Injection rail

Essential equipment

diagnostic tool

"low torque" torque wrench

Tightening torques
cover nut on rail	2.1 daN.m

IMPORTANT

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

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

• 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.

WARNING

• Do not work on the injectors.
• Do not remove the injector filter.
• Always replace any injector that has been opened.
• Do not separate the pressure sensor from the rail.

REMOVAL

• Remove the engine covers.
• Disconnect the battery.
• Remove:

• the high-pressure rail-to-injector pipes (Diesel Injection chapter, High-Pressure Pipe: Replacement, page 13B-80).
• the injection rail mounting bolts,
• the injection rail.

INSTALLATION

CAUTION: Remove the protective caps only at the last moment.

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

• Fit a new high-pressure rail onto the studs.
• Start the nuts by hand.

Note:

• Fit the pump-to-rail pipe before the rail-to-injector pipes.
• For refitting the high-pressure pipes (Diesel Injection chapter, High-Pressure Pipe: Replacement, page 13B-80).

• Refit in the reverse order of removal.
• Prime the diesel circuit using the priming pump.
• Tighten the union nut on the rail to torque (2.1 daN.m) using the "low torque" torque wrench.

WARNING

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

WARNING

Check for diesel leaks:

• check the seal after the repair (Diesel Injection chapter, High-pressure pipe: Sealing check, page 13B-48),
• run the engine at idle until the radiator fan starts,
• rev the engine several times with no load,
• carry out a road test,
• switch off the ignition,
• check that no diesel is leaking.

F9Q

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

Essential equipment

diagnostic tool

"low torque" torque wrench

Tightening torques
fuel rail mounting bolts	2.2 daN.m +/- 0.2
high-pressure injection pipe nuts	2.5 daN.m +/- 0.2
pressure sensor	3.5 daN.m +/- 0.2

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 too 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.

WARNING

• Do not work on the injectors.
• Do not remove the injector filter.
• Always replace any injector that has been opened.

REMOVAL

• Remove the air intake duct (see Mixture chapter).
• Disconnect the oil vapour breather hose.
• Move the oil vapour breather hose aside.
• Remove the engine covers.
• Disconnect:

• the battery,
• the pressure sensor (1),
• the injectors (2),
• the cylinder identification sensor.

• Remove the diesel return pipe.
• Loosen the high-pressure diesel pipes.
• Remove the high-pressure diesel pipes using tool (Mot.1566).
• Fit protective caps to the openings.
• Carefully remove the injection rail (3).

  INSTALLATION

• Position the injection rail.
• Start the mounting bolts (the rail must be free to move) by hand.
• Fit all the new high-pressure pipes by hand:

• injector end,
• pump end,
• rail end.

• Tighten the injection rail mounting bolts to torque (2.2 daN.m +/- 0.2) (6) using the "low torque" torque wrench tool.
• Tighten the high-pressure injection pipe nuts to torque (2.5 daN.m +/- 0.2) using the "low torque" torque wrench tool:

• injector end (4),
• pump end (7),
• injection rail end (5).

• Tighten the pressure sensor to torque (3.5 daN.m +/- 0.2).

Note: The fuel return pipe (8) fitted to the injectors must be replaced whenever it is removed.

• Bleed the 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 radiator fan starts,
• rev the engine several times with no load,
• carry out a road test,
• switch off the ignition,
• check that no diesel is leaking.