Common Rail System – Handling Guidelines

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Common Rail System – Handling Guidelines

Hydraulics, ECU & Sensors

• High Pressure Pump
• Injector
• Rail
• EDC16
• Filter
• Sensors

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Common Rail System – Handling Guidelines
Typical damages due to improper handling

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Common Rail System – Handling Guidelines
Typical damages due to handling

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Common Rail System – Handling Guidelines
Typical damages due to foreign particles inside pump
(Contamination)

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Common Rail System – Handling Guidelines
Critical parts must be always protected

1. Inlet connector
2. Backflow connector
3. HP Connector
4. M-Prop
5. Eccentric Shaft

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Common Rail System – Handling Guidelines

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Common Rail System – Handling Guidelines
In case of reworking
Once a pump has been mounted on engine, we do not suggest
dismounting and assembling it again. If this is absolutely
necessary, it is important to:

 Carefully unplug both LP fittings and unscrew pipe-side

HP connector
damaging on LP fittings and deviation on HP Connector
screwing torque can occur.

 Verify integrity of external O-Ring on pump flange;

change it if it breaks

 Immediately place again all protective caps

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Common Rail System – Handling Guidelines
In case of reworking

 Handle the pump with extremely care:

• If a pump has fallen down, it must be scrapped, even if
visually seems ok
• Pay attention where and how placing pumps for not
scratching the painting
 Do not absolutely try to open the pump or dismount
external components
This will invalidate the warranty on that pump

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Common Rail System – Handling Guidelines
Pump Name Plate Description

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Common Rail System – Handling Guidelines
Injector

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Common Rail System – Handling Guidelines

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Common Rail System – Handling Guidelines

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Common Rail System – Handling Guidelines
Injector Do’s
• Ensure correct Injector inlet HPP connector tightening torque
• Use circlip for the back leak connection
• Right sequence of tightening /loosening to avoid leakage (use two spanners)
• Once the injector is removed, New sealing washer & HPP should be used

• Use special tool to remove sealing washer

Injector Dont’s
• Don’t remove electrical connector when ignition key is ON condition
• Don’t assemble electrical connector when ignition key is ON condition
• Avoid foreign material entry inside the injector

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Common Rail System – Handling Guidelines
Injector Identification

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Common Rail System – Handling Guidelines
Rail

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Common Rail System – Handling Guidelines
Rail general guidelines :
Do’s
✓ Remove protection cap at below connections during assembly only
• Inlet/outlet connector
• Rail pressure sensor (RDS) & Pressure control valve (PCV / DRV)
✓ Assemble all the protection caps immediately after rail is removed

Don’ts
 Don’t try to dismount rail pressure sensor (RDS) to avoid damage
 Don’t allow the rail to fall-off OR hit with other component
 Avoid foreign material entry inside the rail connectors & pressure sensor
 Don’t try to assemble or remove RD
S & PCV electrical connection when
ignition key is in ‘ON’ position

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Common Rail System – Handling Guidelines
Rail Name Plate Description

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Common Rail System – Handling Guidelines
ECU

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Common Rail System – Handling Guidelines
ECU
• Avoid any damages to ECU while handling & assembly
• Always use anti static gloves while handling ECU to
avoid electric overstress
• Tightening torque of mounting screws to be maintained
as per TCD
• Use anti-static mat or straps to avoid entry of electric
overstress
• After mounting ECU, as soon as possible assemble the
harness connector

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Common Rail System – Handling Guidelines
ECU
• Ensure proper grounding / earthing. Ground line of ECU
to be free from paints
• Ensure no power interruptions, communication loss
during flashing of dataset to ECU
• In case check lamp is on, must check with diagnostic
tester for any error
• Avoid short-circuit with battery terminals to avoid flow of
high current to ECU
• Make sure there is no joints in the cable between
PC/laptop & K-line connector
• ECU should not be kept near strong magnetic field

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Common Rail System – Handling Guidelines
ECU
• Avoid any damages to ECU while handling & assembly
• Always use anti static gloves while handling ECU to avoid
electric overstress
• Tightening torque of mounting screws to be maintained as per
TCD
• Use anti-static mat or straps to avoid entry of electric overstress
• After mounting ECU, as soon as possible assemble the harness
connector

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Common Rail System – Handling Guidelines
ECU
• Ensure proper grounding / earthing. Ground line of ECU
to be free from paints
• Ensure no power interruptions, communication loss
during flashing of dataset to ECU
• In case check lamp is on, must check with diagnostic
tester for any error
• Avoid short-circuit with battery terminals to avoid flow of
high current to ECU
• Make sure there is no joints in the cable between
PC/laptop & K-line connector
• ECU should not be kept near strong magnetic field

