Delphi HP Pump Diagnosis
Delphi HP Pump Diagnosis
Delphi HP Pump Diagnosis
Engine : D20DT / D27DT Subject : HP Pump Diagnosis Date : March .13 . 2006 Instructor : Brian Cho
1 2006 INVITATIONAL TRAINING
Contents
I. II. III. HP Pump Overview Cases & Improvements Diagnostics by DTCs
. HP Pump Overview
HP Pump Structure
Low Pressure Regulator Fuel Temp Sensor
Venturi Return Fuel Outlet Port High Pressure Regulator (To Common Rail)
4 1 2 3 5
1. 2. 3. 4. 5.
Transfer Pump & Housing Drive shaft & Driven Cam Roller & Shoe Fuel Temp Sensor Inlet Metering Valve
. HP Pump Overview
Components by Function
Component Function
Driven by 4 vanes, 6bar low pressure generation transfer to Hydraulic head 2 couples of Shoe&Roller, High pressure generation over 250bar accumulation in C.R High pressure regulator controlled by ECU Sensing the fuel temperature transferred to hydraulic head, Reduction of fuel injection amount at hot condition(90) Regulating HP Pump internal high/low pressure to secure stable supply Return port, joining 2 flows one for lubrication and the other for back leak from injectors
Parts supply
HP Pump ASSY
(P/N: 6650700101)
Transfer Pump
HP Pump ASSY
Security mechanism, rare possibility of malfunction Can be used to identify metal chips caused from roller abrasion after taking it off
HP Pump ASSY
HP Pump ASSY
. HP Pump Overview
High Pressure Generation
L/P Regulator(6bar) IMV H/P Limiter
L/P Circuit
: L/P system functions supplying sufficient fuel to hydraulic head Fuel Tank Priming Pump Fuel Filter Transfer Pump Inlet Metering Valve
Transfer Pump
H/P Pump
H/P Circuit
Supply Pump Suction Valve
: H/P system functions generating and accumulating fuel that injectors need. H/P Pump Common Rail H/P Pipes Injectors
Insufficient fuel supply to transfer pump due to air inflow. Abrasion of HP Pump IMV related troubles Injector related troubles
. HP Pump Overview
Inlet Metering Valve _ Fuel Pressure Regulator
Current vs Quantity
Eng RPM APS Signal RPS Signal
Required Quantity and Rail Pressure calculation
Input
IMV Control
Quantity (l/hr)
ECU
Current Control
Current (mA) IMV Function Rail pressure control by regulating fuel amount transferring to the hydraulic head Improves injection efficiency In case of no electric power Max Quantity to the hydraulic head As current increases, quantity decreases (Normal Open Type)
Type
Symptom HP Pump Flange Bolt Broken & Fuel Leak Hard start, Poor acceleration, Stall Impossible to start, Poor acceleration Engine stall while driving Engine stall while driving Impossible to start Intermittent Eng Check Lamp ON, Engine stall HP Pump housing leak Engine noise, Engine oil leak
Cause Insufficient absorption of engine vibration by clamp rubber bush IMV stuck, Transfer pump spring damaged, etc. HP Pump internal abrasion caused metal chips in fuel line IMV connector unsecured IMV internally Stuck Unsecured water sensor in fuel filter caused air infiltration P1253 displayed, Foreign material blocked the fuel sender in fuel tank. Hydraulic head seal assembled pinched One of the HP Pump Sprocket fixing bolts unscrewed caused timing chain & pump damaged
Action Replaced flange bolt & clamp rubber bush Improved quality Replaced HP Pump & Fuel Filter, etc. Secured the connector Replaced IMV (or HP Pump) Secured water sensor Removed the foreign materials Replaced HP Pump Replaced Timing chain, HP Pump and Timing Case
Remark Refer to work procedure Refer to HP Pump Improvement Refer to Metal chip repair Refer to IMV Open circuit Refer to IMV Cleaning Refer to hard start Refer to P1253 diagnosis -
Quality
Quality
Case
Rexton
Case
Rexton
Case
Rexton
Case
Rodius/ Kyron
Case
Rexton
Case
Rexton
Case
7
Quality Quality
Nut B
HP Pipe Tightening Torque : 40 4Nm Replace new rubber bush Mounting bracket tightening torque : 8.9 0.9Nm
8
Quality Quality
Improvement Details 1.TRANSFER PUMP SPRING CRACK [A] 1) Improved spring wire drawing process and changed inspection system 2) Changed the number of spring pitch and the shape of vane (Step Taper) 2.ROLLER&SHOE SCUFFING [B] 1) Necessary to improve the quality of fuel 3. IMV VALVE STUCK [C] - Strengthen engineering spec and crimping condition in assembly line - Strengthen sampling inspection
Probable Causes
Fuel temp signal line shorted to ground or sensor faulty Fuel temp signal line open or sensor faulty IMV drive line shorted to battery or IMV faulty IMV drive line shorted to ground or IMV faulty IMV drive line open or IMV faulty Too much delay of high pressure generation while cranking. IMV faulty or low pressure line abnormal Rail pressure much higher than ECU calculation, IMV faulty or RPS faulty Rail pressure much less than ECU calculation, low pressure line abnormal or excessive back leak.
