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Troubleshooting Common Rail (CR) System

Troubleshooting Common Rail (CR) System

High-pressure pump related issues

P-code Error: 1192 / 1193 / 1250 / 1251

➢Not starting due to rust formation (bad fuel quality/water entry)




Read: Common Problems of the Fuel Delivery System

Common Problems of the Fuel Delivery System
Common Problems of the Fuel Delivery System

Filter to be drained periodically during service

➢Transit damage

Use correct pump packing box

Transit damage
Transit damage

Education and-customer on water draining frequency & fuel filter change interval –

Pump / Fuel Filter Related Issues

P-code Error: 1192 / 1193

➢Wrong removal of the pump for starting problem issues

  • Due to airlock in LPC
  • Due to fuel filter check
  • Particle in filter flap

– Cleanliness level in the tank to be maintained – 

Spec for Pressure drop –0.4 bar max

➢Few filters pressure drop found more than 1bar

➢Particle found in the flap area

– Education and-customer on water draining frequency & fuel filter change interval –

Injector related issues

➢Not starting, late-starting &abnormal noise due to valve seat wear.

P-code error:

  • 1192
  • 1193
  • 1201/0201
  • 1202/0202
Valve seat wear due to foreign particle entry / bad fuel

Rust on valve spool due to a bad fuel

➢Knocking due to foreign particle in A / Zthrottle


– Cleanliness to be taken care of while servicing & Use good fuel –

Injector Related Issues

Conforming to specification:

➢Wrong removal of injectors

  • for high smoke-related issues
  • for knocking related issues

Check the following steps before removing injectors:

1.Error code using a diagnostic tool

2.Check whether IQA/ IMA code on Injector & ECU is matching

3.Back leak quantity check at idle-speed

4.Total injected quantity check at idle-speed

5.Check for the presence of all injections (Pil1, Pil2 & Maininjection)

6.FBC check at idle-speed

Note: FBC check is an approximate check. The FBC variation may be due to one of the following other than the injectors

  • Higher friction between block/piston or engine
  • Piston ring wear or Piston/block wear

Following checks to be done before removal of injectors –

Conforming to specification:

➢Wrong removal of rail due to Low-pressure circuit-related issue

Eg: P1192, P1193 error (rail pr. deviation) is fuel related issues like leakage, air entry, fuel starvation, no fuel supply

Non-Bosch responsibility:

➢Not starting due entry of foreign liquid residue into RDS (Rail pr. Sensor).

P-code Error: 0192 / 0193

Cleanliness to be taken care of while servicing –

ECU Related Issues

➢Not starting, engine goes to limp-home mode

P-code Error:1250 / 1252

P-code Error: 0123

– Care has to be taken while servicing. Avoid jump-starting, ensure proper grounding, avoid using open-ended wires (causing short circuit) –

The complexity of diagnosis on CR diesel engines


Failure Allocation: Consequences

Common Rail System

A systematic approach to problem-solving

1. Engine not starting

Probable Related Error Code: P 1192 / 1193 / 1250 / 0192 /0193

1st Level Reason2nd Level Reason3rd Level ReasonAction
no power supply to ECUbattery level lowreplace battery
power supply disturbed
no fuel supply to HP pumpinsufficient fuel flow from tanklow fuel levelrefill fuel
strainer in fuel tank chockedcheck fuel tank
air lock in systemclear air lock
air entry in systemfuel pipe clamp losentighten low pressure circuit
fuel filter chockedchange filter
fuel filter flap blocked openchange/repair
Irreversible error recordedClear the error memory
Check for system errorRectify in case of error
starter not OK

2. Power loss 

  Probable Related Error Code : P 1192 /1193

1st Level Reason2nd Level Reason3rd Level ReasonAction
air system errorair filter cloggedreplace air filter
MAF sensor signal nokMAF sensor dirtyclean & check for cause of dirt
MAF sensor defectreplace MAF sensor
air leakage in intake systemleakage on pipesreplace pipes
leakage on manifoldreplace manifold
leakage on intercoolerreplace intercooler
EGR errorEGR valve stuckedno vacuum to EGRcheck modulator
EGR lever brokencheck EGR
turbo charger malfunctionVTG stuckedVTG not actuatedcheck modulator and pipes
rotor stuckedreplace turbocharger
rail pressure deviationfuel supply to rail nokfuel filter chokedchange fuel filter
HP pump nokcheck HP pump
system internal leakageinjector nokcheck injector
Rail DRV nokcheck DRV
Check for system errorRectify in case of error

3. Vibration /jerky

Probable Related Error Code: P1192

1st Level Reason2nd Level Reason3rd Level ReasonAction
combustion nokInjector IQA not matchingCheck and reflash IQA
Injector not firingwiring harness nokcheck harness
connection nokcheck connector
engine frictionpower loss in cylindercheck compression
air lock in systemcheck for air lock and clear it
Check for system errorRectify in case of error

Download: REPAIR GUIDE FOR DENSO COMMON RAIL INJECTOR REPAIR

REPAIR GUIDE FOR DENSO COMMON RAIL INJECTOR REPAIR
REPAIR GUIDE FOR DENSO COMMON RAIL INJECTOR REPAIR

Diesel Black Smoke: Reasons And Solutions
Diesel Black Smoke: Reasons And Solutions

Ekster EU

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