Peugeot 308: Safety and cleanliness recommendations : For all repairs

1. Summary

The Safety and Cleanliness Recommendations procedure describes the following sections :

• Foreword
• Engine oil filling
• Repair to the internal combustion engine and/or its environment; Replacement of the internal combustion engine and/or the turbocharger
• Vehicle safety procedure following an accident
• Before taking any action
• After any adjustment
• Electric or hybrid vehicles
• Fuel cell electric vehicles
• Stop and start vehicles fitted with a central voltage retention device
• Petrol direct injection system
• HDI direct injection system
• Air inlet circuit
• Particle filter
• Hydraulic suspension
• Pneumatic suspension
• Pyrotechnic system
• Welding
• Air conditioning circuit
• Braking circuit
• Urea circuit

2. Preamble

2.1. General instructions

All operations must be carried out according to the following instructions and regulations :

• Competent health authorities
• Prevention of accidents
• Protection of the environment

ESSENTIAL : Operations must be performed by specialist personnel who are aware of the safety instructions and precautions to be taken.

CAUTION : Observe the tightening torques using a torque wrench which is checked regularly.

2.2. Individual protections

The wearing of personal protection equipment (PPE) is compulsory in order to work safely on any operation.

The following items of personal protective equipment are compulsory :

• Trousers/overalls or suitable combination
• Safety shoes

Depending on the location and the type of operation, these items of personal protection equipment are compulsory :

• Safety helmet, when operating underneath the vehicle
• Protection goggles, when working on fluid circuits, fuel circuits, air circuits, etc. or for operations that could involve the suspension or projection of particles in the air
• Face masks, for operations that could involve the suspension or projection of particles in the air
• Safety gloves, to guard against cuts or exposure to chemical products
• Ear protections, when working in a noisy environment
• Antistatic overall, shoes and gloves, when working on hydrogen carrying components

All these items of personal protection equipment are available in your Parts shop.

If necessary, consult the Replacement Parts sales manager.

2.3. Protecting the vehicle

Place a protective cover on the following :

• Front wings
• Driver’s seat
• Mat(driver’s side)
• The steering wheel

2.4. Working area

The working area should be clean and tidy.

2.5. Environment

Respect the environmental regulations :

• Separation and collection of waste
• Ejection of used water
• Air pollution
• Noise emissions

3. Repair to the internal combustion engine and/or its environment ; Replacement of the internal combustion engine and/or the turbocharger

CAUTION : Check the cleanliness (absence of metal particles, excessive carbon deposits and any other impurities) of the components of the air inlet and exhaust system :  Turbocharger, air/air heat exchanger, exchanger EGR, hoses, air mixer unit, motorised throttle housing.

CAUTION : Check the turbocharger fins for breakage and excessive play.

N.B. : Check that there is no excessive oil in the air/air heat exchanger.

CAUTION : Systematically replace the turbocharger pressure oil supply and return pipes, the air filter and the fuel.

N.B. : Visually check the condition of the catalyst body (no debris, cracks or clogging).

4. Engine oil filling

CAUTION : For any operation involving the adjustment of the engine oil level or topping up as part of routine servicing, follow the instructions below.

Instructions to be followed for operations involving the engine oil level :

• Protect the alternator and any other electrical components ; Using absorbent paper : Risk of damage to the alternator
• Avoid causing the oil to overflow by filling it up too quickly
• Wipe away any traces of oil splashes that may damage the surrounding components

5. Vehicle safety procedure following an accident

5.1. Internal combustion engine vehicles

ESSENTIAL : Disconnect the ancillaries battery following an accident, before towing and storing.

ESSENTIAL : Follow the instructions after an accident, before towing and storing ; The instructions are available on the manufacturer’s aftersales documentation portal in the "Organisation/Assistance/Practical Roadside Assistance" tab.

5.2. Electric or hybrid vehicles

ESSENTIAL : Follow the instructions after an accident, before towing and storing ; The instructions are available on the manufacturer’s aftersales documentation portal in the "Organisation/Assistance/Electric Vehicles/Hybrids" tab.

5.3. Fuel cell electric vehicles

ESSENTIAL : Follow the instructions after an accident, before towing and storing : The instructions are available on the manufacturer’s aftersales documentation portal in the "Organisation/Assistance/Hydrogen Vehicles" tab.

6. Before taking any action

ESSENTIAL : Depending on the repair to be carried out, respect the recommendations for lifting and supporting the vehicle(hoist or stands).

ESSENTIAL : Before any repairs and without using the diagnostic tool, switch off the ignition..

CAUTION : When recharging the ancillaries battery, check that the clamps are not in contact with the engine management ECU ; Risk of damage to the engine management ECU.

