NEXTECH user's manual(NCT-6000)
Contents
1. coms dans PES nai TT On Adapters for rail pressure sensor D Dust cap Plug HP Regulator Valve Flask 4 DIAGNOSIS 5 Crank the engine for 5 6 seconds For the accuracy of the test perform the test twice and select the higher pressure one as a measured value 6 Judgement If the fuel pressure indicated on the gauge is within the range of specification the high pressure pump is normal But if not check the below items before the High pressure pump replaced a Check the plug or regulator valve if it leaks b If fuel pressure is lower than specification test it again when coolant temperature is below 30C The pump is in normal condition if the pressure restores to normal range c In case of the system in which pressure control valve implemented check the valve condition amp internal leak and replace them if necessary x Refer to 4 6 pressure control valve test procedure Specification of high pressure of common rail BOSCH System 1000 1500 bars DELPHI System 1050 1600 bars If fuel pressure indicated on the gauge is lower than specification there may be a problem in the rail pressure sensor or its circuit even fuel flows out from the regulator valve CRT 1020 4 DIAGNOSIS 4 6 PRESSURE CONTROL VALVE TEST 1 Remove fuel return connector from PCV upper 2 Remove fuel return hose from PCV lower 3 Disconnect Pressure Control Valve connector and connect li the pressure control valv2. common rail system 1 1 Criteria of diagnosis using Commom Rail Tester Impossible to start engine or engine stall while driving It would be recommended performing Power Balance Test by Hi Scan for Bosch system or by disconnecting injector s connecter one by one for Delphi system if vehicle has problem beside the above symptoms such as engine vibration or emission of black white smoke while engine idle The problem may be due to differences of the injected amount in each injector 1 2 Notice A CRDi system has been constructed using precision made components If an extremely small foreign particle enters the system during service it may cause sticking or clogging of injectors Therefore be sure to eliminate any dust or contaminated deposits on or around the engine and fuel lines during service 2 COMPONNENTS Tool Case Regulator Valve Plug for Delphi Plug for Bosch Regulator Valve Adapter for SM model Flask amp Holder Visible Tube el Injector return hose adapter E Injector return hose plug EE SE Clean Case 2 Dust Cap High pressure gauge ve So gt Adapter connector for Delphi old x M12mm Adapter connector for Delphi new Adapter connector for Bosch Pressure Control Valve cable Vacuum Gauge Low pressure gauge Gauge connection tube Connection Adapter Connection adapter with hose Fuel Filter Plug User s Manual CONOOFR D 3
3. Line Test Ko ent Good Failure CmHg Static 1 Cylinder Good Failure Amountioi HH 2 Cylinder Good Failure fuel EMI SIDI HIDS ae g Cylinder Good Failure i Injector Back Leak Test Cm Cm Cm Dynamic fuel Tool supplier Nextech Co Ltd Contact Point Mr Alex Lim Tel 82 2 3140 1489 or 1443 Fax 82 2 3140 1449 E mail sales nex tek com QUALITY ASSURANCE Name of products Commom Rail Tester We hereby certify that the above product is guaranteed by our quality assurance policy and procedures listed below Subject of assurance All components contained in the Common Rail Tester as supplied to all Nextech distributors and dealers by Nextech Co Ltd Parts Guarantee Quality and Durability of each component Guarantee Period 1 Years from the date of purchase Nextech Co Ltd President Printing SEP 2005 Publication No OSTS 20050901 E Seoul Korea Printed in Korea
4. sensor s connector 3 Install the regulator valve CRT 1020 plugs CRT 1021 or CRT 1022 dust caps CRT 1035 adapter connector CRT 1041 CRT 1042 CRT 1043 and High pressure gauge CRT 1040 to the common rail securely as Shown Use regulator valve adaptor CRT 1023 for Santafe SM model Be sure that the regulator valve CRT 1020 and the plugs CRT 1021 or CRT 1022 have installed securely so that there will not be any fuel leakage Delphi Bosch Type I 4 Disconnect the IMV connector from the high pressure pump Bosch Type Il 4 Disconnect Pressure Control Valve connector and connect the pressure control valve cable CRT 1044 to the Pressure Regulator Valve and then connect pressure control valve cable CRT 1044 s lead to battery so that pressure control valve will block fuel return from rail Bosch Type Ill 4 Perform No 4 procedure both Bosch Type I and Bosch Type II so that fuel will be supplied to the high pressure line and pressure control valve will block fuel return from the rail 20 4 DIAGNOSIS Purpose of the test Inspection for mechanical capability of the High pressure pump Maximum pressure check Regulator valve Method Check the pumping capability of the high pressure pump by actuating pump after blocking rail s outlets using the plug and regulator Regulator valve adapter for a Santafe Plug Blocking the rail circuit Reaulator Valve Preventina over pressure of hiah pressure line
