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
Filter to be drained periodically during service
➢Transit damage
Use correct pump packing box
– 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
➢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 Reason | 2nd Level Reason | 3rd Level Reason | Action |
|---|---|---|---|
| no power supply to ECU | battery level low | replace battery | |
| power supply disturbed | |||
| no fuel supply to HP pump | insufficient fuel flow from tank | low fuel level | refill fuel |
| strainer in fuel tank chocked | check fuel tank | ||
| air lock in system | clear air lock | ||
| air entry in system | fuel pipe clamp losen | tighten low pressure circuit | |
| fuel filter chocked | change filter | ||
| fuel filter flap blocked open | change/repair | ||
| Irreversible error recorded | Clear the error memory | ||
| Check for system error | Rectify in case of error | ||
| starter not OK |
2. Power loss
Probable Related Error Code : P 1192 /1193
| 1st Level Reason | 2nd Level Reason | 3rd Level Reason | Action |
|---|---|---|---|
| air system error | air filter clogged | replace air filter | |
| MAF sensor signal nok | MAF sensor dirty | clean & check for cause of dirt | |
| MAF sensor defect | replace MAF sensor | ||
| air leakage in intake system | leakage on pipes | replace pipes | |
| leakage on manifold | replace manifold | ||
| leakage on intercooler | replace intercooler | ||
| EGR error | EGR valve stucked | no vacuum to EGR | check modulator |
| EGR lever broken | check EGR | ||
| turbo charger malfunction | VTG stucked | VTG not actuated | check modulator and pipes |
| rotor stucked | replace turbocharger | ||
| rail pressure deviation | fuel supply to rail nok | fuel filter choked | change fuel filter |
| HP pump nok | check HP pump | ||
| system internal leakage | injector nok | check injector | |
| Rail DRV nok | check DRV | ||
| Check for system error | Rectify in case of error |
3. Vibration /jerky
Probable Related Error Code: P1192
| 1st Level Reason | 2nd Level Reason | 3rd Level Reason | Action |
|---|---|---|---|
| combustion nok | Injector IQA not matching | Check and reflash IQA | |
| Injector not firing | wiring harness nok | check harness | |
| connection nok | check connector | ||
| engine friction | power loss in cylinder | check compression | |
| air lock in system | check for air lock and clear it | ||
| Check for system error | Rectify in case of error |
Download: REPAIR GUIDE FOR DENSO COMMON RAIL INJECTOR REPAIR
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