Leak test, fuel pressure, flow capacity and adaptation procedure
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Leak test, fuel pressure, flow capacity and adaptation procedure
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The car can exhibit certain fault symptoms without generating a diagnostic trouble code. This can be due to an air leak in the system or insufficient fuel pressure and flow capacity.
The fault diagnosis listed below includes checking air leaks, fuel pressure, flow capacity and adaptation procedures. If a trouble code is present the appropriate fault diagnosis procedure should be used. The method below is to be used if the problem cannot be traced with a diagnostic trouble code.
Warning
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Work involving removal of the fuel pressure regulator involves interference with the car fuel system. The following points should therefore be observed in connection with the procedure:
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Ensure good ventilation! If there is approved ventilation for extraction of fuel fumes then this must be used.
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Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation of the skin.
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Have a fire extinguisher class BE at hand! Be aware of the risk for sparks, i.e. in connection with circuit breaking, short-circuiting, etc.
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Absolutely No Smoking!
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Wear protective glasses.
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1.
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Make 2 copies of the checklist at the end of this document. Fill out one of the copies before initiating diagnostic procedures.
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3.
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Remove the upper engine cover.
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6.
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Coat the charge air pipe's O-ring with vaseline and mount it on the throttle body. If needed, replace the O-ring.
Pressure test the system as follows:
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7.
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Detach the crankcase ventilation hoses from the camshaft cover and from the pipe to the banjo fitting.
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8.
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Plug the crankcase ventilation pipe at the cylinder head. Use the hose plug in the plug kit 83 95 659.
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9.
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Detach the hose from the check valve.
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10.
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Detach the hose from the mass air flow sensors. Fit plug kit 83 95 659 in the hose and connect the accompanying pressure regulator to an external air pressure outlet.
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Important
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Close the pressure regulator before connecting it to the air pressure outlet.
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11.
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Detach and plug the upper signal hose to the boost pressure control valve (connection R).
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12.
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Detach the lower quick-release coupling from the EVAP canister purge valve.
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13.
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Pressurize the intake system by carefully turning the pressure regulator until a maximum 0.6 bar of overpressure is attained. The value should be monitored using the charge pressure gauge 83 93 514.
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14.
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The entire intake system is now pressurized and leaks can be located using leak detection spray or soapy water. Check all components, hoses and connections, and rectify any leaks that can be heard.
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Important
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Only leaks that can be heard will affect the function of the engine management system. When leak-detecting spray or soapy water is used, even small leaks will be found. These do not need to be addressed.
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15.
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Remove the plugs and connect the hoses to the mass air flow sensor, the boost pressure control valve, the EVAP canister purge valve and the crankcase ventilation.
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16.
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Check the control module's software version in Tech 2. If there is a more recent version in WIS it should be programmed in to the control module.
Checking fuel pressure / flow capacity
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Important
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Use the assistance of a colleague when measuring on the move.
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17.
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Connect pressure measuring equipment 83 93 852 using adapter 83 94 744 to the connection nipple on the fuel rail. Lead the signal hoses and gauges for fuel pressure and intake pressure through the side window into the cabin. Make sure the hoses are not kinked or pinched.
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18.
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Measure fuel pressure while driving with as high a load as possible. Read the measurements on the manometers. The pressure differential should always be 3 bar of fuel pressure according to the table below.
Drive thereafter with varying loads and engine speeds. Check that the fuel pressure follows the pressure in the intake manifold.
If the pressure differential is incorrect, check the fuel pressure regulator, fuel pump and fuel lines (delivery and return). Check that the EVAP purge valve works. Refer to WIS - Engine - evaporative emission system ORVR - Adjustment/Replacement - Checking for leaks in the evaporative emission system.
Pressure, intake manifold
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Fuel pressure
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-0.6 to -0.4 bar
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2.4-2.6 bar
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0 bar (atmospheric pressure)
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3.0 bar
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0.6 bar
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3.6 bar
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19.
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Check the fuel adaptation with the help of Tech 2. Carry out the adaptation as follows:
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19.a.
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Turn off the A/C or ACC.
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19.b.
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Engine temperature should be over 80°C and the engine should have been running for at least 3.5 minutes. The adaptation must be completed within 10 minutes of engine start-up.
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19.c.
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Drive on a flat road at between 1500 - 2750 rpm in 5th or 4th gear, attempting to keep the accelerator completely still for approximately 2 minutes.
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19.d.
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Stop the car and let the engine idle.
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19.e.
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Read "multiplicative adaptation" on Tech 2.
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19.f.
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Read "additive adaptation" on Tech 2. If the value does not appear within 10 minutes, turn off and restart the engine and repeat steps 19b - 19f. If the value still does not appear, go to step 24.
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20.
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Carry out the adaptation of the throttle opening.
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20.a.
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Coolant temperature should be over 80°C. Turn off the A/C or ACC.
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20.b.
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Let the engine idle for 2 minutes. Turn off the engine.
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20.c.
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Repeat step 20b 3 times.
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21.
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Fill out the second copy of the checklist.
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22.
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Disconnect the pressure measurement equipment and Tech 2.
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23.
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Fit the upper engine cover.
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24.
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If the problems have not been solved, contact the importer's technical support. Have the checklists that were filled out ready.
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1.
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Describe the fault symptom .......................................................................................................................................
...................................................................................................................................................
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3.
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Turn off A/C or ACC and let the engine idle. Coolant temperature should be over 80°C.
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Note
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Do not erase diagnostic trouble codes.
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4.
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Read and note any diagnostic trouble codes: .......................................................................................................................
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5.
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Choose "Engine" - "Trionic" - "Read value / Activate" in Tech 2. Read and note the following values:
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Unit
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Ignition ON
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Idling speed
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Desired value
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Engine RPM
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rpm
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800-850
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Airmass / Combustion
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mg/c
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Coolant Temperature
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°C
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85-100
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Variation from measured air mass
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%
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max. 10
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Intake air temperature
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°C
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40-60
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Atmosphere Absolute Pressure
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kPa
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90-115
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Charge Air Absolute Pressure
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kPa
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95-110
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Manifold Absolute Pressure
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kPa
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25-60
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Additive adaptation
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mg/c
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max. 0.6
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Multiplicative adaptation
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%
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max. 6
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Charge Air Adaptation
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%
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max. 10
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Number of knockings
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Number of misfires
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Cylinder 1
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Cylinder 2
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Cylinder 3
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Cylinder 4
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Under “system information” you will find information on chassis and version numbers for Trionic T7
Vehicle Identification Number
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Software Version Number
(obligatory)
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The plate with the engine number is placed on the cylinder block as specified in WIS - Engine - Basic engine, petrol - Technical data - Engine serial No.
To see the colour of the injectors, remove the upper engine cover.
Engine serial No.
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Fuel injector, colour
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