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 each

injector (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 .

5) Disconnect the IMV(Inlet Metering Valve) connector

from the high pressure pump side.
- High pressure pump operates with maximum
pressure while the is engine cranking.

High pressure gauge set.

To battery

-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.

To rail pressure
sensor

 Diagnostic procedures (Carnival J2.9 CRDi).

1. Engine does not start.
1-1) Back leak Test (Static).
7) Crank the engine for 5 ~ 6 seconds.
- 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

Back leaked fuel length

Result of High pressure pump & Injector back leak test.

Case

High pressure

Injector back leak length

Result

1050 ~ 1500 bars

0 ~ 20 cm

Normal (HP pump & Injector)

0 ~ 1050 bars

0 ~ 20 cm

HP pump abnormal

200 ~ 1050 bars

20 ~ 50 cm

Injector abnormal

Out of range

0 ~ 20 cm

Common rail sensor & tester abnormal

Notice : Do not replace all injectors simultaneously.

 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

Pressure regulator.

Dust cap.

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.

 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.

Priming pump

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.

Result of High pressure pump test.

Case

High pressure

Result

1050 ~ 1500 bars

Normal (High pressure pump)

0 ~ 1050 bars

High pressure pump abnormal

Check the low pressure line

Out of range

Common rail sensor abnormal

Check the rail sensor & tester

Sensor abnormal

Low Pressure

Remark

Normal

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.

 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.

Fuel filter

Hi 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.

 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.

Result of Low pressure line test.

Case

Vacuum

Result

8 ~ 19 cmHg

System normal

20 ~ 60 cmHg

Filter or Fuel line clogging

0 ~ 7 cmHg

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.

Fuel pipe end

Air gun nozzle

1) Make sure to clean the injection pipes

by using air gun.

Cleaning by 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.

Temporarity tighten
the 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 each

injector (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.
Condition

Damaged injector
only

Part Name

Part Number
GQ00/HP00:
33800-4X500.
GQ02:
33801-4X500
HP02:
33801-4X800
CT/PU:
33801-4X900
GQ: (Europe)
0K52A 13480A
HP: (Europe)
31390H1952
HP: (India & S. Ameri)
31390H1970
HP: (India & S. Ameri)
31392H1970
GQ00/HP00:
33100-4X500
GQ02/HP02/CT/PU:
33100-4X700

Damaged high
pressure pump

GQ00/HP00:
31500-4X500
GQ02/HP02/CT/PU:
31500-4X700

GQ: (Europe)
0K52A 13480A
HP: (Europe)
31390H1952
HP: (India & S. Ameri)
31390H1970
HP: (India & S. Ameri)
31392H1970

Qty

Remark

Includes gasket

For India & South

American, Delphi
recommends the use
of a sedimentor.

For India & South

American, Delphi
recommends the use
of a sedimentor.