Fail-safe
ECU reckons fuel temp as 95 and reduces engine max power ECU reckons fuel temp as 95 and reduces engine max power Increases to 1500rpm, engine stalls 1 minute later and not allow to restart Increases to 1500rpm, engine stalls 1 minute later and not allow to restart Increases to 1500rpm, engine stalls 1 minute later and not allow to restart Hard start
P0182 P0183 P0251 P0253 P0255 P1191 P1252 P1253 P1256 P1258 P1254 P1257 P1259
Rail pressure much higher than ECU calculation, IMV faulty or RPS faulty
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DTC DTC
ECU
Yes
No
Sensor internally shorted , replace it
No
Yes
Not current trouble, Check if the 5v drops when shaking each connector and wire between sensor and ECU
Non-continuity
Continuity
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DTC DTC
ECU
Yes
b. Check the voltage at #1 terminal after disconnecting sensor connector 3 when IG ON. Must be approx.5v
No
Yes
c. Check the voltage at #19 terminal after disconnecting connector 2 when IG ON, must be approx.5v
Yes No
d. Check the voltage at #109 terminal with connecting connector1,must be approx.5v
No
. When checking connectors, see if wires are damaged in between connectors. Fuel temp sensor circuit
12
DTC DTC Cases Cases
ECU
1
Yes No
7.5A IMV FUSE (F64)
b. Check the voltage at #87 terminal after disconnecting connector 3 when IG ON, must be approx 2v.
2
Disconnect C115 and check the voltage at IMV #2 terminal, if the 12v continues to be checked, find shorted area in between 2 and 3. Disconnect C115 and check the voltage at ECU #87 terminal, if the 12v continues to be checked, find shorted area in between 2 and 1.
C115
12V
2V 12V
IMV Circuit
13
DTC DTC Cases Cases
ECU
1
Below 1v
Yes
7.5A IMV FUSE (F64)
C115
Below 1v
Yes
c. Disconnect the C115 and connector 1, and conduct the continuity test between #87 and body. must not be in continuity
Continuity
Non-continuity
d. ECU internally shorted. Replace it
IMV Circuit
14
DTC DTC Cases Cases
ECU
approx 2.3V
b. Conduct the continuity test between #87 and #2 after disconnecting the connector 1 and 3 :
If #87 terminal is OK, its not current trouble. needs to check connector 2,3 and fuse box
C115
contact
15
DTC DTC Cases Cases
P1253 P1253 P1256 P1256 P1258 P1258
No current trouble in HP line. If the DTC stores at every cranking with normal starting. faulty ECU can be suspected.
Normal
Air Inflow
Low pressure line checks : - Check for water sensor tightening in fuel filter - Check for tiny hole in low pressure hoses (by applying high pressure air) -Check for clogging of fuel sender inlet pipe by foreign matters.
Normal
d. HP Pump malfunction - Pump abrasion or IMV stuck open Replace the corresponding injector even after performing
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DTC DTC
ECU
b-2. Check if #09. Rail Pressure value while stall test from Scan-100 Data List is similar as other cars. Nevertheless, if engine power is poor, RPS or RPS signal wire faulty is suspected.
