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COMMON RAIL
(Delphi)
Chonan Technical Service Training Center
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Fuel System
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Common Rail System
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Linear
rail
Injector
HP pump
Fuel filter
Electronic
control unit
Diesel injection main
Components
Common Rail System
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Linear
rail
Injector
HP pump
Fuel filter
Electronic
control unit
Diesel injection main
Components
Common Rail System
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High Pressure Pump
Transfer pressure
regulation valve
LP supply
Venturi
Pressure limiter
Diesel oil
temperature sensor
IMV
HP outlet (to the
rail)
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High Pressure Pump
1Inlet MeteringValve(IMV)
2 Hydraulic Head
3 Plunger
4Drive Shaft +
Cam Ring
5 Housing
6 Roller + Shoe
7Transfer PressurePump
8Temperature
Sensor
9 Venting
10Outlet HighPressure Flange
11Transfer PressureRegulator
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High Pressure Pump
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High Pressure Pump
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High Pressure Pump
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Low Pressure(Feed) Pump of High Pressure Pump
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Common Rail (Linear Rail)
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Common Rail (Linear Rail)
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Common Rail (Linear Rail)
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High Pressure Pipes
1. 4 HP pipes rail / injector
2. 1 HP pipe pump / rail
If the Injector or main rail feed pipes are
removed they MUST BE REPLACED WITH
NEW
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Injector
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Injector Operation
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Injector Operation (Phase 1)
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Injector Operation (Phase 2)
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Injector Operation (Phase 3)
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Injector Operation (Phase 4)
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CII for A/S
CII for
production
Calibration Individual Injector
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Individual Injector Correction
To displayCurrent CII
To eraseCurrent CII
Selection of Injectorto change CII
* CII : Calibration Individual Injector
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Information
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Cleared(Default Value)
If CII is cleared from ECM- DTC(P1300 INJECTOR CORRECTION DATA)is set- Failsafe mode and fixed 1250rpm- No acceleration- Check engine lamp on
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Ignition ON, Engine StopThe correction is impossible on Engine Running Condition
ECM
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ECM
Connection
I t / O t t
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AFSAccelerator pedal sensorCMP sensorCKP sensorRail Pressure sensorKnock sensor Accelerometer)Fuel Temperature sensorECT sensorIAT sensorVehicle Speed sensorBrake switchClutch switch M/T)A/C switchA/C Pressure sensor
Input / Output
ECM
Main RelayInjectorCooling Fan controlAir HeaterEGR ValveMIL lampInlet Metering Valve
IMV (Inlet Metering Valve)
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IMV (Inlet Metering Valve)
IMV (Inlet Metering Valve)
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IMV (Inlet Metering Valve)
Fuel Temperature Sensor
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Fuel Temperature Sensor
Venturi
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Venturi
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Auxiliary
Ai I t k H t
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Air Intake Heater
Air Intake manifold
Air Intake heater
Ai I t k H t
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Air Intake Heater
Heater element
Air Intake Heater
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Engine speed
Flow requested
Coolant temperature
DCU
+Bat
Preheating warninglight
Atmospheric pressure
CMEC2
CMED2
CMIJ2
CMED3
CHA1
Battery voltage
+AC
+AC
Preheating resistors
AH control relay
ECM
Air Intake Heater
Air Intake Heater
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Coolant temperature (C) -20 -10 0 20 80
Duration of post-heating (s) 100 50 25 10 10
Engine coolant
temperature
(C)
-30 -25 -20 -15 -10 -5 0 20
Illumination (s) 28 25 15 10 5 3 2 0
Pre-heating
Post-heating
Variable p reheating
Fixed preheating
This begins when the preheating warning light extinguishes. During this second phase, the
preheating resistors remain supplied for 5 seconds.
Air Intake Heater
Exhaust Gas Return (EGR)
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Exhaust Gas Return (EGR)
EGR Valve
Solenoid Valve
EGR Cooler (Heat Exchanger)
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EGR Cooler (Heat Exchanger)
Heat exchanger
Mass Air Flow Sensor
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Mass Air Flow Sensor
Mass Air Flow Sensor
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Mass Air Flow Sensor
Fuel Heater
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Fuel Heater
Fuel
heater Fuel
filter
Priming
pump
Outlet
Inlet
Priming Pump
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Priming Pump
From
fuel tank
To
fuel filter
Accelerator Pedal Position Sensor
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Accelerator Pedal Position Sensor
Fuel Filter
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Fuel Filter
Fuel Input
Fuel Input
Fuel Output
Fuel Filter (Recirculation)
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Fuel Filter (Recirculation)
To Pump
From Pump
To Pump
From Pump
To Tank
Cold
Hot
Fuel Filter
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Fuel Filter
Bi-metal strip
Steel ball
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Handling
Safety Instructions
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It is strictly prohibited to smoke or to eat while working on the Common
Rail injection system.
It is essential to disconnect the battery before any work is done on the
Common Rail injection system.
It is strictly forbidden to work on the Common Rail injection system
with the engine running.
It is necessary to read the value of the rail pressure and of the diesel oil
temperature with the engine running.
It is necessary to read the value of the rail pressure and of the diesel oil
temperature with the aid of the diagnostic tool before any work is done on
the fuel circuit. The opening of the circuit can only begin if the diesel oiltemperature is less than 50C(122 F) and the rail pressure is close to 0
bar. If it is not possible to communicate with the computer, wait for 5
minutes after the engine has stopped before starting any work on the fuel
circuit.
