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Common Rail Diesel Diagnostics in Shropshire & Mid Wales

We provide testing of common rail diesel engine electrics in and around Shrewsbury Shropshire &
Welshpool Mid Wales (UK) areas.

Common rail diesel fuel injection system overview

The common rail diesel injection system was developed by Bosch. Common rail diesel engines can
be found in many modern vehicles including cars, vans, buses, trucks,tractors and earthmovers.
The common rail diesel fuel system is a programmed electro-mechanical system for control of
diesel fluid (fuel) pressure and flow. Diesel fuel injected and atomised in a fine spray to form an air
fuel mixture inside the engine combustion chambers must be delivered at the correct moment of
the engine cyle to allow efficient burning . There are several manufacturers of common rail diesel
fuel injection systems including Bosch , Delphi ,  Nippondenso , Siemens.

Advantages of the Common Rail Diesel System

The electronically controlled common rail system offers many advantages over
traditional systems:
Higher Performance through increased torque at low engine speed
Lower fuel consumption
Lower soot emissions - use of diesel particulate filter ( dpf ) to remove soot
particulates via exhaust system.
Reduced Noise
Closed loop feedback control
Programmable characteristics enabling effective use of alternative biofuels
Electronic diagnostics
Diesel Lambda Control using exhaust gas recirculation to reduce NOx emission

Safety Note

Common rail diesel fuel systems operate at very high pressure and can cause
severe injury. Fuel pressures of up to 2200bar may be present. Please refer to
manufacturers health, safety and training provisions before attempting service or
repair of any common rail or pressurised fuel system. We only recommend
servicing by qualified personnel.

Back leak rate comparison test of

The above diagram shows a very basic layout of a typical
common rail diesel injectors on Bosch
common rail diesel fuel system. Electronic sensors and
CP1 system fitted to 5 cylinder diesel
actuators not shown .
engine.

Diesel Control Unit (DCU)

Precision control of fuel injection delivery, quantity and timing allows smooth quiet
engine operation with increased performance.

The Diesel control unit (DCU) electronics take inputs from sensors such as throttle
pedal position and speed to interpret driver demand, air flow, boost pressure fuel
flow, engine mechanical position etc and processes signals in accordance with
control unit map parameters to provide outputs to actuators such as pump
metering and injectors.

Diesel tuning is possible by Remapping of control unit software or calibration

update however care should be taken to avoid insurance and driveability issues.
Engine Control Unit Diagnostics

The common rail diesel fuel injection system is operated and monitored by an electronic control
unit (DCU, ECU) using closed loop fuel control strategy. If a problem occurs with system operation
fault error codes may be logged and stored in engine controller memory. The control unit is
preprogrammed to take appropriate action and may alert the driver by causing the check engine
management light MIL to illuminate and also by reduction of fuel rail pressure to restrict engine
performance (limp home mode).
Under certain conditions the engine may be stopped by full shutdown of the injection system with
prevention of restart.

Electronic Diagnostics

Logical system diagnostics are first carried out using a scantool with dedicated software to read
fault codes which may be stored on engine management computer.
Scan tool live data(serial data) may be used to monitor fuel rail pressure as seen by engine control
ecu.
Vehicles fitted with telematics may transmit engine data back to the service provider.

Advanced diagnostics can be carried out with checks on individual electrical and electronic
components by use of oscilloscope testing.

Diesel Fuel System Components

Low pressure fuel pump

Diesel fuel is drawn from the fuel tank by a low pressure transfer pump, this may be an electric
pump located in the fuel tank or mechanical pump feeding the main high pressure fuel pump.

Diesel filter

During delivery to the high pressure pump the fuel will pass through at least one fuel filter
assembly.
The diesel fuel filters are a service item requiring periodic change.

High Pressure Common Rail Diesel Fuel Pump

Fuel at a constant transfer pressure flows along pipework to the intake of the mechanical high
pressure pump which acts to increase fuel pressure to a minimum of approx 220 bar during
cranking,  to around 1600 bar  (approx 23000psi) operating pressure whilst the engine is running at
full load. Newer systems are capable of operation at higher fuel pressure.

