Renault Koleos Service Repair Manual: Diesel injector: 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.

 

WARNING Dismantling the interior of the high pressure pump and the injectors is prohibited.

REMOVAL

I - REMOVAL PREPARATION OPERATION

  • Remove the front engine cover.
  • 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 aside the intercooler air inlet pipe.

Diesel injection

  • Remove:
    • the protector plate (3) from the injector rail protector
    • the injector rail protector
    • the oil separator
    • the diesel injector fuel return rail
    • the high pressure pipes between the rail and the injectors
  • Disconnect the injector connectors.

II - OPERATION FOR REMOVAL OF PART CONCERNED

Diesel injection

Note: Cylinder No. 1 is located on the timing end.
  • Remove:
    • the injector clamp bolts (4) ,
    • the injector clamps.
    • the injectors one by one, noting the IMA codes for each injector,
    • the injector copper sealing washer,
    • the seal between the diesel injector and the diesel injector fuel return rail from each injector.

REFITTING

I - REFITTING PREPARATION OPERATION

Diesel injection

WARNING It is strictly forbidden to clean the injectors with:
  • a wire brush,
  • an emery cloth,
  • an ultrasonic cleaner.

 

Note: Use new cloths, part no. 77 11 211 707 soaked in new degreaser to clean:
  • the injector holes,
  • the injector covers,
  • the injector clamps.

 

Note: Use a new cloth to dry components that have been cleaned.
  • Always replace:
    • the copper sealing washer,
    • the seal between the diesel injector and the diesel injector fuel return rail,
    • 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.

  • Clean the diesel injector.

II - REFITTING OPERATION FOR PART CONCERNED

  • Refit:
    • the seal between the diesel injector and the diesel injector fuel return rail on each injector,
    • the new copper sealing washer on the injectors,
    • the copper sealing washer - injector assembly,
    • the injector clamps.
    • the injector clamp bolts.
  • Torque tighten the injector clamp bolts (35 N.m).

III - FINAL OPERATION.

  • Connect the connectors for injector numbers 2, 3 and 4.
  • Refit:
    • the high pressure pipes between the rail and the injectors
    • the diesel injector fuel return rail
    • the oil separator
    • the injector rail protector

Diesel injection

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

Diesel injection

Note: Check whether the intercooler air inlet pipe seal (5) is correctly positioned.
  • 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,
    • Diagnostic tool thick, to the alternator rotor.
  • Enter the injector codes in the diesel injection computer in accordance with command scenario SC002 and reinitialise the program using command scenario SC036 replacing the diesel injector.
  • Prime the circuit using the manual priming pump.
  • Refit the engine cover.
    Fuel temperature sensor: Removal - Refitting

    Antipollution

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