Trouble Shooting Precautions for CRDI Engines Potential Issue / Failure Mode
Causes
Precautions / Solutions
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Contaminated fuel causing deposition of very fine residue / dirt inside injectors having fine tolerances
Reduced power & increased fuel consumption of engine
When the injector becomes dirty, the full ignition detonation of the fuel results in less power & more fuel consumption
Poor fuel economy and / or bluish white smoke at idle
Nozzle erosion causing seepage of fuel.
1. Efficient fuel filtration system with water separator and indicator. 2 Customer & dealer education on importance of quality of fuel for CRDI Engines. 3. Maintain and change the fuel filter regularly according to the manufacturer's recommendations. 4. When changing the fuel filter it is beneficial to empty the old filters contents into a clean container and inspect for evidence of water and foreign debris
Engine not starting due to water ingress / Engine Misfiring / Wiring harness cut / Shorting of wiring harness
1. Rain water entry into harness 2. Water ingress in puddling operation.
Injector rattling blocked.
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sticky
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. 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, Electronic Control Unit, Ambient Temperature sensor, DEF Quality Sensor, Intake Throttle Valve Actuator, Heater Control Unit, Supply Module, Air Mass Sensor, Exhaust Temperature Sensor, NOX Sensor and Controller Unit, Fuel Temperature Sensor, Coolant Temperature Sensor, hoses, connectors, assemblies, clamps, fittings, tubing, sealing gaskets and mounting hardware 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.
ECU - Electronic Control Unit failures
1. Vibrations 2. Handling / tampering
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. 4. Battery ground connections should be tight and properly torqued. 5. ECU should be removed while performing any welding operation on tractor.
High degree of engine maintenance and costly spare parts.
Lapses in service maintenance practices like clogged fuel filter may lead to damaging entire fuel system & replacement will be costly.
Change of fuel filter as per service maintenance interval is a MUST.
May expect more warranty disputes like rejecting claims.
Lapses in service maintenance practices.
Educating customers during promotional events / service camps etc.
The cost of “good will” claims may rise.
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.
8000 Series, Models - 8090/8100 4WD CAB TIER-4 Final