Please note :

• Before disconnecting the battery, partially open the door windows as they could break or damage the passenger compartment side upper trim if the doors are opened or closed (Vehicles with frameless doors)
• Before disconnecting the battery, leave the tailgate or boot lid open (Vehicles with battery in the boot)
• After the ignition has been switched off : Wait 4 minutes before disconnecting the battery to ensure that the programmed values of the various ECUs are stored
• Using cloths may cause fluff to enter the hydraulic circuits - Use special lint free workshop paper or a chamois leather

ESSENTIAL : Before opening the circuit, and if there is any dust or sand present, you must clean the air filter, air ducts and unions towards the air filter, the turbocharger or the air supply unit.

7. After any adjustment

Instructions to be followed

Components involved	Recommendations
Fuel system	Whenever the fuel circuit has been opened, after refitting check the locking of the snap- on unions by pulling/pushing on them
	Whenever the fuel circuit has been opened, check there are no leaks on the whole of the fuel supply line up to the injectors. Check there are no leaks on the fuel return line as far as the tank, at all engine speeds
Air circuit	After opening the air circuit, check that there are clips or fixing bolts and check the condition of the air pipes, clamps and unions
Lubrication system	Whenever the oil circuit has been opened (oil filter, oil vapour, turbocharger unions, etc) check there are no oil leaks (engine hot), at all engine speeds
Hydraulic clutch control circuit	Whenever the hydraulic clutch contro circuitt has been opened, after refitting, check the locking of the unions, including the bleed valve, and the absence of leaks in repeated operation
Exhaust circuit	After any work on the exhaust system, check the absence of gas leaks on the exhaust, at all engine speeds
Hydraulic power steering circuit	Whenever the hydraulic power steering circuit has been opened, after refitting, check the locking of the unions and the absence of leaks in repeated operation
Automatic or piloted manual gearbox	After any work on an automatic or piloted gearbox, after refitting, check the absence of oil leaks at all engine speeds
Hydrogen components	Whenever the hydrogen supply circuit has been opened, after refitting, check the locking of the snap- on unions by pulling/pushing on them
	After any work on the hydrogen system of fuel cell electric vehicles, after refitting, check the absence of hydrogen leaks on all previously opened pipes, clamps and unions with a hydrogen leakage detector

8. Electric or hybrid vehicles

N.B. : The provisions of this chapter apply to the electric drive network and those components supplied directly by the traction battery.

The electric or hybrid vehicle has a traction battery with voltage higher than 200 V and with current greater than 10 mA.

ESSENTIAL : All personnel carrying out work on a vehicle fitted with traction batteries must have received specific electric vehicle training and be authorised to work on these vehicles(observe the regulations in force in the respective country).

ESSENTIAL : Before undertaking any maintenance and repair work on an electric or hybrid vehicle, it is essential to inform yourself of the risks involved and to apply the compulsory safety procedures.

8.1. Dangers of an electric current

CAUTION : An electric or hybrid vehicle is no ordinary vehicle, it can be the source of serious accidents if precautions are not taken during certain operations in After-Sales.

Contrary to widespread belief, the risk of electrocution is not directly linked to the voltage, but depends principally on the intensity of the current (amperage) and on the length of time it takes to pass through the body.

Ampères	Phenomenon caused	Consequences
10 mA	Repulsion	Uncontrolled reactions (dropping of components)
Between 10 and 25 mA	Muscular contraction	Involuntary gripping of components on touch (start of tetanisation, onset of burning)
From 25 mA	Contraction of the thorax muscles (if the current passes through the upper part of the body)	Asphyxia if no action taken (artificial respiration)
Beyond 30 mA	Cardiac fibrillation	Fatality without immediate specialised medical attention

Various factors determine the amount of current which may pass through the human body :

• The voltage
• The tightness of grip (piercing of the skin)
• The contact pressure
• Perspiration
• Ambiant humidity

8.2. Workshop - Work station

It is only sensible to keep to certain rules of safety when installing a work station for an electric or hybrid vehicle in the workshop :

• The work station must be separated off by a safety cordon itself secured on permanent posts
• A notice must mention that only those personnel who are qualified to work on electric vehicles may enter the work area
• An electric or hybrid vehicle must be easily identifiable : Attach the notice provided to this effect either to the vehicle bonnet or to the rear view mirror
• For normal recharging of the traction battery : Use a 230 V - 10 A to 16 A socket (depending on the country) with no other consuming element attached, fitted with an earth connection and protected by a thermo-magnetic circuit breaker of 16 to 20 A with a differential block equal to 30 mA(one protector per socket)

Close to the work station that has the sign "electric or hybrid vehicle" there must be the following elements :

• A fire extinguisher specific to the battery or batteries fitted on the vehicle(s)
• A water supply for heavy rinsing in the event of contact with the electrolyte

8.3. Protective equipment

Instructions to be followed

Obligation / Prohibition	Recommendations
Obligation	Wear a helmet complete with visor, as well as gloves that insulate from both heat and electric current, for taking measurements of voltage and/or depowering the vehicle
	Before taking any action : Check all your items of personal protection
	Check that the protective gloves are not torn(inflate the gloves)
	Check that the visor of the protection helmet is not scratched or cracked
Prohibition	For any intervention, it is prohibited to wear metal objects that conduct electric current (rings, watches, belt buckles, etc.)