C115
Trouble continues
Trouble solved
RPS resistance check RPS signal wire resistance check - After disconnecting connector 3 and1, must be less than 1
RPS Circuit
17
DTC DTC Cases Cases
Pressure Test Cranking Pressure Below 200bar Max Pressure Above 1050bar Max Pressure Below 1050bar / Poor Start
In case of intermittent trouble, mostly caused by air inflow or restricted low pressure line by foreign matters.
b-2. Check if there is Metal Chip in the Venturi-Return. If found, follow the instruction
No current trouble in fuel system - Possible to exist an intermittently restricted low pressure line by foreign matters - Possible to exist an air inflow in low pressure line, etc.
Trouble Remains
Trouble Solved
18
Cases Cases
Below 200bar
The cause of poor starting is not HP Pump related system, Needs to check the other items that affect startability. Low pressure line checks : - Check for water sensor tightening in fuel filter - Check for tiny hole in low pressure hoses (by applying high pressure air) - Check for clogging of fuel sender inlet pipe by foreign matters. If possible to start, perform Injector Cleaning Mode - Replace the corresponding injector(s) if excessive back leak continues even after cleaning. If impossible to start, replace the corresponding injector(s)
Normal
Normal
19
Not exist
Exist
b. Perform Injector Dynamic Back Leak Test c-2. Check if there exists Metal Chip in the Venturi-Return. If found, follow the instruction. c-3. If excessive back leak continues even after Injector Cleaning Mode, replace the corresponding Injector(s)
Normal
Low pressure line checks : - Check for water sensor tightening in fuel filter - Check for tiny hole in low pressure hoses (by applying high pressure air) - Check for clogging of fuel sender inlet pipe by foreign matters.
20
Not exist
Exist
b. Perform Injector Dynamic Back Leak Test c-2. Check if there exists Metal Chip in the Venturi-Return. If found, follow the instruction. c-3. If excessive back leak continues even after Injector Cleaning Mode, replace the corresponding Injector(s)
c-1. Perform Low Pressure Line Visual Check Low pressure line checks : - Check for water sensor tightening in fuel filter - Check for tiny hole in low pressure hoses (by applying high pressure air) - Check for clogging of fuel sender inlet pipe by foreign matters. If trouble continues, replace HP Pump.
Normal
21
2. No DTCs detected related to Battery Voltage, Injector, IMV and RPS 3. Install the back leak tester and keep idling for 2 minutes after starting 4. Perform Scan-100 Fuel Leak Detection - Engine runs up to 3500rpm 4 times by itself 5. Read the graduations on each flask 6. Replace the corresponding Injector(s) if back leaked amount is above 38. 7. Input C2I data after replacing
Engine Stall Engine Stall Poor Power Poor Power Metal Chip Metal Chip P1253,1256,1258 P1253,1256,1258
22
No Leak Detected
23
Below 20cm
1. 2. 3. 4. 5.
Remove each returning hose from injectors and connect the tester as shown in the figure Disconnect IMV connector and Injectors connectors Crank the engine 2 times for 5 seconds each Measure the back leaked length in the tube Replace injector(s) if the length exceeds 20cm P1191 P1191 Poor Starting Poor Starting Metal Chip Metal Chip
24
How to use Scan-100 1. Select Data List 2. Select 09.Rail Pressure 3. Press Line Graph button 4. Press Bar button Check the time that the pressure reaches 200bar
P1191 P1191 1
P1253,1256,1258 P1253,1256,1258
25
Purpose : In order to check if the cause of insufficient high pressure is due to air inflow, which may result in poor acceleration or poor starting.
HP Pump Inlet Priming Pump Fuel Filter Outlet
P/Number: Y99220042B
P1191 P1191 Poor Starting Poor Starting Engine Stall Engine Stall Poor Acceleration Poor Acceleration
26
Cleaning Procedure
When there is excessive back-leak from injectors causing engine poor power or engine stall, follow the below sequence. Disconnect the RPS connector after the engine warm-up when idling, ECU enters into Fail-safe mode, which the rail pressure maintains at 1800bar with pinging.
Rev the engine up to 3000rpm with fully accelerating, stop the engine after repeating 10 times.
Erase the DTC by using Scan-100 Through this process, the foreign matters on the injector control valve can be eliminated by ultra high pressure. If this cleaning mode reduces back-leak amount, but still not normal, additional conduct can be made. 1
27
Cleaning Procedure
If rough idle or excessive rail pressure exists without IMV related DTC, Follow the below procedure.
