV Cleaning Mode
Purpose : In order to get rid of foreign matters from IMV, which may cause rough idle, poor starting, engine stall or excessively high rail pressure due to the stuck open/close of IMV piston. Its recommended performing this mode before replacing the HP Pump or IMV.

27

Cleaning Procedure
If rough idle or excessive rail pressure exists without IMV related DTC, Follow the below procedure.

Take off IMV from HP Pump and connect IMV connector, and remove Screen Filter from IMV.

Turn the IG key on and drive the IMV by using Scan-100 with spraying cleaner, repeat Active/Stop for 2~3 minutes. Install the IMV after flushing in diesel and delete DTC Clean the IMV piston by spraying a WD-40 or Carburetor Cleaner for 2~3 min. With this process, Foreign matters can be removed, however, IMV malfunction itself wont be solved such as broken spring, damaged piston, etc. Caution) Before taking off IMV, make sure to spray with cleaner and blow out the HP Pump to keep the cleanliness, not allowed to wear cotton gloves. 1

Cases Cases P1191 P1191 Engine Stall Engine Stall Poor Starting Poor Starting
P1252,1254,1257,1259 P1252,1254,1257,1259

Poor Acceleration Poor Acceleration

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. Fuel System Check Tips(6)

IMV Cleaning Mode
1

28

IMV Cleaning Step IMV Cleaning Step

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. Fuel System Check Tips(7)

Freeze Frame Data Analysis
Purpose : ECU memorizes 8 items related with the DTC stored in ROM, these data give detailed information on the engine driving situation that ECU detected the DTC.

29
Poor Acceleration Poor Acceleration Engine Engine Stall Stall P1252 P1252

Data Analysis for Rail Pressure related DTC - Example : P1254_Rail Pressure Control Negative

1. In case that P1254 is detected. 2. Place the cursor to the DTC, if multiple. 3. Press the ENTER button, and Freeze Frame Data will be displayed as shown in the right figure.

4. Although IMV Open Demand is as low as 19%, which is requested to make the highest pressure of HP Pump, Rail Pressure Feedback shows only 220bar, which is much less than target pressure. - Normal Spec : Approx. 32% 250bar 5. In conclusion, the cause of DTC P1254 can be HP leak or poor HP generation. 1

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. Fuel System Check Tips(8)

Metal Chip Treatment
Purpose : When metal chips are found in the Venturi-Return, follow the below process in order to prevent 2nd trouble. Metal Chips can cause engine stall or poor starting How to find Metal Chips : See if there are metal chips after taking off the VenturiReturn .

30
Poor Acceleration Poor Acceleration

Poor Starting Poor Starting Cases Cases P1253 P1253 P1256 P1256 P1258 P1258 P1191 P1191 Engine Engine Stall Stall

Venturi-Return

Metal chips presence

1. 2. 3. 4. 5. 6.

Spray the cleaner and blow out in the area of Venturi-return. Remove the Venturi from HP Pump. To find metal chips, insert a magnet into the port. If confirmed metal chips, first clean HP pipes, fuel hoses and fuel tank by using diesel. Perform Injector Static Back-leak Test or Dynamic Back-leak Test after replacing HP Pump and filter. Replace all injectors and common rail if back-leak amount is out of spec. Make sure to keep cleanliness all the time. Recommend to use the above way of checking for metal chips than fuel filter checking. 1 2006 INVITATIONAL TRAINING

. Fuel System Check Tips(9)

HP Pump Components Information
No
1 4 5 6 7 8 9 11 12 15

31

Part Name
Fuel Pump Assy Pump Sprocket Sprocket Bolt Bearing Housing Bearing Shaft Pump Nut Injector Injector Clamp Injector Bolt Fuel Pipe(Cyl.1) Fuel Pipe(Cyl.1&3) Fuel Pipe(Cyl.1) Fuel Pipe(Cyl.2&4) Fuel Pipe(Cyl.3) Fuel Pipe(Cyl.5) Fuel Pipe

Part Number
6650700101 6640750329(D20DT) 6650750129(D27DT) 6679900404(D27DT) 6650700015 6650700014 4656008000 6640170021(D20DT) 6650170121(D27DT) 6650170003 6659900201 6640700033(D20) 6650700633(D27) 6640700133(D20) 6650700733(D27) 6640700333(D20) 6650700833(D27) 6640700032(D20) 6650700733(D27) 6640700195(D20) 6650700295(D27) 914020008011 914020008011 6640700181(D20) 6650700181(D27)

550,000 21,000 100 20,000 7,800 200 240,000 1,500 200 13,000

Torque (Nm)
20+90 656 10180 +20 404

16

13,000 13,000

404

17

404

18

24,000

404

23 24 25 26

Fuel Rail Assy Housing Bolt Fuel Rail Bolt Fuel Return Tube

220,000 200 200 2,900

252.5 252.5 252.5 -

2006 INVITATIONAL TRAINING

. Fuel System Check Tips(10)

Diagnostic Tool set for Fuel System
_ P/Number : Y99220012B

32

Configuration by function Injector Back-leak tester : Tool for Injector Dynamic/Static Back-leak test.

Close Rail (Rail Pressure Sensor) : Tool for HP Pump max Pressure check. Used with Rail Pressure Tester (Substitution for Scan-100) Rail Pressure Tester : Tool for HP Pump max pressure check. Used with Close Rail (Substitution for Scan-100) Coil for IMV check : To check IMV open/short circuit. - P0253/0255

2006 INVITATIONAL TRAINING

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Metal Chip Inspection through Venturi-return

Metal Chips Metal Chips

2006 INVITATIONAL TRAINING

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Remove IMV Fuse to perform Injector Dynamic Back-leak Test

Rexton
Max Pressure Test Max Pressure Test

Main Relay

Actyon/Kyron
Vacuum Modulator

IMV

2006 INVITATIONAL TRAINING

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IMV Cleaning Mode _ Step1

IMV Cleaning IMV Cleaning

2006 INVITATIONAL TRAINING

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IMV Cleaning Mode _ Step 2

2006 INVITATIONAL TRAINING

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IMV Cleaning Mode _ Step 3

2006 INVITATIONAL TRAINING