Injectors

Essential special tools
Mot.1566	High-pressure pump pipe removal tool

Essential equipment

diagnostic tool

"low torque" torque wrench

high-pressure pipe spanner (DM19 spanner)

crowfoot pipe attachment for tightening the injector-to-rail high-pressure pipes ("Crowfoot 18-17" spanner)

pipe union tool for tightening the high-pressure pump-to-rail pipe ("Crowfoot 19-17" spanner)

Tightening torques
injector clamp	2,8 daN.m
rail nuts	2.8 +/- 0.3 daN.m
nut on the injector side	3.8 daN.m
nut on rail side	3.8 daN.m

IMPORTANT

Before any work on the injection circuit, check with the diagnostic tool:

• that the injection rail is no longer under pressure,
• that the fuel temperature is not too high.

• Strictly observe the safety and cleanliness instructions given in this document during every operation.
• Never loosen a high-pressure pipe connection while the engine is running.

WARNING

• Use the special plug kit for the high-pressure injection circuit.
• Always replace any high-pressure pipe and high-pressure pipe clips that have been removed.
• Do not work on the injectors.
• Do not remove the injector filter.
• Always replace any injector that has been opened.

The injectors can be replaced individually.

Only remove the high-pressure pipe concerned.

REMOVAL

• Remove the engine covers.
• Disconnect the battery.
• Remove the high-pressure fuel pipes, rail to injectors (Chapter Diesel Injection, High-Pressure Pipe: Replacement, page 13B-80).

• Disconnect the diesel return pipe from the injector.
• Fit protective caps to the openings.
• Loosen the injector clamp (18).
• Remove the injector.
• Remove the heat shield washer.

INSTALLATION

I - INJECTOR CLEANING

WARNING

It is strictly forbidden to clean the injectors using:

• a wire brush,
• emery cloth,
• an ultrasonic cleaner.

• Soak the injectors in degreaser.
• Wipe with new wipes, part number 77 11 211 707.

II - INJECTOR REFITTING

CAUTION: Remove the caps only at the last moment for each component.

• Program the 16-character code (C2I) (19) of the injector into the injection ECU before refitting, using the diagnostic tool (Chapter Diesel Injection, Diesel Injector Adjustment Value, page 13B-73).
• Clean using wipes, part number 77 11 211 707, soaked in new solvent:

• the injector wells,
• the injector bodies,
• the injector clamps.

• Dry the cleaned parts with a new wipe.
• Replace the heat shield washer with a new one.
• Fit the injector.
• Tighten the injector clamp to torque (2.8 daN.m).

CAUTION Always replace any high-pressure pipe that has been removed.

• Lightly lubricate the nut threads with the oil contained in the sachet supplied in the new parts kit, before fitting the new high-pressure pipe.

WARNING

• Some pipes are supplied with a sachet of oil and some are supplied without one.
• Pipes supplied without a sachet are self-lubricating pipes. The torque is unchanged: 3.8 daN.m.

• Fit the high-pressure pipe:

• remove the protective plugs,
• insert the high-pressure pipe olive into the cone at the injector inlet,
• insert the high-pressure pipe olive into the cone at the rail outlet.

• Start the nut by hand, first on the injector side, then on the rail side.
• Pre-tighten lightly.
• Fit a new clip supplied with the new pipe onto the high-pressure pipes:

• insert the first half-shell using multi-grip pliers.
• insert the second half-shell using multi-grip pliers.

WARNING

Observe the fitting direction of the second shell. The lugs at the centre of the clip can only engage in one position.

• Tighten the rail nuts to torque (2.8 +/- 0.3 daN.m).

WARNING

• Do not hold the pipes with the spanner when tightening to torque.
• When tightening the high-pressure pipes, it is essential to hold the injector intermediate fitting.

• Tighten in sequence and to torque:

• the nut on the injector side (3.8 daN.m),
• the nut on the rail side (3.8 daN.m),

using tool (Mot.1566), possibly fitted with one of the following tools:

• "low torque" torque wrench,
• spanner for high-pressure pipes (spanner DM19),
• crowfoot socket for tightening the injector-to-rail high-pressure pipes ("Crowfoot 18-17" spanner),
• crowfoot socket for tightening the pump-to-rail high-pressure pipe ("Crowfoot 19-17" spanner).

