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HYUNDAI CIT-3500

Common Rail Injector Tester

User’s Manual

A, U, D, J, S, R Engine & U-II, A-II

Digital Controller

Summary of Contents for CIT-3500

Page 1: ...HYUNDAI CIT 3500 Common Rail Injector Tester User s Manual A U D J S R Engine U II A II Digital Controller ...

Page 2: ... High Pressure Test for each system 3 Cleaning procedure of injector 4 Injector Back Leak Test Dynamic 4 DIAGNOSTIC REPAIR INJECTOR CLEAN ASSEMBLY TIPS 1 Diagnostic Repair procedure of CRDi system 2 Cleaning procedure of injector 3 Injector assembly Nozzle area 4 Injector assembly Nozzle area 5 Tips for Injector assembly Nozzle area 5 TECHNICAL INFORMAITON 6 PIEZO INJECTOR 1 PIEZO Injector test 2 ...

Page 3: ...HI DUMMY INJECTOR NEW DELPHI DUMMY INJECTOR L DUMMY INJECTOR ADAPTER Engine Compression Gauge LOW PRESSURE GAUGE VACUUM GAUGE BOSCH CONNECTOR PIEZO CONNECTOR NEW DELPHI CONNECTOR RPS BOSCH DUMMY CONNECTOR RPS NEW DELPHI DUMMY CONNECTOR DUMMY REGISTER PRV DUMMY REGISTER HP SENSOR BACK LEAK CONNECTOR ADAPTER PIEZO RETURN LINE CONNECTOR ADAPTER Back Leak Test bottle LOW PRESSURE GAUGE CONNECTION TUBE...

Page 4: ...rget level NOTE Rail pressure will be maintained 250 350bar automatically by vehicle s ECU Thus you don t need to use HP controller during the test 2 1 INJECTION COMPARISON TEST LOW PRESSURE MODE ECU All the pipes must be cleaned before installed Clean it with an Air gun Tighten Loosen Flushing IG on or Cranking Tighten Flushing Crank the engine and find the fuel leaks from the fitting area for fl...

Page 5: ...or from the rail 2 Install Dummy Resister and Rail Pressure Sensor Dummy in each wiring connectors 3 Connect HP controller s wire to the PRV rail pressure sensor 5 Connect HP controller s power cable to battery 4 Crank the engine until the injection amount level of 1 or 2 test body are close to target level 5 scale in LOW 8 scale in HIGH NOTE Rail pressure can be adjusted from 100 to 1000bar by pr...

Page 6: ...Quick coupling on dummy injector will help you to perform cylinder compression test easily and quickly Judgments Please note that the engine compression standard is showed on the shop manual Compression Test Crank the engine until the injection amount of 2nd largest fuel amount injector is close to target level 5 scale when low pressure mode 8 scale when high pressure mode Measure the other inject...

Page 7: ... 3 HIGH Set the pressure by 800 1000bar 4 MAX HIGH Set the pressure over 1000bar Particulars adjustment Press the UP DOWN button by click Fast Adjustment Press the UP DOWN button continuously 3 CURRENT DATA Monitoring Crank In pressure by the power on status of Pressure Regulating Valve CURRENT DATA Use only for the high pressure pump test Run the current data mode without press any other key when...

Page 8: ... line HP pump leakage or damaged The Purpose of this test is to confirm the High pressure pump performance or to reconfirm high pressure pump performance when measured value of pressure was lower than 700bar during Step 2 1 Avoid injector back leak completely by blocking rail outlet Test Procedure Remove the Injector pipes from the rail Block the rail outlet using rail plug Install the HP controll...

Page 9: ... DELPHI Above 1000 bar NOTE If measured rail pressure value was out of specification check following items Low pressure pump or suction pump and its strainer Including fuel tank High pressure pump and IMV Inlet Metering Valve If the vehicle problem is still persisted while rail pressure value is in specification check whether the fuel pump was contaminated or damaged 3 2 HIGH PRESSURE TEST for eac...

