M9R
| IMPORTANT
Consult the safety and cleanliness advice and operation
recommendations before carrying out any
repair. |
IMPORTANT
Use the diagnostic tool before any operation is carried
out on the injection circuit to check:
- that the rail is not under pressure,
- that the fuel temperature is not too high.
Working on the circuit with the engine running is
strictly forbidden. |
IMPORTANT
During this operation, be sure to:
- refrain from smoking or bringing red hot objects
close to the working area,
- be careful of fuel splashes when disconnecting the
union.
|
| WARNING
Dismantling the interior of the high pressure pump
and the injectors is prohibited. |
| WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run. |
REMOVAL
I - REMOVAL PREPARATION OPERATION
- Remove:
- the engine cover
- the battery
- the battery tray
- the injector rail protector
II - OPERATION FOR REMOVAL OF PART
CONCERNED
- Remove the high pressure pipe between the pump
and the rail .
- Remove:
- the quick-release union (1) from the high pressure
pump supply pipe,
- the quick-release union (2) from the high pressure
pump return pipe.
- Insert the blanking plugs.
- Disconnect the high pressure pump pressure regulator
connector.
- Remove:
- the high pressure pump bolts (3) ,
- the high pressure pump.
REFITTING
I - REFITTING PREPARATION OPERATION
- Always replace:
- the high pressure pump O-ring,
- the high pressure pump bolts,
- the high pressure pipe between the high pressure
pump and the injector rail,
- the intercooler air inlet pipe seal.
- Lubricate the new O-ring using engine oil.
If replacing the high pressure pump
- Secure the high pressure pump pinion in a vice's
protective jaws.
- Fit the (Mot. 1906) (4) on the high pressure pump
pinion.
- Fit:
- the washers of the (Mot. 1906) on the high pressure
pump,
- the nuts (5) of the (Mot. 1906) on the high pressure
pump.
- Tighten the nuts (5) on the high pressure pump.
- Remove:
- the high pressure pump pinion nut (6) ,
- the nuts of the (Mot. 1906) from the high pressure
pump,
- the washers of the (Mot. 1906) from the high pressure
pump,
- the (Mot. 1906).
- Fit a separator (7) under the high pressure pump
pinion (8) .
- Fit an arm (9) on the separator.
- Remove:
- the high pressure pump pinion,
- the separator and the arm.
- Refit:
- the pinion to the new high pressure pump,
- the high pressure pump nut,
- Put the high pressure pump in a vice with jaws.
- Fit:
- the (Mot. 1906),
- the washers of the (Mot. 1906) on the high pressure
pump,
- the nuts of the (Mot. 1906) on the high pressure
pump.
- Tighten the nuts on the high pressure pump.
- Torque tighten the high pressure pump pinion nut
(90 N.m).
- Remove:
- the nuts of the (Mot. 1906) from the high pressure
pump,
- the washers of the (Mot. 1906) from the high pressure
pump,
- the (Mot. 1906).
II - REFITTING OPERATION FOR PART
CONCERNED
| WARNING
Do not remove the blanking plugs from each
component until the last moment.
Also, do not remove the components from their
packaging until they are to be fitted to the vehicle. |
| Note:
Do not apply pressure to the high pressure pump
pinion teeth.
Check that the high pressure pump is in contact
with the cylinder head before positioning the
bolts. |
- Refit the high pressure pump.
- Refit the high pressure pump bolts.
- Torque tighten the high pressure pump bolts (initial
torque) (5 N.m).
- Torque tighten the high pressure pump bolts (25
N.m).
- Remove the blanking plugs.
- Refit the high pressure pipe between the pump and
the injector rail.
- Connect the fuel pressure regulator connector.
- Connect:
- the high pressure pump return pipe quick-release
union,
- the high pressure pump supply pipe quick-release
union.
III - FINAL OPERATION
- Fit the wiring.
- Refit:
- the seal of the intercooler air inlet pipe temporarily
- the battery tray
- the battery
- Prime the fuel circuit using the manual priming pump.
- Check for leaks.
- Disconnect the intercooler air inlet pipe.
- Move the intercooler air inlet pipe to one side.
- Refit the injector rail protector.
- Remove the intercooler air inlet pipe seal using a .
| Note:
Check that the intercooler air inlet pipe seal is fitted
in the right direction. |
- Refit:
- the new seal (10) of the intercooler air inlet pipe,
- the protector plate on the injector rail protector.
- Turn the intercooler air inlet pipe to refit the clip in its
housing.
- Clip the intercooler air inlet pipe onto the turbocharger.
- Refit the intercooler air inlet pipe bolt on the fuel pipe
support.
- Torque tighten the intercooler air inlet pipe bolt (8
N.m).
- Refit the engine cover.
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