• Refit in the reverse order of removal.
• Prime the diesel circuit using the priming pump.

WARNING

Connect the battery; carry out the necessary re-learns (see Electrical Equipment chapter).

WARNING

Check for diesel leaks:

• Run the engine at idle until the cooling fan starts.
• Rev the engine several times without load.
• Carry out a road test.
• Switch off the ignition.
• Check that there is no diesel leakage.

F9Q

Essential special tools
Mot.1566	High-pressure pump pipe removal tool

Essential equipment

diagnostic tool

Tightening torques
injector clamp bolt	2.5 daN.m
rail mounting bolts	2.2 daN.m
high-pressure pipe nuts	2.5 daN.m

IMPORTANT

Before any work on the injection system, use the diagnostic tool to check:

• that the injection rail is no longer under pressure,
• that the fuel temperature is not high.

• Always observe the safety and cleanliness instructions given in this document during every operation.
• Never loosen a high-pressure pipe connection while the engine is running.

WARNING

• Use the special plug kit for the high-pressure injection circuit.
• Always replace any high-pressure pipe and high-pressure pipe clips that have been removed.
• Do not work on the injectors.
• Do not remove the injector filter.
• Always replace any injector that has been opened.
• It is forbidden to separate the injector holder from the nozzle.

The injectors can be replaced individually.

Only remove the high-pressure pipe concerned.

REMOVAL

• Remove the engine covers.
• Disconnect the battery.
• To remove the injector on the flywheel side, remove the air intake duct (see Chapter Mixture, page ).

• Disconnect and move aside the oil vapour return pipe (1).

• Remove the high-pressure pipe using tool (Mot.1566).
• Fit the cleanliness plugs.
• Remove:

• the engine covers,
• the injector clamp,
• the injector,
• the heat shield washer.

INSTALLATION

I - INJECTOR CLEANING

WARNING

It is strictly forbidden to clean the injectors using:

• a wire brush,
• emery cloth,
• an ultrasonic cleaner.

• Soak the injectors in degreaser.
• Wipe with new wipes, part number 77 11 211 707.

II - INJECTOR REFITTING

WARNING

Only remove the protective caps at the last moment for each component.

• Program the six-character alphanumeric code (IMA) of the injector into the injection ECU before refitting, using the diagnostic tool (Chapter Diesel Injection, Diesel Injector Adjustment Value, page 13B-73).

• Replace the heat shield washer.
• Refit the injector.
• Tighten the injector clamp bolts to torque (2.5 daN.m).

CAUTION Do not fit the high-pressure pipes under stress.

• Loosen the injection rail (the rail must be free-floating).

CAUTION Always replace all high-pressure pipes that have been removed.

• Lightly lubricate the high-pressure pipe nut threads with the oil in the sachet supplied in the new parts kit.

Note: If the new parts kit does not contain a sachet, do not lubricate the pipe threads (pipe is self-lubricated).

• Position the high-pressure pipe olive in the cone at the high-pressure pump outlet.
• Position the high-pressure pipe olive in the cone at the rail inlet.
• Start the high-pressure pipe nuts by hand, beginning with the rail-side nut.
• Pre-tighten the high-pressure pipe nuts lightly.
• Tighten the rail mounting bolts to torque (2.2 daN.m).

WARNING

• Do not put the spanner on the high-pressure pipes when tightening to torque.
• Always hold the injector intermediate fitting when tightening.

• Tighten the high-pressure pipe nuts to torque (2.5 daN.m) in sequence, on the pump side and the rail side.
• Refit in the reverse order of removal.

CAUTION Always replace the fuel return pipe (2).

• Prime the diesel circuit using the priming bulb.

WARNING

Connect the battery; carry out the necessary re-learns (see Electrical Equipment chapter).

WARNING

Check for diesel leaks:

• Run the engine at idle until the cooling fan starts.
• Rev the engine several times without load.
• Carry out a road test.
• Switch off the ignition.
• Check that there is no diesel leakage.