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. |
| WARNING
Dismantling the interior of the high pressure pump
and the injectors is prohibited. |
REMOVAL
I - REMOVAL PREPARATION OPERATION
- Remove the front engine cover.
- 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 aside the intercooler air inlet pipe.
- Remove:
- the protector plate (3) from the injector rail protector
- the injector rail protector
- the oil separator
- the diesel injector fuel return rail
- the high pressure pipes between the rail and the injectors
- Disconnect the injector connectors.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
| Note:
Cylinder No. 1 is located on the timing end. |
- Remove:
- the injector clamp bolts (4) ,
- the injector clamps.
- the injectors one by one, noting the IMA codes for
each injector,
- the injector copper sealing washer,
- the seal between the diesel injector and the diesel
injector fuel return rail from each injector.
REFITTING
I - REFITTING PREPARATION OPERATION
WARNING
It is strictly forbidden to clean the injectors with:
- a wire brush,
- an emery cloth,
- an ultrasonic cleaner.
|
Note:
Use new cloths, part no. 77 11 211 707 soaked
in new degreaser to clean:
- the injector holes,
- the injector covers,
- the injector clamps.
|
| Note:
Use a new cloth to dry components that have
been cleaned. |
- Always replace:
- the copper sealing washer,
- the seal between the diesel injector and the diesel
injector fuel return rail,
- the intercooler air inlet pipe seal.
| 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. |
- Clean the diesel injector.
II - REFITTING OPERATION FOR PART
CONCERNED
- Refit:
- the seal between the diesel injector and the diesel
injector fuel return rail on each injector,
- the new copper sealing washer on the injectors,
- the copper sealing washer - injector assembly,
- the injector clamps.
- the injector clamp bolts.
- Torque tighten the injector clamp bolts (35 N.m).
III - FINAL OPERATION.
- Connect the connectors for injector numbers 2, 3
and 4.
- Refit:
- the high pressure pipes between the rail and the injectors
- the diesel injector fuel return rail
- the oil separator
- the injector rail protector
- Remove the intercooler air inlet pipe seal using a
tweezers.
| Note:
Check whether the intercooler air inlet pipe seal
(5) is correctly positioned. |
- 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,
- Diagnostic tool thick, to the alternator rotor.
- Enter the injector codes in the diesel injection computer
in accordance with command scenario SC002
and reinitialise the program using command scenario
SC036 replacing the diesel injector.
- Prime the circuit using the manual priming pump.
- Refit the engine cover.
|
