▣ Diagnostic procedures (Carnival J2.9 CRDi). 1. Engine does not start. 1-1) Back leak Test (Static).

1) Remove the engine cover and intercooler.

2) Remove the back leak hose from eachinjector (4EA).

◈ Back leak tester.

3) Install the visible hoses of the back leak tester to the injector fuel return hole (4EA) as shown in the pictures.

▣ Diagnostic procedures (Carnival J2.9 CRDi). 1. Engine does not start. 1-1) Back leak Test (Static).

4) Disconnect the common injector connector.

- The ECM cannot operate the injectors .

from the high pressure pump side.

pressure while the is engine cranking.

◈ High pressure gauge set.

-When you want to check the high pressure, turn on the power switch after connecting the line to the battery and rail pressure regulating valve

6) Connect the high pressure gauge set to the battery and rail pressure sensor after disconnecting the rail pressure sensor connector.

5) Disconnect the IMV(Inlet Metering Valve) connector

- High pressure pump operates with maximum

To battery

To rail pressuresensor

▣ Diagnostic procedures (Carnival J2.9 CRDi). 1. Engine does not start. 1-1) Back leak Test (Static).

- Read the maximum pressure on the high pressure gauge set while cranking.

◈ Normal pressure : Above 1050 bars.

- Measure the length of the back leaked fuel in each visible hose. (See pictures).

- Measure and compare each back leaked fuel amount in the visible hoses.

- Make sure to conduct a back leak test at least twice

▶ Notice : Do not replace all injectors simultaneously.

Common rail sensor & tester abnormal

HP pump abnormal

3 200 ~ 1050 bars 20 ~ 50 cm Injector abnormal

Result

1 1050 ~ 1500 bars 0 ~ 20 cm Normal (HP pump & Injector)

High pressure Injector back leak length

2 0 ~ 1050 bars 0 ~ 20 cm

4 Out of range 0 ~ 20 cm

7) Crank the engine for 5 ~ 6 seconds.

⊙ Result of High pressure pump & Injector back leak test.

Case

Back leaked fuel length

▣ Diagnostic procedures (Carnival J2.9 CRDi). 1. Engine does not start. 1-2) Hi pressure pump test (Capacity)

1) Remove the fuel injector pipes (4 EA) between the common rail and injector.

- The injector hole should be covered by a dust cap.

◈ SST for high pressure pump test

① Pressure regulator.

② Dust cap.

③ Plug.

2) Install the pressure regulator (1EA) and plugs (3EA) from the CRDi SST set.

3) Connect the high pressure gauge set to the battery and rail pressure sensor after disconnecting the rail pressure sensor connector.

1

3

2

▣ Diagnostic procedures (Carnival J2.9 CRDi). 1. Engine does not start. 1-2) Hi pressure pump test (Capacity)

4) Disconnect the IMV connector from the high pressure pump side.

- Press the hand priming pump several times.

5) Crank the engine for 5~6 seconds.

6) Measure the fuel pressure with a high pressure gauge set while cranking the engine

- Make sure to conduct the high pressure pump test at least twice.

※ Note : Before replacing the High pressure pump, check the metal chip in the fuel filter first. If metal chips are found in the fuel filter, flush the fuel line, inclusive of the fuel tank, and replace the parts as needed.

2

Case High pressure Result Remark

⊙ Result of High pressure pump test.

0 ~ 1050 bars High pressure pump abnormal

1 1050 ~ 1500 bars Normal (High pressure pump)

Check the low pressure line

3 Out of range Common rail sensor abnormal Check the rail sensor & tester

Priming pump

Sensor abnormal Low Pressure Normal

▣ Diagnostic procedures (Carnival J2.9 CRDi). 1. Engine does not start. 1-3) Low pressure line test

◈ Low pressure line tester (Vacuum).

- Be sure to use a vaccum gauge because the fuel feeding pump is inside the HP pump.

1) Disconnect the fuel hose between the outlet port of the fuel filter and the inlet port fuel hose of the high pressure pump.

2) Install a low pressure gauge between the fuel filter outlet port and the high pressure pump inlet port.

3) Remove the air in the low fuel line by using a hand priming pump.

Fuel filter Hi pressure pump

▣ Diagnostic procedures (Carnival J2.9 CRDi). 1. Engine does not start. 1-3) Low pressure line test

4) Check air infiltration while cranking the engine. If you can see excessive air bubbles in the fuel line, then check the fuel line from the fuel tank to filter outlet port.

5) Check for low pressures at the low pressure line while cranking the engine.

3 0 ~ 7 cmHg

1 8 ~ 19 cmHg

2 20 ~ 60 cmHg

VacuumCase

⊙ Result of Low pressure line test.

Result

System normal

Filter or Fuel line clogging

Air leak in the system / Suction pump Damage

Remark

▣ Diagnostic procedures (Carnival J2.9 CRDi). 1. Engine does not start. 1-4) Flushing procedure for injection pipe and common rail

◈ Make sure to clean the injection pipes and common rail before assembling.

1) Make sure to clean the injection pipes by using air gun.

2) Temporarily tighten the injection pipes using hand to the common rail side and injector side as shown in the picture.

3) Disconnect the IMV connector from the IMV on the high pressure pump.

4) Crank the engine 2~3 times for 5~6 seconds.

5) Remove all test components and assemble the injection pipes to the common rail and injectors

6) Install the IMV connector to the IMV in the high pressure pump. 7) Tighten the all injection pipes.

8) Make sure to clean the leaked fuel.

9) Check for fuel leakage in the fuel system after starting the engine.

Fuel pipe end

Cleaning by air gun

Air gun nozzle

Temporarity tightenthe injection pipes

▣ Diagnostic procedures (Carnival J2.9 CRDi). 2. Engine possible to start. 2-1) Back leak Test (dynamic).

1) Remove the engine cover and intercooler.

2) Remove the back leak hose from eachinjector (4EA).

3) Install the visible hoses of the back leak tester to the injector fuel return hole (4EA) as shown in the pictures.

4) Run the engine and keep it at idle for 3 min., then raise the engine rpm to 2500 rpm, and keep at 2500 rpm for 2 minutes. After 2 minutes, stop the engine.

5) Measure the amount of fuel leakage.

- Measure and compare the volume of the back leaked fuel from each bottle.

- If the measured volume is above 25ml, replace the injector.

- Perform the back leak test again with the newly replaced injector.

2. Parts Required.

Qty

GQ00/HP00:33800-4X500.GQ02:33801-4X500HP02:33801-4X800CT/PU:33801-4X900GQ: (Europe)0K52A 13480AHP: (Europe)31390H1952HP: (India & S. Ameri)31390H1970HP: (India & S. Ameri)31392H1970

GQ00/HP00:33100-4X500GQ02/HP02/CT/PU:33100-4X700

GQ00/HP00:31500-4X500GQ02/HP02/CT/PU:31500-4X700

GQ: (Europe)0K52A 13480AHP: (Europe)31390H1952HP: (India & S. Ameri)31390H1970HP: (India & S. Ameri)31392H1970

For India & SouthAmerican, Delphirecommends the useof a sedimentor.

Remark

Damaged injectoronly

1

1

1

1Damaged highpressure pump

1

Includes gasket

For India & SouthAmerican, Delphirecommends the useof a sedimentor.

Condition Part Name Part Number