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GENERAL
4
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.
Do’s