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1.5L REVOTORQ ENGINE
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Fuel System Cleanliness Instructions
Follow the below recommended cleanliness
procedures before removal of any common rail
system components:
This is to prevent dust entry
in the system and to avoid damage to the accurately
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 ground cable, before
working on the 1.5 CRAIL system.
Always follow the cleanliness and safety
instructions and use the correct tightening
torques.
Once the engine stops wait for 3 min then start
working on the 1.5 CRAIL system. Do not work
on the injection system with the engine running.
After opening the injection circuit it is strictly
forbidden 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 introduce contaminants into the system.
Do not clean 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
installing 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 1.5 CRAIL 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 1.5
CRAIL 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
unnecessarily
HP pipe lines should not be bent and force
should not be applied.
Failed or broken 1.5 CRAIL 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 ‘MIL’ / ‘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
below 6 volts. Replace the battery and then start
the engine.
Do not remove the rail unnecessarily. The rail
can perform maximum 10 assembly/
disassembly cycles of pipes without any
damage.
Do not use any failed/ broken water Sedimenter
/fuel filters, even if there’s no external sign of
damage.
Keep hands or face (particularly eyes) out of any
high pressure leak.
Do not remove the HP sensor from the rail.
Do not try to measure the resistance of the HP
sensor. This test is destructive for the internal
components.