crankshaft pulley
Engine operation
Do not carry out any work on the hydraulic systems while the engine is running.
Remember that the pressure in the fuel system can reach up to 1600 bar.
Keep hands and face (especially the eyes) away from any high pressure leak.
Remember that fuel is harmful to health.
System pressure sensor
Unless necessary, do not remove the fuel pressure sensor from the line.
Do not attempt to measure the resistance of the fuel pressure sensor as this may damage the sensor.
Fuel injectors
The fuel injector control operating voltage is greater than 100 V.
The fuel injector electronics have polarity. Be careful not to reverse the polarity of the wires, as this will cause a malfunction of the piezo components.
Do not energize injectors unless their body is connected to «mass» battery (there is a risk of electrostatic discharge). For example, the fuel injector body must be in contact with the cylinder block.
The piezo element of the fuel injector must not be de-energized while the engine is running, as there is a risk of serious engine damage due to the fuel injector being opened for a long time.
Clogging risks
The high pressure direct injection system is very sensitive to various kinds of blockages. The risks associated with clogging are as follows:
- damage or destruction of the high pressure injection system,
- jamming of components,
- damage to the seals of the system components.
All maintenance operations on the fuel system must be carried out in a perfectly clean environment. This means that no impurities should be allowed to enter (particles as small as a few microns) into the system during disassembly and assembly. This condition must be strictly observed in the area from the fuel filter to the injectors.
Sources of clogging in particular are:
- metal or plastic filings;
- dye;
- fibers of cardboard, brushes, paper, fabrics, clothes;
- foreign bodies such as hair;
- ambient air.
Note. Do not use high pressure to clean the engine as this may damage the connections.
Precautions for any work on the vehicle
Note. Before carrying out any work on the high pressure fuel system, secure:
- attachments and drive belts;
- electrical equipment (starter, alternator, electric power steering);
- flywheel surface (to prevent diesel fuel from getting on the working surface of the clutch discs).
1. Check for plugs for connections to be depressurized (a set of plugs is available in the sale of spare parts). All plugs are for single use and must be disposed of as they are contaminated and cleaning cannot provide the desired cleanliness. Unused plugs from the kit are also not subject to long-term storage for the same reason.
2. Make sure that the spare parts storage bags are sealed, as this reduces the risk of foreign particles getting on the parts. The packages are not reused, after removing the parts from them, the packages must be disposed of.
3. Do not use fibrous cloth or paper to clean as it may cause high pressure. Fibre-free fabrics should only be used once.
4. Use fresh solvent for each cleaning procedure (used solvent is contaminated). Pour the solvent into a clean container.
5. For each cleaning procedure, use only a clean brush in good condition (bristles should not fall out).
6. Before opening connections, they must be cleaned from the outside with a brush and solvent.
7. Use compressed air to clean the tool and work area, as well as the parts to be cleaned. Make sure no stubble remains.
8. Wash hands before performing, and if necessary, also during the performance of operations.
9. When using leather gloves, also use latex gloves over them to prevent clogging.
10. Immediately after the depressurization of the connections, it is necessary to plug them with plugs. Under no circumstances should the plugs be reused.
11. Close the plastic bag, even if you plan to use it soon, because the ambient air can be a source of blockage.
12. All parts removed from the injection system must be carefully packed in a sealed plastic bag immediately after they have been plugged.
13. The use of a brush, thinner, compressed air, sponge or cloth is strictly prohibited once the fuel system has been depressurized as the fuel injection system may be clogged as a result.
14. A new replacement part should be unpacked immediately prior to installation, not prematurely.