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					Model: Model Year: Application: TSB No.: Issue Date: 2005/08/03 Group: Type: Diesel CRDi Revise Date: Area: ,,,,, SST(SPECIAL SERVICE TOOL) FOR DIAGNOSIS OF DIESEL COMMON RAIL SYSTEM Subject: Pages: 7

This bulletin provides information related to the SST(Special Service Tool) for proper diagnosis of the diesel common rail system. Some KIA vehicles with a CRDi engine (J2.9, A2.5, D2.0, U1.5) may experience intermittent rough idling or stalling and/or it may be impossible to start the engine. Injector inner parts or high pressure pump inner parts that are damaged caused by foreign objects in the vehicle’s fuel. If you are experiencing the above symptoms, check the fuel system. In some cases, the following DTCs (Diagnostic Trouble Codes) will be recorded in the ECM (Engine Control Module). – See the chart below If a vehicle shows signs of one of the related symptoms and DTCs, you are requested to perform the "Fuel injection system inspection procedure" (attached) to identify the causal parts and repair the fuel system according to the inspection results.

1. Affected vehicle information
▶ Model : Carnival 2.9 with CRDi engine (J2.9) Sorento 2.5 with CRDi engine (A2.5) New Sportage 2.0 with CRDi engine (D2.0) Cerato 2.0 with CRDi engine (D2.0) Cerato 1.5 with CRDi engine (U1.5) New Rio 1.5 with CRDi engine (U1.5)

2. Suspected cause of problem
1) The injector back leak flow incrementally increases when the internal part of the injector is worn out by particles which can lower the efficiency of an injector sealing. Possible reasons: - Heavy contamination of the fuel. - Wear and tear of the pump may lead to the production of metallic particles that may seriously disturb the injector function. - A mechanical worn out of injector due to the erosion by fuel contamination. 2) The fuel pump’s capacity to supply the required pressure is decreased due to a worn-out internal pump or a fuel feeding problem. Possible reasons: - Presence of air in the low pressure circuit. - Excessive negative pressure in the pump inlet due to a blockage of the fuel filter and fuel hose. - Mechanical worn out of pump inside. - Excessive pump inlet temperature (above 65 ℃).

3. Logical order for diagnosis procedure:

※ DTCs for CRDi system
Vehicle Model Carnival Engine Model J-2.9 DTC Malfunction

P1119 Inlet Metering Valve Control Malfunction P1120 Inlet Metering Velve Circult Malfunction

Sportage Cerato

D-2.0

P1185 Fuel Pressure Monitering - Maximun Pressure Exceeded P1186 Fuel Pressure Monitering - Minimun Pressure at Engine speed Too low P1187 Fuel Pressure Monitering - Regulator Valve Stick P1188 Fuel Pressure Monitering - Leakage P1189 Fuel Pressure Monitering - Governor Deviation at Engine speed Too high

Sorento

A-2.5

P1180 Rail Pressure Regulator Malfunction P1181 Fuel Pressure Monitering

Cerato New Rio

U-1.5

P0087 Rail Pressure Monitering - Minimun Pressure at Engine speed Too low P0088 Rail Pressure Monitering - Maximun Pressure Exceeded

4. Tester Composition
1) Standard Set Part No. CRT-1000 Part Name Common Rail Tester Unit Price 18000 рублей Remark FOB Korea

2) A/S supplement parts - To repair damaged Common Rail System
NO Part Name Part No Quantity Figure

1

Tool Case

CRT-1010

1EA

2

Regulator Valve

CRT-1020

1set

3

Plug (for Delphi) M14mm

CRT-1021

3EA

4

Plug (for Bosch) M12mm

CRT-1022

3EA

5

Adapter (for Bosch)

CRT-1023

1EA

6

Flask & Holder

CRT-1030

1set

7

Visible Tube

CRT-1031

4EA

8

Injector Return Hose Adapter

CRT-1032

4EA

9

Injector Return Hose Plug

CRT-1033

1EA

10

Flushing Tube

CRT-1034

4EA

11

Dust Cap

CRT-1035

8EA

12

High Pressure Meter

CRT-1040

1set

13

Adapter Connector (for Delphi Old)

CRT-1041

1EA

14

Adapter Connector (for Delphi New)

CRT-1042

1EA

15

Adapter Connector (for Bosch)

CRT-1043

1EA

16

IMV Control Valve

CRT-1044

1set

17

Vacuum Gauge

CRT-1050

1EA

18

Pressure Gauge

CRT-1051

1EA

19

Gauge Connection Tube

CRT-1052

1EA

20

Connection Adapter

CRT-1053

1EA

21

Connection Adapter with Hose

CRT-1054

1EA

22

Hose Clamp

CRT-1055

2EA

23

User's Guide

CRT-1060

1EA

5. Tester Warranty Condition
- Supplier guarantees three (3) -year warranties (from the date of purchase) for parts and shipping charge for any defected kits. - Products subject to abnormal use are not covered by warranty - A consumable product: Warrant only available against defects in workmanship or materials that prevent its use. * Abnormal use: Misuse, accidents, modification, unreasonable and/or excessive use, neglect, and lack of maintenance.

6. KMC Warranty Procedure
1) Inspection labor cost reimbursement -Labor operation code name: Fuel injection system inspection -Operation code & Time: 33800F00 / 0.2M/H 2) Test record retention

-For all injectors and fuel pump replacement, the below check sheet must be attached to the Repair Order Sheet.
Check Sheet Model : NO VIN : Test Items Max High pressure 1 Fuel Pressure Test Low fuel pressure ( or ( ( (
Kg/㎠) cm Hg) Cm )

Milage : Remark ( bar) Test with High pressure Meter Test with Low pressure gauge If engine running If impossible to engine running

Dynamic mode 2 Injector Back Leak test Static mode

Cm )

7. Recommendation
KMC strongly recommends that all KMC dealers use the Common Rail Tester as a mandatory warranty repair tool for future repairs.

※ Attachment:
1. Order form for Common Rail Tester 2. Detail diagnosis procedures for each model


				
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