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 intercooler air inlet pipe bolt (2) 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
- the air inlet flap
- the turbocharger pressure sensor unit
- the exhaust gas recirculation solenoid valve
- the oil separator
- the diesel injector fuel return rail
- the high pressure pipes between the rail and the injectors
- the high pressure pipes between the high pressure
pump and the injector rail
| Note:
Do not allow any diesel fuel to enter the engine
via the rocker cover opening during this operation. |
- Disconnect the diesel return pipe quick-release
union (4) from the injector rail.
- Insert the blanking plugs.
- Disconnect:
- the pressure regulator connector (5) on the injector
rail,
- the connector (6) from the rail pressure sensor,
- the heater plug connectors (7) .
- Move the fuel pipes aside.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
- Remove:
- the injector rail bolts (8) ,
- the injector rail,
- the injector rail seal.
REFITTING
I - REFITTING PREPARATION OPERATION
- Always replace:
- the injector rail seal,
- 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. |
II - REFITTING OPERATION FOR PART
CONCERNED
- Remove the blanking plugs.
- Refit:
- the injector rail along with its seal,
- the injector rail bolts.
- Torque tighten the injector rail bolts (25 N.m).
III - FINAL OPERATION
- Connect:
- the heater plug connectors ,
- the rail pressure sensor connector,
- the pressure regulator connector on the injector
rail,
- the diesel return pipe quick-release union on the injector
rail.
- Refit:
- the high pressure pipes between the high pressure
pump and the injector rail
- the high pressure pipes between the rail and the injectors
- the diesel injector fuel return rail
- the oil separator
- the exhaust gas recirculation solenoid valve
- the turbocharger pressure sensor unit
- the air inlet flap
- the injector rail protector.
- Remove the intercooler air inlet pipe seal using a
tweezers.
| Note:
Check that the seal (9) 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).
- Prime the fuel circuit using the manual priming pump.
- Connect the battery .
- Refit:
- the air intake sleeve on the air filter unit.
- the clips of the air intake sleeve,
- the engine cover.
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