KRYOTEC ENGINE 27 SAFETY PRECAUTIONS NOTE Only trained technician should work on common rail system 1. Switch off engine. 2. Open the hood and disconnect the battery before working on the injection system. 3. High pressure pump and injectors should not be removed. 4. Ensure no flame or sparks are near to the work place. 5. Do not use ECU metal box as ground point, as the stored data can get corrupted. DO’S and DON’TS of handling common rail system DO’S 1. Check battery voltage, recharge if necessary. 2. Drain water from fuel filter at regular intervals 3. If connector to ECU is removed, plug the same to prevent entry of dust / moisture. 4. When a connection to the common rail is removed, plug the port with proper plastic cap. 5. When injectors are replaced/changed, injector I2C values must be recorded into the ECU as per cylinder order. 6. Engine Management System wiring harness has to be properly routed using clamps/clips and brackets. 7. Tighten the mounting nuts / cap nuts etc. to specified torque values. 8. Always remove the injectors before removing cylinder head, to avoid damage to injector nozzle tips which protrude out of the cylinder head. Proper care has to be taken during removal of high pressure pump to avoid damage to inlet pipe, back-leak pipe and connectors 9. Using diagnostics tool, check for malfunctioning in the common rail system before cranking the engine (after any repair). 10. If engine does not start check the respective fuses related to common rail components. DON’TS 1. Injury can be caused to the technician or ECU can get damaged, by trying to remove battery, sensor and actuator connections, when the ignition switch is in ON position. 2. Avoid unnecessary removal of high pressure pump pipes. Should be removed, always replace with new pipes as they can be used only once. Avoid applying force on, or bending of high pressure pump pipe lines, as the pipes can get damaged. 3. Do not leave open inlets and outlets of common rail components, as dust particles can accumulate. 4. Flushing of common rail components should be avoided. 5. Failed or broken common rail components should not be used. 6. Do not unnecessarily remove common rail. The common rail can be removed/installed for a maximum 10 cycles without any damage to pipes. 7. Do not clean the Injectors with pressurized water. 8. Do not spray water on the ECU. 9. Do not let the ECU body touch any electrical/ electronic part while the ECU is powered ON (Ignition key switched “ON”), as the ECU can malfunction. 10. Never try to dismantle any engine part while the ECU is powered ON. 11. Do not crank the engine without connecting the sensors. 12. Do not let any sensor wire hanging/loose during assembly. 13. Do not drive the vehicle, if ‘Check engine lamp’ inside the cluster is glowing. 14. Do not bleed the air by removing or loosening the high pressure pump pipes. 15. Do not jump start the vehicle if battery voltage is low. The ECU gets tripped if the battery voltage is below 6 volts. Replace/recharge battery and then start the engine. ii. Mechanical Failures Defective water pump, idler tensioner, damaged turbocharger, engine mounts or alternator can be a source of mechanical noise. Defect can be located by replacing alternator, water pump, engine mounts, and idler tensioner with a new one. Metallic knocking sound from an engine may be due to faulty injectors, excessive clearance in main and big end bearings, small end bush, HLA, piston slap, seizing of piston rings, scored cylinder bore or breakage of any moving parts. Overhauling of fuel system will set right Diesel Knock. Dismantling of engine may be considered if still noise occurs even after attending all above mentioned problems. Check for EMS problems if any.
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