Safety Instructions
Safety Instructions
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Safety Instructions
It is strictly prohibited to supply an actuator directly off an external power supply.
The injector must not be dismantled.
The HP sensor must not be removed from the rail. If the HP sensor fails, It is
essential to replace the complete rail.
The IMV, the diesel temperature sensor and the venturi must not be removed
from the pump. If one of these components is faulty, the whole pump mustbe replaced.
The HP pipes are not reusable : a removed pipe must be replaced.
Decarbonizing the injector in an ultrasonic bath is strictly prohibited.
The computers metal casing must never be used as an earth.
The packaging of the spare parts should be opened just before they are used.Moreover, the sealing plugs must not be removed until the final connection is made.The plugs and the sealed pouches must be discarded after use.
Removal a rail/injector pipe(rail/HP pump)
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Removal a rail/injector pipe(rail/HP pump)1. Clean the nuts of the HP unionswith a solvent (CARCLEAN type)
applied with a clean brush.
2. Vacuum the particles with the aidof a BLOVAC BV11 type suctiondevice(Figure4).
Removal a rail/injector pipe(rail/HP pump)
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Removal a rail/injector pipe(rail/HP pump)3. Disconnect the injector with the aid of pliers, applying
pressure to the locking clips on the side of the connector.
Removal a rail/injector pipe (rail/HP pump)
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Removal a rail/injector pipe (rail/HP pump)
4.. Slacken the nut screwed onto theinjector using a 17 mm(0.67 in) openwrench(Figure4)
5. Slacken the nut screwed onto the railusing a 17 mm(0.67 in) openwrench(Figure 5).
* NoticeIt is important to positions the wrench
level with the solid end of the nut, inorder to apply the stresses to thestrongest part of the nut. If the torque isapplied to the open end of the nut,.There is a risk of distortion of the nutwhen it is tightened. Or use a pipe-wrench with cloth.
Removal a rail/injector pipe (rail/HP pump)
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Removal a rail/injector pipe (rail/HP pump)
6. Move the nut along the pipe, keepingthe olive in contract with the injectorcone(Figure 6) and vacuum the particlesin the contact area between the oliveand the cone, using a pneumatic suctiondevice.
7. Carry out the same operation on the railside.
8. Remove the pipe and vacuum theparticles inside the injector cone with theaid of the pneumatic suction device(Figure 7).
Removal a rail/injector pipe (rail/HP pump)
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Removal a rail/injector pipe (rail/HP pump)
9. Carry out the same operation on the rail side.
10. Immediately seal the HP outlets with the aid of the recommendedplugs (Figure 8).
Plugs
Assembly a rail/injector pipe (rail/HP pump)
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Assembly a rail/injector pipe (rail/HP pump)
1. Take the new pipe out of its packingjust before fitting it.
* WARNINGIT IS FORBIDDEN TO RE-USE AN
OLD PIPE.
2. Remove the plug inserted at each endof pipe.
3. Lubricate the threads of the nuts withthe lubricant supplied in the kit beforefitting the pip(Figure 9)
4. Remove the protective plugs from theHP outlets of the rail and the injector.
* WARINGTHE PLUGS MUST BE DISCARDEDAFTER USE
5. Fit the pipe olive into the injector coneand the rail cone. Tighten the nut by hand(Figure 10).
Assembly a rail/injector pipe (rail/HP pump)
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Assembly a rail/injector pipe (rail/HP pump)
6 Fit the pipe olive into the railcone and tighten the nut byhand
7. Tighten the nut on the
injector side to 40 Nm(29.5lb-ft), applying reversetorque with the support toolfor the injector holder(Figure 12).
Assembly a rail/injector pipe (rail/HP pump)
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Assembly a rail/injector pipe (rail/HP pump)
* Notice
When tightening the nut, ensure
that the connector remainsaligned with the injector row axis(Figure 13).
7. Tighten the nut on the rail side toa torque of 40 Nm(29.5 lb-ft)
ESSNTIAL
To validate the repair, startthe engine an check thetightness of the HP connection.
Injector holder-removal
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Injector holder removal
1. Remove the HP pipe of the injectorbeing removed (following the methodindicated in refer to page).
2. Disconnect the injector connector
3. Disconnect the injector leakage returnhose(Figure2).
4. Slacken off the flange of the injectorholder(Figure3).
5. Remove the injector with the flangeand its bolts.Use a special tool if the injector is stuck.
Assembly of injector holder
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Assembly of injector holder
1. Clean the socket of the injector holder andvacuum the particles using the pneumaticsuction device(Figure 5).
2. Clean the flange of the injector holder withsolvent (CARCLEAN type) using a cleanbrush.
3. Place a new heat protection washer on theseat of the injector holder.
* WARNINGIT IS PROHIBITED TO RE-USE AN OLDHEAT PROTECTION WASHER!
4. Fit the injector holder with its flange.
5. Tighten the injector holder flange bolt to a
torque of 19 Nm(14.01 lb-ft)(Figure 6).
6. Reconnect the return hose of the injectorholder. Reconnect the injector connector.
7. Reassembly the HP pipe, referring to themethod described in page.
Delphi Common Rail Cap Kit
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p p
Delphi Common Rail Cap Kit
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p p
Delphi Common Rail Cap Kit
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p p
Delphi Common Rail Cap Kit
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p p