E2AK0ZK1 - 406D9 DW10 ENGINE DW12TED4 ENGINE

CONDITIONS FOR WORKING ON THE DIESEL CIRCUIT (BOSCH SYSTEM)

1 - RECOMMENDATIONS

WARNING : the addition of additives such as fuel circuit cleaner/remetalliser, is prohibited .

2 - SAFETY PRECAUTIONS (WHEN CARRYING OUT WORK)

2 - 1 - FOREWORD

All operations on the injection system must be carried out in conformity with the following instructions and regulations :

• of the health authorities
• for the prevention of accidents
• for protection of the environment

The operations must be carried out by specialist personnel informed of the safety advice and the precautions to be taken .

2 - 2 - SAFETY PRECAUTIONS

Bearing in mind the high pressures (1350 bars) which may exist in the fuel circuit, follow the instructions below :

• do not smoke in the immediate vicinity of the high pressure circuit when work is being carried out
• avoid working near flames or sparks
• do not carry out any operations on the high pressure fuel circuit with the engine running
• after the engine has stopped, wait 30 seconds before carrying out any operations

NOTE : the waiting time is necessary to allow the high pressure fuel circuit to return to normal atmospheric pressure .

Engine running :

• always stay out of range of a possible jet of fuel which may cause serious injuries
• do not place your hands near the site of a leak on the high pressure fuel circuit

2 - 3 - WORK AREA

The working area (ground etc.) must be clean and free from clutter; parts being repaired must be stored away from dust .

2 - 4 - PRELIMINARY OPERATIONS

BEFORE CARRYING OUT ANY OPERATIONS ON THE SYSTEM, IT MAY BE NECESSARY TO CLEAN THE CIRCUIT CONCERNED .

Sensitive components of the circuit :

• fuel filter
• high pressure fuel pump
• supply rail
• high pressure fuel pipes
• injector holders

IMPERATIVE : advice on cleanliness: the operator must wear clean overalls .

IMPERATIVE : following removal immediately plug the high pressure circuit unions to prevent entry of impurities into the high pressure circuit .

IMPERATIVE : safety torques: always observe the high pressure circuit tightening torques (pipes, injector holder clips), using a regularly checked torque wrench .

3 - REPLACEMENT OF PART(S) ; OPERATION(S) TO BE CARRIED OUT

WARNING : before carrying out any operations on the engine, read the injection ECU memories .

3 - 1 - PROHIBITED OPERATIONS

Do not detach the high pressure fuel pump (4) from the following components :

• 3rd piston deactivator on the high pressure fuel pump (2)
• sealing ring (1)
• high pressure outlet union (3) (malfunction)

Do not detach the unions (5) from the supply rail (6) (Malfunction) .

Do not detach the diesel injector holder (8) from the following components :

• injector (7)
• electromagnetic element (10) (non operation)

Do not turn the nut (9) (Malfunction) .

Do not separate the union (11) from an injector .

WARNING : cleaning of the carbon deposit on the diesel injector nozzle and diesel or ultrasound cleaning is prohibited ; all work on the high pressure pipes requires systematic replacement of these pipes .

3 - 2 - REPLACEMENT OF PART(S)

When an injection ECU is replaced, the engine immobiliser system must be relearned .

To carry out the operation, the following conditions are necessary :

• possession of the analogue module access code (written on the customer's confidential card)
• possession of a new injection ECU and diagnostic equipment
• carry out a learning process for the engine ECU (Engine ECU Learning)
• if necessary : download the injection ECU

3 - 3 - DOWN-LOADING OF THE CONTROL UNIT

The ECU software is updated by downloading using the DIAG 2000 .

This operation is carried out using the diagnostic equipment .

3 - 4 - REPLACEMENT OF THE INJECTION ECU

WARNING : exchanging the injection ECU between two vehicles results in it being impossible to start the vehicle .

4 - PACKAGING FOR WARRANTY RETURN

4 - 1 - INJECTION SYSTEM PARTS RETURN

Before return to the technical inspection centre, the following components must be plugged, placed in a plastic bag and packed in the original packaging of the replacement parts :

• injectors
• high pressure fuel pump
• supply rail
• high pressure fuel sensor