B1HG2FK1 - 406D9 DW10TD ENGINE DW10ATED ENGINE

REMOVAL - REFITTING INJECTORS

IMPERATIVE : when working on the diesel circuit, follow the advice on cleanliness ; conditions for working on the diesel circuit .

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

1 - SPECIAL TOOLS

[1] Pipe spanner (-).1603-F (4220-TD) .

[2] Pipe spanner (-).1603-G (4220-TC) .

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

[4] Tightening kit (-).1603-A/E/B/D (4220-T(B-G-J)) .

2 - IDENTIFICATION

NOTE : 2 injector categories .

The injector holders are marked by engraving or a paint mark on the upper section of the coil towards the diesel return opening :

• reference number : 1 = paint mark(s) : blue = category 1 injector
• reference number : 2 = paint mark(s) : green = category 2 injector

Identification marking comprising :

• (A) : identification : supplier(s)
• (B) : PSA identification number
• (C) : identification of categories

IMPERATIVE : when replacing an injector holder, order a component of the same categorythe engine must be fitted with 4 injector holders of the same category .

3 - REMOVAL

Remove the style cover .

Disconnect :

• the battery
• the sensors (1) - (2)
• the connectors (6)

Move aside :

• the oil vapours breather tube (7)
• the harness (3)

Removal :

• the diesel return hose (4)
• plug the openings (using the tool [3])
• the bracket (5)

IMPERATIVE : clean the fuel unions before slackening .

Apply a counter-torque at (a) .

Slacken the unions .

Apply a counter-torque at (b) .

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

Remove : The 4 high pressure pipes .

IMPERATIVE : plug the openings (using the tool [3]) .

IMPERATIVE : do not handle the nut (c) .

Remove :

• the nuts (8)
• the washers (9)
• the injector clamps (10), the injectors (12)
• the sealing rings (13)
• the copper seals (14)
• the thrust buttons (11)

NOTE : if the injector cannot be removed, remove the stud (15) by using a lock-nut, then, using an open ended spanner, turn the injector at (d) .

IMPERATIVE : plug the diesel injector wells, plug the openings (using the tool [3]) .

4 - REFITTING

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

WARNING : when the nuts (8) are removed, it is possible that the studs (15) may unscrew with the nut; in this case, on refitting, strictly observe the direction of the studs .

Refit the studs in the cylinder head using a nut/lock-nut .

Fit : The studs (15) (if removed) in the cylinder head (Tightening torque : 0.75 da.Nm) .

WARNING : when refitting, make sure the clamp (10) is curving the right way .

WARNING : observe the direction of fitting of the washers (9) .

Remove the diesel injector well blanks .

Fit :

• the thrust buttons (11)
• the new copper seals (14)
• the new sealing rings (13)
• the injectors (12), the injector clamps (10)
• the washers (9)
• the new nuts (8)

Clip the high pressure pipes onto the injectors and the rail .

Tighten the nuts (8) to 3 da.Nm .

Apply a counter-torque at (a) .

Tighten : The 4 high pressure pipes (Using the tool [2], [4], Tightening torque : 2 da.Nm) .

Apply a counter-torque at (b) .

Tighten : The high pressure pipes (Using the tool [1], [4], Tightening torque : 2 da.Nm) .

Fit :

• the bracket (5)
• the hose (4)

Refit :

• the harness (3)
• the hose (7)

Reconnect :

• the connectors (6)
• the battery

Carry out a road test :

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

Check the sealing of the various unions .

Continue the fitting operations in the reverse order to removal .