5. 055 2 Start the engine and keep idle approxmately 5seconds then turn of the engine 4 DIAGNOSIS Internal suction pump type Bosch Type Vacuum Gauge Vacuum Gauge Test Tube Assay Connection Adapter 4 DIAGNOSIS Electric pump type Bosch Type Il Pressure Gauge Low Pressure Gauge Test Tube Assay Connection Adapter Connection Adapter with Hose Fuel pump Electric Vacuum Gauge Test Tube Assay Connection Adapter Fuel Filter Plug 4 DIAGNOSIS 3 Read the fuel pressure or suction pressure indicated 4 Judgement Electric pump type Bosch Type Il CASE PRESSURE bar JUDGEMENT 1 5 3 kg m System normal Ea 4 6 kg cm Filter or fuel line clogging O 1 5 kg cm Pump or fuel line leak Internal suction pump type Bosch Type and Delphi CASE VACUUM JUDGEMENT 1 8 19 cmHg System normal good condition EY 20 60 cmHg Filter or fuel line clogging pump in good condition Er 0 7 cmHg Air leak in to the system or Suction pump damage 4 3 INJECTOR BACK LEAK TEST STATIC 1 Remove the return hose from each injector and Install injector return hose adapter CRT 1032 visible tubes CRT 1031 and connect the visible tube s end to the flasks CRT 1030 2 Disconnect A point on the fuel return hose in below photograph and block the fuel return hose in the direction of the high pressure pump with injector return hose plug CRT 1033 3 Connect the adapte
6. Common Rail Tester Nextech FOREWARD This manual is intended for use by service technicians to helo provide efficient and correct service on CRDi vehicles using Common Rail Tester To ensure customer satisfaction with Nextech product it is essential quick and accurate service operation as well as reasonable price Consequently it is important that the service personnel fully understand the contents of this manual which should be kept within reach for future reference All information in this manual including photographs drawings and specifications is current at the time of publication Nextech reserves the right to make any changes to the design or to make additional improvements in this manual No part of this manual hereon may be reproduced or used in any form of by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems without written permission of the publisher DEC 2005 Printed in Korea CONTENTS 1 GENERAL 2 COMPONENTS 3 PARTS INDEX 4 DIGNOSIS 4 1 DIAGNOSIS PROCEDURE ACCORDING TO SYMPTOM 4 2 LOW PRESSURE FUEL LINE TEST 4 3 INJECTOR BACK LEAK TEST STATIC 4 4 INJECTOR BACK LEAK TEST DYNAMIC 4 5 HIGH PRESSURE PUMP TEST 4 6 PRESSURE CONTROL VALVE TEST 5 FUEL LINE FLUSHING 6 DIAGNOSIS CHECK SHEET 1 GENERAL This Tester has been developed to diagnose efficiently and accurately for diesel vehicles with
7. D4FA U ENG D4CB 2 5A ENG 3 Start engine 1minute at idle gt accelerate engine up to 3000 rom and keep the 3000rpm for 30seconds Stop Engine 4 When the test is completed measure the amount of fuel in each flask CRT 1030 30sec 3000rpm sta tmin sto 4 DIAGNOSIS DELPHI J3 2 9L 3 Connect the Hi Scan and select the High Pressure Leak Test mode 4 Conduct the High Pressure Leak Test untill the Hi Scan finish the test automatically or manualy Start engine gt 2minutes at idle 3 times acceleration gt Stop Engine X One acceleration Accelerate up to 3800rpm for 2 seconds and keep idle for 2 seconds stan 2mn LJ L Idle Fuel Press are acceleratio A Stop 4 DIAGNOSIS 5 For the accuracy of the test perform the test more than twice and select the largest amount as a measured value X The flasks CRT 1030 should be empty before the 2nd test started 6 Judgement BOSCH Type I Il Il Replace the injector which is shown more 3 times than the minimum value Example om I DELPHI Replace the injector which indicates exceeds 25cc 2 Injector abnormal Service Limit 25ccy IE Abnormal injector 4 DIAGNOSIS 4 5 HIGH PRESSURE PUMP TEST 1 Clean the regulator valve CRT 1020 regulator valve adaptor CRT 1023 and plugs CRT 1021 or CRT 1022 with diesel fuel 2 Remove all 4 fuel injector pipes from the common rail and disconnect the rail pressure
