SAFARI

ENGINE 52 Instructions for the removal of the CR Injection system Working on the system : l Wash hands before and during the work as necessary (wear new plastic gloves) l Plug all resulting fuel system openings immediately. All plugs and packaging are disposable and should be discarded after single use. l 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 . l 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. l 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. l 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 l 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. l 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 : l 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. l Any part dropped must not be used. l Before installing the injector, it is essential to ensure that the wells are clean. l Before connecting the harness, check the cleanliness of the connectors, particularly for the absence of fluids on the electrical connections. l 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: l Tank to priming pump l Priming pump to sedimenter l Sedimenter to filter l Filter to pump l Pump to venturi l Filter to venturi l 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.