Take off IMV from HP Pump and connect IMV connector, and remove Screen Filter from IMV.
Turn the IG key on and drive the IMV by using Scan-100 with spraying cleaner, repeat Active/Stop for 2~3 minutes. Install the IMV after flushing in diesel and delete DTC Clean the IMV piston by spraying a WD-40 or Carburetor Cleaner for 2~3 min. With this process, Foreign matters can be removed, however, IMV malfunction itself wont be solved such as broken spring, damaged piston, etc. Caution) Before taking off IMV, make sure to spray with cleaner and blow out the HP Pump to keep the cleanliness, not allowed to wear cotton gloves. 1
Cases Cases P1191 P1191 Engine Stall Engine Stall Poor Starting Poor Starting
P1252,1254,1257,1259 P1252,1254,1257,1259
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29
Poor Acceleration Poor Acceleration Engine Engine Stall Stall P1252 P1252
Data Analysis for Rail Pressure related DTC - Example : P1254_Rail Pressure Control Negative
1. In case that P1254 is detected. 2. Place the cursor to the DTC, if multiple. 3. Press the ENTER button, and Freeze Frame Data will be displayed as shown in the right figure.
4. Although IMV Open Demand is as low as 19%, which is requested to make the highest pressure of HP Pump, Rail Pressure Feedback shows only 220bar, which is much less than target pressure. - Normal Spec : Approx. 32% 250bar 5. In conclusion, the cause of DTC P1254 can be HP leak or poor HP generation. 1
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Poor Acceleration Poor Acceleration
Poor Starting Poor Starting Cases Cases P1253 P1253 P1256 P1256 P1258 P1258 P1191 P1191 Engine Engine Stall Stall
Venturi-Return
1. 2. 3. 4. 5. 6.
Spray the cleaner and blow out in the area of Venturi-return. Remove the Venturi from HP Pump. To find metal chips, insert a magnet into the port. If confirmed metal chips, first clean HP pipes, fuel hoses and fuel tank by using diesel. Perform Injector Static Back-leak Test or Dynamic Back-leak Test after replacing HP Pump and filter. Replace all injectors and common rail if back-leak amount is out of spec. Make sure to keep cleanliness all the time. Recommend to use the above way of checking for metal chips than fuel filter checking. 1 2006 INVITATIONAL TRAINING
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Part Name
Fuel Pump Assy Pump Sprocket Sprocket Bolt Bearing Housing Bearing Shaft Pump Nut Injector Injector Clamp Injector Bolt Fuel Pipe(Cyl.1) Fuel Pipe(Cyl.1&3) Fuel Pipe(Cyl.1) Fuel Pipe(Cyl.2&4) Fuel Pipe(Cyl.3) Fuel Pipe(Cyl.5) Fuel Pipe
Part Number
6650700101 6640750329(D20DT) 6650750129(D27DT) 6679900404(D27DT) 6650700015 6650700014 4656008000 6640170021(D20DT) 6650170121(D27DT) 6650170003 6659900201 6640700033(D20) 6650700633(D27) 6640700133(D20) 6650700733(D27) 6640700333(D20) 6650700833(D27) 6640700032(D20) 6650700733(D27) 6640700195(D20) 6650700295(D27) 914020008011 914020008011 6640700181(D20) 6650700181(D27)
550,000 21,000 100 20,000 7,800 200 240,000 1,500 200 13,000
Torque (Nm)
20+90 656 10180 +20 404
16
13,000 13,000
404
17
404
18
24,000
404
23 24 25 26
Fuel Rail Assy Housing Bolt Fuel Rail Bolt Fuel Return Tube
32
Configuration by function Injector Back-leak tester : Tool for Injector Dynamic/Static Back-leak test.
Close Rail (Rail Pressure Sensor) : Tool for HP Pump max Pressure check. Used with Rail Pressure Tester (Substitution for Scan-100) Rail Pressure Tester : Tool for HP Pump max pressure check. Used with Close Rail (Substitution for Scan-100) Coil for IMV check : To check IMV open/short circuit. - P0253/0255
33
34
Main Relay
Actyon/Kyron
Vacuum Modulator
IMV
35
36
37