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DIESEL INJECTION
Fault finding – Tests13B
TEST10
CONTINUED 2
Part C: Measuring fuel return flow
1. Fitting the tool:
Carry out this part only if the PR063 Fuel temperature is greater than 50C (see step 2 of part C of this test).
Remove the engine undertray
Disconnect the entire fuel return pipe in accordance with the following procedure (do not remove the clips):
– press the clip,
– Pull vertically the end piece of the fuel return pipe (see arrow the illustration).
IMPORTANT
The end piece is fragile. Be careful not to break it by pulling it too hard. Replace all removed clips
AFTER REPAIRCarry out a road test followed by a complete check with the diagnostic tool.
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58
Page 419 of 431
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DIESEL INJECTION
Fault finding – Tests13B
TEST10
CONTINUED 3
Fit the blanking plugs (B), from the kit (part number 77 01 208 229), on the end pieces of the fuel return pipe.
If fitting of Mot. 1760 onto the injectors is not being performed immediately, place blanking plugs (A) on the injector
fuel return openings.
AFTER REPAIRCarry out a road test followed by a complete check with the diagnostic tool.
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58
Page 420 of 431
13B-420V9 MR-372-J84-13B450$200.mif
DIESEL INJECTION
Fault finding – Tests13B
TEST10
CONTINUED 4
On the pipes of the tool Mot. 1760 (see illustration 113195), remove the clips and the end piece plugs (to right on
the picture) and leave the plugs (to the left on the picture) in place.
AFTER REPAIRCarry out a road test followed by a complete check with the diagnostic tool.
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58
Page 421 of 431
13B-421V9 MR-372-J84-13B450$200.mif
DIESEL INJECTION
Fault finding – Tests13B
TEST10
CONTINUED 5
Connect the pipes of the tool mot. 1760) to the injectors (without removing the clips on the injectors):
– press on the injector clip,
– insert the end piece in the injector fuel return opening.
– remember to fit the end piece plugs to the injector fuel return openings with the clips provided.
– Remove the plugs left in place on the tool mot.1760
AFTER REPAIRCarry out a road test followed by a complete check with the diagnostic tool.
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58
Page 422 of 431
13B-422V9 MR-372-J84-13B450$200.mif
DIESEL INJECTION
Fault finding – Tests13B
TEST10
CONTINUED 6
Insert the ends of the pipes into the measuring cylinders of tool Mot.1760; the cylinders are taken from tool Mot.
1711.
AFTER REPAIRCarry out a road test followed by a complete check with the diagnostic tool.
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58
Page 423 of 431

13B-423V9 MR-372-J84-13B450$200.mif
DIESEL INJECTION
Fault finding – Tests13B
2. Check the injector return flow balance:
TEST10
CONTINUED 7
Does the engine start?–Fit Mot. 1760 as shown in the tool fitting procedure.
– Start the vehicle or do a starting sequence of 15 s (with ignition
key).
– Measure the length travelled by the diesel fuel in the pipes of the
Mot. 1760.
– Replace the injector if the length travelled by the fuel is more than
10 cm compared with the average of the other three injectors.
– The injector return pipes must be fitted to the injectors.
– Start the engine.
– Display the sub-function Fuel circuit in the CLIP diagnostic tool.
– Raise the temperature of the engine.
– Read the diesel fuel temperature with the PR063 Fuel temperature until the diesel fuel temperature is greater
than 50°C
– Switch off the engine.
–Fit Mot. 1760 as shown in the installation procedure (see step 1).
– Check the value of the PR038 Rail pressure.
– Ask another Cotech to monitor the rise in fuel in the cans during engine turnover, as one of the cans will fill up
quickly if one of the injectors is leaking.
– Start the engine.
– Accelerate the engine until the pressure in the rail is 550 bar:
– if the engine speed is less than 3,000 rpm, maintain this pressure.
– if the engine speed is more than 3,000 rpm, reduce the engine speed until the rail pressure is 500 bar
and maintain this pressure.
– Maintain these conditions for 1min.
– Release the accelerator pedal and maintain the idle speed for 10 seconds.
– Switch off the engine.
– Measure the quantity of fuel contained in each measuring cylinder.
– Replace the injector if the quantity of fuel is more than 50 ml.
– Remove Mot. 1760 as shown in the tool removal procedure (see step 3).
NO
YES
AFTER REPAIRCarry out a road test followed by a complete check with the diagnostic tool.
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58
Page 424 of 431
13B-424V9 MR-372-J84-13B450$200.mif
DIESEL INJECTION
Fault finding – Tests13B
3. Removing the tool:
TEST10
CONTINUED 8
IMPORTANT
Use a cleaning cloth (part number 77 11 211 707) to absorb fuel run-off.
Disconnect the pipe from an injector:
– press on the injector clip,
– pull vertically on the end piece of the pipe of the tool Mot. 1760 while putting a rag on the end piece to prevent
drips.
Lift the end piece vertically so that the fuel contained in the pipes flows into the measuring cylinders of tool
Mot. 1760.
Remove the other 3 pipes using the same procedure.
AFTER REPAIRCarry out a road test followed by a complete check with the diagnostic tool.
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58
Page 425 of 431
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DIESEL INJECTION
Fault finding – Tests13B
END OF TEST 10.
TEST10
CONTINUED 9
Remove the plug welds from the fuel return pipe end pieces.
Connect the complete fuel return pipe to the injectors.
Wipe up any fuel run-off using a cleaning cloth (part number 77 11 211 707).
AFTER REPAIRCarry out a road test followed by a complete check with the diagnostic tool.
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58