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Delphi Injectors

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To all Delphi Injector Customers:

FAILURE TO COMPLY NOTICE

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Failure to follow the Delphi Injector Installation and Bleeding Procedure exactly as instructed will result in control valve jamming, leading to injector failure.

In such cases, repair costs will be charged to the buyer, as the damage is considered a result of incorrect installation and is explicitly excluded from warranty coverage.

No exceptions will be made. Proper installation is mandatory to validate warranty terms and prevent avoidable damage.

Step-by-Step Bleeding Procedure:

  1. Record Injector Codes:

    • Before proceeding, write down all injector codes and record the cylinder position each injector is fitted to. This is essential for correct ECU coding later in the process.

  2. Install Injectors:

    • Fit the injectors into the engine while observing all cleanliness standards and torque settings as per manufacturer specifications.

  3. Initial Bleeding of Fuel Rail:

    • Before tightening the high-pressure pipes:

      • Crank the engine briefly to allow diesel to fill the high-pressure rail and injector pipes.

      • After bleeding, continue with secure attachment of all high-pressure pipes.

  4. Dry Cranking Sequence (Electrical & Leak-Off Disconnected):

    • Leave all injector electrical plugs and leak-off pipes disconnected.

    • Perform the following cranking sequence:

      • Crank the engine for 7 seconds.

      • Wait 10 seconds to prevent overheating of components.

      • Crank again for 7 seconds.

      • Repeat this crank-pause cycle until fuel returns from all injector leak-off outlets.

  5. Reconnect and Code Injectors:

    • Once fuel flow is confirmed:

      • Reconnect the injector drive cables.

      • Proceed to code the injectors to the vehicle’s ECU using diagnostic equipment.

  6. Final Start-Up:

    • With all connections secured and coding completed, start the engine.

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Additional Tips & Precautions:

  • For improved fuel system pressurisation during bleeding, you may disconnect the IMV (Inlet Metering Valve) plug on the high-pressure pump.

    This will cause the pump to generate maximum pressure, which aids in system priming.

  • All open fuel galleries, connectors, and components must be capped during installation to:

    • Prevent dirt ingress or contamination.

    • Minimise unnecessary diesel loss during bleeding.

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This injector bleeding procedure is mandatory for DFi1.5 injector systems to ensure optimal performance and prevent premature injector failure. Any deviation from these steps may result in irreversible damage and void the product warranty.

If you have questions or need assistance, please contact AA Diesel Technical Support before proceeding.

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