B1HG37K1 - 206 DV4TD ENGINE

REMOVAL - REFITTING HIGH PRESSURE FUEL INJECTION COMMON RAIL

1 - SPECIAL TOOLS

[1] Plugs kit (-).0194-T .

[2] Tightening kit (-).1609-ZZ .

2 - REMOVAL

Disconnect the battery .

Remove :

• the style cover
• the top timing cover
• THE INTEGRAL INTAKE SYSTEM

clean the high pressure unions before slackening .

Support the end piece (A) .

Slacken the pump outlet union (1) .

Slacken the injection rail inlet union (2) .

Remove the hose (3) .

Support the end piece (B) .

Unscrew :

• the unions (4) on the diesel injectors
• the hoses (5)

Remove the pipes (6) .

Close the openings using the plugs kit [2] .

Remove the fuel return pipe on the injection rail .

Slacken the bolts (8) .

Remove the injection rail (9) .

Disconnect the high pressure sensor (7) .

IMPERATIVE : do not separate the high pressure sensor (7) from the supply rail (9) .

3 - REFITTING

Replace the high pressure pipe(s) removed as well as the seals .

Refit the injection rail (9) .

Reconnect the fuel high pressure sensor (7) .

Replace a new high pressure tube (3) .

Manually tighten the connectors (1) - (2) .

Support the end piece (A) .

Tighten ; The hoses (1) - (2) :

• pre-tightening to 1.7 da.Nm
• tightening torque 2.2 da.Nm

Fit new pipes (6) .

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

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

Tighten the bolts (8) to 2.3 da.Nm. .

Support the end piece (B) .

Tighten ; The hoses (4) - (5) :

• pre-tightening to 1.7 da.Nm
• tightening torque 2.2 da.Nm

Fit :

• THE INTEGRAL INTAKE SYSTEM
• the top timing cover
• connect the battery

Carry out a road test :

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

Remove :

• the plastic reinforcing crossmember
• the air filter bowl
• check the sealing of the unions

Fit :

• the air filter bowl
• the style cover