Special Accessories; Offboard Diagnosis; Product Description; Functional Description - Pressure Buildup - Bosch Diesel Set 3.1 Manual Original

en 22 | Diesel Set 3.1 | Product description
Overview
Abb. 1: Overview Diesel Set 3.1
3.3

Special accessories

i
Extension set for rail pressure sensor - comparison
test (see Chapter 4.2.2).
Designation
180 MPa extension set
3.4

Offboard diagnosis

Terms:
Offboard diagnosis: Aids and tools that assist manual
troubleshooting on the vehicle.
Onboard diagnosis (OBD): Control module-internal
diagnosis, with sensor and actuator monitoring as well
as storage of diagnostic trouble codes (DTC).
3.5

Product description

3.5.1 Functional description – Pressure buildup
Testing of diesel common rail high-pressure pumps
under engine starting conditions
For use with complaints such as:
R
Engine does not start, starter turns
R
Engine dies, won't start again, starter turns (break-
down)
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1 689 989 210 2015-10-20
The pressure sensor module (fig. 1, item 11) is con-
nected directly to the high-pressure connection on
common rail high-pressure pumps with a high-pressure
connection by means of the black 60 MPa hose assem-
bly.
This requires disconnecting the high-pressure hose assembly
from the injection pump.
i
The engine cannot start in this condition!
i
On common rail high-pressure pump type CP4.2,
join the two high-pressure connections via the
combining rail (fig. 14, item 5) and connect to the
pressure sensor module. Individual testing of high-
pressure elements of this pump is not possible.
When the starter is actuated, the fuel being delivered
accumulates in the collecting container of the module
and the pressure is indicated on the digital pressu-
re display. The pressure attained is a measure of the
pressure buildup capability of the common rail high-
pressure pump under engine starting conditions. When
a pressure of about 50 MPa is reached, a pressure
limiter in the module opens to protect the common rail
high-pressure pump. The overflowing quantity flows into
the collecting container of the module.
3.5.2
Comparison test in the common rail system
Order number
0 986 613 925 For use with complaints such as:
R
Poor performance (No DTC entry)
The pressure sensor (fig. 1, item 12) is connected
directly to a high-pressure connection of the vehicle rail
by means of the blue 180 MPa hose assembly.
This requires disconnecting the high-pressure hose as-
sembly between the rail and a readily accessible injector.
The digital pressure display connected to the pressure
sensor shows the actual value of the pressure in the
rail.
A system diagnostic device connected to the vehicle (e.g.
Bosch KTS 5XX / 6XX) displays the pressure sensed by
the rail pressure sensor installed in the rail and, in turn,
any possible faulty value. When a pressure of about
180 MPa is reached, the pressure limiter in the pres-
sure sensor opens for safety reasons. The overflowing
quantity is discharged through a hose.
Functional description – Rail pressure sensor
Robert Bosch GmbH