How to code Delphi diesel injectors

PF Jones are an official Delphi repair centre. Here are the steps our technicians followed to code Delphi injectors.

Delphi Diesel Fuel Injector

Step 1

The technician connected Delphi’s DS150 diagnostic tool to the 16-pin EOBD diagnostics socket to interrogate the vehicle's fault code history. Fault returned ‘P0263 Injector cylinder 1-Drift’ indicating an injector related fault.

Step 2
The technician checked all of the injectors backleakage using the Delphi Sealed rail kit (YDT278) in order to identify which injectors are not performing to specification, and to confirm correct levels of rail pressure.

In this case, it was a fault with one of the injectors but if low rail pressure was an issue, the technician would have used Delphi's False Actuator Kit (YDT410) to determine whether or not the pressure was generated mechanically by the pump or if there was possible fault with the pump's Inlet Metering Valve 9IMV) or Pressure Control Valve.

Step 3

To ensure the damage was not due to contaminated fuel, the technicians next step was to test  the fuel within the system with the Delphi fuel analyser (YDT553).
After testing the fuel from the vehicle’s tank, and/or the fuel filter assembly, it was found the fuel was not contaminated.
If the analyser had shown fuel contamination, the technician could use this diagnosis to explain the damage, as well as to refute any possible warranty claims.

The fuel analyser can be connected to a PC so results can be downloaded and printed for the workshop or customer records.

Step 4
Once the technician concluded the fault was a worn injector, he removed all of the injectors from the vehicle. As all of the injectors had done the same mileage, it was important to have the complete set diagnosed to rule out any other potential problems. The injectors were sent to a local Delphi Diesel Centre. (We are a fully approved Delphi diesel centre).
The Delphi Diesel Centre tested the injectors on a Delphi authorised test bench to confirm which injector was at fault. This included electrically testing the injectors for resistance and insulation failures.

Step 5
After the injectors had been tested, any which did not pass the authorised test were dismantled, repaired and reassembled in a clean, filtered environment. In this case the one repaired injector was again put through a complete test procedure on an authorised test bench and finally, recalibrated with a new C2i/C3i code, which was printed onto a label attached to the injector body.
The new calibration code is critical for the operation of the repaired injector. When fitted to the engine, it allows the software within the ECU to accurately control the injectors fuel delivery and switching times according to the specific parameters and performance for the vehicle.

Step 6
Once the technician received the tested, repaired and recalibrated injectors, he was able to refit them to the engine continuing to maintain a high standard of cleanliness at all times.
After the injectors were fitted to the engine, the technician utilised the DS diagnostic tool to calibrate the vehicle with the new C2i/C3i code for the repaired injector and to recheck the other three. This is a straightforward process as the tool provides help files for the technician to guide them through the process.

Please note, recalibrating the vehicle with the new codes is essential – of the new codes are not entered, the vehicle will have poor running and idling issues and fault codes are likely to be generated.

Step 7
The final step for the technician was to re-interrogate with the DS diagnostic tool and clear all the fault codes to confirm the fault was eliminated.

Job Done!

Technician time: approximately 2 hours. 


Technician's Tool Box

  • DS Diagnostic Tool
Providing comprehensive all makes and diagnostics across the key electronic systems, the DS solution is available on variety of platforms, ensuring the right tool for any business.
  • Sealed Rail Kit
Delphi's Sealed Rail Kit is able to accurately measure the rail pressure generated by all makes of Common Rail (CR) pump and the backleakage returning from each injector while the components are still fitted to the engine. If the vehicle does not run, the tests can be carried out at engine cranking speed. This avoids removing the CR pump and injectors to later find there is no fault with these components. In most cases, this work can be carried out in less than one hour.

  • False Actuator Kit
If it is proven the rail pressure at engine cranking speed is below the minimum required value, this may be caused by a faulty Rail Pressure Valve or Inlet Metering Valve attached to the CR Pump. Suspect valve can be removed and replaced with a false (or dummy) actuator from this all-makes kit. The Sealed Rail test (described above) can then be repeated. If sufficient rail pressure is generated, work can be completed by fitting a replacement valve.

  • Fuel Analyser
Delphi's fuel analyser is a robust, hand-held unit which provides immediate and accurate results via a digital display screen. The tool specifies the level of biodiesel present in the fuel sample. If the fuel is contaminated with unrefined biodiesels or vegetable oils, a simple error code will be displayed identifying the potential cause of contamination. Using this data can immediately identify whether there is an unacceptable amount of biodiesel present or contamination which will have impacted on the fuel injection system.


No posts found

Write a review