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1.5L REVOTORQ ENGINE
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The following components must not, under any
circumstances, be removed from the pump inlet
hydraulic connector; Hp outlet hydraulic
connector and fuel return connector.
Do not carry the pump using drive shaft.
Injector electronics are polarized. In case of
intervention or wiring harness, do not invert
wires. It is destructive for the solenoid injector.
Don’t drive the injectors if their body is not
connected to the battery ground. Injector body
has to be in contact with cylinder head.
Do not try to drive the injectors with anything but
the ECU.
Do not make a short circuit between grounds of
injectors. Injectors will remain open: broken
engine.
Do’s
Monitor battery voltage continuously – recharge
battery if voltage drops below 10 Volts
Drain water from Sedimenter / filter at regular
intervals
Fix the rubber cover to the ECU to prevent dust /
moisture entry inside ECU.
EMS W/H to be properly routed as specified
using clamps / clips and brackets.
Do check for any faults /malfunctioning in the
system using diagnostics tool before cranking
the engine
(after any repair).
Do fix ECU connector branch properly while
transporting engine.
If engine does not start check the respective
fuses related to 1.5 CRAIL components.
When Injectors are replaced/Changed Injector IC
values must be loaded correctly as per cylinder
order.
Plug the port of Common rail system
components whenever any pipe connections are
removed.
If the fuel tank is dry
(no diesel)
fill diesel and
use priming pump to suck the diesel till fuel filter.
Tighten the mounting nuts / cap nuts etc. only to
the specified torque values.
Always remove the Injectors before dismantling
the cylinder head. This is to avoid damage to the
injector nozzle tips which protrude out of cylinder
head. In case of HP pump removal handle the
pump with proper care to avoid any damage to
inlet pipe, venturi and connectors.
Always use specified tightening torques, during
assembling of 1.5 CRAIL components.
Components
A. Injector
The injector used in this engine is a solenoid
injector. This is controlled by the EMS ECU. The
timing of injection and quantity is controlled by the
EMS ECU. It operates at a pressure of 1600 bar. It
makes multiple injections.
The solenoid actuator is an electrically energized
device that acts similar to a solenoid but is much
more precise. A piezo actuator is a composition of
piezo discs, that when electrically energized, cause
the discs to deform resulting in an expansion. This
expansion results in a longitudinal motion thus
controlling the injector. When energized, the piezo
actuator pushes downward against the valve piston.
The piezo actuator is returned to its non energized
state via the ECU switching the polarity of the
electrical feed to the injector.