REMOVAL AND INSTALLATION



RECOMMENDED TOOLS





Designation
Reference
[1] Torque wrench
4220-T.B


Designation
Reference
[2] Extension
4220-T.J


Designation
Reference
[3] Pipe spanner
4220-T.D


Designation
Reference
[4] Leak detector
ARDROX 9D1 BRENT


Designation
Reference
[5] Set of plugs
(-). 0188-T


Designation
Reference
[6] Diesel injector union tightening spanner
4704-T


Designation
Reference
[7] Torque wrench
4220-T.A


Designation
Reference
[8] 10mm tightening spanner
(-). 1603-U

REMOVAL



Remove the engine cover.
Disconnect the battery.

Disconnect:

  • The connector (at "a")
  • The connector (at "b")
Disconnect the pipe (1).
Remove: The bolt (2) (Turbocharger vacuum pipe retaining clip).

caution Clean the fuel high pressure unions before untightening (see the relevant operation).
caution Apply a counter-torque (at "c").
Slacken the connector (3); Using tool [6].

Slaken the 5 unions (4); By means of tools [2], [3].

Slaken the 4 high pressure fuel supply pipe *3 unions (6) (5) unions *2; By means of tools [2], [3].
Remove:

  • The 4 high pressure fuel supply pipes (5)
  • The screws (7), (8) (Fuel high pressure common injection rail (9))

caution Do not remove the EGR pipe (10) to gain access to the bolt (13)
Remove:

  • The bolt (13) (High pressure fuel supply pipe *2 retaining clip (12) (11) retaining clip *1); Using tool [8]
  • The high pressure fuel pipe (11)
Release: The turbocharger vacuum pipe.
Remove the fuel high pressure common injection rail (9).
caution Blank all the apertures of the fuel high pressure circuit; Using tool [5].

INSTALLATION



caution Always fit new high pressure fuel pipes.
Remove the tools [5]
Fit:

  • The high pressure common fuel rail (9)
  • The bolts (7), (8) (Without tightening)
  • The 4 new high pressure fuel supply pipes (5)
Screw in without tightening: The high pressure fuel supply pipe *2 unions (4), (6) (5) unions *1.


Position: The retention bracket (12) of the high pressure fuel supply pipe (11) (according to the assembly operations):

  • "A": Correct fitting
  • "B": Incorrect fitting
Position: The high pressure fuel pipe (11) (new).
caution The retaining clip (12) must rotate freely on the high pressure fuel pipe; The retaining clip must not be closed.
Screw in without tightening:

  • The unions (3), (4) of the new high pressure fuel pipe (11)
  • The bolt (13) (High pressure fuel supply pipe *2 retaining clip (12) (11) retaining clip *1)

caution The following operations require the intervention of a second person to support the high pressure fuel pipe (11); Using an 5.4 mm shim (During the union tightening method).
Position a 5.4 mm shim between the new high pressure fuel pipe (11) and the engine lifting eye (at "d").
Pretighten the high pressure fuel pipe union (11) on the high pressure fuel pump to 2.2 ± 0.2 m.daN·m; By means of tools [1], [2], [3].

Pre-tighten the 4 unions (6) on the diesel injectors to 2.2 ± 0.2 m. daN; By means of tools [1], [2], [3].

Pre-tighten the 5 (4) of the pipes (11), (5) to 2.2 ± 0.2 m. daN
; By means of tools [1], [2].

caution Apply a counter-torque (at "e")
Pre-tighten the high pressure fuel pipe *2 union (3) (11) union *1 on the high pressure fuel pump to 2.2 ± 0.2 m. daN; By means of tools [1], [6].
Tighten the unions (6) on the diesel injectors to 2.5 ± 0.2 daN·m; By means of tools [1], [2], [3].
Tighten the 5 unions (4) on the fuel high pressure common injection rail to 2.5 ± 0.2 m.daN; By means of tools [1], [2], [3].
caution Apply a counter-torque (at "e")
Tighten:

  • The unions (3) to 2.5 ± 0.2 m.daN; By means of tools [1], [6]
  • The screws (7), (8) to 1.8 ± 0.2 m.daN

caution The retaining clip (12) must not rotate during tightening of the bolt (13); Do not complete the torque tightening of the bolt (13) if the tool [8] fouls the retaining clip (12).
Tighten the bolts (13) to 0.8 ± 0.2 daN·m; By means of tools [7], [8].

COMPLEMENTARY OPERATIONS


Perform the rest of the operations in the reverse order to the removal operations.
caution Operations to be carried out following reconnection of the battery (see the relevant operation).

CHECKING FOR LEAKS


Operating procedure:

  • Spray the product [4] onto the diesel injector unions and the fuel high pressure common injection rail
  • Leave the product to dry
  • Start the engine
  • Check there are no leaks
  • Accelerate to a speed of 4000 rpm
  • Check there are no leaks
  • Carry out a road test
  • Check there are no leaks
  • Replace any defective parts (IF necessary)

CHECKING FOR LEAKS


Refit the engine cover.