207 High Pressure Bosch
207 High Pressure Bosch
1. Tooling
Equipment :
Leak detector
Diagnostic station
Figure : E5AB0WLT
[1613-B] (kit 1613) fuel decompression
container
Figure : E5AB08YT
[1613-D] (kit 1613) fuel pressure display
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Figure : E5AB090T
[1613-E1] (kit 1613) high pressure fuel
pipe
Figure : E5AB091T
[1613-F] (kit 1613) containers for return
of diesel injector
leaks
Figure : E5AD012T
[1613-G] (kit 1613) container for
measuring the high
pressure fuel
injection pump
return flow
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Figure : E5AB092T
[1613] Tools for checking
for checking HDi
systems
Figure : E5AB0YKT
[1520] plugs for click-fit
unions
Figure : E5AB0EKT
[1613-K] (kit 1613) plugs kit
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Figure : E5AD011T
BOSCH/SIEMENS [1613-J] (kit 1613) union for return of
leaks on diesel
injector
Figure : E5AB094T
BOSCH/DELPHI [1613-P] (kit 1613) union for return of
leaks on diesel
injector
Figure : E5AD013T
SIEMENS / BOSCH [1613-N] (kit union for return of
1613) leaks on diesel
injector
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Figure : E5AB0N1T
BOSCH CP1 (-).1613/2-A (1613/2 kit) Dummy fuel
pressure regulator
Figure : E5AB0WNT
BOSCHCP1H/CP1H3/CP3S3/CP3.2/(- dummy flow
).1613/2-B (1613/2 kit) electrovalve
Figure : E5AB0WQT
2. Identification
Engine code Factory symbol Injection system Pump type
DW10 RHS BOSCH CP1
RHZ BOSCH CP1
RHX BOSCH CP1
RHV BOSCH / SIEMENS CP1
RHY BOSCH /SIEMENS CP1
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3. Preliminary checks
ESSENTIAL : Respect the safety and cleanliness recommendations that are specific to high pressure diesel
injection (HDi) engines .
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4. Check
4.1. Checking the pressure sensor on the fuel high pressure common injection rail,
DW10/DW12/DT20C/SOFIM engines (absence of engine starting)
Disconnect the connector of the fuel high pressure sensor.
Operate the starter :
The engine starts
Check the electrical connection between the engine ECU and the fuel high pressure sensor
If the connection is ok, replace the fuel high pressure sensor
The engine will not start : Continue the checking
4.2. Checking the pressure sensor on the fuel high pressure common injection rail, F 13DTE5
engines (absence of engine starting)
For the F 13DTE5 engine : The fuel high pressure sensor must remain connected in order for the starter function to
operate.
Carry out all the following checks.
4.3. Checking the diesel injectors
CAUTION : Do not uncouple the rubber pipes from the diesel injector leak return unions.
CAUTION : Block the fuel return pipe from the diesel injectors after the fuel return manifold (soil the engine).
Fit the unions tools [1613-J]* or [1613-N]* or [1613-P]* on the diesel injectors.
Couple the containers tools [1613-F] on the unions [1613-J]* or [1613-N]* or [1613-P]*.
* : According to equipment and engine.
Attach the container carrier bar [1613-F] to the engine bonnet.
Operate the starter :
The engine starts : Allow the engine to idle for 2 minutes
The engine will not start : Operate the starter motor for 15 seconds
CAUTION : The volume of returned fuel at the injectors is a few millilitres; the volume of returned fuel at the
injectors increases according to the condition of the diesel injectors (wear).
Replace any diesel injectors that have a fuel return flow greater than that for the other injectors.
N.B. : Matching low volume for all the injectors : After replacing one or more diesel injectors, do a diesel injectors
check.
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CAUTION : Before slackening, clean the high pressure unions(See the corresponding operation).
Remove the fuel high pressure pipe linking the fuel high pressure common injection rail and the diesel injector of cylinder
n°5.
Bend the fuel high pressure pipe previously removed to fit to the tool [1613-A] ; Tighten to 2 daN.m.
