ALTROZ SERVICE MANUAL

1.5L REVOTORQ ENGINE 87  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.