8.4. Safety instructions

ESSENTIAL : It is essential to carry out a check on the voltage, using a voltage absence verifier on the affected vehicle.

ESSENTIAL : Before taking any action : Test the checking equipment.

Test the following functions of the multimeter :

• Ohmmeter
• Voltmeter

CAUTION : Only a voltage absence verifier should be used for checking the voltage.

Check that the leads and probes of the voltage absence verifier (insulations and fixings) are in good condition.

Use the voltage absence verifier to check the voltage of a known voltage source (Example : 230 V mains socket).

ESSENTIAL : It is forbidden to carry out operations or electrical checks on the electrical network when it is powered up.

ESSENTIAL : Switch the vehicle’s power off (In accordance with the procedure that is specific to the type of vehicle).

CAUTION : Depowering the vehicle consists of "cutting off the current" from the traction battery.

ESSENTIAL : The action of depowering the vehicle must be taken by an operator specially trained for this purpose.

ESSENTIAL : Disconnect the charging cable from the 230 volt mains before carrying out any work on the vehicle (If it is a rechargeable vehicle).

Depowering is essential for any operation on the following components :

• Components of the electric drive train
• Electric machines
• Electronic control units
• Traction battery
• Charging socket
• Traction chain tension cables (Orange colour)
• Electric cabin heating (Orange colour)
• Electric air conditioning compressor (Orange colour)

Depowering is essential for the following types of bodyworking :

• Electric spot welding
• Grinding, drilling, cutting in proximity to components of the traction chain

ESSENTIAL : The temperature of the paint cabin must not exceed 60 °C.

ESSENTIAL : The vehicle must not remain in the heated spray booth for longer than one hour.

Before painting, the vehicle must be stored at a temperature between 20 and 30°C.

Installation and de-installation of electrical checking and measuring equipment(multimeter).

In cases where the vehicle has an isolating device (fuse or circuit-breaker) for the traction battery, the following operations are compulsory when depowering :

• Remove the isolating fuse
• Or action (trigger) the circuit-breaker

ESSENTIAL : The isolating fuse must be stored in a location that is locked with a key (in accordance with the depowering procedure).

ESSENTIAL : Only the person who has removed the isolating fuse or triggered the circuit-breaker is authorised to refit the isolating fuse or action (release) the circuit-breaker.

ESSENTIAL : After the work, reconnect the vehicle electrical supply (in accordance with the procedure that is specific to the type of vehicle).

CAUTION : The action of reconnecting the vehicle consists of "restoring the current" from the traction battery.

ESSENTIAL : The action of reconnecting the vehicle must be taken by an operator specially trained for this purpose.

ESSENTIAL : After any operation on a component of the traction chain or on the cabling : Check the insulation.

8.5. Cleanliness instructions

CAUTION : After uncoupling them, block the unions of the system that cools the components of the traction chain with plugs, to prevent the entry of any impurities.

CAUTION : After disconnecting them, place the voltage cable end and base end connectors in plastic bags.

The components that have been removed must be stored away from any dust.

8.6. Damaged traction battery

In an accident, internal destruction of a pack may lead to leaking of electrolyte from one of the battery compartments.

ESSENTIAL : Protective gloves and glasses must be worn when carrying out any work.

Electrolyte causes serious burns if it comes into contact with the skin.

In the event of an accident, immediately rinse the affected area of skin with large amounts of water.

If the body of the vehicle and the ground are contaminated by electrolyte, wash them immediately with large quantities of running water.

9. Fuel cell electric vehicles

ESSENTIAL : All personnel working on vehicles with a fuel cell stack must have completed the STELLANTIS training courses required to work on these vehicles(observe the regulations in force in the respective country).

ESSENTIAL : Before undertaking any maintenance or repair work on a fuel cell electric vehicle, inform yourself of the risks involved and apply the given safety recommendations.

N.B. : The provisions of this chapter apply to all hydrogen carrying components and those components supplied directly by the hydrogen storage system.

9.1. Dangers of hydrogen

CAUTION : Fuel cell electric vehicles are not like regular vehicles, these vehicles can be the cause of accidents if precautions are not taken during certain aftersales work.

Hydrogen is a colourless, odorless, and extremely volatile gas.

A hydrogen concentration over approximately 4 % in the ambient air is already flammable.

Hydrogen is very willing to ignite and requires a very low ignition energy.

A burning hydrogen-air mixture is barely visible in daylight and reaches temperatures of over 2000°C.

Highly pressurized escaping hydrogen can cause serious cold burns on skin contact.

9.2. Workshop - Work station

There are specific safety rules to follow for the installation of a workshop workstation for a fuel cell electric vehicle :

• The work area must be officially approved for work on hydrogen vehicles (According to the regulations in force in the respective country)
• The work station must be physically separated, inaccessible to unauthorised persons, well ventilated and equipped with a sufficient hydrogen concentration detection system (According to the regulations in force in the respective country)
• A fuel cell electric vehicle must be easily identifiable : Attach the notice provided to this effect either to the vehicle bonnet or to the rear view mirror

9.3. Protective equipment

ESSENTIAL : Follow all instructions for fuel cell electric vehicles, in addition to those for electric and hybrid vehicles.

