B1HG2GK1 - 607 DW12TED4 ENGINE

REMOVAL - REFITTING INJECTORS

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

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

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

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

[4] Tightening kit (-).1603-A/B/D/E .

[5] Injectors extractor rings .

2 - REMOVAL

Remove the style covers .

Disconnect :

• the battery
• the connectors (1)
• the sensor (2)

Remove :

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

Empty the bottle (5) .

Remove the dipstick tube (6) .

Uncouple the pipes (7) - (8) - (9) - (10) - (11) and close them using tool [3] .

Move aside the pipes (7) - (8) - (9) - (10) - (11) .

Remove the bottle (5) and its bracket .

Move aside :

• the oil vapours breather tube (12)
• the harness (13)

Remove the diesel return pipe (14) (Plug the holes using tool [3]) .

IMPERATIVE : clean the fuel unions before slackening .

Apply a counter-torque at (a) .

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 [3] .

IMPERATIVE : do not handle the nut (b) .

Remove :

• the nuts (15)
• the injectors 16
• the sealing rings (17)
• the copper seals (18)

NOTE : if it is impossible to remove the injector, use the tool [5] .

Position the tools [5] on the nuts (15) .

Position the tools [5], pivoting them on the nuts (15) .

WARNING : gradually unscrew the nuts (15), taking each in rotation until they are slack .

IMPERATIVE : plug the diesel injector wells (using the tool [3]) .

3 - REFITTING

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

Replace the pillar bolts (19) (if they have been removed) from the cylinder head (Tightening torque : 1 da.Nm) .

Remove the diesel injector well blanks .

Fit :

• the new copper seals (18)
• the new sealing rings (17)
• the injectors 16
• the nuts (15)

Clip the high pressure pipes onto the injectors and the rail .

Tighten the nuts (15) to 0,3 da.Nm + 45 ° .

Apply a counter-torque at (c) .

Tighten the high pressure pipes 4 using the tool [2] - [4] (Tightening torque : 2,25 da.Nm) .

Tighten the high pressure pipes using the tool [1] - [4] (Tightening torque : 2,25 da.Nm) .

Fit :

• the hose (14)
• the bottle bracket (5)
• the bottle (5)

Remove the tools [3] .

Connect the pipes (7) - (8) - (9) - (10) - (11) .

Carry out bleeding of the bottle (5) .

Refit the dipstick tube (6) .

Refit :

• the harness (13)
• the hose (12)

Fit :

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

Reconnect :

• the connectors (1) - (2)
• the battery

Carry out a road test :

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

Check the sealing of the various unions .

Continue the fitting operations in the reverse order to removal .