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Special notes
13
13-5
POST-REPAIR CHECK
A fuel cock is fitted to the fuel filter at the level of the diesel return pipe leading to the tank. It should be in open
position for normal operation.
However, to carry out a circuit reignition after an intervention, a filter change or a fuel fault, you should:
– close the fuel cock,
– start the low pressure pump by switching on the ignition several times,
– start the engine,
– OPEN THE FUEL COCK (the valve is open when the two coloured lines are aligned).
NOTE: certain vehicles are not fitted with a fuel cock. In this case, ignore this operation.
IMPORTANT: the engine must not run with diesel containing more than 10 % diester.
The system can inject the diesel into the engine up to a pressure of 1350 bars. Before any intervention, check
that the injector rail is depressurised.
It is absolutely vital that you observe the tightening torque:
– of the high pressure pipes,
– of the injector on the cylinder head,
– of the pressure regulator,
– of the pressure sensor.
When the high pressure pump, injectors, supply, return and high pressure output unions are repaired or
removed, the bores should be fitted with new and appropriate core seals to avoid impurities.
When replacing a high pressure pipe, the following procedure should be observed:
– remove the high pressure pipe,
– fit the cleanliness plugs,
– loosen the high pressure rail and the pump/rail pipe,
– fit the high pressure pipe,
– tighten the injector side union to torque,
– tighten the connection on the high pressure pump side to torque,
– tighten the high pressure rail fastenings to torque.
– tighten the pump/rail pipe to torque (pump side first).
It is prohibited to remove the interior of the pump.
It is vital that you replace the fuel return pipe placed on the injectors during removal.
The diesel temperature sensor is not removable. It is part of the fuel return rail.
It is forbidden to loosen a high pressure pipe connection when the engine is running.After any operation, check that there are no diesel leaks. Start the engine at idling speed until the fan starts up,
then accelerate several times under no load.
Page 63 of 118

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Injection warning light
13
13-12
Injection warning light
Vehicles using the high pressure diesel system are fitted with two injection warning lights used during the preheating
phase and in case of an injection fault (or engine overheating).
WARNING LIGHT PRINCIPLE
!When ignition is switched on, the preheating light is lit during the preheating phase and then goes out (see section
13 "Pre-postheating control").
!When there is a fault on the injection system the "fault" warning light lights up. These faults are:
– internal computer fault,
– engine speed fault (the vehicle doesn't start),
– main relay or low pressure fault (the vehicle doesn't start),
– injector fault,
–TDC sensor coherence fault and camshaft sensor,
– rail pressure sensor fault,
– rail pressure regulator fault,
– accelerator potentiometer fault,
– engine immobiliser fault,
– computer supply voltage fault,
– engine overheating.
NOTE: the OBD warning light (symbolised by an engine), visible when the ignition is switched on, is never visible
when the engine is running.
Page 64 of 118

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Immobiliser function
13
13-13
Immobiliser function
This vehicle is fitted with an engine immobiliser controlled by a random rolling code key recognition system.
REPLACING AN INJECTION COMPUTER
The injection computers are supplied without a code but they must all be programmed with one.
When the computer is replaced, the vehicle code must be programmed in and then a check must be made to ensure
that the immobiliser system is operational.
To do this, simply switch on the ignition for a few seconds without starting the engine then switch it of f. When the
ignition is off, the engine immobiliser function will be activated after approximately 10 seconds (red engine
immobiliser warning light flashes).
IMPORTANT:
With this engine immobiliser, the computer keeps its immobiliser code for life.
In addition, this system does not have a security code.
Consequently, it is forbidden to perform tests with computers borrowed from the stores or from another
vehicle which must then be returned.
It will no longer be possible to decode them.
Page 68 of 118
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Pre-postheating control
13
13-17
Pre-postheating control
The pre-postheating function is controlled by the preheating unit.
OPERATING PRINCIPLE FOR PRE-POST HEATING
1) "Preheating" on ignition
a) Variable preheating
The warning light lighting time and the
supply to heater plugs time depends on the
coolant temperature and the battery
voltage.
In all cases the injection warning light
lighting time cannot exceed 15 seconds.
b) Fixed preheating
After the warning light goes out the plugs
remain supplied for a fixed period of
10 seconds.2) Starting
The plugs remain supplied while the starter is
being activated.
