Renault Koleos Service Repair Manual: High pressure pipe between pump and rail: Removal - Refitting

Renault Koleos Service Repair Manual / Engine and peripherals / Diesel injection / High pressure pipe between pump and rail: Removal - Refitting

M9R

Diesel injection

IMPORTANT Consult the safety and cleanliness advice and operation recommendations before carrying out any repair.

 

IMPORTANT Use the diagnostic tool before any operation is carried out on the injection circuit to check:
  • that the rail is not under pressure,
  • that the fuel temperature is not too high.

Working on the circuit with the engine running is strictly forbidden.

 

IMPORTANT During this operation, be sure to:
  • refrain from smoking or bringing red hot objects close to the working area,
  • be careful of fuel splashes when disconnecting the union.

 

WARNING To avoid any corrosion or damage, protect the areas on which fuel is likely to run.

REMOVAL

I - REMOVAL PREPARATION OPERATION

  • Remove:
    • the engine cover,
    • the clips from the air intake sleeve,
    • the air intake sleeve from the air filter unit.
  • Disconnect the battery .

Diesel injection

  • Rotate the intercooler air inlet pipe clip (1) on the turbocharger.

Diesel injection

  • Remove the bolt (2) from the intercooler air inlet pipe from the fuel pipe support.
  • Move the intercooler air inlet pipe to one side.

Diesel injection

  • Remove:
    • the protector plate (3) from the injector rail protector,
    • the injector rail protector.

Diesel injection

  • Unclip:
    • the control pipe from the turbocharger pressure regulator valve at (4) ,
    • the wiring at (5) .
  • Remove the mounting (6) .

Diesel injection

  • Disconnect:
    • the fuel temperature sensor connector (7) ,
    • the connector (8) from the camshaft position sensor.

Diesel injection

  • Disconnect the brake servo pipe (9) from the non-return valve.

Diesel injection

  • Unclip the injector wiring from the oil separator at (10) .
  • Remove:
    • the wiring channel bolt (11) ,
    • the wiring (12) .

Diesel injection

  • Remove the bolt (13) from the high pressure pipe between the high pressure pump and the injector rail.
  • Move aside the wiring.

Diesel injection

  • Remove the oil vapour rebreathing pipe (14) from the oil separator.

Diesel injection

  • Loosen the air outlet pipe clips (15) of the air filter unit.
  • Disconnect the air outlet pipe from the air filter unit.
  • Unclip:
    • the brake servo pipe (16) ,
    • the turbocharger cooling pipe (17) ,
    • the high pressure pipe nut protector (18) on the high pressure pump.
  • Move aside the high pressure pipe nut protector.

II - OPERATION FOR REMOVAL OF PART CONCERNED

Diesel injection

  • Undo:
    • the nut (19) from the high pressure pipe on the injector rail using a 19 mm long lever spanner, part number 77 11 223 721,
    • the nut (20) from the high pressure pipe on the high pressure pump using a 17 mm long lever spanner, part number 77 11 223 720.
  • Mark the position of the pad (21) between the high pressure pipe and the lower cover.

Diesel injection

Note: Do not allow any diesel fuel to enter the engine via the rocker cover opening during this operation.
  • Remove:
    • the high pressure pipe bolt (22) on the lower cover.
    • the high pressure pipe between the high pressure pump and the injector rail.
  • Insert the blanking plugs.

REFITTING

I - REFITTING PREPARATION OPERATION

  • Always replace:
    • the high pressure pipes between the high pressure pump and the injector rail,
    • the intercooler air inlet pipe seal.
WARNING Before fitting a new high pressure pipe, lightly lubricate the nut threads with the oil from the applicator provided in the new parts kit.

Be careful not to allow oil into the high pressure pipe.

Do not lubricate high pressure pipes supplied without an applicator, as these high pressure pipes are self-lubricating.

 

WARNING Do not remove the blanking plugs from each component until the last moment.

Also, do not remove the components from their packaging until they are to be fitted to the vehicle.

II - REFITTING OPERATION FOR PART CONCERNED

  • Remove the blanking plugs.
  • Position:
    • the high pressure pipe olive in the injector rail taper.
    • the high pressure pipe olive in the high pressure pump outlet taper.
  • Correctly position the pad between the high pressure pipe and the rocker cover.
  • Fit the high pressure pipe nuts without tightening them, starting with the nut at the injector rail end.
  • Torque tighten:
    • the high pressure pipe nut on the high pressure pump (32 N.m) using a 17mm long lever spanner, part number 77 11 223 720,
    • the high pressure pipe nut on the injector rail (32 N.m) using a 19mm long lever spanner, part number 77 11 223 721.
  • Refit the high pressure pipe bolts between the high pressure pump and the injector rail.
  • Torque tighten the high pressure pipe bolts between the high pressure pump and the injector rail (10 N.m)

III - FINAL OPERATION

  • Clip:
    • the high pressure pipe nut protector on the high pressure pump,
    • the turbocharger cooling pipe,
    • the brake servo pipe .
  • Connect the air filter unit air outlet pipe to the air filter unit and to the turbocharger.
  • Torque tighten the air filter unit air outlet pipe clips (5 N.m) using the tool (Mot. 1608).
  • Connect the oil vapour rebreathing pipe to the oil separator.
  • Fit the wiring channel.
  • Refit the wiring channel bolt.
  • Torque tighten the wiring channel bolt (8 N.m).
  • Clip the injector wiring onto the oil separator.
  • Connect:
    • the camshaft position sensor connector,
    • the fuel temperature sensor connector,
    • the brake servo pipe to the non-return valve.
  • Refit the support.
  • Clip:
    • the wiring,
    • the turbocharger pressure regulator valve control pipe.
  • Refit the injector rail protector.

Diesel injection

  • Remove the intercooler air inlet pipe seal using a tweezers.

Diesel injection

Note: Check that the seal (23) on the intercooler air inlet pipe is fitted the correct way round.
  • Refit:
    • the new seal of the intercooler air inlet pipe,
    • the protector plate on the injector rail protector.
  • Turn the intercooler air inlet pipe to refit the clip in its housing.
  • Clip the intercooler air inlet pipe onto the turbocharger.
  • Refit the intercooler air inlet pipe bolt on the fuel pipe support.
  • Torque tighten the intercooler air inlet pipe bolt (8 N.m).
  • Connect the battery .
  • Prime the fuel circuit using the manual priming pump.
  • Refit:
    • the air intake sleeve on the air filter unit,
    • the clips of the air intake sleeve,
    • the engine cover.
    Injector rail protector: Removal - Refitting

    High pressure pipe between rail and injector: Removal - Refitting

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