Page 309 - CTS - Mechanic Diesel - TP

MECHANIC DIESEL - CITS

TASK 4: Removal and Refitting of High pressure pump
1 Relieve the fuel pressure on the high pressure circuit

2 Disconnect the battery negative cable
3 Remove Engine cover
4 Remove high pressure pipe between high pressure pump and common rail
5 Remove fuel return hose from high pressure pump
6 Disconnect the high pressure pump metering solenoid connector
7 Remove High pressure pump supporting Bolts on Engine

8 Remove high pressure pump from engine
9 Check the High pressure pump drive gear/coupling. If it is damaged, Replace with new one
10 Clean mating surface of high pressure pump and engine
11 Install a new gasket

12 Mount the pump and Tighten the mounting bolts with specified torque
13 Reconnect the High pressure pipe line to common rail and Fuel return line
14 Reconnect the metering solenoid wiring connector
15 Re fix the engine cover
16 Connect Battery negative cable

17 Start engine and Check for fuel leakage

TASK 5: Checking of fuel Injector leak
1 Turn OFF ignition switch.
2 Disconnect all Injectors wiring connectors.
3 Remove the lock clips from Injectors and Disconnect the fuel return hose from all fuel Injectors.

4 Plug the fuel return hoses.
5 Connect the measuring Jars (special tools) with fuel Injectors.
6 Crane Engine for 5 seconds.
7 Check the fuel return Quantity from each Injector is approximately same and little. If more volume of fuel
returns replace that fuel Injector.

TASK 6: Checking of high pressure fuel circuit
1 Turn Ignition switch off.
2 Disconnect the wiring connectors from all Injectors.

3 Connect the scan tool to Data line connector.
4 Crane the engine for 5 seconds.
5 Check the fuel pressure shown on scan tool.If it is more than 300 bar when the engine speed is more than 200
rpm then it is ok.If not check and replace fuel pressure sensor and fuel pressure regulator.

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CITS : Automotive - Mechanic Diesel - Exercise 17.2