Instructions to be followed
Obligation / Prohibition	Recommendations
Obligation	Wear antistatic clothing, shoes and gloves when working on hydrogen systems
	Wear a functional and operational handheld hydrogen detector
	Before any intervention : Check all your items of personal protection
Prohibition	For any intervention, it is prohibited to wear metal objects that conduct electric current (rings, watches, belt buckles, etc.)

9.4. Safety recommendations

ESSENTIAL : Follow all instructions for fuel cell electric vehicles, in addition to those for electric and hybrid vehicles.

ESSENTIAL : No smoking near fuel cell electric vehicles.

ESSENTIAL : Before entering the workshop, visually check the fuel cell electric vehicle for external damage.

If you can see external damage on the vehicle, check for hydrogen leakage ; Using the hydrogen leakage detector.

Check that no hydrogen-related warning text or lights are activated on the dashboard.

ESSENTIAL : Before usage : Test the checking equipment.

Check that the hydrogen leak detector is functional and operational ; Using the hydrogen gas test kit.

ESSENTIAL : The action of filling, draining and flushing hydrogen storage systems must be performed by an operator specially trained for this purpose.

Drain and rinse the hydrogen storage system before replacing it (Shipping preparation).

Hydrogen- filled hydrogen storage systems must be stored outside the workshop in a gas storage room (According to the regulations in force in the respective country).

The filling and hydrogen pressure maximisation of a replacement hydrogen storage system must be performed gradually and strictly in accordance with the repair manual.

ESSENTIAL : The vehicle must only be lifted at the lifting points provided.

It is prohibited to lift the vehicle by the hydrogen storage system or other components transporting hydrogen.

ESSENTIAL : Do not heat hydrogen components.

Keep hydrogen components away from direct heat sources over 60°C.

Never expose frozen hydrogen components to heat.

ESSENTIAL : Prior to entering a paint cabin, the hydrogen storage system pressure must be reduced to less than 350 bar.

Use a diagnostic tool to determine the system pressure.

ESSENTIAL : The temperature of the paint cabin must not exceed 60 °C.

ESSENTIAL : The vehicle must not remain in the heated spray booth for longer than one hour.

Before painting, the vehicle must be stored at a temperature between 20 and 30°C.

ESSENTIAL : It is prohibited to drill holes in the underbody from inside the fuel cell electric vehicle.

ESSENTIAL : A hydrogen leakage test must be performed after any repair on hydrogen components.

Check for hydrogen leaks at any hydrogen fittings that have been uncoupled :

• Using the hydrogen leakage detector
• Using a permitted gas leakage detection spray

Before returning to service after repairs, check that all hydrogen components are intact and functional.

9.5. Cleaning recommmendations

CAUTION : After uncoupling them, block the unions of the system that cools the components of the traction chain with plugs, to prevent the entry of any impurities.

CAUTION : After uncoupling, seal all fittings of the fuel cell air supply system with caps, to prevent any impurities from entering.

CAUTION : After uncoupling them, seal all open unions of the hydrogen system, to prevent the escape of gas and the entry of any impurities.

The components that have been removed must be stored away from any dust.

ESSENTIAL : Do not use oil or grease for corrosion protection.

Soiled hydrogen components must be cleaned and protected from ageing ; Using permitted products only.

9.6. Damaged hydrogen system

ESSENTIAL : Never enter the workshop with a fuel cell electric vehicle that poses a potential hazard or leak risk.

ESSENTIAL : Protective equipment must be worn when carrying out any work on a potentially unsafe vehicle.

ESSENTIAL : Any sparking or electrostatic discharge may cause a fire or an explosion.

In an accident, the destruction of hydrogen carrying components may lead to the leakage of gas.

If the fuel cell electric vehicle has been involved in an accident and/or if a hydrogen-related warning light or warning text is activated on the dashboard, check the technical tightness of the components transporting hydrogen, outside the workshop ; Using the hydrogen leakage detector.

10. Stop and start vehicles fitted with a central voltage retention device (DMTC)

The central voltage retention device is composed of a switch control unit and a power accumulator (UCAP).

The power accumulator (UCAP) contains aceto-nitrile, a fluid that is toxic (to inhale and to touch), irritating to the eyes and inflammable.

ESSENTIAL : Opening up the power accumulator (UCAP) is forbidden.

10.1. Safety instructions

ESSENTIAL : Before any intervention, it is essential to put on the appropriate gloves and goggles.

ESSENTIAL : Before any intervention on a power accumulator (UCAP) that is either damaged or faulty, check the condition of the breathing mask.

ESSENTIAL : Before handling it, visually inspect the power accumulator (no leaks or traces of salt).