Pump metering valve

The pressure at the high pressure pump is regulated by proportional electromechanical control of
fuel quantity entering the pumping elements within the high pressure pump via inlet metering valve
(IMV), or by control of the amount of pressurised fuel returning from the fuel rail to the
tank.Lubrication of the pump is provided by fuel circulation.

Diesel Common Rail Injectors

The highly pressurised fuel is pumped to the common rail. The diesel fuel accumulated in the
common rail is delivered to each engine cylinder by an electronically controlled fuel injector.
Each injector is electronically controlled allowing precise operation to deliver the required amount
of fuel at the correct time.
Common rail diesel fuel systems with electromagnetic solenoid valve type injectors allow a degree
of fuel to return to the tank by internal leakage through the injector body, referred to as injector
back leakage.

Diesel Injector Fault Codes

Injector fault codes may be logged in engine control unit (ecu) memory and read with diagnostic
tester.
Fault codes may relate to Misfire, Open circuit wiring, Short to ground, short to positive etc, and be
caused by electronic or mechanical faults.

Injector back leakage test

A small quantity of back leaked fuel provides lubrication for each injector.

Excessive back fuel leakage from fuel injectors may indicate excess wear, and result in lowered
common rail fuel pressure. Lower than desired fuel pressure may prevent the vehicle engine from
being started.

Seized Injectors

A common problem with removing common rail diesel engines appears to be injectors seized in
the cylinder head requiring use of special injector puller kit to remove before injectors can be
bench tested.

Fuel Injector Calibration (Coding)

Common fault codes:  P2336 , P2337 , P2338

p> The amount of fuel injected is proportional to the injector duration (opening time) , fuel rail
pressure , fuel temperature  & fluid viscosity.

A target value for injector duration under specific conditions is programmed into the diesel control
unit (DCU) engine control map.

Fuel injectors are machined to very fine tolerances but because of individual characteristics such
as friction, pressure drop, magnetic force , wear during service etc,  very slight variations in flow
can occur.

Slight difference between target flow and actual flow can occur due to high operating pressures.
Certain common rail diesel fuel injectors require calibration during manufacture or overhaul  on a
specialised diesel injection  test rig  to produce  a data code relating to the characteristics of each
individual injector. This data code may be referred to as the C2i code (Delphi) or IMA code (Bosch)
depending on manufacturer.

The data code is programmed into the diesel engine control unit identifying to which cylinder the
injector is fitted. This data code allows the engine control module to correct the pulse duration
applied to each individual injector to maintain optimum performance.
Fitment of replacement injectors will often require new injector codes to the engine control unit.

We have facilities for injector coding of several makes of vehicle.

Commor Rail Fuel Pressure Sensor

A fuel rail pressure sensor is used to provide a fuel pressure feedback signal to the engine
controller.
Fuel rail pressure sensor out of range can indicate faults elsewhere in the system which may cause
reduced or excessive fuel pressure

Rail Pressure Relief Valve

A high pressure relief (limiting) valve is often fitted on the common fuel rail to allow fuel flow return
to tank if set fuel pressure is exceeded due to wiring or ecu fault.

Useful part numbers:

6C1Q-9H321-AB (finis code 1497165> PRV commonly used on Ford Transit mk7 2.4 and 2.2 TDCi
2006> with Denso fuel system.
166384578R (Renault) - Renault Master - Bosch 0281006188

Servicing

Regular servicing is essential to prevent fuel flow restriction, contamination of precision

components and consequent engine running problems.

Fuel filter specification is important to prevent dirt ingress to fuel injection components which will
increase wear rate of pump and injectors.

Fuel quality

Fuel quality is of premier importance due to close tolerance of machined precision system
components. Misfuelling of a diesel vehicle with another fuel of incorrect grade or viscosity such
as petrol can cause extensive damage.

Some common rail pumps have internal coatings intended to prolong component life at high
operating pressures which can be destroyed by petrol or solvents.

Certain vehicle insurers are now offering insurance policies protecting against misfuelling.

