Fuel System - MIL ON/Low Power/Hard Start
NUMBER: 14-001-05GROUP: Fuel
DATE: March 10, 2004
SUBJECT:
Common Rail Fuel Injection Diagnosis
OVERVIEW:
This bulletin provides diagnostic procedures for the fuel injection system.
MODELS:
2001 - 2003 (VA) Sprinter
SYMPTOM/CONDITION:
The vehicle operator may describe:
^ MIL illumination.
^ The engine may lack power while driving.
^ Engine may not start; or may crank for longer than normal before starting.
DIAGNOSIS:
NOTE:
The following diagnostic procedure can be performed with the DRBIII(R).
1. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts.
2. Using the DRBIII(R), perform a "Vehicle Module Scan". Record any DTC's on the repair order and then erase the DTC's.
3. Try to reproduce the Symptom/Condition at the engine temperature stated by the customer. Test drive the vehicle if necessary. Document the current ambient conditions on your repair order.
4. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this service bulletin.
5. Check vehicle history for when the fuel filter change was last serviced. Replace the fuel filter if it has been more than 10,000 miles since it was last serviced. Refer to the detailed removal and installation procedures available in TechCONNECT, under:
Service Info, 14 - Fuel System/Fuel Delivery/Fuel Filter.
NOTE:
Proceed to Diagnosis Procedure C if the engine does not start at all.
6. Perform the following DRBIII(R) tests:
^ Compression Test
^ Fuel Pressure Solenoid
^ Rail Pressure Sensor
^ High Pressure Pump Pump Pressure Generation
^ Injector Correction Quantity Test
^ Fuel Leak Quantity Test (Engine Running)
7. If a defective component was discovered, repair as necessary and repeat the failed test. If a defective component was not discovered, proceed to Step # 8.
NOTE:
In the case of a high pressure pump failure, prior to reassembly, thoroughly flush all high and low pressure fuel lines with diesel fuel and blow through with compressed air. Replace the fuel filter and the preheat valve. Check the fuel tank and fuel pump module for contamination and/or debris. If contamination andlor debris is found, clean the fuel tank and fuel pump module completely, replace if necessary.
8. Inspect the 0-rings on the fuel pressure solenoid. Replace both 0-rings and the support ring if necessary. If no problem was detected, proceed with diagnosis and repair based on the following:
^ If engine lacks power while driving or DTC P1187 or P2007 are stored proceed to Diagnostic Procedure A.
^ If the engine does not start after it has been turned off, or needs a very long cranking time, proceed to Diagnostic Procedure B.
SPECIAL TOOLS/EQUIPMENT REQUIRED:
DIAGNOSTIC PROCEDURE A:
Engine lacks power while driving or DTC P1187 or P2007 are stored.
1. Check fuel line between fuel pump and high pressure pump. If air bubbles can be seen while accelerating, search for air being sucked into the fuel system between the fuel tank and the high pressure pump.
2. Replace fuel filter if it is not new.
DIAGNOSTIC PROCEDURE B:
Engine does not restart after it has been turned off or cranks for a very long time.
1. Disconnect the electrical connector on the fuel pressure solenoid and crank the engine for 10 seconds. Using the DRBIII(R) from the "Engine Menu" select "Sensor Display". Monitor the variation of the "Engine Speed". For a sufficient frequency of updating the value, it is necessary to display only this single sensor.
2. If the engine speed varies more then 100 rpm, while cranking, and/or the maximum engine speed while cranking is less then 170 rpm; check the battery voltage and crankshaft sensor. Replace the starter if the voltage while cranking remains above 9.6 volts and the crankshaft sensor is all right.
3. If the Symptom/Condition still occurs, disconnect the electrical connector on the fuel pressure solenoid and crank the engine for 10 seconds. Using the DRBIII(R) from the "Engine Menu" select "Sensor Display". Monitor the rail pressure. For a sufficient frequency of updating the value, it is necessary to display only this single sensor. The rail pressure should increase to 800 psi within 2 seconds. If it takes longer than 3 seconds, replace the high pressure pump.
DIAGNOSTIC PROCEDURE C:
Engine does not start.
1. Perform the following DRBIII tests:
^ Compression Test
^ Fuel Rail Pressure Sensor
^ Fuel Leak Quantity Test (Engine cranking)
2. If a defective component was discovered, repair as necessary and repeat the failed test. If a defective component was not discovered, proceed to Step # 3.
3. Inspect the 0-rings on the fuel pressure solenoid. Replace both 0-rings and the support ring if necessary.
4. If the Symptom/Condition still occurs, crank the engine for 10 seconds. Using the DRBIII(R) from the "Engine Menu" select "Sensor Display". Monitor the variation of the "Engine Speed". For a sufficient frequency of updating the value, it is necessary to display only this single sensor. If the engine speed varies more then 100 rpm, while cranking, and/or the maximum engine speed while cranking is less then 170 rpm; check the battery voltage and crankshaft sensor. Replace the starter if the voltage while cranking remains above 9.6 volts and the crankshaft sensor is all right.
5. If the Symptom/Condition still occurs, disconnect the electrical connector on fuel pressure solenoid and crank the engine for 10 seconds. Using the DRBIII(R) from the "Engine Menu" select "Sensor Display". Monitor the rail pressure. For a sufficient frequency of updating the value, it is necessary to display only this single sensor. The rail pressure should increase to 800 psi within 2 seconds. If it takes longer than 3 seconds, replace the high pressure pump.
6. Disconnect the electrical connector on the fuel pressure solenoid. Disconnect the fuel return line from number 1 injector and install an empty test vial on the fuel injector. Collect the fuel coming out of the return line in an appropriate container. Crank the engine for 10 seconds. Measure the collected fuel by using a vial from the 9545 special tool kit.
7. If Volume is equal to or less than 40 ml replace high pressure pump (Fig. 1).
8. If Volume is greater than 40 ml, replace fuel pressure solenoid (Fig. 1).
POLICY:
Reimbursable within the provisions of the warranty using diagnostic labor operations for actual labor time. The Operation Diagnostic labor operations can be located in the 80/90 - Special Services tab in the Labor Operations Manual. Usage of these operations must follow the guidelines outlined in the Global Warranty Administration Manual.
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.