Work on Pressure Regulator Valve (as of CDI3, 1600 bar system) (S-B-07.16/80d, April 2, 2009)

Transcription

1 Work on Pressure Regulator Valve (as of CDI3, 1600 bar system) (S-B-07.16/80d, April 2, 2009) Topic number Version 2 Design group LI07.16-P Date Validity Model /822 Model /026 Model Diesel injection system common rail Reason for change New DTB version S-B-07.16/80d April 2, 2009 Complaint: Fuel loss at the pressure regulator valve and/or poor engine running characteristics (shakes, knocks, surges, changes to limp-home mode, poor output, poor fuel economy, combustion noise) Cause: Malfunction at the pressure regulator valve (PRV) due to improper installation. Remedy: Refer to possible fault codes / text on picture attached and follow the guided tests indicated in SDS to resolve. In the event of a faulty pressure regulator valve or an external leak between the rail and the pressure regulator valve, the entire rail must be replaced. Refer to WIS documents: AR07.03-P-1010T ( ), AR07.03-P-1010Ti ( ), and WIS document: AR07.03-P-1010GZB (164 and 251). [i] Note: The pressure regulator valves cannot be replaced individually due to possible imprecise installation processes in the workshop. [i] Note: A copy of all tests performed (as listed below and continued on page 2) must accompany returned parts. If the documentation is missing or does not support the diagnosis, the warranty claim may be debited. - Test of the high pressure circuit [including injectors, pressure control valve (fuel distributor if CDI5), quantity control valve (high pressure pump)] - Short test - Control unit log for CDI module - Internal leakage results (if CDI5) - Test of the low pressure circuit (fuel pump M3) - Internal resistance results (if CDI5) [i] Note: Warranty claims for pressure regulator valves that were replaced individually or retightened will be rejected. Copyright Daimler AG Page 1/6

2 [i] Note: The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generated on April 2, Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance. Attachments File Description cdi3.jpg CDI 3 cdi4.jpg CDI 4 cdi5.jpg CDI 5 Control unit/fault code Control unit Fault code Fault text 2051 (001) Rail pressure monitoring via pressure control valve The rail pressure 2151 (004) Y74 (Pressure control valve)analogue-digital converter Signal faulty ((DEF@Not Exist)) 2050 (001) Rail pressure monitoring via volume control valve The on/off ratio in neutral is not plausible (001) Rail pressure monitoring via pressure control valve The rail pressure 2020 (004) Rail pressure monitoring via pressure control valve The rail pressure 2021 (001) Rail pressure monitoring via pressure control valve The rail pressure 2500 (004) Check component Y74 (Pressure control valve). Signal line is interrupted (001) Rail pressure monitoring via pressure control valve The rail pressure 2048 (001) Rail pressure monitoring via volume control valve The pressure reduction during deceleration is implausible (001) Rail pressure monitoring via volume control valve The rail pressure 2016 (001) Rail pressure monitoring via volume control valve The rail pressure 2151 (001) Y74 (Pressure control valve)analogue-digital converter Value is above limit. ((DEF@Not Exist)) 2052 (001) Rail pressure monitoring via pressure control valve The measured pressure is implausible in relation to the power consumption of the pressure regulator valve. ((DEF@Not Exist)) 2018 (001) Rail pressure monitoring via volume control valve The rail pressure 2019 (001) Rail pressure monitoring via pressure control valve The rail pressure 2500 (004) Check component Y74 (Pressure control valve). Signal line is interrupted. Copyright Daimler AG Page 2/6

3 2021 (001) Rail pressure monitoring via pressure control valve The rail pressure 2017 (002) Rail pressure monitoring via volume control valve The rail pressure 2151 (001) Y74 (Pressure control valve)analogue-digital converter Value is above limit (002) Rail pressure monitoring via pressure control valve The rail pressure is too low for the engine speed (001) Rail pressure monitoring via pressure control valve The measured pressure is implausible in relation to the power consumption of the pressure regulator valve (008) Rail pressure monitoring via volume control valve Standard deviation in idle 2020 (001) Rail pressure monitoring via pressure control valve The rail pressure is too high for the closed pressure regulator valve (002) Y74 (Pressure control valve)analogue-digital converter Value is below limit (001) Rail pressure monitoring via volume control valve The rail pressure 2016 (002) Rail pressure monitoring via volume control valve The pressure reduction during deceleration is implausible (001) Rail pressure monitoring via volume control valve The rail pressure 2016 (004) Rail pressure monitoring via volume control valve Standard deviation in deceleration mode 2501 (001) Check component Y74 (Pressure control valve). Short circuit to positive 2051 (001) Rail pressure monitoring via pressure control valve The rail pressure 2023 (001) Rail pressure monitoring via pressure control valve The maximum pressure has been exceeded (004) Y74 (Pressure control valve)analogue-digital converter Signal faulty 2502 (002) Check component Y74 (Pressure control valve). Short circuit to ground Copyright Daimler AG Page 3/6