ESSENTIAL : If there is a leak, trace of salt, or any mechanical alteration of the power accumulator (UCAP), it is essential to use new gloves and a suitable protective breathing mask, throwing away all these protections at the end of the operation.

ESSENTIAL : Before any intervention, check the equipment for discharging the power accumulator (UCAP) (in accordance with the power accumulator (UCAP) discharging procedure).

ESSENTIAL : Replace the gloves if there is contact with the aceto-nitrile for longer than 15 minutes.

ESSENTIAL : In the case of a leak, always replace the faulty power accumulator (UCAP) and place it in a hermetically-sealed bag available from Replacement Parts.

ESSENTIAL : Before any intervention on one of the components of the DMTC (switch control unit or power accumulator (UCAP)), discharge the power accumulator (UCAP) (using special equipment).

ESSENTIAL : Immediately after removing it, put the power accumulator (UCAP) in the hermetically-sealed bag provided for that purpose (available from Replacement Parts).

ESSENTIAL : The faulty power accumulator (UCAP) must either be entered into the recycling chain (DIS) or returned to Warranty, in the same packaging by which the new component was delivered, in the hermetically-sealed bag available from Replacement Parts.

Storage requirements :

• A special labelling must be placed on the storage zone, describing the risks involved both by the contents and by entering the storage zone (the same labelling as that for the component)
• At ambient temperature (For preference between 0°C and 30°C)
• Out of direct sunlight
• In a storage zone that is ventilated (typically a space of more than 200 m3)
• Away from any dripping water
• Far away from any source of flame or spark
• Availability of CO2 extinguishers at the entrance to the storage zone and close to the labelling of the risks

CAUTION : For any paint retouching operation producing only a local heating (on the component) below 80°C, it is not necessary to remove the central voltage retention device (DMTC) assembly.

10.2. Cleanliness instructions

The components that have been removed must be stored away from any dust.

10.3. Damaged power accumulator

It is possible that the accumulator could lose its electrolyte as a result of being impacted or dropped.

In the event of a leaking of electrolyte :

• Remove any potential source of heat or spark
• Warn those in charge of safety of the location of the incident
• The operator must use the equipment for handling faulty components
• Immediately recover the liquid product after having covered it up with inert absorbent matter (For example: sand, earth)
• Keep the soiled absorbent matter in a dedicated receptacle
• Then clean the surface that has been soiled with copious amounts of water
• Ventilate the zone for a minimum of 5 minutes
• Do not dispose of water that has been polluted with aceto-nitrile down the drain

ESSENTIAL : Prior to any operation, it is essential to put on goggles and to use new gloves as well as a suitable protective breathing mask, throwing away all these protections at the end of the operation.

If there is any incident, immediately wash the skin affected with copious amounts of water for 15 minutes.

ESSENTIAL : In all cases consult a doctor.

11. Petrol direct injection system

11.1. Recommendations

CAUTION : The addition of additives such as fuel circuit cleaner/remetalliser is prohibited ; Only fuel additives approved by the manufacturer in accordance with standard "B71 5001" are permitted.

11.2. Safety instructions

ESSENTIAL : In view of the extremely high pressures prevailing inside the fuel high pressure circuit, it is essential to respect the following rules.

No smoking near to the high pressure circuit during repair work.

Avoid working near to a naked flame or sparks.

Engine running :

• Do not work on the high pressure fuel circuit
• Do not carry out any repair of the electrical control circuit of the petrol injectors
• Always remain out of the way of a possible jet of fuel which may cause serious injury
• Do not place your hand near to a leak on the high pressure fuel circuit

After the engine stops, wait 5 seconds before any operation so that the pressure in the petrol high pressure circuit can fall to a value around 30 bar.

ESSENTIAL : Effect a return to atmospheric pressure using the fuel pressure venting pipe before operating on the fuel high pressure circuit.

11.3. Cleanliness instructions

ESSENTIAL : The operator should wear clean overalls.

Before handling the fuel injection circuit components, wash your hands thoroughly or use new plastic gloves.

The use of working gloves (leather, cotton, kevlar, etc) is prohibited when handling the fuel injection circuit components.

Before working on the injection circuit, the connectors of the following sensitive components may have to be cleaned :

• Fuel delivery and return union
• High pressure fuel pump
• Fuel high pressure common injection rail
• Fuel high pressure sensor
• Fuel pressure regulator
• Petrol injectors

Have plugs ready before removing any component from the fuel injection circuit so as to minimise the time the latter is exposed to the air.

Use a clean brush and new degreaser for each operation.

ESSENTIAL : After dismantling, immediately fit a blank to the connector of the sensitive components to prevent the ingress of impurities.

Only take the plugs from the sachet after the component to be blanked has been removed.

The blanked components should be placed in a clean plastic bag.

CAUTION : After the opening of the fuel injection system, all cleaning is strictly forbidden.

The plugs are to be used once only.

Recommended cleaning product : Degreaser SODIMAC 35.

