User manual HTC 1000

[. . . ] 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. [. . . ] INJECTOR BACK LEAK TEST (DYNAMIC) 1) Remove the return hose from each injector and Install injector return hose adapter (NCT-1032), visible tubes (NCT-1032), flasks (NCT-1030) and injector return hose plug (NCT-1033) referring to Injector back leak test (STATIC) in previous page. 2) Conduct the high pressure leak test referring to following explanation. BOSCH Type , , : D3EA(1. 5D-ENG), D4EA(2. 0D-ENG), D4FA(U-ENG), D4CB(2. 5A-ENG) 3) Start engine 3 minutes at idle accelerate engine up to 2500 rpm and keep the 2500rpm for 2 minutes Stop Engine after 2 minutes 4) When the test is completed, measure the amount of fuel in each flask (NCT-1030). 5) Judgments 30sec / 3000rpm Start 1min stop BOSCH Type , , Replace the injector which is shown more 3 times than the minimum value. Normal condition 2 Injector abnormal 2min Idle acceleration Start Stop 1 2 3 4 1 2 3 4 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 2minutes at idle 3 times acceleration Stop Engine 5) For the accuracy of the test, perform the test more than twice and select the largest amount as a measured value. 6) Judgments DELPHI Replace the injector which indicates exceeds 25cc. Service Limit 25cc 1 2 3 4 Abnormal injector 5 3. HIGH PRESSURE PUMP TEST Purpose of the test : Inspection for mechanical capability of the High pressure pump (Maximum pressure check) Method : Check the pumping capability of the high pressure pump by actuating pump after blocking rail's outlets using the plug and regulator. Plug : Blocking the rail circuit Regulator Valve : Preventing over pressure of high pressure line 1) Clean the regulator valve, regulator valve adaptor and plugs with diesel fuel. 2) Remove all 4 fuel injector pipes from the common rail and disconnect the rail pressure sensor's connector. 3) Install the regulator valve, plugs dust caps adapter connector and High pressure gauge to the common rail securely as shown. Be sure that the regulator valve and the plugs (NCT-1020 or NCT-1021) have installed securely so that there will not be any fuel leakage. Delphi, Bosch Type(A engine U engine) 4) Disconnect Pressure Control Valve connector and connect the PRV connector and battery lead wire to the battery for the test. And then turn on the power switch so that pressure control valve will block fuel return from rail. For the accuracy of the test, perform the test twice and select the higher pressure one as a measured value. [. . . ] 2) Assemble all fuel pipes except the fuel pipe fitting nuts of injector side. 3) Temporarily tighten the fuel pipe fitting nuts to injectors by hand after aligning the nuts to the injectors. 4) To prevent contamination on engine room, wrap up around the injector pipe using paper towel or shop rag as shown. [. . . ]