Renault Koleos Service Repair Manual: Injector 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 intercooler air inlet pipe bolt (2) 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
    • the air inlet flap
    • the turbocharger pressure sensor unit
    • the exhaust gas recirculation solenoid valve
    • the oil separator
    • the diesel injector fuel return rail
    • the high pressure pipes between the rail and the injectors
    • the high pressure pipes between the high pressure pump and the injector rail

Diesel injection

Note: Do not allow any diesel fuel to enter the engine via the rocker cover opening during this operation.
  • Disconnect the diesel return pipe quick-release union (4) from the injector rail.
  • Insert the blanking plugs.

Diesel injection

  • Disconnect:
    • the pressure regulator connector (5) on the injector rail,
    • the connector (6) from the rail pressure sensor,
    • the heater plug connectors (7) .
  • Move the fuel pipes aside.

II - OPERATION FOR REMOVAL OF PART CONCERNED

Diesel injection

  • Remove:
    • the injector rail bolts (8) ,
    • the injector rail,
    • the injector rail seal.

REFITTING

I - REFITTING PREPARATION OPERATION

  • Always replace:
    • the injector rail seal,
    • the intercooler air inlet pipe seal.
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.
  • Refit:
    • the injector rail along with its seal,
    • the injector rail bolts.
  • Torque tighten the injector rail bolts (25 N.m).

III - FINAL OPERATION

  • Connect:
    • the heater plug connectors ,
    • the rail pressure sensor connector,
    • the pressure regulator connector on the injector rail,
    • the diesel return pipe quick-release union on the injector rail.
  • Refit:
    • the high pressure pipes between the high pressure pump and the injector rail
    • the high pressure pipes between the rail and the injectors
    • the diesel injector fuel return rail
    • the oil separator
    • the exhaust gas recirculation solenoid valve
    • the turbocharger pressure sensor unit
    • the air inlet flap
    • the injector rail protector.

Diesel injection

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

Diesel injection

Note: Check that the seal (9) 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).
  • Prime the fuel circuit using the manual priming pump.
  • Connect the battery .
  • Refit:
    • the air intake sleeve on the air filter unit.
    • the clips of the air intake sleeve,
    • the engine cover.
    High pressure pipe between rail and injector: Removal - Refitting

    Rail pressure sensor: Removal - Refitting

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