12. HDI direct injection system

12.1. Recommendations

CAUTION : The addition of additives such as fuel circuit cleaner/remetalliser is prohibited ; Only fuel additives approved by the manufacturer in accordance with standard "B71 5000" are permitted.

12.2. Safety instructions

ESSENTIAL : In view of the extremely high pressures prevailing inside the fuel high pressure circuit, it is essential to respect the following rules.

No smoking near to the high pressure circuit during repair work.

Avoid working near to a naked flame or sparks.

Engine running :

• Do not work on the high pressure fuel circuit
• Always remain out of the way of a possible jet of fuel which may cause serious injury
• Do not place your hand near to a leak on the high pressure fuel circuit
• Do not disconnect the fuel return pipe from the diesel injectors

After switching off the engine, wait for 30 seconds before starting any repair work.

N.B. : This period of time is required to allow the high pressure fuel circuit to return to atmospheric pressure.

12.3. Cleanliness instructions

ESSENTIAL : The operator should wear clean overalls.

Before working on the injection circuit, the connectors of the following sensitive components may have to be cleaned(according to equipment) :

• Fuel filter
• High pressure fuel pump
• Third piston deactivator
• Flow solenoid valve
• Fuel high pressure regulator
• Fuel high pressure sensor
• Fuel high pressure common injection rail
• High pressure fuel pipes
• Low pressure fuel pipes
• Diesel injector body

ESSENTIAL : After dismantling, immediately fit a blank to the connector of the sensitive components to prevent the ingress of impurities.

Parts being repaired should be protected from dust.

13. Particle filter

13.1. Safety instructions

ESSENTIAL : Wait at least an hour before any operation on the exhaust line.

Forced regeneration of the particle filter :

• Check that there are no aerosols or inflammable products inside the boot
• Protect yourself with high temperature gloves
• Connect the vehicle to a gas extractor approved for this type of repair
• Make the work area secure
• Make sure that nobody walks behind the vehicle during the forced regeneration

ESSENTIAL : Where the recommended installation is not available, carry out the forced regeneration of the particle filter outside the workshop, on an area of hard standing and remote from any inflammable materials.

13.2. Repair on the fuel additive circuit

ESSENTIAL : For all operations on the additive circuit, wear protective spectacles and gloves resistant to hydrocarbons.

The work area should be ventilated.

In case of any substantial escape of additive :

• Wear a particle filtring breathing mask
• Collect as much as possible of the product
• Place the product thus collected in a suitably labelled receptacle
• Wash the area affected with copious amounts of water
• Dispose of solid substances and residues at an authorised collecting point

ESSENTIAL : If the vehicle has a rigid reservoir : The filling kit should be recycled after the repair. Any container of "Eolys" additive that has been opened should not be kept.

ESSENTIAL : If the vehicle has a flexible reservoir : The flexible additive reservoir must be recycled after a repair (exchange).

14. Air inlet circuit

14.1. Safety instructions

You can use a compressed air gun for areas that are difficult to access as long as you wear appropriate PPE (protective goggles, dust mask, overalls, gloves, hat, safety shoes) and ensure that there is no one else nearby.

14.2. Repair work on the air circuit

Plug each duct or component during any work that involves opening the air circuit.

Clean and vacuum all particles of dust or sand which have entered or are present in and on the components of the air circuit before refitting (air filter, air ducts).

Check that the new replacement components are clean and vacuum and clean if necessary (air filter, air ducts and other components).

15. Hydraulic suspension

15.1. Safety instructions

ESSENTIAL : Do not operate on the hydraulic circuit without having lowered the pressure.

ESSENTIAL : The hydraulic circuit must be depressurised with the wheels not hanging.

Wait for the pressure to fall completely in the hydraulic circuit before disconnecting the unions on the following components(risk of an abrupt sinking of the vehicle) :

• Integrated BHI (BHI)
• Front suspension cylinder
• Rear suspension cylinder
• Front firmness regulator
• Rear firmness regulator
• Suspension pressure sensors

Engine running :

• Do not operate on the hydraulic suspension circuit
• Always stay out of range of a possible projection of fluid which could cause serious injuries

N.B. : In the event of the fluid LDS coming into contact with the eyes, rinse with copious amounts of water and contact a specialist.

N.B. : In the event of the fluid LDS coming into contact with the skin for any length of time, wash with soap and water.

CAUTION : After switching off the engine, wait for 30 seconds before starting any repair work.

ESSENTIAL : Do not remain underneath the vehicle during an adjustment of heights or an actuator test(solenoid valve).

ESSENTIAL : Any distortion of the wheel movement sensor supports is prohibited. If deformation is noticed, replace the part.

15.2. Cleanliness instructions

CAUTION : Non-compliance with the cleanliness requirements may allow a contamination of the circuit and subsequent malfunctioning of the suspension.

Before an operation on the suspension system, all the unions and hydraulic components should be cleaned.

ESSENTIAL : Recommended cleaning product : Degreaser SODIMAC 35.

ESSENTIAL : After removal, immediately seal off the unions and hydraulic components with plugs. The plugs are to be used once only.

