SB-17-016 – Fuel Injectors Test Procedure – HINO

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NHTSA ID Number: 10117566

Manufacturer Communication Number: 167-B1701-09

Summary

SB-17-016 FUEL INJECTORS TEST PROCEDURE — The purpose of this fuel injector test procedure is to determine if abnormal fuel injector wear is present by measuring the actual amount of fuel compared to the calculated amount of fuel used with the engine running. Do not perform this fuel injector test unless necessary. This may cause unnecessary replacement of good fuel injectors.

 

1 Affected Product

Vehicle

MAKE MODEL YEAR
HINO HINO 9999

 


TECHNICAL SERVICE BULLETIN

SB-17-016 FUEL INJECTORS TEST PROCEDURE

GROUP: 22-FUEL SYSTEM
BULLETIN NO: SB-17-016
DATE: 8-14-2017

 

SUBJECT VEHICLES: All Hino Trucks.

Note: This service bulletin is provided as technical information and is not authorization for a warrantable repair.

 

OVERVIEW:

The purpose of this fuel injector test procedure is to determine if abnormal fuel injector wear is present by measuring the actual amount of fuel compared to the calculated amount of fuel used with the engine running. Do not perform this fuel injector test unless necessary. This may cause unnecessary replacement of good fuel injectors.

 

BEFORE YOU BEGIN:

  • Read and understand all instructions and procedures before you begin the work.
  • Read and follow all WARNINGS and NOTICES set forth in this publication. These alerts help to avoid damage to components, serious personal injury, or both.
  • Park the vehicle on a flat, level and solid surface.
  • Place the gear shift lever in “Neutral” or “Park”.
  • Apply the parking brake firmly and confirm parking brake activation.
  • Turn off the engine and remove the key from the ignition switch.
  • Always wear safety glasses or goggles to protect your eyes.
  • Place wheel chocks in front of and behind all the wheels to prevent the vehicle from moving.

WARNING: To prevent a fire, avoid smoking and open flames near the vehicle while performing this procedure.

 

FUEL INJECTOR TEST KIT :

PART NUMBER QUANTITY
HDT-650591 1

 

VEHICLE PREPARATION

  1. Park the vehicle on a flat, level and solid surface.
  2. Confirm the engine is stopped, the ignition switch is in the off (LOCK) position, and the key is removed.
  1. Apply the parking brake.
  2. Chock all of the wheels.

 

FUEL INJECTOR TEST KIT SETUP:

 

CONNECTING TOOLS PROCEDURE:

Important: The engine must be at 158°F (70°C) – Truck in P or N with the parking brake on, all symptoms repaired and all accessories must be off (exhaust brake, PTO, air condition, audio system, wipers; do not operate steering wheel or actuate the air brake while test is taking place).

Important: Hose connections must be clamped, using clamps provided in the kit.

Important: Customers main fuel tank should have no less than ¼ tank of fuel or air may not purge.

Important: Once the air is purged with using steps 4 thru 8 below, if the fuel system is opened for any reason (with exception of connecting the return hose), purge cycle will need to be performed again following steps 4 thru 8.

NOTICE: If the fuel hoses cannot be connected according to Plan A, use Plan B as an alternative. Refer to the table at the end of the procedure “Location of the connecting fuel lines”.

 

Conventional Fuel Hose Connections

  1. Remove the fuel hose from the trucks fuel filter inlet (driver’s side engine compartment). Connect the single 7’ foot fuel hose from the straight barbed fitting (top of valve assembly), to the fuel filter inlet on the truck (no adaptor needed).
  2. Connect the other 7’ foot fuel hose that is connected to the 90° barb fitting from the valve, to the fuel hose removed from the fuel filter inlet (use 3/8”-3/8” barbed adaptor to complete the connection).
  3. Connect the 2.5’ foot fuel hose (barbed fitting with valve) to the fuel feed from the injector test bottle.

 

CEO Fuel Hose Connections

  1. Remove the fuel hose from the trucks fuel filter inlet; separate the fuel line on the drivers side directly behind the cab near the transmission bell housing. Connect the single 7’ foot fuel hose from the straight barbed fitting (use short 1/2” fuel hose with 3/8” barb to complete connection).
  2. Connect the other 7’ foot fuel hose that is connected to 90° barb fitting from the valve to the rubber fuel hose removed from the fuel inlet behind the cab (use 3/8”-1/2” barbed adaptor to complete connection).
  3. Connect the 2.5’ foot fuel hose (barbed fitting with valve), connect this to the fuel feed from the injector test bottle.

