NEXON

1.5L REVOTORQ ENGINE 92 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.