Back Leak Test

«Mondeo 2001 Table of Contents»«Group 3: Powertrain»«Section 303-04E: FUEL CHARGING AND CONTROLS - 2.0L DURATORQ-TDCI (PUMA) DIESEL»«DIAGNOSIS AND TESTING»

Fuel Charging and Controls

PINPOINT TEST A: FUEL INJECTOR BACK LEAK TEST

A1 FUEL SYSTEM HIGH-PRESSURE TEST

CAUTION:Do not run the fuel system high-pressure test more than twice. Failure to follow this instruction may result in damage to the fuel pump.

CAUTION:Do not crank the engine for more than 5 seconds during the fuel system high-pressure test. Failure to follow this instruction may result in damage to the fuel pump.

1

Vehicles built from 12/2002: Disconnect the fuel injector fuel return lines.— Release the locking clip.

2

Vehicles built before 12/2002: Disconnect the fuel injector fuel return lines.— Release the locking clips

3

Note:

Blanking plugs must be installed to the fuel injector return lines, to prevent air entering the fuel system.

Install the blanking plugs supplied with the special tool to the fuel injector fuel return lines.

4

Note:Make sure that the clear plastic hoses of the special tool are equal in length. If a hose is damaged, a hose of equal internal diameter and original length (500mm) should be installed.

Install the special tool to the fuel injectors.

5 Using WDS, guided diagnostic, run the fuel system pressure test.

Is the fuel system pressure greater than 1050 bar?

Yes

Go to «A2».

No

Go to «A4».




A2 CHECK THE FUEL INJECTOR BACK LEAK AFTER 1 MINUTE ENGINE RUN TIME

1 Remove the special tool.

2 Empty the special tool of fuel.

3 Remove the blanking caps from the fuel injector fuel return lines.

4 Connect the fuel injector fuel return lines to the fuel injectors.

5 Connect the fuel metering valve electrical connector.

6 Connect the fuel injector electrical connectors.

7 Start the engine.

8 Using WDS datalogger, PCM function, select the signal for CHT. Allow the engine to reach 70ºC.

9 Stop the engine.

10

Install the special tool to the fuel injectors.

11 Install the blanking plugs supplied with the special tool to the fuel injector fuel return lines.

12 Start the engine.

13 Allow the engine to idle for 1 minute.

14 Stop the engine.

15

Invert the containers of the special tool, raise the containers above the engine and allow the collected fuel to drain into the clear plastic hoses connecting the containers to the fuel injectors.

16 Observe the quantities of fuel collected within the lengths of clear plastic hoses.

Are the quantities of fuel contained within the clear plastic hoses approximately equal?

Yes

Go to «A3».

No

If one or more fuel volumes is significantly higher within the special tool clear plastic hose, INSTALL a new fuel injector(s) as required. TEST the system for normal operation.

If the fuel volumes for all four fuel injectors exceed the length of clear plastic hose, using WDS Program Module Routine, INPUT the fuel injector correction values. TEST the system for normal operation.




A3 CHECK THE FUEL INJECTOR BACK LEAK AFTER 4 MINUTES ENGINE RUN TIME

1 Position the containers of the special tool below the height of the fuel injector fuel return line connection.

2 Start the engine.

3 Allow the engine to idle for 4 minutes.

4 Stop the engine.

5 Disconnect the special tool from the fuel injectors and allow the fuel in the clear plastic hoses to flow into the special tool containers.

6

Record the volumes of fuel collected in the special tool containers.

7 Multiply the lowest recorded value by 1.4 to calculate the maximum permissible value (maximum permissible value = minimum recorded value + 40%).

Example:

Quantity of lowest volume container = 10ml

1.4 X 10ml = 14ml

Maximum permissible value = 14ml

Are the volumes of fuel in each of the special tool containers lower than the calculated maximum permissible value?

Yes

NO fault is indicated with the fuel injectors. To continue diagnostics, RETURN to the Symptom Chart.

No

If one or more fuel volumes in the special tool containers has a volume above the maximum permissible value, using WDS Program Module Routine, INPUT the fuel injector correction values. TEST the system for normal operation.




A4 CHECK THE FUEL INJECTOR BACK LEAK AFTER FUEL SYSTEM PRESSURE TEST

1

Invert the containers of the special tool, raise the containers above the engine and allow the collected fuel to drain into the clear plastic hoses connecting the containers to the fuel injectors.

2 Measure and record the length of clear plastic hose containing fuel for each fuel injector.

Do one or more clear plastic hoses contain no fuel and one or more have a recorded value greater than 21cm in length?

Yes

Go to «A5».

No

Go to «A6».




A5 FUEL INJECTOR BACK LEAK TEST FAILURE MODE 1

1 Install new fuel injectors for those injectors with recorded values of greater than 20cm.

2 Empty the special tool of fuel.

3 CAUTION:Do not run the fuel system high-pressure test more than twice.

Using WDS repeat the fuel system pressure test.

4 Measure and record the length of clear plastic hose containing fuel for each fuel injector.

Do all of the clear plastic hoses contain fuel?

Yes

ASSEMBLE the vehicle. TEST the system for normal operation.

No

INSTALL new fuel injectors for those injectors where no fuel is present within the clear plastic hose. TEST the system for normal operation.





1 Compare the recorded values for the clear plastic hoses containing fuel.

Do all of the clear plastic hoses contain fuel and one or more have a recorded value greater than 20cm in length?

Yes

INSTALL new fuel injectors for recorded values greater than 20cm. TEST the system for normal operation.

No

Go to «A7».





1 Compare the recorded values for the clear plastic hoses containing fuel.

Are all of the recorded values less than 20cm and one or more clear plastic hoses contain no fuel?

Yes

INSTALL new fuel injectors for those injectors where no fuel is present within the clear plastic hose. TEST the system for normal operation.

No

INSTALL a new fuel pump. For additional information, refer to «Fuel Pump(303-04 Fuel Charging and Controls - 2.0L Diesel, Vehicles With: Common Rail Fuel Injection,reminst-ri)» in this Section.

Back Leak Test

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