3) "Postheating" while the engine is running
During this phase the plugs are supplied
continuously according to coolant temperature.
time (s)
Coolant
temperature °C For idling speed without
depression of the accelerator
pedal.
Page 72 of 118
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Low pressure pump (supercharging pump)
13
13-21
Low pressure pump (supercharging pump)
The supercharging pump is an electric pump located in
the engine compartment.
REMOVAL
IMPORTANT: take note of the quantity of diesel and
the residual pressure in the pipes.IMPORTANT:
A fuel cock (R) is fitted to the fuel filter at the level of
the return pipe leading to the tank.
It should be in open position for normal operation.
To reprime the circuit after an intervention, a filter
change or a fuel fault you should:
– close the fuel cock (R),
– start the low pressure pump by switching on the
ignition several times,
– start the engine,
– OPEN THE FUEL COCK (the valve is open when the
two coloured lines are aligned).
NOTE: certain vehicles are not fitted with a fuel cock.
In this case, ignore this operation. YOU SHOULD FOLLOW THE CLEANNESS
INSTRUCTIONS CLOSELY.
16776S
16870R3
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Fuel filter
13
13-22
Fuel filter
The fuel filter is located in the engine compartment. It is contained in an unremovable cartridge. This cartridge
contains a regulating valve which limits the flow of diesel circulating to the engine.
To replace the filter it is therefore necessary to replace the whole unit.
REMOVAL
IMPORTANT: take note of the quantity of diesel and
the residual pressure in the pipes.
Disconnect the pipes on the filter which:
– feed the engine (1),
– come from the fuel tank (2) (low pressure pump),
– return to the tank (3) via the fuel cock (depending on
version),
– return from the engine (4),
– which return to the tank via the temperature
exchanger (5).
NOTE: certain vehicles are not fitted with a fuel cock.
In this case, ignore the repriming procedure.REFITTING
It is vital that you respect the position of the
connections to the filter.
Be careful not to squeeze or damage the pipes.
IMPORTANT:
A fuel cock (R) is fitted to the fuel filter at the level of the
diesel return pipe to the tank.
It should be in open position for normal operation.
To reprime the circuit after an intervention, a filter
change or a fuel fault you should:
– close the fuel cock (R),
– start the low pressure pump by switching on the
ignition several times,
– start the engine,
– OPEN THE FUEL COCK (the valve is open when the
two coloured lines are aligned).
It is necessary to periodically bleed the water trapped
in the diesel filter via the bleed plug (6). YOU SHOULD FOLLOW THE CLEANNESS
ADVICE CLOSELY.
15773R
16870R3
Page 77 of 118
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High pressure pump
13
13-26
Reprime the circuit:
– close the fuel cock (R),
– start the low pressure pump while switching on the
ignition several times,
– start the engine,
– OPEN THE FUEL COCK (R) (the valve is open
when the two coloured lines are aligned).
NOTE: certain vehicles are not fitted with a fuel cock.
In this case, ignore the repriming procedure.
16870R3
After any intervention, check that there are no
leaks in the diesel circuit. Start the engine at idling
speed until the fan starts up, then accelerate several
times under no load.
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Checking diesel pressure and flow
13
13-37
Checking diesel pressure and flow
It is possible to check the pressure and flow in the low pressure fuel circuit.
The low pressure is delivered by the supercharging pump (electric pump located under the diesel filter designed to
feed the high pressure pump).
SPECIAL TOOLING REQUIRED
Mot. 1311-01
Pressure gauge or
Mot. 1328
Mot. 1311-08 Pressure measuring connector
ESSENTIAL SPECIAL TOOLING
Graduated 2000 ml test tube
CHECK LOW PRESSURE
(SUPERCHARGING PUMP)
Place a "T" connector Mot. 1311-08, to position the
pressure gauge Mot. 1311-01 or Mot. 1328 at the
outlet (S) of the fuel filter or at the HP pump inlet.
Turn the fuel pump using the diagnostic tool or by
directly feeding the pump (each time the ignition is
switched on the low pressure pump is supplied for
30 seconds).
Measure the pressure which should be between
2.5 and 4 bars.CHECK THE FLOW (SUPERCHARGING PUMP)
Make the pump flow into a 2000 ml graduated test
tube. Turn on the ignition to run the pump. The pump is
supplied for 30 seconds if the engine is not started.
The flow read should be 80 to 100 litres/hour
minimum.
IMPORTANT: it is forbidden to measure the
pressure and the flow of the high pressure pump.
15773R1