DIESEL INJECTION

Fault finding – Cleanliness guidelines

I - RISKS ASSOCIATED WITH CONTAMINATION

The high pressure direct injection system is highly sensitive to contamination. The risks caused by the introduction
of contamination are:
– damage to or destruction of the high pressure injection system,
– a component seizing up,
– a component losing its sealing.

All After-Sales operations must be performed under very clean conditions. This means that no impurities
(particles a few microns in size) should have penetrated the system during dismantling.

The cleanliness guidelines must be applied from the filter through to the injectors.

What are the sources of contamination?

– metal or plastic chips,
– paint,
– fibres:
– from cardboard,
– from brushes,
– from paper,
– from clothing,
– from cloths,
– foreign bodies such as hair,
– the ambient atmosphere,
– etc.

IMPORTANT
Cleaning the engine using a high pressure washer is prohibited because of the risk of damaging connections. In
addition, moisture may collect in the connectors and create faults in the electrical connections.
 Fault finding – Cleanliness guidelines

II - INSTRUCTIONS TO BE FOLLOWED BEFORE CARRYING OUT ANY WORK

IMPORTANT
Before carrying out any work on the high pressure injection system, protect:
– the accessories belts,
– the electrical accessories, (starter, alternator, electric power-assisted steering pump),
– the flywheel surface, to prevent any diesel from running onto the clutch friction plate.
– timing chain

Ensure that you have plugs for the unions to be opened (set of plugs available from the Parts Department). Plugs are
to be used only once. They must be discarded after use (once used they are soiled and cleaning is not sufficient to
make them reusable). Unused plugs must be thrown away.

Ensure that you have hermetically resealable plastic bags for storing removed parts. Parts stored in this way will be
less susceptible to the risk of contamination. The bags are to be used once only, and discarded after use.

Use lint-free cleaning cloths (cloth part reference 77 11 211 707). The use of ordinary cloth or paper is not permitted.
They are not lint-free and could contaminate the fuel circuit. A lint-free cloth should only be used once.

Use fresh cleaning agent for each operation (used cleaning agent is contaminated). Pour it into a clean receptacle.

For each operation, use a clean brush in good condition (the brush must not shed its bristles).

Use a brush and cleaning agent to clean the unions to be opened.

Blow compressed air over the cleaned parts (tools, workbench, the parts, unions and injection system zones). Check
that no bristles are left.

Wash your hands before and during the operation if necessary.

When wearing leather protective gloves cover them with latex gloves to prevent contamination.

III - INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION

As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system.
The plugs to be used are available from the Parts Department. The plugs must not be reused under any
circumstances.

Seal the pouch shut, even if it has to be opened shortly afterwards. The ambient atmosphere carries contamination.

All components removed from the injection system must be stored in a hermetically-sealed plastic bag once
the plugs have been inserted.

Using a brush, cleaning agent, air gun, brush or normal cloth is strictly prohibited once the circuit has been opened.
These items could allow contamination to enter the system.

A new component replacing an old one must not be removed from its packaging until it is to be fitted to the vehicle.