ENGINE 77 Avoid cleaning of 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 CR 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 CR 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 CR 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’ 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 clean the Injectors with pressurized water. The injector is not designed to be washed with pressurized water. Do not clean the HP pipes with compressed air, oil or water. Cleaning may dirt HP pipes and CR system. Do not use any failed/ broken water Sedimenter /fuel filters, even if there’s no external sign of damage. 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 uses related to CR 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.
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