Using a clip-on ammeter of motor tester, check actuation of injector. Clip-on ammeter must satisty the following conditions.
Measuring range ＞ 25A
Bandwidth ＞ 100kHz
Attach the plug to the injector. Fasten clip-on ammeter around lead to pin.2 of corresponding injector. Allow engine to be at idle.
Refer to the set value(current) as following figure.
Length of holding current phase (max.12A) is governed by engine speed, injection time and changes on velocity.
The first current curve shows the pre-injection.
Check the injector for injecting of fuel. As checking procedure, detach the injector plug from each boxes and connect to replaced injector.
If change to enine running results, injector is injecting. If no change to engine running results, injector is not injecting.
This test cannot however establish whether an injector is injecting an correct quantity.
If necessary, all injectors have to be replaced.
Measure the supply voltage at ECM pin 33(Cylinder #1 Injector), to pin 36 and pin 39(Cylinder #3 Injector), pin 40(Cylinder #2 Injector) to pin 37 with ignition OFF.
Set value : 0V
Check wiring if set value is not attained. If wiring is OK, replace the ECM.
Detach the connector from injector.
Measure the resistance between terminals.
0.3 ~ 0.6 Ω(at 20°C)
Connect the connector to the injector.
Fuel system is subject to extremely high pressure (1350 bar).
Never perform any work on injection system with engine running or within 30 seconds after stopping the engine.
Always pay attention to safety precautions.
Ensure the absolute cleanliness.
Never remove the injectors.
Removal
Disconnect the negative battery (-) terminal.
Pull off the injector electric connector.
Unfasten the high pressure pipe at rail and injector.
Press in clip to back leak rail by hand and pull out back leak rail.
Attach the connection of back leak rail. Never fit without clip.
Remove the copper sealing ring.
Before re-installing injector, clean the cylinder head bore and sealing surface.
Insert the brush.
Clean the sealing surface and blow out.
Installaion
Insert a new copper sealing ring (if necessary, apply small quantity of grease to bond it to injector).
Install the injector (do not touch the nozzle tip) and sliding clamp with clamp bolt.
Screw the clamp bolt.
25 ~ 29 N.m (250 ~ 290 kgf.cm)
Install the high pressure pipes.
31 ~ 35 N.m (310 ~ 350 kgf.cm)
When mounting the high pressure pipes, fix the hexagon component of high pressure fuel injection parts not to squeeze heavily the high pressure fuel injection parts.
Attach the connection of back leak rail. Never fit without clip.
Check the tighteness of back leak rail by tugging it.
Attach the electric connector.
Re-connect the negative battery(-) terminal.
Start the engine and check the high pressure circuit for leaks.
Read out the fault memory and cancel the faults stemming from the detached injector plug.
