Trouble Shooting Precautions for CRDI Engines Potential Issue / Failure Mode
Causes
Precautions / Solutions
Injector rattling / sticky / Contaminated fuel causing deposition of 1. Efficient fuel filtration system with water separator blocked................................ very fine residue / dirt inside injectors and indicator. having fine tolerances 2 Customer & dealer education on importance of Reduced power & increased When the injector becomes dirty, the quality of fuel for CRDI Engines. fuel consumption of full ignition detonation of the fuel 3. Maintain and change the fuel filter regularly results in less power & more fuel engine according to the manufacturer's recommendations. consumption 4. When changing the fuel filter it is beneficial to Poor fuel economy and / or empty the old filters contents into a clean container bluish white smoke at idle Nozzle erosion causing seepage of and inspect for evidence of water and foreign fuel. debris Engine not starting due to water ingress / Engine Misfiring / Wiring harness cut / Shorting of wiring harness
ECU - Electronic Control Unit failures
High degree of engine maintenance and costly spare parts. May expect more warranty disputes like rejecting claims. The cost of “good will” claims may rise.
100
1. Rain water entry into harness 2. Water ingress in puddling operation. 3. Electrical wiring harness tampering is done in the field for doing all extra connections. 4. A fuel tank that is hot from continuous driving will suddenly be cooled if submerged in cold water and will cause a slight suction back into the tank. This will allow water to enter the tank through any loose or leaking seals, hoses, fuel level sender unit gaskets etc. 5. Solenoid coil windings short.
1. Vibrations 2. Handling / tampering
1. Ensure that the filler cap seal is in good condition and all fuel lines and connections to the tank are in good condition and tight (especially in puddling application). 2. Wiring harness tampering should be mandatorily avoided & to be linked with warranty acceptance / rejection criteria. 3. All the wiring harness couplers should be made water sealed & all Dealers to be instructed & trained for proper assembly, removal & replacement of electrical connectors & couplers. 4. Proper enclosures should be designed to avoid exposure of electrical sensors e.g. Boost pressure, crankshaft position, Accelerator pedal sensors, etc. to dust, water, mud, etc. 5. No extra welding during implement fitments to be carried out. 6. Wiring harness protection conduits / cot tubes to be used. 7. Proper routing of wiring harness with clips to avoid contact with moving parts or hot surfaces like exhaust manifold/UHMs to be done. 1. Mounting with AVMs to be explored. 2. No accessibility to user/customer for loosening. 3. Keep fuel hose clamps tight and ensure anti vibration clamps on injector lines are tight, with the rubber insulators in the correct position.
Lapses in service maintenance practices like clogged fuel filter may lead to damaging entire fuel system & replacement will be costly. Lapses in service maintenance practices.
Change of fuel filter as maintenance interval is a MUST.
per
service
It is very difficult to prove the fuel adulteration as a root cause without opening engine. The warranty claims will be rejected by QA after receiving & opening these engines at warranty yard.
Proper training of dealer mechanics & workmen to handle problems reported. Diagnosis should be preferably done at workshops than in the field by proper trained personnel only.
Educating customers during promotional events / service camps etc.
6065 / 6075 2WD & 4WD Open Station Rev 01