Tighten the union of the fuel high pressure pipe to the fuel high pressure common injection rail ; Tighten to 2 daN.m.
Remove the high pressure pipe linking the high pressure fuel pump to the high pressure fuel common injection rail.
Depending on the type of high pressure fuel pump, connect tool [1613-A] with the aid of either tool [1613-E1] or the fuel
high pressure pipe already removed.
Tighten the high pressure union of the tool pipe [1613-E1] or of the high pressure pipe connecting the high pressure pump
to the fuel high pressure injection common rail ; to 2 dan.m.
Couple the container of tool [1613-B] on tool [1613-A].
Connect tool [1613-D] on tool [1613-A].
Common operations.
CAUTION : Spray the leak detector product on the fuel high pressure pipe previously removed, and allow the leak
detector product to dry.
ESSENTIAL : Stand away from the fuel high pressure pipe when the engine is running.
CAUTION : Check that there is no leak on the fuel high pressure pipe previously removed.
N.B. : Pressure lower than 300 bars ; Check the flow electrovalve and/or the pressure regulator. The display of the tool
[1613-D] flashes if the value of the residual pressure in tool [1613-A] is above 50 bars.
The fuel pressure is higher than 300 bars : Do the preliminary checks once again.
N.B. : For the F 13DTE5 engine : The fuel pressure is higher than 300 bars ; Replace the fuel high pressure sensor.
N.B. : DT20C engine : Maximum pressure : 900 bars (At 3000 rpm) : (The fuel flow regulator is jammed open) Replace
the fuel flow regulator and high pressure pump assembly. The display of the tool [1613-D] flashes if the value of the
residual pressure in tool [1613-A] is above 50 bars.
CAUTION : Open the fuel decompression screw ["a"] before uncoupling tool [1613-A].
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N.B. : The display of the tool [1613-D] flashes if the value of the residual pressure in tool [1613-A] is above 50 bars.
CAUTION : Open the fuel decompression screw ["a"] before uncoupling tool [1613-A].
CAUTION : Reused high pressure fuel pump component : Replace the seals and/or the sealing ring .
CAUTION : Replace the high pressure fuel pipe that was removed.
If the volume is not correct : Replace the fuel high pressure common injection rail, fuel pressure regulator, fuel pressure
sensor assembly.
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If the volume is not correct : (The fuel flow regulator is jammed open) Replace the fuel flow regulator and high pressure
pump assembly.
The engine will not start : Check to be made :
Verify : Param. measuring : Pressure regulation ; Using a diagnostic tool
Erase the fault codes.
Disconnect the fuel return pipe from the fuel high pressure common injection rail
Plug by means of the tool [1520] : The fuel return pipe
Connect the tool [1613-L] to the fuel high pressure common injection rail
Operate the starter motor for 10 seconds
Check the volume collected in the tool [1613-L]
4 ml(Normal operation)
20 ml +/- 2 ml (Abnormal operation)
Check :
The electrical connection between the engine ECU and the fuel pressure regulator
If the connection is ok, replace the fuel high pressure common injection rail and fuel pressure regulator assembly
N.B. : Volume correct : Check the fuel high pressure pump (The fuel flow regulator is either jammed shut or clogged).
4.8. Check : Output solenoid valve CP1 / CP1H / CP1H3 / CP3.2 / CP3S3
Remove : The flow electrovalve.
Replace the flow electrovalve with the tool [1613/2-B].
Tighten the securing bolts to 0,5 dan.m.
N.B. : For the F 13DTE5 engine : Connect the flow solenoid valve to the engine harness in order for the starter function
to operate.
N.B. : The display of the tool [1613-D] flashes if the value of the residual pressure in tool [1613-A] is above 50 bars.
CAUTION : Open the fuel decompression screw ["a"] before uncoupling tool [1613-A].
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CAUTION : Reused high pressure fuel pump component : Replace the seals and/or the sealing ring .
CAUTION : Replace the high pressure fuel pipe that was removed.
If the volume is not correct : (The fuel flow regulator is jammed open) Replace the fuel flow regulator and high pressure
pump assembly.
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