SsangYong Rexton. Service manual — part 144
DI10-181
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.4
Example of Pressure/Volume Loss in Pump
Pressure/Volume Loss in High Pressure Pump
When the required target pressure/volume cannot be delivered due to fuel supply line or pump damage
Ex.:
• Air in fuel supply line
• Excessive vacuum pressure in fuel supply line (-300 mbar)
• Burnt out or mechanically damaged pump
• Supply fuel with increased temperature ( > 65°C)
Y220_10065
Decreased pressure/volume from
pump
Pressure/volume loss
Pump capacity
Pressure/volume
build up
Pressure/volume
consumption
Fuel injection
volume
Injector back
leak volume
DI10-182
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.4
FUEL SYSTEM PRESSURE TEST
Test Tool Kit
For High Pressure Line
For Transfer Line
Y220_10066
Y220_10067
DI10-183
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.4
Prerequisite
1. Check the connections in fuel supply lines.
2. Check the fuel level in fuel tank.
3. Check if the air exists in fuel supply lines (air bubbles in fuel supply lines or fuel with air bubbles).
4. Check the fuel supply lines for leaks (transfer and high pressure).
5. Check if the specified fuel is used.
6. Check the fuel filter for contamination and abnormality.
Fuel System Test Process
Determine DTC
DTC Detected?
Fuel system
related DTC:
P1252, P1253,
P1254...P0251
High pressure fuel
related problem
No
No
Yes
no
Check and repair
transfer and H/P fuel
system
Check fuel filter and H/P
fuel system
Diagnose and repair
according to the de-
tected DTC
Notice
If more than one DTC have been detected, check the wiring
harness for open or short first.
Check the transfer fuel system and fuel filter before
proceeding the high pressure fuel system check in next page.
DI10-184
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.4
FUEL SYSTEM CHECK PROCESS
Initial Check
• Transfer fuel system (air in system), specified fuel used
• Fuel leaks, fuel filter
• Diagnostic Trouble Code
• Wiring harness
• Abnormal noise from injector
No Abnormality
in Initial Check?
No
Check and repair
No
Check transfer fuel system (refer to 4-2)
Install the transparent tube between fuel
filter and priming pump. Check the trans-
fer fuel system for clogged or air bubbles.
Check if the vacuum pressure is proper.
Check the injector
back leak volume
Replace high pressure pump
Yes
Yes
No
Yes
No
Yes
Yes
Replace the injector
Enter new injector C2I data into ECU
after replacing the injector
Replace the injector
Enter new injector C2I data into ECU
after replacing the injector
Perform the initial check again.
Method 1
Method 2
Dynamic Test for Injector Back leak Volume (refer to 4-4)
(with engine running)
1. Warm up engine (coolant temp.: over 60°C), place an
empty plastic container under the return of injector, and
start engine.
2. Run the engine for 30 seconds at idle speed, perform :
fuel system pressure leakage test” with Scan-i, and
check the fuel level in container. It should be over 38 ml.
Check fuel rail pressure (refer to 4-1)
When cranking engine for 5 seconds
after disconnecting IMV connector, is
the rail pressure over 1,050 bar?
* Thoroughly clean the components
before installation
High Pressure Pump Test (refer to 4-5)
Install the closed rail into high pressure
pump at outlet port. Remove IMV connector
and crank engine for 5 seconds. Is the pres-
sure over 1,050 bar?
Static Test for Injector Back leak Volume
(refer to 4-3)
(with engine cranking but not running)
Place an empty plastic container under the return of
injector:
Remove IMV and injector connectors, crank for 5
seconds, and check the injector back leak volume.
The fuel length in tube should be over 20 cm.
No
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