B1HG1YK1 - 607 DW12TED4 ENGINE

REMOVAL - REFITTING HIGH PRESSURE FUEL INJECTION COMMON RAIL

IMPERATIVE : when carrying out an operation on the diesel circuit, respect safety instructions .

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

1 - SPECIAL TOOLS

DW12TED4 ENGINE

[1] Torque wrench (-).1603-A/B/D .

[2] Pipe spanner (-).1603-G .

[3] Pipe spanner (-).1603-F .

[4] Extension (-).1603-E .

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

ALL MODELS

2 - REMOVAL

DW12TED4 ENGINE

Remove the style covers .

Disconnect the battery .

Move aside the harness (1) .

Uncouple and move aside the breather pipe (2) .

Remove :

• the air ducts (3)
• the throttle unit (4)

Empty the bottle (5) .

Uncouple the pipes (6) - (7) - (8) - (9) - (10) and close them using tool [6] .

Move aside the pipes (6) - (7) - (8) - (9) - (10) .

Remove the dipstick tube .

Remove the bottle (5) and its bracket .

IMPERATIVE : clean the high pressure unions before slackening .

Apply a counter-torque at (a) .

Loosen the union (11) .

Loosen the union (12) .

Remove :

• the high pressure supply pipe (13)

ALL MODELS

3 - REMOVAL OF HIGH PRESSURE INJECTOR PIPES

DW12TED4 ENGINE

Apply a counter-torque at (b) .

Unscrew : The unions on the diesel injectors .

Slacken the unions on the high pressure fuel direct injection rail .

Remove : The high pressure supply pipes .

IMPERATIVE : plug the holes using tool [6] .

Disconnect :

• the high pressure fuel sensor (14)
• the fuel temperature sensor (15)

Remove :

• the bolts (16)
• the high pressure fuel direct injection rail (17)

ALL MODELS

4 - REFITTING

DW12TED4 ENGINE

IMPERATIVE : replace the removed high pressure diesel injection pipe(s) .

Fit :

• the high pressure fuel direct injection rail (17)
• run up the bolts (16)

Connect :

• the high pressure fuel sensor (14)
• the fuel temperature sensor (15)

Fit : The high pressure supply pipe (13) ; Finger tighten : The hoses (11) - (12) .

Fit : The high pressure supply pipes (Diesel injectors) .

Finger tighten : The hoses .

Tighten (Using the tools [1] - [4] - [3]) :

• the union (11) to 2.25 daN.m
• the union (12) to 2.25 daN.m; apply a counter-torque at (a)

WARNING : if it is not possible to fit the pipes: remove the injectors and follow the injector refitting method .

Tighten : The bolts (16) to 2.25 da.Nm .

Apply a counter-torque at (b) .

Tighten : The unions on the diesel injectors : 2.25 da.Nm (Using the tools [1] - [4] - [3]) .

Tighten the unions on the high pressure direct injection rail : 2.25 da.Nm (Using the tools [1] - [2]) .

Fit :

• the bottle bracket (5)
• the bottle (5)

Remove the tools [6] .

Couple up the pipes (6) - (7) - (8) - (9) - (10) .

carry out bleeding of the bottle (5) .

Fit :

• the dipstick tube
• the hose (2)
• the harness (1)
• the throttle unit (4)
• the air ducts (3)

Connect the battery .

Refit the styling covers .

Carry out a road test :

• engage 3rd gear ; stabilise the engine speed at 1000 rpm
• accelerate fully up to 3500 rpm

Check all the pipes for leaks .