ALTROZ SERVICE MANUAL

1.5L REVOTORQ ENGINE 42 iii. Extremely Low Engine Oil Pressure If suspecting inadequate oil pressure, check the pressure by removing oil pressure transducer and connecting a gauge directly to the engine block.  Check the following: External leakages.  Oil level in sump up to maximum mark on dipstick / Check oil level.  Oil pressure switch / indicator for proper functioning.  Functioning of pressure relief valve on oil pump.  Oil pumps performance using a suitable pressure gauge. If low oil pressure is not on account of above factors, wear of journals/bearings is indicated for which overhaul of engine may be considered.  Leakage through oil pumps back plate. Test procedure 1. Park the vehicle on a flat surface and engage the parking brake. 2. Check that the oil level is at the ‘MAX’ mark on the engine oil dipstick. Add oil as necessary. 3. Verify the correct quantity of oil used. 4. Inspect the engine thoroughly for signs of external leaks through the cylinder head cover gasket, crankshaft main seals, camshaft seal, oil sump gasket, oil pump gasket, oil sump drain plug, etc. Repair any external leaks. 5. Install a pressure gauge in the oil pressure transducer port. 6. Place the vehicle in neutral and start the engine. Allow the engine to warm up to normal operating temperature. 7. Read the oil pressure indicated on the gauge at idle and at maximum engine speed. 8. If the oil pump output is not at minimum pressure, the oil pump may be clogged or defective. This is also an indication of excessive wear of the crankshaft journals and/or bearings and an engine overhaul may be considered. Maintenance Instructions FOR Common Rail Common rail refers to a small fuel accumulation tank called Rail, where the pressure of the fuel remains almost constant and always available to injectors. The high-pressure pump compresses the fuel at a pressure of 1600 bar and transfers it through a connection pipe to the high-pressure accumulation duct or Common Rail. The common rail then softens the pressure oscillations caused by the opening and closing of the injectors and by the continuous discharge of the high pressure pump. The fuel is then transferred from the common rail through pipes to the electronic injectors Due to high pressure developed in the common rail system, care and cleanliness is of utmost importance during removal and installation of the common rail system. Tiny dust particles (0.2 mm) can block injector nozzle in opening position, which will then continuously inject fuel into the cylinder there by increasing the cylinder pressure leading to engine damage. NOTE  The ambient conditions to store common rail parts are: -30°C to +60°C, and humidity between 0 to 80%.  The nozzle holder should not place in or near a magnetic field source above 400 A/m.  All system components must be thermally sealed in plastic bags and clearly labeled.  Prior to working on common rail system, the technician must thoroughly wash hands before and during the work as necessary. !! WARNING Smoking is strictly prohibited while working on common rail system, as the system is under high pressure and may cause serious injury, or component damage. Prior cleaning of engine and injection system Clean the area around the engine and then fuel injection system with clean brush and degreasing agent. Cover electrical unit’s viz., starter, alternator etc., to avoid fuel spray/splash. Clean the joints and external surface of the injection system and each connection that is to be opened, by a vacuum cleaner. The surface of the workstation on which the work on common rail is to be carried, should preferably be stainless steel. The workplace should be a closed room, clean and free from machine tools and welding equipment.