207 (A7) - B1HD0105P0 - Check : Fuel high pressure supply circuit (BOSCH assembly) Page 1 of 11

CHECK : FUEL HIGH PRESSURE SUPPLY CIRCUIT (BOSCH ASSEMBLY)

ESSENTIAL : Observe the safety and cleanliness recommendations .

1. Tooling
Equipment :
 Leak detector
 Diagnostic station

tool Reference Designation

[1613-A] (kit 1613) dummy high
pressure fuel
injection rail

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

[1613-L] container for

measuring the high
pressure fuel
injection pump
return flow

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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RHK BOSCH CP1

RHU BOSCH CP1
RHM BOSCH CP1
DW12 4HY BOSCH CP1
4HW BOSCH CP1
4HX BOSCH CP1
4HZ BOSCH CP1
DW12B 4HP BOSCH CP1H3
4HR BOSCH CP1H3
4HS BOSCH CP1H3
4HT BOSCH CP1H3
DW12M 4HN BOSCH CP1H3
DW12C 4HL BOSCH CP1H3
DV4 8HX BOSCH /SIEMENS CP3.2
8HZ BOSCH CP1H
DV6 9HY BOSCH CP1H/CP3.2
9HZ BOSCH CP1H
9HX BOSCH CP1H
9HP BOSCH CP1H
DT20C X8Z BOSCH CP4.2
SOFIM 8140.43S BOSCH CP1
8140.23 BOSCH CP1
8140.43N BOSCH CP1
F 13 DTE5 FHZ BOSCH CP1H3
F 30DT F1 CE 0481D BOSCH CP1S3

3. Preliminary checks

ESSENTIAL : Respect the safety and cleanliness recommendations that are specific to high pressure diesel
injection (HDi) engines .

3.1. Electrical circuit

Check :
 The battery charge
 The fault codes ; Using the diagnostic equipment
 The fuel high pressure value using the diagnostic tool : Measure parameters

3.2. High pressure environment

Check :
 The quantity of fuel in the tank : 15 litres minimum
 Fuel quality (if in doubt over the fuel quality, use an auxiliary tank with a filter, filled with fuel which you know
where it came from)
 The low pressure fuel supply circuit (see the relevant operation)

3.3. Engine operation

Check the driving of the camshaft(s) (timing belt).
Check the components that could cause lack of engine power :
 Obstructed exhaust
 Clogged air filter

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 Clogged fuel filter

 The condition of the fuel feed and return hoses

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

CAUTION : Deletion of fault codes ; Using the diagnostic equipment.

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.

Uncouple 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.

CAUTION : Clean, cap and carefully store the tools used.

CAUTION : Deletion of fault codes ; Using the diagnostic equipment.

4.4. Checking the high pressure fuel pump

Disconnect the connector from the camshaft position sensor.

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CAUTION : Before slackening, clean the high pressure unions(See the corresponding operation).

N.B. : DT20C engine.

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.

N.B. : Other DT20C engines.

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.

Fuel pressure control ; Using tool [1613-D] :

 Press the test button
 The display on tool [1613-D] indicates the battery charge
 The display on tool [1613-D] indicates the last fuel pressure value tested (for 5 seconds)
 Press the test button and action the starter at the same time
 When the "stop" message appears on the display of the tool [1613-D], stop the action on the starter
 The display on the tool [1613-D] indicates the maximum fuel pressure value (for 5 seconds)
 The display on the tool [1613-D] indicates the residual pressure value

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].

Remove the tools [1613-A]*, [1613-B]*, [1613-D]*, [1613-E1]*.

* : According to equipment and engine.

CAUTION : Replace the high pressure fuel pipe .

CAUTION : Clean, cap and carefully store the tools used.

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CAUTION : Deletion of fault codes ; Using the diagnostic equipment.

4.5. Checking the fuel pressure regulatorCP1

Remove : The fuel pressure regulator .
Replace the fuel pressure regulator with the tool [1613/2-A].
Tighten the securing bolts to 0,5 dan.m.
Check the high pressure fuel pump.
The pressure is higher than 300 bars : The fuel pressure regulator is considered as being faulty.
Replace the fuel pressure regulator.
Tighten the fuel pressure regulator fixing bolts to 0,5 daN.m.
The fuel pressure is lower than 300 bars : The high pressure fuel pump is faulty.

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].

Remove the tools [1613-A]*, [1613-B]*, [1613-D]*, [1613-E1]*.

* : According to equipment and engine.

CAUTION : Clean, cap and carefully store the tools used.

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.

CAUTION : Deletion of fault codes ; Using the diagnostic equipment.

4.6. Checking the fuel pressure regulator CP1H3

Disconnect the fuel return pipe from the fuel high pressure common injection rail.
Connect the tool [1613-G] to the fuel high pressure common injection rail.
Plug by means of the tool [1613-K] : The fuel return pipe .
Start the engine.
Run the engine at idle For 1 minute(s).
The volume collected in the tool [1613-G] should be 300 ± 20 ml :
 If the volume is correct, the regulator is not faulty
 If the volume is not correct : Replace the fuel high pressure common injection rail, fuel pressure regulator, fuel
pressure sensor assembly

The engine will not start : Check to be made :

 Verify : Param. measuring : Pressure regulation ; Using a diagnostic tool
 If the next message is : Regulation by the pressure regulator only ; Check to be made
 Unplug : The fuel return pipe on the fuel high pressure common injection rail
 Connect the tool [1613-G] to the fuel high pressure common injection rail
 Plug by means of the tool [1613-K] The fuel return pipe
 Operate the starter motor for 10 seconds
 Pour the fuel collected in the tool [6] into a measuring cylinder
 10 ml +/- 2 ml (Normal operation)
 25 ml +/- 2 ml (Abnormal operation)

If the volume is not correct : Replace the fuel high pressure common injection rail, fuel pressure regulator, fuel pressure
sensor assembly.

CAUTION : Clean, cap and carefully store the tools used.

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CAUTION : Deletion of fault codes ; Using the diagnostic equipment.

4.7. Checking the fuel pressure regulator CP4.2

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.
Start the engine.
Allow the engine to idle for 1 minutes :
 Check the volume collected in the tool [1613-L]
 30 ml +/- 5 ml (Normal operation)
 Greater than 50 ml (Abnormal operation)

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)

N.B. : If the volume is not correct.

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).

CAUTION : Clean, cap and carefully store the tools used.

CAUTION : Deletion of fault codes ; Using the diagnostic equipment.

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.

Check the high pressure fuel pump.

The pressure is higher than 300 bars : The flow electrovalve is faulty.
Replace : The flow electrovalve.
Tighten the flow electrovalve fixing bolts to 0,5 daN.m.
The fuel pressure is lower than 300 bars : The high pressure fuel pump is faulty.

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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Remove the tools [1613-A]*, [1613-B]*, [1613-D]*, [1613-E1]*.

* : According to equipment and engine.

CAUTION : Clean, cap and carefully store the tools used.

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.

CAUTION : Deletion of fault codes ; Using the diagnostic equipment.

4.9. Check of the fuel flow regulator CP4.2

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.
Start the engine.
Allow the engine to idle for 1 minutes :
 Check the volume collected in the tool [1613-L]
 30 ml +/- 5 ml (Normal operation)
 Greater than 50 ml (Abnormal operation)

If the volume is not correct : (The fuel flow regulator is jammed open) Replace the fuel flow regulator and high pressure
pump assembly.

CAUTION : Clean, cap and carefully store the tools used.

CAUTION : Deletion of fault codes ; Using the diagnostic equipment.

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