TIAGO

GENERAL

1.3 PRECAUTIONS OF COMMON RAIL

SYSTEM (CR SYSTEM)

Follow the below recommended cleanliness

procedures before removal of any system

components:

This

is to prevent dust entry in the system and to

avoid damage to the precisely machined common

rail system components·

• Wash hands before the work. If necessary

wear new plastic gloves.

• As soon as there is an opening into the

system, it must be blocked using special cap.

After removal and plugging, each component

of the injection system must be stored in a

new hermetically sealed bag.

• All plugs / caps and packaging are disposable

and should be discarded after single use.

• •Before disconnecting the battery make sure

that no data is required from the electronic

control unit (ECU), as battery cable

disconnection will erase any fault codes and

idle / drive values held in the keep alive

memory (KAM). It is not necessary to

disconnect or remove electronic control

modules.

• Disconnect the battery negative cable.

• Follow the cleanliness and safety instructions

and use the correct tightening torques.

• Once the engine stops wait for 5 min., and

then start working on the CR system. Do not

work on the injection system with the engine

running.

• After opening the injection circuit it is strictly

for-bidden to use any tools/ equipment made

of a material which may cause a risk of

shedding particles or fibers (wood, cloth,

cardboard…). In the same way, the use of a

blower, brush or bristles is banned because

these tools are liable to intro-duce

contaminants into the system.

• Avoid cleaning of the injectors, even with an

ultrasonic cleaner.

• The packaging for the spare parts should be

opened just before use. The special caps

must not be removed until the final

connection/installation. The plugs and bags

must be discarded after use.

• Any part dropped must not be used. Before

in-stalling the injector, it is essential to ensure

that the wells are clean.

• Before connecting the harness, check the

cleanliness of the connectors, particularly any

fluids near electrical connections.

• Before removing any CR components,

vacuum external area with the help of vacuum

cleaner to avoid possible contamination.

Don’ts

• HP pipes are one time use only avoid

unnecessary removal and do not reuse.

• Do not leave open inlets and outlets of CR

components–Cap them immediately

• Flushing of CR components should be

avoided.

• Do not remove battery, sensor & Actuator

connections when key is ON

• Do not spray water on the ECU

• Sensor connections should not be removed

un-necessarily

• HP pipe lines should not be bent and force

should not be applied.

• Failed or broken CR components should not

be used, leakage may cause injury

• Don’t let ECU body touch any metallic part

while the ECU is powered ON (Ignition key

switched “ON”).

• Never try to dismantle any engine part while

the ECU is powered ON.

• Don’t keep any sensor branch hanging /loose

while assembly. Fix them properly using clips

provided in W/H.

• Don’t try to crank the engine without

connecting any of the sensors.

• Don’t remove any sensor /injector connector

once fitted and locked properly.

• Do not run the vehicle with Check Engine

lamp ON.

• Do not remove back-leak pipes unless the

Injectors have to be removed.

• Do not bleed the air by removing or loosening

the HP pipes.

• Do not start the vehicle if battery voltage is

low.

• The ECU gets tripped if the battery voltage is

be-low 6 volts. Replace the battery and then

start the engine.

• Do not remove the rail unnecessarily.

• Do not clean the Injectors with pressurized

water. The injector is not designed to be

washed with pressurized water.

• Do not clean the HP pipes with compressed

air, oil or water. Cleaning may dirt HP pipes

and CR system.

• Do not use any failed/ broken water

Sedimenter /fuel filters, even if there’s no

external sign of damage.