EM-256
< PRECAUTION >
[K9K]
PRECAUTIONS
SPECIAL FEATURES
CAUTION:
• The engine must not operate with:
- Diesel engine fuel containing more than 10% diester,
- Petrol, even in tiny quantities.
• The system can inject the diesel into the engine at a pressure up to 1400 bars. Before carrying out
any work, check that the injector rail is not under pressure and that the fuel temperature is not too
high.
• You must respect the cleaning and safety advice specified in this document for any work on the high
pressure injection system.
• Removal of the interior of the pump and injectors is prohibited. Only the flow actuator, the fuel tem-
perature sensor and the venturi can be replaced.
• For safety reasons, it is strictly forbidden to slacken a injection tube union when the engine is run-
ning.
• It is not possible to remove the pressure sensor from the fuel rail because this may cause circuit
contamination malfunctions. If the pressure sensor fails, the pressure sensor, the rail and the five
injection tubes must be replaced.
• It is strictly forbidden to remove any high pressure supply pump pulley marked number 070 575. If
the pump is being replaced, the pulley must be replaced.
• It is forbidden to repair the wiring connecting the knock sensor (accelerometer) and the CKP sensor
(engine speed sensor). If the wiring should fail, it has to be replaced with new wiring.
• Applying 12 volts directly to any component in the system is prohibited.
• Ultrasonic carbon removal and cleaning are prohibited.
• Never start the engine without the battery being connected correctly.
• It is essential to replace all the disconnected air inlet plastic pipes.
INSTRUCTIONS FOR INJECTION TUBES
CAUTION:
All the injection tube removed must be systematically replaced along with the clips.
TIGHTENING THE INJECTION TUBES
NOTE:
fit the pump/rail pipe before the rail/injector pipes.
Rail-pump pipe
• Undo the rail,
• Grease the threads of the injection tube nuts,
• Insert the injection tube olive into the taper of the high pressure pump outlet,
• Insert the injection tube olive into the taper of the high pressure rail inlet.
• Move the nut into position by hand, on the rail side then the pump side,
• Tighten the rail,
• Tighten the injection tube nuts on the rail side then on the pump side.
Rail/injector pipes
• Undo the rail,
• Grease the threads of the injection tube nuts,
• Insert the injection tube olive into the taper of the high pressure injector inlet,
• Insert the injection tube olive into the taper of the high pressure rail outlet,
• Move the nuts into position by hand, on the injector side then the rail side,
• Tighten the rail,
• Ensure that the new clip, supplied with the new injection tube, is fitted,
• Tighten the nuts of the injection tubes on the injector side first and then on the fuel rail side.
NOTE:
Before fitting a new injection tube, move back the nuts on the pipe then lightly lubricate the nut
threads with the oil from the sachet provided in the parts kit.
CHECKING SEALING AFTER REPAIR
CAUTION:
After any operation, check that there are no diesel leaks.
• Reprime the circuit using the priming pump.
• Start the engine and allow to warm up at idle speed, visually inspecting for any fuel leaks.
• Apply tracing fluid around the high pressure connections of the pipe that has been replaced.
• Once the engine coolant temperature is above 50
°
C and provided there are no malfunctions present, carry
out a road test, taking the engine speed up to 4000 rpm at least once to check that there are no leaks.
• Perform a visual inspection after the road test to make sure that there are no high pressure leaks.
• Clean off the tracing fluid.