engine does not start

7/30/2019 Engine Does Not Start

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Diagnostic procedures (Carnival J2.9 CRDi).1. Engine does not start.

1-1) Back leak Test (Static).

1) Remove the engine cover and intercooler.

2) Remove the back leak hose from eachinjector (4EA).

Back leak tester.

3) Install the visible hoses of the back leak tester

to the injector fuel return hole (4EA)

as shown in the pictures.


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4) Disconnect the common injector connector.

- The ECM cannot operate the injectors .

from the high pressure pump side.

pressure while the is engine cranking.

High pressure gauge set.-When you want to check the high pressure,turn on the power switch after connecting theline to the battery and rail pressure regulatingvalve

6) Connect the high pressure gauge set to the battery

and rail pressure sensor after

disconnecting the rail pressure sensor connector.

5) Disconnect the IMV(Inlet Metering Valve) connector

- High pressure pump operates with maximum

To battery

To rail pressuresensor


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- Read the maximum pressure on the highpressure gauge set while cranking.

Normal pressure : Above 1050 bars.

- Measure the length of the back leaked fuelin each visible hose.

(See pictures).

- Measure and compare each back leaked

fuel amount in the visible hoses.

- Make sure to conduct a back leak test

at least twice

Notice : Do not replace all injectors simultaneously.

Common rail sensor & tester abnormal

HP pump abnormal

3 200 ~ 1050 bars 20 ~ 50 cm Injector abnormal

Result1 1050 ~ 1500 bars 0 ~ 20 cm Normal (HP pump & Injector)

High pressure Injector back leak length

2 0 ~ 1050 bars 0 ~ 20 cm

4 Out of range 0 ~ 20 cm

7) Crank the engine for 5 ~ 6 seconds.

Result of High pressure pump & Injector back leak test.Case

Back leaked fuel length


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1-2) Hi pressure pump test (Capacity)

1) Remove the fuel injector pipes (4 EA)between the common rail and injector.

- The injector hole should be covered bya dust cap.

SST for high pressure pump test Pressure regulator.

Dust cap.

Plug.

2) Install the pressure regulator (1EA) and

plugs (3EA) from the CRDi SST set.

3) Connect the high pressure gauge set tothe battery and rail pressure sensor afterdisconnecting the rail pressure sensorconnector.

1

3

2


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1-2) Hi pressure pump test (Capacity)

4) Disconnect the IMV connector from the highpressure pump side.

- Press the hand priming pump several times.

5) Crank the engine for 5~6 seconds.

6) Measure the fuel pressure with a highpressure gauge set while cranking the engine

- Make sure to conduct the high pressure pump

test at least twice.

Note : Before replacing the High pressure pump, check the metal chip in the fuel filter first.

If metal chips are found in the fuel filter, flush the fuel line, inclusive of the fuel

tank, and replace the parts as needed.

2

Case High pressure Result Remark Result of High pressure pump test.

0 ~ 1050 bars High pressure pump abnormal

1 1050 ~ 1500 bars Normal (High pressure pump)

Check the low pressure line

3 Out of range Common rail sensor abnormal Check the rail sensor & tester

Priming pump

Sensor abnormal Low Pressure Normal


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1-3) Low pressure line test

Low pressure line tester (Vacuum).- Be sure to use a vaccum gauge because

the fuel feeding pump is inside the HP pump.

1) Disconnect the fuel hose between the outlet

port of the fuel filter and the inlet port fuel hoseof the high pressure pump.

2) Install a low pressure gauge between thefuel filter outlet port and the high pressurepump inlet port.

3) Remove the air in the low fuel line by usinga hand priming pump.

Fuel filter Hi pressure pump


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1-3) Low pressure line test

4) Check air infiltration while crankingthe engine.If you can see excessive air bubbles in the fuel

line, then check the fuel line from the fuel tankto filter outlet port.

5) Check for low pressures at the low pressure line

while cranking the engine.

3 0 ~ 7 cmHg

1 8 ~ 19 cmHg

2 20 ~ 60 cmHg

Vacuumase Result of Low pressure line test.

ResultSystem normal

Filter or Fuel line clogging

Air leak in the system / Suction pump Damage

Remark


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1-4) Flushing procedure for injection pipe and common rail

Make sure to clean the injection pipes andcommon rail before assembling.

1) Make sure to clean the injection pipesby using air gun.

2) Temporarily tighten the injection pipes usinghand to the common rail side and injector sideas shown in the picture.

3) Disconnect the IMV connector from the IMVon the high pressure pump.

4) Crank the engine 2~3 times for 5~6 seconds.

5) Remove all test components and assemble the

injection pipes to the common rail and injectors

6) Install the IMV connector to the IMV inthe high pressure pump.

7) Tighten the all injection pipes.

8) Make sure to clean the leaked fuel.

9) Check for fuel leakage in the fuel system afterstarting the engine.

Fuel pipe end

Cleaning by air gun

Air gun nozzle

Temporarity tightenthe injection pipes


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Diagnostic procedures (Carnival J2.9 CRDi).2. Engine possible to start.

2-1) Back leak Test (dynamic).

1) Remove the engine cover and intercooler.

2) Remove the back leak hose from eachinjector (4EA).

3) Install the visible hoses of the back leak tester

to the injector fuel return hole (4EA)as shown in the pictures.

4) Run the engine and keep it at idle for3 min., then raise the engine rpm to2500 rpm, and keep at 2500 rpm for 2minutes. After 2 minutes, stop the engine.

5) Measure the amount of fuel leakage.

- Measure and compare the volume of the backleaked fuel from each bottle.

- If the measured volume is above 25ml,replace the injector.

- Perform the back leak test again with thenewly replaced injector.


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2. Parts Required.

QtyGQ00/HP00:

33800-4X500.

GQ02:

33801-4X500

HP02:33801-4X800

CT/PU:

33801-4X900

GQ: (Europe)

0K52A 13480A

HP: (Europe)

31390H1952

HP: (India & S. Ameri)

31390H1970


31392H1970

GQ00/HP00:

33100-4X500

GQ02/HP02/CT/PU:

33100-4X700

GQ00/HP00:

31500-4X500

GQ02/HP02/CT/PU:31500-4X700

GQ: (Europe)

0K52A 13480A

HP: (Europe)

31390H1952


31390H1970


31392H1970

For India & South

American, Delphi

recommends the use

of a sedimentor.

Remark

Damaged injectoronly

1

1

1

1Damaged highpressure pump

1

Includes gasket

For India & South

American, Delphi

recommends the use

of a sedimentor.

Condition Part Name Part Number

engine does not start

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