B1HG1YK1 - 406D9 DW10TD ENGINE DW10ATED ENGINE

REMOVAL - REFITTING HIGH PRESSURE FUEL INJECTION COMMON RAIL

IMPERATIVE : when carrying out an operation on the diesel circuit, respect safety instructions .

WARNING : if any work is carried out on the high pressure pipes they must always be replaced .

1 - SPECIAL TOOLS

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[1] Torque wrench (-).1603-A/B/D .

[2] Pipe spanner (-).1603-G .

[3] Pipe spanner (-).1603-F .

[4] Extension (-).1603-E .

[6] Set of plugs (-).0188-T .

ALL MODELS

2 - REMOVAL

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Disconnect the battery negative terminal .

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Remove the style cover .

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Move aside the harness (5) .

Uncouple and move aside the breather pipe (7) .

Uncouple the pipes (1) - (2) - (3) - (4) and close them using tool [6] .

Move aside the pipes (1) - (2) - (3) - (4) .

Remove the support (6) .

IMPERATIVE : clean the high pressure unions before slackening .

Apply a counter-torque at (a) .

Loosen the union (10) .

Loosen the union (9) .

Remove :

• the high pressure supply pipe (8)

3 - REMOVAL OF HIGH PRESSURE INJECTOR PIPES

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Apply a counter-torque at (b) .

Unscrew :

• the unions on the diesel injectors

Apply a counter-torque at (c) .

Slacken the unions on the high pressure fuel direct injection rail .

Remove :

• the high pressure supply pipes

IMPERATIVE : plug the holes using tool [6] .

Disconnect :

• the high pressure fuel sensor (11)
• the fuel temperature sensor (12)

Remove :

• the bolts (13)
• the high pressure fuel direct injection rail (14)

4 - REFITTING

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IMPERATIVE : replace the removed high pressure diesel injection pipe(s) .

Fit :

• the high pressure fuel direct injection rail (14)
• run up the bolts (13)

Connect :

• the high pressure fuel sensor (11)
• the fuel temperature sensor (12)

Fit :

• the high pressure supply pipe (8) ; finger tighten : the hoses (9) - (10)
• the high pressure supply pipes (diesel injectors)

Finger tighten : The hoses .

Tighten (Using the tools [1] - [4] - [3]) :

• the union (9) to 2 daN.m
• the union (10) to 2 daN.m ; apply a counter-torque at (a)

WARNING : if it is not possible to fit the pipes: remove the injectors and follow the injector refitting method .

Tighten : The bolts (13) to 2.3 da.Nm .

Apply a counter-torque at (b) .

Tighten :

• the unions on the diesel injectors : 2 da.Nm (using the tools [1] - [4] - [3])

Apply a counter-torque at (c) .

Tighten the unions on the high pressure direct injection rail : 2 da.Nm (Using the tools [1] - [4] - [2]) .

Refit the support (6) .

Put the tools in place [6] .

Couple up the pipes (1) - (2) - (3) - (4) .

Fit :

• the hose (7)
• the harness (5)

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Fit : The style cover .

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Connect the battery negative terminal .

Carry out a road test :

• engage 3rd gear ; stabilise the engine speed at 1000 rpm
• accelerate fully (to : 3500 rpm)

Check all the pipes for leaks .