Delphi Service Center
Technical Bulletin
TB0008(EN)
Common Rail injector causing
engine to run erratically, low
power and bad emissions
1. VEHICLE APPLICATIONS
Make Model System
Ford Mondeo 2.0 TDCi Diesel Systems
2. SUMMARY
Fault type Engine runs erratically low power bad emissions and mil lamp on.
Fault Code Description
F2336 Injector 1 fault
F2337 Injector 2 fault
F2338 Injector 3 fault
F2339 Injector 4 fault
These fault codes can sometimes be overcome by re-inputting the C2I code for the injector.
However it is a good indication that the injector is coming to the end of its useful life.
This can be for a number of reasons:
1. High mileage
2. Degradation through fuel contamination
3. Previous repairs not respecting clean environment
4. Incorrect fuel being used
5. Incorrect filtration being used
6. Over-tightening of injector pipes or retaining clamps
The fault is accompanied with a descriptor “Accelerometer out of range”. This typically means that
the tolerance window of 80 micro seconds has been exceeded and therefore the system cannot
modify the drive to the injector to maintain stability.
If the fault code is accompanied by a rail pressure fault code it is likely that the whole system has
been contaminated. In all cases a hydraulic diagnostic check (using the Delphi Sealed Rail Kit)
should confirm which parts are at fault.
Delphi Product & Service Solutions, Spartan Close, CV34 6AG, Warwick, United Kingdom.
Tel: +44 (0)1926 472900 Fax: +44 (0)1926472901 © Delphi - MAR 2011
TB0008(EN) - MAR 2011 - 2 of 3
3. RESOLUTION
3.1 Diagnostic procedure
At this stage the fault codes should be confirmed and if the code is one or all of the above the
following is recommended:
1. Remove the fuel filter and empty the contents into a clean container. If the content is not clear
or full of particulates or has high water content then first of all the system must be cleaned out
from the tank to the filter. If the sample is clear and the amount of particulates in the sample
covers less than one square centimetre then proceed to the hydraulic test. More than one
square centimetre suggests heavy contamination and if the particles are of a metallic nature
a full system overhaul will be required. Ferrous metallic particles can be identified by using a
magnet under the base of the container.
At this stage it is advised to check for damage to the other mechanical components in the
system using a hydraulic or “wet side” diagnostic on the pump, injectors and rail. A bio check
can be utilised at this stage using the Delphi Fuel Analyser to confirm if the sample is suitable
for further use.
2. Hydraulically test the pump and injectors for max pressure and backleakage using the Delphi
Sealed Rail Kit. If the pump pressure is lower than the recommended spec stated in the kit
instructions this indicates that the pump is worn and requires attention.
Further testing with the False Actuator Kit will determine whether the damage is internal or
the external IMV.
Note: Any contamination in the high pressure pump will also be in the rail and
injectors and will result in a system replacement.
If the pressure can be recovered by a new IMV proceed to the next step. The injector
backleakage is critical and must be within the parameters outlined in the test kit manual. If the
backleakage is not uniform between the cylinders then the highest backleak injectors should
be serviced in accordance with Delphi service standards or replaced with new injectors.
Note: The high backleak injectors should align with the fault codes present for the
relevant injector number. If all of the injectors have high backleakage this is
probably due to fuel contamination and will indicate further intervention is
required and all of the injectors require service.
Note: If contamination is present in the system, changing injectors alone will run
the high risk of repeat failure, thus increasing the cost of repair to the
customer.
3. When replacing the fuel filter ensure a genuine Delphi or Ford part is used as the filter screen
is 2 microns which is necessary for system protection. Non-genuine filters may have a larger
filter screen typically 5 to 10 microns which is inadequate for this application.
Ensure all pipes are tightened to the correct torque setting to prevent distortion of the pipe
and/or injector. Ensure that injector mountings are also torqued in accordance with the
specification.
Ensure that the correct C2I is embedded into the software as this is representative of the
parameters of a new or serviced injector and resets the Accelerometer update strategy.
Always respect the clean environment when working on CR systems. Clear all fault codes, road
test the vehicle and recheck for codes after the road test.
TB0008(EN) - MAR 2011 - 3 of 3
Parts Used
Part Number Description
HDF924 Ford Mondeo filter
Injectors Please refer to Delphi CR catalogue
4. FURTHER INFORMATION
Read the relevant Common Rail workshop manual on Direct Evolution:
Part Number Description
DDNX275 Ford 2.0 TDCi Removal & Refit manual
DDGX200A Principals of CR Operation
5. TOOLS & EQUIPMENT
Part Number Description Operation
DS100E Diagnostic tool Coding of CR injector into ECU
YDT247 Sealed Rail Kit Backleak check
YDT410 False Actuator kit IMV diagnostic check
YDT209 Pump Removal tool Correct pump removal tools
YDT568 Injector Removal tool Removing injector and washer
YDT275 Delphi Injector Connectors Connection of leak bottles