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Common Rail System – Handling Guidelines
Filter

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Common Rail System – Handling Guidelines
Filter
• Remove connector protection caps as late as
possible
• Right connection (inlet & outlet) for the vehicle
level connector to be assembled
• Tightening torque of inlet & outlet connector is 25
- 30 N-m
• Remove the air (using hand primer) from low
pressure circuit from air vent screw / filter outlet

• Don’t try to dismount fuel temperature sensor

• Assemble all the protection caps immediately
after filter is removed

Cleanliness of fuel tank & LPC pipes to be ensured

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Common Rail System – Handling Guidelines
Filter
• Don’t try to dismount fuel
temperature sensor
• Assemble all the protection caps
immediately after filter is removed
• Don’t allow the filter to fall-off OR
hit with other components
• Make sure strainer in the fuel tank
to avoid choking of fuel filter

Cleanliness of fuel tank & LPC pipes to be ensured

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Common Rail System – Handling Guidelines
Filter
• Make sure that the water is drained as per
the recommendation in service interval &
immediately whenever there is indication
on dash board
• Make sure the water level sensor is
tightened to the right tightening torque (2 - 3
Nm) after draining the water
• Make sure that the filter insert (element /
bowl) is replaced according to service
recommendation (10,000 kms as per
Bosch recommendation)
Water draining & filter insert replacement has to be done as per
recommendation for better life of hydraulic components @Autogurukul
Common Rail System – Handling Guidelines

Filter
• Tightening torque of filter
insert (bowl) is 10 - 15 Nm
• Remove the air (using hand
primer) from low pressure
circuit from air vent screw /
filter outlet
• Ensure right connection &
tightening torque of inlet &
outlet connector

Water draining & filter insert replacement has to be done as per

recommendation for better life of hydraulic components @Autogurukul
Common Rail System – Handling Guidelines

Sensors

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Common Rail System – Handling Guidelines
Engine speed sensor & Phasesensor

✓ Do’s
-Sensors must be removed from its packing just prior to
installation
-Specified tightening torque should be maintained

-Replace any damaged O-Ring.

-Clean and grease O-Ring prior to installation with mineral oil-
based grease.
-Storage temperature: -20ºC to 50ºC

No warranty for tampered / damaged speed / phase sensor

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 Common Rail System – Handling Guidelines
Engine speed sensor & Phasesensor
Don’ts
-Don’t drop the sensor
-Do not Hammer the sensor while fitting
-Avoid moisture (water traces) near to the sensors
-Do not short circuit the connector pins of the sensor
-Sensors should not be kept near Hot medium or objects with
Temp > 120 ºC.
-Sensors should not be kept near any strong Magnetic
Materials.
-None of the application guidelines should be deviated (Air gap,
tightening torque etc)

No warranty for tampered / damaged speed / phase sensor

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Common Rail System – Handling Guidelines
Accelerator Pedal Module
- Do’s
- Tightening Torque of the retaining screws should not exceed 9 ±1.5
Nm.
- Use only self locking screws.
-Any damage or in doubt of damage (e.g. dropped APM) the
APM has to be separated and scrapped.
- Don’ts
- Don’t drop the sensor.
- Don’t dismount screws
- Do not exceed the maximum permissible tightening Torque.
- Do not dip in any liquid.
No warranty for tampered / damaged APM
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Common Rail System – Handling Guidelines
Coolant Temperature Sensor (WTF)
- Do’s
- During service - After removing temperature
sensor, existing Aluminum washer is to be
carefully cut (without damaging the brass
threading) and taken out.
-Replace the washer with Copper washer

- Don’ts
-Don’t drop the sensor.
-Do not exceed the maximum
permissible tightening Torque of
18Nm for copper washer and
25Nm for aluminium washer.
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Common Rail System – Handling Guidelines
Air Mass Sensor (HFM5
-Do,s

Care should be taken for the orientation of HFM connector

during installation.

Tightening torque for inlet and outlet connections 2.5 ± 0.5N-m

- Don’ts
- None of the application guidelines should be deviated.
- Don’t drop the sensor.
- Do not over tight the pipe clamps.
- Avoid entry of traces of oil, dirt into sensor
- Don’t dip or wash the sensor in any liquid

No warranty for tampered / damaged HFM (traces of oil, dirt)

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THANK YOU

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