 

Conventional/COE

Important: 12’ foot return fuel hose from injector test bottle is not connected at this time

  1. Connect the fuel lines as shown. Fill the fuel injector test bottle with 600cc of diesel fuel. Have the fuel valve turned to supply from tank.
  2. Open DXII Diagnosis > Engine ECU > Inspection Menu > Injector Inspection > Click Start > All-Cylinder Inspection
  1. With the fuel valve directed from the main tank open, start the truck and allow it to idle. Monitor the clear fuel hose(s) to remove air (shaking clear fuel hose slightly may be necessary to remove air from fuel hose).
  2. Once air is removed from the clear fuel hose from the main fuel tank, rotate the lever valve to draw fuel from the injector test bottle. Keep running from the injector test bottle until 2.5’ foot clear fuel hose between injector test bottle and valve has purged air. Use approximately 200cc of fuel from injector test bottle.

Once air is removed from this fuel hose, rotate valve so fuel is now drawing from main fuel tank.

  1. Click Start Inspection.
  2. Run the truck from the main fuel tank, use 180 second purge cycle in DXII (beginning of the injector test procedure), allowing all of the air to be purged from the fuel system, while fuel is returning to the trucks main fuel tank.
  3. After the purge cycles completes (180 seconds), click Cancel. Turn the truck off, pause for a moment and then attempt to start the truck. If the truck restarts easily, turn ignition off again and connect clear return fuel hose. If truck does not easily restart (due to air in the lines) run another 180 second purge cycle by clicking on Start inspection before connecting return hose.

Important: Do not choose a different location for the return hose connection.

Conventional – make the connection on the frame rail under the cab on driver’s side, slide the hose on the metal fuel return pipe.

COE: make the connection on the driver’s side frame rail, directly behind the cab and connect the hose to the metal fuel return pipe.

  1. Once connections are secure, start the truck and while truck is running at idle, valve still select for drawing fuel from main fuel tank, allow return fuel and air to enter injector test bottle.

Once air is purged from the return fuel line, fill the injector test bottle just past 900cc (regulate fuel level with valve). Once full, turn the valve to draw from the injector test bottle; prepare for the injector test procedure.

  1. While the truck is still running, start 180 second purge cycle again in DXII Start Inspection, then perform injector test as outlined. Use the valve to regulate fuel in the injector test bottle; when the main fuel tank is being used as a fuel source, return raises fuel level in the injector test bottle (use caution never to overfill the injector test bottle), measurement and purge cycle should begin with no less than 800cc of diesel fuel in the injector test bottle.
  2. If you can see the metal tubes in the bottle through the fuel then a sufficient amount of air has been removed. If you cannot see the metal tubes through the fuel then more air needs to be removed by running additional purge cycles.
  3. Once injector test bottle is at proper level, turn valve to run truck from injector test bottle. Click Start inspection.
  4. Allow 180 second purge cycle to complete then click OK.
  1. Monitor the injector test bottle until it reaches a line graduation that can be used as a start point. Once this is reached, click Measurement Start. Document the start of the measurement, subtract 300cc from the selected number and this will be the point where measurements ends.
  2. Once the fuel injector test bottle decreases by 300cc, click Measurement End. For example if you started at 900cc click Measurement end at 600cc.
  3. Once Judgment is provided and there are no abnormalities detected, click End Inspection.
  4. Once the DX session is complete, be sure to click New Diagnosis in the upper right to end the DX session and upload the report with test results for your records.

 

INDIVIDUAL INJECTORS TESTING

  1. Refill the bottle using valve just above the 900cc mark on the bottle. Click Inspecting #1 cylinder when the fuel is at 900cc.
  2. When the fuel level in the bottle has gone down 300cc, click on Measurement end.
  3. Refill the bottle using valve just above the 900cc mark on the bottle. Click Inspecting #2 cylinder when the fuel is at 900cc. At this point you would continue testing for each of the remaining fuel injectors.
  4. After checking the last injector, click on inspection result display.
  5. Record and replace any injectors that have failed the test which are denoted with NG. ONLY replace the injector(s) that are NG. If only one injector failed the test, ONLY replace the one failed injector.

