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Diesel Injector Coding and Pilot Learning

Diesel injectors are tested and coded by manufacturers to optimize emissions and performance. The injector coding number must be input into the engine control unit (ECU) during replacement to compensate for variations. Injector programming can be done with diagnostic scan tools and incorrect coding may cause programming to fail. Pilot injections before the main injection are used to reduce noise and smoke. The ECU can automatically learn pilot quantities but a scan tool may be needed to perform pilot learning procedures following coding or servicing. Injector compensation values in scan tool data show if corrections are needed for optimum fuel delivery.

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684 views

Diesel Injector Coding and Pilot Learning

Diesel injectors are tested and coded by manufacturers to optimize emissions and performance. The injector coding number must be input into the engine control unit (ECU) during replacement to compensate for variations. Injector programming can be done with diagnostic scan tools and incorrect coding may cause programming to fail. Pilot injections before the main injection are used to reduce noise and smoke. The ECU can automatically learn pilot quantities but a scan tool may be needed to perform pilot learning procedures following coding or servicing. Injector compensation values in scan tool data show if corrections are needed for optimum fuel delivery.

Uploaded by

ddaanniieellssaa
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Diesel Injector Coding and Pilot Learning

Common Rail Diesel Injectors are manufactured with very tight tolerances, however, slight
variations will always occur and as such all new injectors are tested and then stamped with a
coding number which is used to inform the ECU how much compensation is required to
achieve the optimum in lowering emissions and provide smooth running.
The injector coding number should be noted by the technician prior to fitting the new injectors
and after replacement is completed the technician can then program in the new injector
numbers to replace the ones previously programmed into the ECU
Injector programming can be carried out with high level Diagnostic Scan Tools such as G-
Scan or Autocom ICON.
Care must be taken when reading the identification code stamped on the injector to ensure
the correct number is entered into the ECU for the corresponding cylinder. Inputting an
incorrect number or fitting the wrong injectors for the engine will result in the injector failing
the programming procedure.
New Injector Calibration Data has been entered here. After pressing OK, the ECU will then
check the number to complete the programming procedure

The actual number of characters to be entered will depend on the vehicle and can vary
greatly.
If injectors have been removed from an engine and are to be reused, the injectors should be
tagged to ensure they are being fitted back into the correct cylinders, alternatively, they
would need to be recoded to the new cylinder in which they are fitted. Should a technician
wish to swap injectors between cylinders to help diagnose a problem, the correct coding
must be also changed with the injector to the new cylinder.

Pilot Injection
In order to reduce engine noise and exhaust smoke in Common Rail Diesel Vehicles, a small
amount of fuel is injected through one or more small microinjections, also called Pilot
Injection. These microinjections occur just prior to the main injection pulse. The actual
number of microinjections will vary between vehicles or ECU Programs for a particular
vehicle. The number of Pilot Injections will also depend on the running conditions at the time
i.e. engine temperature, speed, load etc.
Microinjection learning maybe performed automatically whilst driving under certain conditions
by the ECU monitoring changes in RPM immediately after pilot injection has occurred. The
ECU can then increase or decrease the microinjection quantity to achieve the optimum
quantity required.
As described below, a scan tool may also be required to perform Pilot Learning in some
vehicles.

Injector Pilot Learning or Small Quantity Learning


Following Injector Coding or in some cases during routine servicing, manufacturers may
require the technician carry out a procedure to teach the ECU the ideal Pilot Injection for the
engine. This is called ‘Pilot learning’ or Small quantity learning’
The procedure for carrying out Injector Pilot Learning will vary, depending on the
manufacturer. The exact procedure and pre-requisites must be met otherwise, the procedure
will fail. One example of Pilot Learning procedure requires the technician to enter Pilot
Injector learning mode on the Scan tool and then accelerate the engine a number of times as
per the manufactures instructions.

Performing Small Quantity Learning


Small quantity or Pilot Learning will be found in ‘Special Functions’ on G-Scan

Pilot Injection Testing may be performed on some vehicles in the G-Scan Actuation Test as
seen below using the new G-Scan 2
Checking Injector Compensation Values in Data
Analysis
In closed loop systems, the ECU will output ‘Compensation Values’ which can be read in the
Scan Tool Data. The compensation values show any corrections required to obtain the
desired fuel delivery. The closer the compensation value is to zero, the closer the delivery is
to the optimum delivery.
As time goes by, injector contamination or other cylinder related problems will cause the
compensation values to increase in either a ‘positive’ or ‘negative’ direction.
As long as there are no engine mechanical faults, higher than normal compensation values
(+ or -) on one or more cylinders, usually indicate the injectors require service/replacement.
The Injector Compensation Values shown here show no major fuel problems in any
cylinders.

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