Page 10: ... Filter or fuel line strainer or etc clogging 3 no pressure Abnormal function of fuel pump EURO Ⅳ model CASE PRESSURE bar JUDGMENT 1 2 5 5 kg System normal 2 0 5 2 0 kg Filter or fuel line clogging pump in good condition 3 no pressure Abnormal function of fuel pump Internal suction pump type DELPHI Type CASE VACUUM JUDGMENT 1 10 20 cmHg System normal good condition 2 20 60 cmHg Filter or fuel line...

Page 11: ...ts BOSCH Type Replace the injector which is shown more 3 times than the minimum value 30sec 3000rpm stop Start 1min 30sec 3000rpm Stop Idle acceleration Start 2min Normal condition 2 Injector abnormal 1 2 3 4 Service Limit 25cc 1 2 3 4 Abnormal injector DELPHI Type Replace the injector which indicates exceeds 25cc DELPHI Type 3 Connect the Hi Scan and select the High Pressure Leak Test mode 4 Cond...

Page 12: ...ed after cleaning Replace injector assembly when the internal parts are not available 4 1 Diagnostic Repair procedure of CRDi system Repair or replace the part related to problem OK Check the function of EGR VGT WGT system NG Repair or Replace Fuel line or pump problem Engine stall Hard start Impossible to start Fuel pump noise DTC set related with pressure line OK Cleaning Test NG Replace Injecto...

Page 13: ...dust free environment to prevent injector contamination Soaking more than 5 minutes Washing Rinse Note Do not use brush while rinse to avoid contamination Do not interchange internal parts of injectors as it will influence on its calibration Use only original parts to maintain the proper performance Thinner Caution Thinner and its evaporated gas is harmful to people Bottle cap must be closed while...

Page 14: ...0 27900 2 Type 2 33800 27000 Direction Shim Spring Guide Pin Nozzle holder Cap Nut Shim 4 3 Injector assembly Nozzle area Spindle should be inserted into nozzle holder freely without any resistance Spindle Should be moving freely Spindle Thinner Required parts for thinner soaking More than 5min Repairing injector must be done in a clean and dust free environment to prevent injector contamination D...

Page 15: ...Return spring Nozzle Spindle Cap nut Free movement are required Thinner Required parts for thinner soaking More than 5min Tightening Torque 45N m NOTE When you test injector after cleaning operate injector more than 3 4 times in high pressure mode of HP controller for bed in and flushing Repairing injector must be done in a clean and dust free environment to prevent injector contamination Should b...

Page 16: ...spindle of nozzle are due to wearing The damaged spindle causes friction increase and produce low or over injection Normally you must replace the damaged nozzle assembly or change to new injector But it is possible to fix the injector without replacing the parts by using the above method Usually 100 scratch marks match with the fuel supply hole therefore if you change the direction of scratched ar...

Page 17: ...cess The data is then affixed to the injector in the form of a data matrix code This data is transferred to the ECU during vehicle production While the engine is running these values are used to compensate for deviation in metering and switching response But Incase of re manufactured injectors for in use car service it is almost impossible to classify control and label due to technical limitation ...

Page 18: ...ched the injectors form engine and set up the dummy injectors 5 Cleaning the nozzle at end of Injector by sinner 6 Attached the test pipe and injector on the rail 7 Connecting the injector wire line 8 Tighten pipe connection to stand up test body 9 Check all connection are right to connect including HP controller Test 1 Keep ignition engine on until injected fuel 2 If not to injected fuel please c...

Page 19: ...st above 1 5 scales is normal condition In case of standard injector is on 5 scales Low pressure test above 4 scales is normal condition In case of standard injector is on 8 scales Warning The injected fuel quantity is very important because a injector has a good condition as closed to injected fuel quantity of standard injector It can be possible to estimate life time of the injector with the inj...

Page 20: ...be connect before the fuel filter Install 24 LOW PRESSURE GAUGE CONNECTION TUBE 3 Connect the connection adapter with hose Install 27 4 Engine on ignition on Check any fuel leaking 4 Read the low pressure gauge Judgment 1 E G Idle RPM should be maintain at normal condition 2 Check any fuel leaking again and again 3 Based on the below table to judge the low pressure line 3 Injector Return Measureme...

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