COMMON RAIL

(Delphi)

Chonan Technical Service Training Center

Fuel System
Common Rail System
 Common Rail System

Injector
Linear
rail

HP pump

Electronic
control unit

Fuel filter

Diesel injection main

Components
 Common Rail System

Injector
Linear
rail

HP pump

Electronic
control unit

Fuel filter

Diesel injection main

Components
High Pressure Pump

Transfer pressure
regulation valve
Diesel oil
temperature sensor

LP supply IMV

Venturi HP outlet (to the

rail)
Pressure limiter
High Pressure Pump
1 Inlet Metering
Valve(IMV)

2 Hydraulic Head

3 Plunger

Drive Shaft +
4
Cam Ring
5 Housing

6 Roller + Shoe

7 Transfer Pressure
Pump

8 Temperature
Sensor

9 Venting

10 Outlet High
Pressure Flange
11 Transfer Pressure
Regulator
High Pressure Pump
High Pressure Pump
High Pressure Pump
Low Pressure(Feed) Pump of High Pressure Pump
Common Rail (Linear Rail)
Common Rail (Linear Rail)
Common Rail (Linear Rail)
High Pressure Pipes

1. 4 HP pipes rail / injector

2. 1 HP pipe pump / rail

If the Injector or main rail feed pipes are

removed they MUST BE REPLACED WITH
NEW
Injector
Injector Operation
Injector Operation (Phase 1)
Injector Operation (Phase 2)
Injector Operation (Phase 3)
Injector Operation (Phase 4)
Calibration Individual Injector

CII for A/S

CII for
production
Individual Injector Correction

Selection of To display To erase

Injector Current Current
to change CII CII CII

* CII : Calibration Individual Injector

Information
Cleared(Default Value)

If CII is cleared from ECM

- DTC(P1300 INJECTOR CORRECTION DATA)is set
- Failsafe mode and fixed 1250rpm
- No acceleration
- Check engine lamp “on”
Ignition ON, Engine Stop
The correction is impossible on Engine Running Condition
ECM

Connection
Input
AFS / Output
Accelerator pedal
sensor
CMP sensor
CKP sensor
Rail Pressure sensor
Knock
Main Relay
sensor(Accelerometer)
Injector
Fuel Temperature
Cooling Fan control
sensor
ECM Air Heater
ECT sensor
EGR Valve
IAT sensor
MIL lamp
Vehicle Speed sensor
Inlet Metering Valve
Brake switch
Clutch switch(M/T)
A/C switch
A/C Pressure sensor
IMV (Inlet Metering Valve)
IMV (Inlet Metering Valve)
Fuel Temperature Sensor
Venturi
Auxiliary
Air Intake Heater

Air Intake heater

Air Intake manifold

Air Intake Heater

Heater element
Air Intake Heater

CMEC2

Battery voltage CMED2 +Bat

Coolant temperature AH control relay

Flow requested ECM

DCU
Engine speed

Atmospheric pressure CMIJ2

+AC
CMED3
CHA1

Preheating warning
light

+AC Preheating resistors

Air Intake Heater
Pre-heating
Variable preheating

Engine coolant
temperature -30 -25 -20 -15 -10 -5 0 20
(°C)

Illumination (s) 28 25 15 10 5 3 2 0

Fixed preheating
This begins when the preheating warning light extinguishes. During this second phase, the
preheating resistors remain supplied for 5 seconds.

Post-heating
Coolant temperature (°C) -20 -10 0 20 80

Duration of post-heating (s) 100 50 25 10 10

Exhaust Gas Return (EGR)

EGR Valve

Solenoid Valve
EGR Cooler (Heat Exchanger)

Heat exchanger
Mass Air Flow Sensor
Mass Air Flow Sensor
Fuel Heater

Priming
pump
Inlet

Fuel
heater Fuel
filter

Outlet
Priming Pump

To From
fuel filter fuel tank
Accelerator Pedal Position Sensor
Fuel Filter
Fuel Input

Fuel Output

Fuel Input
Fuel Filter (Recirculation)

To Pump

Cold
From Pump

To Pump To Tank

Hot
From Pump
Fuel Filter

Bi-metal strip

Steel ball
Handling
Safety Instructions
It is strictly prohibited to smoke or to eat while working on the Common Rail
injection system.
It is essential to disconnect the battery before any work is done on the
Common Rail injection system.
It is strictly forbidden to work on the Common Rail injection system with the
engine running.
It is necessary to read the value of the rail pressure and of the diesel oil
temperature with the engine running.
It is necessary to read the value of the rail pressure and of the diesel oil
temperature with the aid of the diagnostic tool before any work is done on
the fuel circuit. The opening of the circuit can only begin if the diesel oil
temperature is less than 50°C(122 ° F) and the rail pressure is close to 0 bar.
If it is not possible to communicate with the computer, wait for 5 minutes
after the engine has stopped before starting any work on the fuel circuit.
Safety Instructions
It is strictly prohibited to supply an actuator directly off an external power supply.