Any component removed should be plugged and placed in a clean plastic bag.

ESSENTIAL : After removal, any cleaning using either chemical products or compressed air is strictly forbidden. Any LDS fluid recovered must not be re-used. Any topping up should be with new fluid.

16. Pneumatic suspension

16.1. Safety instructions

ESSENTIAL : Deactivate the pneumatic suspension before lifting the vehicle (2 or 4 post lift, workshop jack or vehicle jack).

ESSENTIAL : Do not work on the pneumatic suspension circuit without releasing the pressure. Observe the pneumatic suspension circuit depressurisation procedure.

16.2. Cleanliness instructions

CAUTION : Plug the pneumatic suspension circuit immediately to prevent destruction of the suspension compressor drying cartridge.

CAUTION : Failure to observe the instructions on cleanliness may result in contamination of the pneumatic circuit and a malfunction of the suspension.

CAUTION : Recommended cleaning product : Degreaser SODIMAC 35.

Before carrying out any work on the suspension circuit, clean the unions and pneumatic components.

CAUTION : Following removal, plug the unions and pneumatic components immediately.

Any component removed should be plugged and placed in a clean plastic bag.

CAUTION : After removal, any cleaning using either chemical products or compressed air is strictly forbidden.

17. Pyrotechnic system

ESSENTIAL : For any operation on the pyrotechnic systems : Wear antistatic shoes and gloves.

ESSENTIAL : Apply the safety instructions for pyrotechnic components.

ESSENTIAL : Apply the procedure for disarming/arming the central airbags and seat belts system.

18. Welding

Respect the safety and fire regulations.

Cover each piece of equipment with the appropriate individual protection(protection suit, protective goggles to guard against leaping sparks).

18.1. Protection of electric and electronic equipment against currents induced by welding implements(ECUs, battery, pyrotechnic components etc.)

In the case of any welding system powered by electricity, disconnect the vehicle battery (or batteries in the case of electric vehicles).

18.2. Protection against sparks

Protect vulnerable equipment and paintwork from any leaping of sparks by the use of fire-resistant covers.

18.3. Protection from heat

Components at risk of being damaged by either heat or flame produced by welding should be protected by using fire resistant covers or screens, or else by removing them.

Components or parts of components that could be damaged by heat conduction should be protected with a protective compound.

18.4. Precautions to be taken on petrol or diesel vehicles

Never leave a fuel tank or circuit unclosed.

Never carry out a welding operation in proximity to inflammable fluid conduits or containers, even if they are empty(fuels, fuel additives, brake fluids, power steering or suspension fluids).

Depending on the closeness of these elements, protect them from heat and from sparks by using protective screens, or otherwise by removing them.

18.5. Precautions for fuel cell electric vehicles

Never leave hydrogen carrying components unclosed.

Never weld within 1 m of flammable hydrogen-carrying components, even if they are drained (fuel cells, hydrogen supply pipes, hydrogen storage systems, hydrogen filling receptacle flaps).

Depending on the closeness of these elements, protect them from heat and from sparks by using protective screens, or otherwise by removing them.

19. Air conditioning circuit

19.1. Safety instructions

ESSENTIAL : Always observe the general precautions.

Wear gloves and protective goggles to avoid the risk of frostbite.

Do not handle the refrigerant near a flame or very hot object (e.g. cigarette) to avoid any risk of the emission of toxic vapours.

Work in a ventilated area.

Handle used compressor lubricating oil with care as it can contain acids.

ESSENTIAL : The compressor lubricant is extremely hygroscopic, use new fluid for any operation.

CAUTION : Never switch on the air conditioning system if the refrigerant circuit is drained. Do not remove the compressor filler plug when the circuit is full.

19.2. Precautions to be taken when opening the circuit

Plug all of the ducts quickly to prevent the entry of moisture ; Using the set of plugs (-)1701-HZ.

New parts should be at ambient temperature before unpacking to avoid condensation.

The plugs in the component unions must be removed at the last moment before fitting.

CAUTION : Avoid fitting parts which are not fitted with plugs.

The filtering and drying cartridge must not remain in the open air for than 5 minutes, even when connected to the air conditioning circuit(risk of saturation with humidity).

If the air conditioning circuit has been in the open air, it is necessary to replace the following components :

• The filtering and drying cartridge (or the condenser if the cartridge is incorporated in it)
• The compressor oil (Drain the air conditioning compressor )

19.3. Precautions to be taken (With air conditioning compressor)

Handle the air conditioning compressors carefully :

• Do not hold the air conditioning compressor by the connectors or the pulley
• Do not place the air conditioning compressor on the pulley
• Avoid impacts on the pulley and connectors (fragile areas)
• Do not put air conditioning compressor oil or other lubricant on the clutch of the compressor

The air conditioning compressors must be stored in enclosed premises, between 5°C et 50°C.

The plastic plugs delivered with the new air conditioning compressor can be reused later.

If an air conditioning compressor is returned to the supplier, pack the compressor correctly to prevent any damage during transport.

