SAFARI

ENGINE

Instructions for the removal of the CR Injection

system

Working on the system :

Wash hands before and during the work as

necessary (wear new plastic gloves)

Plug all resulting fuel system openings

immediately. All plugs and packaging are

disposable and should be discarded after single

use.

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 .

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 ground cable.

Follow the cleanliness and safety instructions

and use the correct tightening torques. Clean

the HP connector nuts with solvent applied

using a clean brush. Remove particles with a

vacuum cleaner.

Once the engine stops wait for 5 mins 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

forbidden to use any utensil made of a material

which may present a risk of shedding particles or

fibres (wood, cloth, cardboard…). In the same way,

the use of a blower, brush or bristles is banned

because these tools are liable to introduce

contaminants into the system.

Avoid cleaning of the injectors, even with an

ultrasonic cleaner.

Use of leak detection cycle can be done to purge

system after having changed parts & check there is

no leaks (to be done by LIS).

Instructions for refitting :

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 installing the injector, it is essential to

ensure that the wells are clean.

Before connecting the harness, check the

cleanliness of the connectors, particularly for the

absence of fluids on the electrical connections.

Before removing any of the CR components

vacuum external area with the help of vacuum

cleaner to avoid possible contamination.

Before removing any of the CR components on

vehicle, the following procedure needs to be

followed:

1) Disconnect Battery terminals

2) Remove Engine cover

3) Disconnect

all

Electrical

connections

(eg.: ECU, Sensors & Actuators)

4) Disconnect vacuum lines connected to EGR

Modulator.

5) Disconnect the hoses connecting:

Tank to priming pump

Priming pump to sedimenter

Sedimenter to filter

Filter to pump

Pump to venturi

Filter to venturi

Back-leak pipes from injectors and venture

And Plug the openings using suitable

special caps.

6) Disassemble & takeout filter and sedimenter

along with the mounting bracket after plugging

the openings with suitable caps.

7) Remove Oil separator and hoses connected to

PS pump (Only incase of HP pump removal)

Refer “Engine Removal from Vehicle” section of the

Workshop Manual for the above Procedures.