Cleanliness

RISKS ASSOCIATED WITH CONTAMINATION

The high pressure direct injection system is highly sensitive to contamination. The risks associated with contamination are:
• damage to or destruction of the high pressure injection system, • components jamming,
• components losing seal integrity.

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

The cleanliness principle must be applied from the filter to the fuel 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, • ambient air
• etc.

NOTE

:
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 electrical connection malfunction.

INSTRUCTIONS TO BE FOLLOWED BEFORE CARRYING OUT ANY WORK

NOTE

:
Before any work is carried out on the high pressure injection system, protect: • the accessories and timing 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.

• Check that you have plugs for the unions to be opened (set of plugs available from the Parts Department).

The plugs are single-use only. After use, they must be discarded (once used they are soiled and cleaning is not sufficient to make them reusable). Unused plugs must be discarded.

• Check that you have hermetically resealable plastic bags for storing removed parts. Stored parts will therefore be less subject to the risk of impurities. The bags are to be used once only, and discarded after use.

• Use lint-free cleaning cloths. Using normal cloth or paper is prohibited. They are not lint-free and could contaminate the fuel circuit. Each cloth should only be used once.

• Use fresh cleaning agent for each operation (used cleaning agent is contaminated). Pour it into an uncontaminated container.

• 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.

• Blast compressed air over the cleaned parts (tools, workbench, the parts, unions and injection system zones). Check that no bristles remain.

• Wash your hands before and during the operation if necessary.

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

INSTRUCTIONS TO BE FOLLOWED WHEN CARRYING OUT ANY WORK

• 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. Ambient air carries contamination.

• All components removed from the injection system must be stored in a hermetically sealed plastic bag once they have been plugged.

• Using a brush, cleaning agent, air gun, sponge 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.