Tool Equipment

Multimeter
Diagnostic scan tool
Oscilloscope

Common Rail Diesel Fuel Systems

Common Rail Diesel Troubleshooting
Fuel system diagnosis
Testing rail pressure control valve
Step 1
Test internal resistance of valve solenoid winding using a multimeter, typical value
approximately 3.6 Ohms

Step 2
Use the diagnostic scan tool to DTCs and monitor the rail pressure values

Step 3
Test supply voltage and earth switching signal from engine ECM using oscilloscope. Test the
stability of waveform.

Before start the troubleshooting, check if:

-

Sufficient diesel in the fuel tank?

Fuel contamination?
Fuel leak and damage to components?
Battery state of charge?
Adequate low pressure fuel supply from the fuel tank?
Does engine start or crank and try to start?
Is white smoke emitted from exhaust during engine cranking?
Are any DTCs stored on fault memory of engine ECM?

Is the system capable of generation sufficient fuel pressure?

Typical minimum manufacturer specified value during engine cranking approximately

between 200-300 bar.

Injector leak back test

There should not normally be any fuel collected in receptacles during engine cranking.
Example of acceptable leak back value with engine idling:
Approximately 20ml per injector over a 2 minute period
(always refer to manufacturer data for exact specifications)

Maximum fuel pressure

Reference
- https://personel.omu.edu.tr/docs/ders_dokumanlari/894_52413_1913.pdf
- https://en.wikipedia.org/wiki/Common_rail