NOTICE

  • Be sure to reconnect each hose to avoid fuel leaks.
  • After completing the test, confirm that fuel does not leak from any of the hoses.
  • Confirm the determination result for judgment.
  • Determination value of the each cylinder inspection will only be used by the specialized agency.

 

NOTE: This procedure is provided as technical information and is not an authorization for a warranty repair.

NOTE: For any warranty claims with injector replacement to be paid after October 1st 2017, this injector test will need to be performed.

 

CLAIM APPLICATION

* Reimbursable in accordance within the terms and policies of the Hino limited warranties.

Fuel Injector Test:

  1. Labor Charge: 1.0 hour
  2. Warranty Code: 06195
  3. Trouble Code: 40
  4. Operation Code: 01002AOT

Individual Injectors Test as needed: a. Labor Charge: 0.5 hour

  1. Warranty Code: 06195
  2. Trouble Code: 40
  3. Operation Code: 06150AOT

167-B1701-09

https://www.nhtsa.gov/recalls?nhtsaId=10117566

https://static.nhtsa.gov/odi/tsbs/2017/MC-10117566-9999.pdf

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“This site contains affiliate links for which OEMDTC may be compensated”
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  • Large Measuring Range: With precision dual scale gauge, the measuring value range from 0-600 bar/ 0-8000 psi, Max test pressure up to 60M Pa. (100 mm Dial, 3/8" BSP thread.) The transparent fuel measuring cup can hold 0.8L oil, and with the filter to help conduct kinds of injector nozzles tests.
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  • Large Measuring Range: With precision dual scale gauge, the measuring value range from 0-600 bar/ 0-8000 psi, Max test pressure up to 60M Pa. (100 mm Dial, 3/8" BSP thread.) The transparent fuel measuring cup can hold 0.8L oil, and with the filter to help conduct kinds of injector nozzles tests.
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  • Standard Accessories: The injector pop tester kit is equipped with 60MPa pressure gauge, handle, high-pressure pipes, A and B type with m.m. size nuts (12 X 1.5) and (14 X 1.5) for connections, 0.8L fuel cup with a 5-micron original Bosch filter, piston/element, and delivery valve. Two extra oil pipes are included in the package for your testing use.
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  • Our diesel injector tester is capable of accomplishing proper injection nozzle opening pressure test, leakage test, chattering test, an inspection of spray pattern, and Atomization. With such a multifunctional test capability, the diesel injector tester is the ideal tool for the examination of auto diesel injectors.
  • The injector pop tester kit is equipped with 60MPa pressure gauge, handle, high-pressure pipes, A and B type with m.m. size nuts (12 X 1.5) and (14 X 1.5) for connections, 0.8L fuel cup with a 5-micron original Bosch filter, piston/element, and delivery valve. Two extra oil pipes are included in the package for your testing use.
  • Large engine compression tester features a solid 4.5 x 3.5-inch mountable base, a 4-inch dual scale gauge, and a rotating handle; Kit also includes an attachable 15.5-inch long lever with 4.5-inch rubber grip, a 6.5 x 4.5-inch semi-clear fuel container, and 3 high-pressure nozzles
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  • Premium Aluminum Quality: The diesel injector tester forged by high-quality aluminum, with a casting process, its durability and rigidity is dramatically increased. It also consists of a plastic fuel cup to contain the fuel, and with a stainless pressure gauge to detect air pressure precisely.
  • Superior Tests Ability: The tool set is capable of accomplishing proper injection nozzle opening pressure test, leakage test, chattering test, an inspection of spray pattern, and Atomization.
  • Standard Accessories: The injector pop tester kit is equipped with 60MPa pressure gauge, handle, high-pressure pipes, A and B type with m.m. size nuts (12 X 1.5) and (14 X 1.5) for connections, 0.8L fuel cup with a 5-micron original Bosch filter, piston/element, and delivery valve. Two extra oil pipes are included in the package for your testing use.
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  • 【Widely Application】These diesel injector testers are suitable for all types of diesel injectors except Common Rail (CRDI) diesel injectors.
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