The injector must not be dismantled.

The HP sensor must not be removed from the rail. If the HP sensor fails, It is
essential to replace the complete rail.

The IMV, the diesel temperature sensor and the venturi must not be removed
from the pump. If one of these components is faulty, the whole pump must
be replaced.

The HP pipes are not reusable : a removed pipe must be replaced.

Decarbonizing the injector in an ultrasonic bath is strictly prohibited.

The computer’s metal casing must never be used as an earth.

The packaging of the spare parts should be opened just before they are used.
Moreover, the sealing plugs must not be removed until the final connection is
made. The plugs and the sealed pouches must be discarded after use.
Removal a rail/injector pipe(rail/HP pump)
1. Clean the nuts of the HP unions with a solvent
(CARCLEAN type) applied with a clean
brush.

2. Vacuum the particles with the aid of a

‘BLOVAC BV11’ type suction
device(Figure4).
Removal a rail/injector pipe(rail/HP pump)
3. Disconnect the injector with the aid of pliers, applying pressure to the locking
clips on the side of the connector.
Removal a rail/injector pipe (rail/HP pump)
4.. Slacken the nut screwed onto the
injector using a 17 mm(0.67 in) open
wrench(Figure4)

5. Slacken the nut screwed onto the rail

using a 17 mm(0.67 in) open
wrench(Figure 5).

* Notice
It is important to positions the wrench
level with the solid end of the nut, in order
to apply the stresses to the strongest part of
the nut. If the torque is applied to the open
end of the nut,. There is a risk of distortion
of the nut when it is tightened. Or use a
pipe-wrench with cloth.
Removal a rail/injector pipe (rail/HP pump)
6. Move the nut along the pipe, keeping the
olive in contract with the injector
cone(Figure 6) and vacuum the particles
in the contact area between the olive and
the cone, using a pneumatic suction
device.

7. Carry out the same operation on the rail

side.

8. Remove the pipe and vacuum the

particles inside the injector cone with the
aid of the pneumatic suction device
(Figure 7).
Removal a rail/injector pipe (rail/HP pump)
9. Carry out the same operation on the rail side.

10. Immediately seal the HP outlets with the aid of the recommended
plugs (Figure 8).

Plugs
Assembly a rail/injector pipe (rail/HP pump)
1. Take the new pipe out of its packing just
before fitting it.

* WARNING
IT IS FORBIDDEN TO RE-USE AN
OLD PIPE.

2. Remove the plug inserted at each end of

pipe.
3. Lubricate the threads of the nuts with the
lubricant supplied in the kit before fitting
the pip(Figure 9)
4. Remove the protective plugs from the HP
outlets of the rail and the injector.

* WARING
THE PLUGS MUST BE DISCARDED
AFTER USE

5. Fit the pipe olive into the injector cone

and the rail cone. Tighten the nut by hand
(Figure 10).
Assembly a rail/injector pipe (rail/HP pump)
6 Fit the pipe olive into the rail cone and
tighten the nut by hand

7. Tighten the nut on the injector side to

40 Nm(29.5 lb-ft), applying reverse
torque with the support tool for the
injector holder (Figure 12).
Assembly a rail/injector pipe (rail/HP pump)
* Notice
When tightening the nut, ensure that the
connector remains aligned with the injector row
axis (Figure 13).

7. Tighten the nut on the rail side to a torque of

40 Nm(29.5 lb-ft)

ESSNTIAL
To validate the repair, start the engine an
check the tightness of the HP connection.
Injector holder-removal
1. Remove the HP pipe of the injector being
removed (following the method indicated
in refer to page).

2. Disconnect the injector connector

3. Disconnect the injector leakage return

hose(Figure2).

4. Slacken off the flange of the injector

holder(Figure3).

5. Remove the injector with the flange and

its bolts.
Use a special tool if the injector is stuck.
Assembly of injector holder
1. Clean the socket of the injector holder and
vacuum the particles using the pneumatic
suction device(Figure 5).

2. Clean the flange of the injector holder with

solvent (CARCLEAN type) using a clean brush.

3. Place a new heat protection washer on the seat

of the injector holder.
* WARNING
IT IS PROHIBITED TO RE-USE AN OLD
HEAT PROTECTION WASHER!

4. Fit the injector holder with its flange.

5. Tighten the injector holder flange bolt to a

torque of 19 Nm(14.01 lb-ft)(Figure 6).

6. Reconnect the return hose of the injector

holder. Reconnect the injector connector.

7. Reassembly the HP pipe, referring to the

method described in page.
Delphi Common Rail Cap Kit
Delphi Common Rail Cap Kit
Delphi Common Rail Cap Kit
Delphi Common Rail Cap Kit