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How to Diagnose Common Rail injector faults on Ford Mondeo

Posted on 1/1/2016 2:05:03 PM

When you see the low power and poor emission from your engine,the reason maybe caused by the Common rail injectors.

There are several fault codes will be shown:
F2336 Injector 1 fault  / F2337 Injector 2 fault  / F2338 Injector 3 fault  / F2339 Injector 4 fault

If you see the note “Accelerometer out of range”,it means that the excess of the 80 micro seconds tolerance window are happening which caused the stability of injector can't be maintained by the drive of systems.If the fault code also coming with a rail pressure fault code,there is possiblity that the whole system has been contaminated.  
In this situation,we could use the Delphi Sealed Rail Kit to check which parts are at fault.

Below is the resolution recommended for the fault codes shown above:
Step 1:
Remove the fuel filter and empty the contents into a clean container.
The systems must be cleaned out from the tank to the filter if the contact is not clear,or full of particulates,or has high water contents.If the sample is clear and the amount of particulates in the sample covers less than one square centimeter,then proceed to the hydraulic test. More than one square centimeter suggests heavy contamination, and if the particles are of a metallic nature, a full system overhaul will be required. 

Tips:we could use the magnet to identify the ferrous metallic particles in the base of container.

We also need to check for damage to the other mechanical components in the system using a hydraulic or “wet side” diagnostic on the pump, injectors and rail at this stage.Meanwhile we could use Delphi’s fuel analyzer to confirm if the sample is suitable for further use.

Step 2:
We could use Delphi Sealed Rail Diagnostic Kit to test the pump and injectors for max pressure and back leakage hydraulically.
If the pump pressure is lower than the recommended spec stated in the kit instructions, this indicates that the pump is worn and requires attention. Then we need to check whether the damage is internal or to the external IMV by using False Actuator Kit.

Note:We need to replace the system directly if there is any contamination in the high pressure pump,rail and injectors.

We could go ahead for next if the pressure can be recovered by a new IMV.The injector back leakage is critical and must be within the parameters outlined in the test kit manual.
If every cylinders back leakage is not uniform,then the highest back leak injectors should be serviced in accordance with Delphi service standards, or replaced with new injectors. 

Notes:The high back leak injectors must match with the fault codes of the relevant injector number.If all of the injectors have high back leakage,it might be caused by the  fuel contamination and it means all the injectors now require service.

Note:If there is contamination in the system,it also has high possiblity of repeat failure and the repairing cost to customer will be increased.

Step 3:
Replace the fuel filter.

A genuine Delphi or Ford part is used when the filter is replaced.System protection highly need the 2 microns filter screen.Non-genuine filters may have a larger filter screen, typically 5 to 10 microns – this is inadequate for this application. 

Step 4:Ensure the correct torque setting
In order to prevent the distortion of the pipe and/or injector,all the pipes have to be tightened to the correct torque settings.Meanwhile this injector Ensure the correct torque setting.

Ensure all pipes are tightened to the correct torque setting to prevent distortion of the pipe and/or injector and that the injector mountings are also torqued in accordance with the specification. 

Step 5:Reprogram the ECU.
For each new or repaired DELPHI common rail injectors,it needs a related label with a characterization code.

Step 6:clear all fault codes,road test the vehicle and recheck for codes after the road test. 

We could take advantage of the established network such as Delphi Service Centre and China Balin Parts Plant's Aftermarket service centre to offer the extensive technical support and training.Comparing to Delphi Service Centre to offer the technical guidance on key system and vehicle issues,China Balin Parts Plant's Aftermarket service centre have an access to offer professional guide to deal with all the possible problems in the common rail injection systems.

common rail injectors

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