Cleanliness rules

I - MANDATORY REQUIREMENTS WHEN WORKING ON THE HIGH-PRESSURE DIRECT INJECTION SYSTEM

The system is very sensitive to contamination. The risks caused by introducing contamination are:

• damage or destruction of the high-pressure injection system,
• seizure of an element,
• leakage of an element.

All after-sales work must be carried out in very clean conditions.

Working in clean conditions means that no contaminants (particles of a few microns) have entered the system during dismantling or into the fuel circuits through the fuel fittings.

Cleanliness principles must be applied from the filter through to the injectors.

What contaminates the system?

• metal or plastic shavings,
• paint,
• fibres:

• from cardboard,
• from brush bristles,
• from paper,
• from clothing,
• from rags,

• foreign bodies such as hair,
• ambient air,
• etc.

II - TO BE OBSERVED BEFORE ANY WORK ON THE INJECTION SYSTEM

Obtain plugs for the fittings to be opened (bag of plugs sold at the spare parts store).

The plugs are single-use. After use, they must be discarded (once used, they are contaminated and cleaning is not sufficient to make them reusable). Discard any remaining plugs from the bag.

Obtain plastic bags that can be resealed several times, for storing the parts that will be removed. This reduces the risk of contamination of the stored parts.

The bags are single-use; once used, they must be discarded.

Obtain lint-free cleaning wipes (wipes reference 77 11 211 707). The use of standard rags or paper is prohibited, as they shed fibres and can contaminate the fuel system. Each wipe may only be used once.

III - TO BE OBSERVED BEFORE OPENING THE FUEL SYSTEM

Use new thinner for every operation (used thinner contains contaminants). Pour it into a container free of contaminants.

Use a clean brush in good condition for every operation (the brush must not shed its bristles).

Clean the fittings to be opened using the brush and thinner.

Blow down the cleaned parts with compressed air (tools, workbench, as well as the parts, fittings and areas of the injection system). Check that no brush bristles remain.

Wash your hands before and during the operation if necessary.

When wearing protective gloves, cover leather gloves with latex gloves.

IV - TO BE OBSERVED DURING THE OPERATION

As soon as the circuit is opened, it is essential to plug any openings through which contamination could enter. The plugs to be used are available at the spare parts store. Plugs must never be reused.

Reseal the bag airtight, even if it must be opened again shortly afterwards. Ambient air carries contamination.

Any injection system component that has been removed must, after being plugged, be stored in a sealed plastic bag.

Once the circuit has been opened, the use of brushes, thinner, air blow guns, swabs or standard rags is strictly prohibited, as these items may introduce contaminants into the system.

When replacing a component with a new one, unpack the new component only when it is being fitted to the vehicle.

V - FITTING INSTRUCTIONS FOR THE PLUG KIT

K9K

reference 77 01 206 804

F9Q

reference 77 01 206 381