CAUTION : When the air conditioning compressor is started for the first time, do not exceed 1500 rpm for the first minute in order to distribute the oil in the air conditioning circuit.

19.4. Special features : Air conditioning compressor without clutch (DENSO)

The "DENSO" compressors without clutch operate continuously while the engine is running.

CAUTION : Do not operate the compressor (and consequently the engine) without refrigerant in the air conditioning circuit and above all under vacuum extraction.

If it is necessary to run the engine without there being any refrigerant in the air conditioning circuit :

• The air conditioning must be switched off
• The speed of the air conditioning compressor must be less than 2000 rpm for a maximum duration of 15 minutes

CAUTION : If these precautions cannot be complied with, replace the air conditioning compressor.

19.5. Precautions to be taken when fitting unions

Use only new seals.

CAUTION : Lubricate the seals with compressor oil.

Tighten the unions to the specified torque using a second spanner whenever possible.

19.6. Electrical checks

Before re-connecting a connector, check :

• The condition of the various contacts (distortion, corrosion ...)
• The presence of the seal
• The presence and condition of the connector locking mechanism

During electrical checks :

• The battery must be fully charged
• Never use a voltage source greater than 12 V
• Never use a test lamp
• Do not produce sparks

Do not disconnect :

• The battery with the engine running
• The air conditioning ECU ; Ignition on

ESSENTIAL : For the refrigerant draining/refilling operation : Consult the approved equipment instructions.

20. Braking circuit

N.B. : The instructions of this section apply to the braking hydraulic circuit as well as to the vacuum assistance circuit.

20.1. Safety and cleanliness recommendations

Instructions to be followed

Obligation / Prohibition	Recommendations
Obligation	Wear lint-free gloves coated with polyurethane on the palm and the end of the fingers
	Wear protective goggles
	No impurity is tolerated in the braking circuit
	The brake fluid is hygroscopic : Use new lubricant after repairs
	Any component removed should be plugged and placed in a clean plastic bag

CAUTION : Non-compliance with the cleanliness requirements can lead to contamination of the circuit and malfunctioning of the braking circuit.

The environment of the work station and the associated equipment must guarantee the absence of contamination of the circuit by :

• Particulate pollution (environment, type of gloves, cloth, tools, etc.)
• Chemical pollution (solvent, lubricant, etc.)
• Moisture or any other element which could damage the quality of the product

20.2. Precautions to be taken when opening the circuit

Instructions to be followed

Obligation / Prohibition	Recommendations
Obligation	Before carrying out any work on the braking circuit, clean all of the unions and hydraulic components
	After uncoupling, immediately plug the unions and hydraulic components with plastic protective plugs to prevent the entry of moisture and impurity. The protective plugs are single-use
	The protective plugs on the unions of the parts must be removed at the last minute before coupling
	The brake fluid is corrosive, clean up any splashes
	During the filling operation, the filler cap must be placed in readiness nearby in a flat, clean area
	The reservoir filter must be put in place immediately at the end of the filling operation, if filling with the filter assembled on the reservoir is not possible
	Handle the servo, master cylinder and reservoir assembly with care and without knocking it
Prohibition	Gripping and handling by the thrust rod, by the gaiter or by the reservoir is prohibited
	Resting on the parts is prohibited
	Any parts which have suffered a knock or damage must not be fitted

CAUTION : Avoid fitting parts which do not have a protective plug.

21. Urea circuit

The urea solution is a colourless, aqueous liquid of pH10 which smells of ammonia.

ESSENTIAL : Never mix the urea solution with a product containing chlorine (risk of explosion).

21.1. Personal protection equipment

ESSENTIAL : For all work on the urea circuit, wear protective goggles and gloves of the painting type (in addition to the work clothing).

ESSENTIAL : When draining the urea circuit, wear a spraying mask of the painting type.

ESSENTIAL : Work in a ventilated area.

21.2. Instructions to be applied in the event of contact with the urea solution

ESSENTIAL : In case of contact with the skin : Remove the contaminated clothing, wash the skin carefully with soap and water, rinse thoroughly.

ESSENTIAL : In case of contact with the eyes : Wash with plenty of soft water for 15 minutes, eyelids apart.

ESSENTIAL : Ingestion : Rinse your mouth with water. Do not vomit.

21.3. Precaution to be taken before opening the urea circuit (excluding the urea reservoir filling - draining operation)

ESSENTIAL : Check that the urea circuit is not pressurised; using the diagnostic tool.

ESSENTIAL : Drop the pressure using the diagnostic tool.

ESSENTIAL : When working on the urea circuit, protect all of the surrounding disconnected connectors from any risk of urea solution leakage.

21.4. Draining the urea reservoir

ESSENTIAL : When draining the urea circuit, wear a spraying mask of the painting type.

ESSENTIAL : Never mix the urea solution with a product containing chlorine (risk of explosion).

CAUTION : The urea solution must not be mixed with other fluids to ensure that it can be recycled.