B1HG2XK1 - 307 DW10TD ENGINE

REMOVAL - REFITTING HIGH PRESSURE FUEL INJECTION COMMON RAIL

IMPERATIVE : when working on the diesel circuit, follow the advice on cleanliness .

IMPERATIVE : if any work is carried out on the high pressure pipes they must always be replaced .

1 - SPECIAL TOOLS

[1] Set of plugs (-).0188-T .

[2] Torque wrench (-).1603-ZZ .

2 - REMOVAL

Remove the styling cover from the engine .

Disconnect :

• the battery
• the connections of the injectors
• the diesel temperature sensor
• the high pressure fuel sensor
• the connections of the pressure and ultrasonic control solenoid valves
• the camshaft position sensor

Move aside the harness (1) .

Remove :

• the bracket on the priming pump
• the bracket (2) for the style cover
• the diesel temperature sensor

Uncouple and move aside the breather pipe .

IMPERATIVE : clean the high pressure unions before slackening .

IMPERATIVE : with the caps [1] cover the connectors to the supply rail the injectors and the high pressure fuel pump .

Apply a counter-torque at (A) .

Loosen the union (5) .

Remove the high pressure pipe (6) .

Apply a counter-torque at (B) ; On each injector .

Slacken the unions (7) - (8) .

Remove the high pressure fuel pipes .

Remove :

• the bolts (9)
• the high pressure fuel supply rail (10)

3 - REFITTING

WARNING : always replace the high pressure fuel pipes .

Refit the supply rail (10) .

Manually tighten the bolts (9) (in such a way that the supply rail is still mobile) .

Refit the high pressure pipes connected to the injectors .

Manually tighten the connectors (7) - (8) .

Refit the high pressure fuel pipe (6) .

Manually tighten the connectors (4) - (5) .

Using the tool [2] ; Tighten :

• the high pressure connectors (5) - (8) ; 2.8 da.Nm
• the bolts (9) ; 2.3 da.Nm
• the high pressure connectors (7) ; 2.5 da.Nm
• the high pressure connectors (4) ; 2.5 da.Nm

Proceed in the reverse order to removal .

Initialise the various ECUs .

Check that the connectors are correctly sealed .

3 - 1 - LEAKAGE CHECK

Start the engine .

Check that there are no fuel leaks .