4 2049 (001) Rail pressure monitoring via volume control valve The on/off ratio in deceleration mode is not plausible. Exist)) 2015 (001) Rail pressure monitoring via volume control valve The rail pressure 2020 (004) Rail pressure monitoring via pressure control valve The rail pressure 2047 (001) Rail pressure monitoring via volume control valve The rail pressure 2017 (001) Rail pressure monitoring via volume control valve The rail pressure 2020 (001) Rail pressure monitoring via pressure control valve The pressure control valve jams in the closed position (001) Check component Y74 (Pressure control valve). Short circuit to positive 2151 (002) Y74 (Pressure control valve)analogue-digital converter Value is below limit (004) Y74 (Pressure control valve)analogue-digital converter Signal faulty 2500 (004) Check component Y74 (Pressure control valve). Signal line is interrupted (001) Rail pressure monitoring via volume control valve The rail pressure 2019 (002) Rail pressure monitoring via pressure control valve The rail pressure is too low for the engine speed (001) Rail pressure monitoring via pressure control valve The rail pressure 2015 (001) Rail pressure monitoring via volume control valve The rail pressure 2016 (001) Rail pressure monitoring via volume control valve The rail pressure 2016 (004) Rail pressure monitoring via volume control valve Standard deviation in deceleration mode 2017 (002) Rail pressure monitoring via volume control valve The rail pressure Copyright Daimler AG Page 4/6

5 2018 (001) Rail pressure monitoring via volume control valve The rail pressure 2019 (002) Rail pressure monitoring via pressure control valve The rail pressure is too low for the engine speed (001) Rail pressure monitoring via pressure control valve The measured pressure is implausible in relation to the power consumption of the pressure regulator valve (004) Rail pressure monitoring via pressure control valve The rail pressure 2019 (001) Rail pressure monitoring via pressure control valve The rail pressure 2015 (001) Rail pressure monitoring via volume control valve The rail pressure 2023 (001) Rail pressure monitoring via pressure control valve The maximum pressure has been exceeded (002) Rail pressure monitoring via volume control valve The pressure reduction during deceleration is implausible (002) Check component Y74 (Pressure control valve). Short circuit to ground 2016 (008) Rail pressure monitoring via volume control valve Standard deviation in idle 2020 (001) Rail pressure monitoring via pressure control valve The rail pressure is too low for the closed pressure regulator valve (001) Y74 (Pressure control valve)analogue-digital converter Value is above limit (001) Rail pressure monitoring via volume control valve The rail pressure 2021 (001) Rail pressure monitoring via pressure control valve The rail pressure 2151 (002) Y74 (Pressure control valve)analogue-digital converter Value is below limit. Exist)) 2047 (001) Rail pressure monitoring via volume control valve The rail pressure 2502 (002) Check component Y74 (Pressure control valve). Short circuit to ground Parts Copyright Daimler AG Page 5/6

6 Part number ES1 ES2 Designation Quantity Note EPC A Left rail (left fuel distributor) (OM642) A Rail (fuel distributor) (OM648) 1 1 Operation numbers/damage codes Op. no. Operation text Time Damage code SHORT TEST, PERFORM 0.3 hrs Model Indicator (s): BD, EB, T6, TC, Z FUEL RAIL, R&R/REPLACE IF NECES- SARY LEFT RAIL, REMOVE/INSTALL / RE- PLACE IF NECESSARY LEFT RAIL, REMOVE/INSTALL / RE- PLACE IF NECESSARY LEFT RAIL, REMOVE/INSTALL / RE- PLACE IF NECESSARY TEST PROGRAM AFTER SHORT TEST, PERFORM Note 1.3 hrs. T6 0.9 hrs. TC, Z4 1.1 hrs. BD 1.2 hrs. EB 0.5 hrs. BD, EB, T6, TC, Z4 WIS-References Document number Title Note Allocation AR07.03-P-1010T Remove/install rail Remedy AR07.03-P-1010Ti Remove/install rail Remedy AR07.03-P-1010GZB Remove/install rail 164 and 251 Remedy Copyright Daimler AG Page 6/6