Precautionary measures
1. Strict precautions must be observed when working on fuel system components, especially on the high pressure side. Before doing any work on the fuel system, read the safety precautions in paragraph «Safety first!» at the beginning of this Guide, and the following additional information:
- Do not repair the high pressure fuel system unless you are qualified to do so, unless you have all the necessary tools and equipment, and are familiar with the appropriate safety precautions.
- Before starting any repair to the fuel system after shutting off the engine, wait at least 30 seconds to ensure fuel pressure is relieved.
- Never work on a high pressure fuel system while the engine is running.
- Stay away from all possible sources of fuel leakage, especially when starting the engine after repairs have been made. A leak in the system can create a very strong jet of fuel that can cause serious personal injury.
- Never place your hands or any part of your body near a leak in a high pressure fuel system.
- Do not use steam cleaning equipment or compressed air to clean the engine or any part of the fuel system.
Repair procedures and important information
2. When working on any part of the fuel system, be sure to maintain absolute cleanliness. This applies to the work area as a whole, to the person doing the work, and to the elements that are being worked on.
3. Before working on fuel system components, they must be thoroughly cleaned with a suitable degreasing fluid. Peugeot/Citroen recommends the use of a special (SODIMAC degreaser available from Peugeot/Citroen dealers). Alternatively, a suitable brake cleaner can be used. Cleanliness is especially important when working with fuel system connections on the following items:
- A) fuel filter,
- b) high pressure fuel pump,
- V) fuel rail,
- G) fuel injectors,
- d) high pressure fuel lines.
4. After disconnecting any fuel lines or components, open connections or openings should be immediately plugged to prevent dirt or foreign material from entering the system. Particularly suitable for this are plastic plugs and caps in various sizes, which are sold as kits in auto parts stores (pic. 2.4). To protect items such as fuel lines, fuel injectors and electrical connectors, use «fingers», cut off from rubber gloves; they can be fixed to the elements with suitable elastic bands. Suitable gloves of this type can be purchased at many petrol stations.
Pic. 2.4. Typical set of plastic plugs and caps for sealing disconnected fuel lines and elements
5. Whenever any of the high pressure fuel lines are disconnected or removed for installation, new lines must be purchased.
6. At the end of any repair to the high pressure fuel system, it is recommended to use a leak detection tool. Peugeot/Citroen recommends the use of ARDROX 9D1 BRENT Leak Detector. It is a powder that is applied to fuel line connections. When dry, this powder is white in color. Any leak in the system causes the powder to darken, indicating the location of the leak.
7. When tightening bolts/nuts for fastening elements and connections, it is necessary to strictly follow the values of tightening torques specified in «Specifications». This is especially important when tightening high pressure fuel line connections. Two specially shaped adapters are required to use a torque wrench on fuel line fittings (Peugeot/Citroen special tools (-).1603-G and (-).1603-F) (pic. 2.7). Suitable similar tools can be purchased from many auto parts stores.
Pic. 2.7. Two special adapters are required to tighten the fuel line fittings