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
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 clips from the air intake sleeve,
- the air intake sleeve from the air filter unit.
- Disconnect the battery .
- Rotate the intercooler air inlet pipe clip (1) on the turbocharger.
- Remove the bolt (2) from the intercooler air inlet pipe
from the fuel pipe support.
- Move the intercooler air inlet pipe to one side.
- Remove:
- the protector plate (3) from the injector rail protector,
- the injector rail protector.
- Unclip:
- the control pipe from the turbocharger pressure
regulator valve at (4) ,
- the wiring at (5) .
- Remove the mounting (6) .
- Disconnect:
- the fuel temperature sensor connector (7) ,
- the connector (8) from the camshaft position sensor.
- Disconnect the brake servo pipe (9) from the non-return
valve.
- Unclip the injector wiring from the oil separator at
(10) .
- Remove:
- the wiring channel bolt (11) ,
- the wiring (12) .
- Remove the bolt (13) from the high pressure pipe
between the high pressure pump and the injector
rail.
- Move aside the wiring.
- Remove the oil vapour rebreathing pipe (14) from
the oil separator.
- Loosen the air outlet pipe clips (15) of the air filter
unit.
- Disconnect the air outlet pipe from the air filter unit.
- Unclip:
- the brake servo pipe (16) ,
- the turbocharger cooling pipe (17) ,
- the high pressure pipe nut protector (18) on the
high pressure pump.
- Move aside the high pressure pipe nut protector.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
- Undo:
- the nut (19) from the high pressure pipe on the injector
rail using a 19 mm long lever spanner, part
number 77 11 223 721,
- the nut (20) from the high pressure pipe on the high
pressure pump using a 17 mm long lever spanner,
part number 77 11 223 720.
- Mark the position of the pad (21) between the high
pressure pipe and the lower cover.
| Note:
Do not allow any diesel fuel to enter the engine
via the rocker cover opening during this operation. |
- Remove:
- the high pressure pipe bolt (22) on the lower cover.
- the high pressure pipe between the high pressure
pump and the injector rail.
- Insert the blanking plugs.
REFITTING
I - REFITTING PREPARATION OPERATION
- Always replace:
- the high pressure pipes between the high pressure
pump and the injector rail,
- the intercooler air inlet pipe seal.
| WARNING
Before fitting a new high pressure pipe, lightly
lubricate the nut threads with the oil from the
applicator provided in the new parts kit.
Be careful not to allow oil into the high pressure
pipe.
Do not lubricate high pressure pipes supplied
without an applicator, as these high pressure
pipes are self-lubricating. |
| 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. |
II - REFITTING OPERATION FOR PART
CONCERNED
- Remove the blanking plugs.
- Position:
- the high pressure pipe olive in the injector rail
taper.
- the high pressure pipe olive in the high pressure
pump outlet taper.
- Correctly position the pad between the high pressure
pipe and the rocker cover.
- Fit the high pressure pipe nuts without tightening
them, starting with the nut at the injector rail end.
- Torque tighten:
- the high pressure pipe nut on the high pressure
pump (32 N.m) using a 17mm long lever spanner,
part number 77 11 223 720,
- the high pressure pipe nut on the injector rail
(32 N.m) using a 19mm long lever spanner, part
number 77 11 223 721.
- Refit the high pressure pipe bolts between the high
pressure pump and the injector rail.
- Torque tighten the high pressure pipe bolts between
the high pressure pump and the injector
rail (10 N.m)
III - FINAL OPERATION
- Clip:
- the high pressure pipe nut protector on the high
pressure pump,
- the turbocharger cooling pipe,
- the brake servo pipe .
- Connect the air filter unit air outlet pipe to the air filter
unit and to the turbocharger.
- Torque tighten the air filter unit air outlet pipe
clips (5 N.m) using the tool (Mot. 1608).
- Connect the oil vapour rebreathing pipe to the oil
separator.
- Fit the wiring channel.
- Refit the wiring channel bolt.
- Torque tighten the wiring channel bolt (8 N.m).
- Clip the injector wiring onto the oil separator.
- Connect:
- the camshaft position sensor connector,
- the fuel temperature sensor connector,
- the brake servo pipe to the non-return valve.
- Refit the support.
- Clip:
- the wiring,
- the turbocharger pressure regulator valve control
pipe.
- Refit the injector rail protector.
- Remove the intercooler air inlet pipe seal using a
tweezers.
| Note:
Check that the seal (23) on the intercooler air
inlet pipe is fitted the correct way round. |
- Refit:
- the new seal 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).
- Connect the battery .
- Prime the fuel circuit using the manual priming pump.
- Refit:
- the air intake sleeve on the air filter unit,
- the clips of the air intake sleeve,
- the engine cover.
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