8. PARTS INDEX Common Rail Tester CRT 1000 1SET Regulator Valve CRT 1020 TSET Plug for Delphi M14mm E Plug for Bosch M12mm CRT 1022 Regulator Valve Adapter E Flask amp Holder CRT 1030 1SET Visible Tube CRT 1031 Injector Return Hose CRT 1032 AEA Adapter EA A A A Injector Return Hose Plug CRT 1033 o o 3 PARTS INDEX High Pressure Gauge CRT 1040 TSET Adapter Connector for Delphi Old eae EN Adapter Connector E 14 for Delphi New E en 5 Adapter Connector CRT 1043 1 for Bosch 3 PARTS INDEX Quantity he Pressure Gauge CRT 1051 O Gauge Connection Tube CRT 1052 ee TEA TEA EA 1 20 Connection Adapter CRT 1053 Connection Adapter With CRT 1054 Hose Fuel Filter Plug CRT 1055 4 DIAGNOSIS 4 1 DIAGNOSIS PROCEDURE ACCORDING TO SYMPTOM 1 When the engine is not able to start Low Pressure Line Test gt Injector Back Leak Test Static Test gt 3 High Pressure Line Test 2 When the engine is able to start Low Pressure Line Test gt Injector Back Leak Test Dynamic Test gt 3 High Pressure Line Test 4 2 LOW PRESSURE FUEL LINE TEST 1 Remove fuel hose from fuel filter and connect low pressure gauge CRT 1051 or vacumn gauge CRT 1050 according to engine system as shown x Additional parts needed tube for gauge connection CRT 1052 Connection adapter with hose CRT 1054 connection adapter CRT 1053 Fuel Filter Plug CRT 1
9. e cable CRT 1044 to the Pressure Control Valve and then connect the pressure control valve cable CRT 1044 s lead to battery so that pressure control valve will block fuel return from rail 4 Put fuel return pipes to flasks CRT 1030 5 Crank the engine for 5 seconds 6 Check fuel return amount X Service Limit Less than 10cc Fuel pressure must over 1000 bars Fuel return Fuel return connector Return Hose Leaked fuel Pressure control Limit 10cc 5sec valve cable 1 Before connecting the fuel pipes to the engine be sure Fuel pipe that all the pipe outlet surfaces inner passages and especially fuel pipe fitting nuts are clean 3 Clean using air gun if necessary fj av VA 2 Assemble all fuel pipes except the fuel pipe fitting nuts of injector side F Ti 3 Temporarily tighten the fuel pipe fitting nuts to injectors by hand after iz aligning the nuts to the injectors i 4 To prevent contamination on engine room wrap up around the injector using paper towel or shop rag as shown cleaning by air gun 5 Crank the engine 2 to 3 times for 5 to 6 seconds to flow out the fuel contamination from injector connection area 6 Tighten the nuts with specified torque using special tool 7 Erase the DTC code by Hi Scan Air gun nozzle Special tool Loosen the nuts il tpi JE 5 Tighten the nuts Fuel with contaminations Raper towel 6 DIAGNOSIS CHECK SHEET VIN 1 Low Pressure Fuel
10. ed the 5seconds in any case X Cranking RPM must exceed 200 RPM X Perform the test under 30 with coolant temperature If the fuel pressure test performed over 30 C the fuel pressure indicated may be diffrent accoding to fuel viscosity change 7 Read the pressure from high pressure gauge CRT 1040 and measure the amount of fuel contained at each visible tube CRT 1031 8 Judgement Fi PRESSRUE bar INJECTOR BACK LEAK JUDGEMENT FACTOR TO BE CHECKED 1000 1800 T 200mm Ne above 1000 T 200 O 1000 200 400 Faulty injector Replace injector if there is only below 1000 above 200 excessive back leak excessive back leak over 200mm O 1000 0 200 HP Pump Conduct the high pressure pump below 1000 below 200 Insufficient pressure test 4 DIAGNOSIS 500 1000 500 1000 500 1000 1500 1500 1500 0 1800 D 1800 DELPHI D HI DELPHI BOSOH bar B H bar BOSOH b the cit I SOALE 100 bar 1 LE SO LE 100 bar i CRDi CAD CAD Her onic P FRE Tronic Fler onic Sensor abnormal Low pressure Normal 4 4 INJECTOR BACK LEAK TEST DYNAMIC 1 Remove the return hose from each injector and Install injector return hose adapter CRT 1032 visible tubes CRT 1031 flasks CRT 1030 and injector return hose plug CRT 1033 referring to Injetor back leak test STATIC in previous page 2 Conduct the high pressure leak test refering to following explanation BOSCH Type I Il Il D3EA 1 5D ENG D4EA 2 0D ENG
11. r connector CRT 1041 CRT 1042 CRT 1043 to rail pressure sensor and connect high pressure gauge CRI 1040 as shown 4 Disconnect the injector connectors to prevent its operating High pressure Gauge gt gry 2 TG 8 Ay lt RC vw i 2 af EE F x ar RR Adapters for a rail pressure ii Li mm sensor Injector return hose adapter 4 DIAGNOSIS Delphi Bosch Type 5 Remove the Inlet Metering Valve connector to allow fuel feeding to high pressure line Bosch Type 5 Disconnect the Pressure Control Valve connector and connect the pressure control valve cable CRT 1044 to the Pressure Regulator Valve and then connect pressure control valve cable CRT 1044 s lead to battery so that pressure control valve will block fuel return from rail Bosch Type Il 5 Perform No 5 procedure both Bosch Type and Bosch Type so that fuel will be supplied to the high pressure line and pressure control valve will block fuel return from the rail Pressure control valve cable e Delphi Bosch Type I Bosch Type III e Bosch Type Il Bosch Type Ill X Notice Do not supply the battery power over 5 minutes It may cause to damage PCV Engine Type Delphi J3 2 9L Bosch Type D4CB 2 5A ENG Bosch Type Il D3EA 1 5D ENG D4EA 2 0D ENG Bosch Type Ill D4FA 1 5U ENG 6 Crank the engine once for 5 seconds Sensor abnorme Low pressure Normal X Do not exce
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