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1.5L REVOTORQ ENGINE
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The workplace should be a closed room, clean
and free from machine tools and welding
equipment.
Safety Precautions
NOTE
Only trained technician should work on common
rail system
1. Switch off engine.
2. Open the hood and disconnect the battery
before working on the injection system.
3. High pressure pump and injectors should not
be removed.
4. Ensure no flame or sparks are near to the work
place.
5. Do not use ECU metal box as ground point, as
the stored data can get corrupted.
Do’s and Don’ts of handling common rail
system
Do’s
1. Check battery voltage, recharge if necessary.
2. Drain water from sedimenter at regular
intervals
3. If connector to ECU is removed, plug the
same to prevent entry of dust / moisture.
4. When a connection to the common rail is
removed, plug the port with proper plastic
cap.
5. When injectors are replaced/changed, injector
I2C values must be recorded into the ECU as
per cylinder order.
6. Engine Management System wiring harness
has to be properly routed using clamps/clips
and brackets.
7. Tighten the mounting nuts / cap nuts etc. to
specified torque values.
8. Always remove the injectors before removing
cylinder head, to avoid damage to injector
nozzle tips which protrude out of the cylinder
head. Proper care has to be taken during
removal of high pressure pump to avoid
damage to inlet pipe, back-leak pipe and
connectors
9. Using
diagnostics
tool,
check
for
malfunctioning in the common rail system
before cranking the engine (after any repair).
10. If engine does not start check the respective
fuses related to common rail components.
Don’ts
1. Injury can be caused to the technician or ECU
can get damaged, by trying to remove battery,
sensor and actuator connections, when the
ignition switch is in ON position.
2. Avoid unnecessary removal of high pressure
pump pipes. Should be removed, always
replace with new pipes as they can be used
only once. Avoid applying force on, or
bending of high pressure pump pipe lines, as
the pipes can get damaged.
3. Do not leave open inlets and outlets of
common rail components, as dust particles
can accumulate.
4. Flushing of common rail components should
be avoided.
5. Failed or broken common rail components
should not be used.
6. Do not unnecessarily remove common rail.
The common rail can be removed/installed for
a maximum 10 cycles without any damage to
pipes.
7. Do not clean the Injectors with pressurized
water.
8. Do not spray water on the ECU.
9. Do not let the ECU body touch any electrical/
electronic part while the ECU is powered ON
(Ignition key switched “ON”), as the ECU can
malfunction.
10. Never try to dismantle any engine part while
the ECU is powered ON.
11. Do not crank the engine without connecting
the sensors.
12. Do not let any sensor wire hanging/loose
during assembly.
13. Do not drive the vehicle, if ‘Check engine
lamp’ inside the cluster is glowing.
14. Do not bleed the air by removing or loosening
the high pressure pump pipes.
15. Do not jump start the vehicle if battery voltage
is low. The ECU gets tripped if the battery
voltage is below 6 volts. Replace/recharge
battery and then start the engine.
iv.
Mechanical Failures
Defective water pump, idler tensioner, damaged
turbocharger, engine mounts or alternator can be
a source of mechanical noise. Defect can be
located by replacing alternator, water pump,
engine mounts, and idler tensioner with a new
one. Metallic knocking sound from an engine may
be due to faulty injectors, excessive clearance in
main and big end bearings, small end bush, HLA,
piston slap, seizing of piston rings, scored cylinder
bore or breakage of any moving parts.
Overhauling of fuel system will set right Diesel