Fitment Instructions
Correct installation is the key to ensuring your repaired/rebuild/ new units doesn't give problems in the future.
First things first, why did the original unit fail? Did you know that over 90% of failures are caused due to outside influence? This can be oil contamination, oil starvation, foreign object damage, as well as fuel contamination , fuel delay or starvation. Before fitting a repaired/rebuild/ new unit, you MUST find the cause of the original failure and correct it before fitting the repaired/rebuild/ new unit.
Distributor Pumps
Common Rail Systems
Before Installation
Always New
•Diagnose And Solve The Reason For The Failure Of The Fuel System (Possibly A Fault On Or Around Engine).
•Compare Fuel System Model Number With The Engine Specifications And The Fuel System Manufacturer’s Model Number.
•Fitting Must Take Place In A Safe , Clean Environment
•To Start, Check There’s No Residual Pressure Left In The System Using A Diagnostic Tool.
•Check High Pressure Pump Gear Is Okay.
•Torque Fasteners As Specified By The Engine And Vehicle Manufacturer.
•Make Sure The Flanges And Threads Are Free Of Damage, Debris And Wear & Tear.
•Use Only Brand New Gaskets And Seals.
•Diesel Taken To Be Checked For Contamination/Blockage.
•Fuel In Taken To Replaced With New When Water , Or Any Adulteration Is Found.
•Injector Seat Is Clean Of Carbon And Debris And Injector Washers.
•High Pressure Pipes Are To Be Replaced With New.
•Battery To Be Properly Charged.
•No Damage To Ecu Or Wiring Should Be There.
•High Pressure Pump Mounting Plate Is To Be Checked For Wear And Tear Or Cracks.
•All Low Pressure Pipes Lines Are To Be Flushed.
•Feed Pump Performance To Be Checked
•New Water Separator To Be Fitted If Available
•New Diesel Filter To Be Fitted.
•Rail High Pressure Pipe Seating Area Is To Be Checked For Damages , Debris , Rust.
During Installation
•Proper Torque Is To Be Given To High Pressure Pipes.
•Attention Paid To Correct Handling.
•Prior To Fitting The Replacement Injector, It’s Important To Note The New Correction Code.
•Remove The Protection Cap From The Nozzle And Slide The New Injector Carefully Into Position.
•Bleed Air From The Fuel System
•Ensure The Fuel Tank Has Minimum 30% Fuel Of Total Capacity Of The Tank, When Starting Vehicle For The First Time After Refurbishment/Repair.
•Before Injector Fitment Check The HPP IMV And Common Rail Sensor For Metal Chips. If The Same Is Seen, Stop The Fitment And Firstly Get The HPP And Common Rail Checked.
Post Installation
•Idle For Approximately 120 Seconds After Engine Is Running.
•During Idling: All Connections (Air, Exhaust, Water And Oil) Checked For Firm Seating, Tightness And Free Of Leaks, Gas-tightness Checked With Soapy Water If Necessary
•Reprogram The ECU With The New Correction Code Using A Diagnostic Tool. This Will Ensure That The Adjustment To The Pulse Times Is Made And The Correct Fuel Delivery Is Maintained.
•Clear All Error Codes That Have Come During Fitment
Turbo Chargers
Before Installation
Always New
•Diagnose And Solve The Reason For The Failure Of The Old Turbocharger (Possibly A Fault On Or Around Engine).
•Compare Turbocharger Model Number With The Engine Specifications And The Turbocharger Manufacturer’s Model Number.
•Sump Must Be Removed And Cleaned.
•Oil Strainer Must Be Removed And Replaced Due To Residual Carbon/Sludge Build-up.
•Oil Pump Should Be Removed And Checked.
•Oil Cooler And Filter Assembly Should Be Removed And Cleaned.
•Check For Proper Engine Cooling.
•Check Oil Supply, Make Sure Oil Return From The Turbocharger To The Crankcase Is Clear.
•Intake, Charge Air And Exhaust Area:- Check For Functional Capability , Clean Out Any Contamination By Foreign Bodies Or Fluids And Solve Why They Were Present And Clean Any Undamaged Air Supply Hoses And Pipes.
•In The Case Of Liquid-cooled Turbochargers: Check For Adequate Coolant Flow.
•Check Whether An Adjustment Of The Housing Position Is Necessary.
•Torque Fasteners As Specified By The Engine And Vehicle Manufacturer.
•Make Sure The Flanges And Threads Are Free Of Damage, Debris And Wear.
•Use Only Brand New Gaskets And Seals.
•Exhaust System To Be Checked For Contamination/Blockage (Catalyst, DPF Etc.).
•Turbocharger Oil Feed Pipe & Banjo Bolts Must Be Replaced.
•New Oil Filter And Oil To Be Fitted.
New Air Filter To Be Fitted.
During Installation
•Before Securing The Oil Supply Line The Turbocharger Should Be Filled With New Engine Oil Through The Oil Inlet Hole, While Slightly Turning The Rotor Manually.
•Attention Paid To Correct Handling.
•Oil Flow Must Be Checked:
– Fit Turbocharger To Engine Leaving Oil Return Pipe Off.
– Install A Longer Oil Return Line And Feed Into Suitable Container.
– Start Engine And Idle For 60 Seconds, Then Switch Off Engine.
– Measure Volume Of Oil In Container – 60 Seconds Of Idle Should Produce At Least 0.3 Liters Of Oil.
– Repeat Test Two Or Three Times To Confirm Oil Flow Is Correct.
– During This Test, Do Not Allow Engine To Run Below Minimum Oil Level!
Post Installation
•Idle For Approximately 120 Seconds After Engine Is Running.
•During Idling: All Connections (Air, Exhaust, Water And Oil) Checked For Firm Seating, Tightness And Free Of Leaks, Gas-tightness Checked With Soapy Water If Necessary