Common Rail Fuel System Faults Chart

Typical Fault Possible effect Possible Cause

Difficult staring Worn fuel injectors with
excessive back leak rate.
Non Start
Worn or defective fuel pump
Engine cuts out
Too slow engine cranking
Excessive exhaust emissions speed

High Pressure Fuel System : Misfire Fuel pressure

Loss of  Rail pressure regulator,IMV,MPROP, wiring,
Control unit reverts to limp home etc
mode
 
Rail pressure sensor signal out of
expected range  

   

Low pressure Fuel delivery Difficult Starting Blocked or damaged fuel


Carbon build up around fuel
injectors
Air intake system faults
Exhaust system faults
Electrical and electronic faults
Engine cutting out
Faults with the common rail fuel system often result in loss of  fuel pressure causing the engine to
cut out .
Fuel Quality resulting in contamination of filters causing flow restriction.
Incorrect Fuel used causing damage to system components - particularly when a driver has
Non start supply lines.
Engine cuts out Fuel filters restricted by
blockage
Pump related fault codes
Electric fuel pump
High pressure fuel system faults
Low pressure gear pump
Loss of seal between fuel
injector and cylinder head.
Loss of cylinder pressure may require injectors
removed and specialist
machining to cylinder head
Restricted air filter
Non start MAF (Mass Air Flow sensor)
fault
Difficult starting
Loss of  Turbocharger boost
Misfire
pressure
Poor performance under load
Exhaust gas recirculation
system faults
EGR system restricted , faulty
Non start , or inoperative.
Difficult starting Blocked or restricted Diesel
particulate filter (dpf)
Loss of power
Broken wiring
Damaged wiring insulation
Corroded connections
Non start
Low battery voltage
Misfire
Electronic control system
Engine cuts out faults with Sensors
,Actuators, ECU, coding.
Mechanical faults causing
electronic system faults.
accidentally refuelled with petrol instead of diesel.
Electrical wiring , Sensor and Actuator faults
Most common rail fuel systems use a fuel accumulator rail mounted pressure sensor which will
provide an electrical  feedback signal to the engine management controller.
A loss of fuel pressure or a deviation from the desired amount of fuel pressure may be interpreted
as a fuel system leak by the engine management controller in which case total system shut down
may occur as a safety feature . Certain electronic management systems can lock out and prevent
engine start until faults have been repaired.
Faults caused by Exhaust gas recirculation resulting in excessive carbon build up and blockage of

intake components.

Typical example of vehicle suffering from engine running fault

The vehicle in question was a late model luxury car fitted with a high performance 6 cylinder
common rail diesel engine which had covered around 90,000 miles.
The customer reported an intermittent fault which caused sluggish acceleration and rough engine
running was sometimes present.
Unusually,the dashboard check engine management light , in this particular instance was not
illuminated.
The customer had already tried to locate the fault by unplugging and reconnecting wiring to various
engine components.
A visual check of the engine bay was done, then using the diagnostic scantool we interrogated the
engine control module for stored fault codes. Several fault codes relating to different fuel injectors,
engine stability, and P3505 pre heat device faults were present.
Fault codes were recorded ,then cleared from engine control unit memory. The vehicle was then
road tested to complete a driving cycle by accompanying the customer.
On road test the vehicle hesitated briefly during acceleration. After road test the control unit
memory was once again read using the diagnostic scanner.
A P0204 cylinder fault code relating to an electrical fault within the circuit to cylinder 2 injector
valve was present.
Wiggle test: Moving the wiring to cylinder 2 injector located this fault to a bad connection at the
injector electrical connector plug , noted audible changes in engine note. The bad connection was
rectified and fault codes once again cleared.
A back leakage test was carried out of all six injectors with the engine running.
Five of the injectors had back leakage values within 10% of each other.
However the remaining 6th fuel injector had almost twice the back leakage fuel flow in comparison
to the others indicating a badly worn fuel injector.
Injectors were removed from the engine for calibration test bench assessment of spray pattern
,recondition and calibration.
The serviced injectors were refitted together with new high pressure pipes and new fuel filters as
recommended and road test carried out resulting in a much smoother drive.

Tel: 01743 884888 for Auto electrical & Diesel car mobile
breakdown service in Shrewsbury , Shropshire & Mid Wales
areas. www.autoelectrics.net
Autoelectrics Mobile Product Services
2 Stretton Heath
Shrewsbury
Shropshire
SY5 9EF
Tel: 01743 884888
Mobile: 07703 558610

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Page last updated 27/02/2020