Renaul Clio PDF

T.N.
3470A
XB07
Basic manual: Workshop Repair Manual 337
Special features of Clios fitted with K9K

700 engines
This note cancels and replaces Technical Note 3458A
77 11 301 382 JUNE 2001 EDITION ANGLAISE
"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes introduced by the manufacturer reference numbering system is forbidden without the prior written authority of Renault.
in the production of the various component units and accessories from which his
vehicles are constructed."
RENAULT 2001
Contents
Page Page
07 VALUES AND SETTINGS 13 DIESEL EQUIPMENT

Accessories belt 07-1 Cleanliness 13-1
Tightening the cylinder head 07-4 Special features 13-4
Location of components 13-11
Accelerator pedal potentiometer 13-15
Technical specifications 13-16
10 ENGINE AND PERIPHERALS Diesel filter 13-18
High pressure pump 13-19
Sump 10-1 Flow actuator 13-23
Oil pressure 10-5 Diesel temperature sensor 13-26
Identification 10-6 Venturi 13-28
Engine and gearbox assembly 10-7 Injector rail 13-30
Pressure sensor 13-35
Injectors 13-36
High pressure pipes 13-40
11 TOP AND FRONT OF ENGINE Computer 13-44
Injection warning light 13-49
Timing belt 11-1 Immobiliser function 13-51
Cylinder head gasket 11-13 Idle speed adjustment 13-52
Injection/air conditioning program 13-54
Pre-postheating control 13-56
Heater plugs 13-57
12 TURBOCHARGING FUEL MIXTURE Centralised coolant temperature
management (GCTE) 13-58
Fuel mixture Thermoplungers 13-59
Air intake 12-1
Air filter 12-2
Manifold 12-3
EGR unit 12-5 14 ANTI-POLLUTION
Turbocharging Oil vapour rebreathing 14-1
Turbocharger 12-7 Exhaust gas recirculation
Pressure adjustment 12-10 EGR 14-2
16 STARTING - CHARGING
Starter motor 16-1
Alternator 16-3
Page
19 COOLING - EXHAUST - FUEL TANK

Cooling
Radiator 19-1
Filling - bleeding 19-2
Diagram 19-3
Exhaust
Exhaust system 19-4
Catalytic converter 19-5
Engine mounting
Suspended engine mounting 19-7
VALUES AND 107
SETTINGS
07
WITHOUT AIR
CONDITIONING
Accessories belt
SPECIAL TOOLING REQUIRED
Mot. 1505 Belt tension setting tool
REMOVAL REFITTING
Put the car on a two-post lift. After refitting the accessories belt make sure to turn
the engine over twice fully to position the belt correctly.
Disconnect the battery.
Remove:
The belt tension is set using tool Mot. 1638 to tighten
the front right wheel,
the nut (1), (when the two tensioner mounting bolts
the front right wheel arch,
have been unscrewed).
the engine undertray,
the accessories belt by unscrewing the tension wheel
support bolts,
the grille.
NOTE: the accessories belt has five Vs, while the

alternator pulleys, assisted steering pump and the
crankshaft have six. It is therefore imperative that
you ensure, when fitting the belt, that tooth "E"
remains free.
07-1
VALUES AND SETTINGS
07
WITHOUT AIR
CONDITIONING
Accessories belt
The tension value is 233 5 Hertz.
A crankshaft
B power steering pump
C alternator
T tensioner
point for checking belt tension
For all other operations, refitting is the reverse of

removal.
07-2
VALUES AND SETTINGS
07
WITH AIR
CONDITIONING
Accessories belt
REMOVAL NOTE: the accessories belt has five Vs whilst the

air conditioning compressor pulley, power
Put the car on a two-post lift. steering pulley and the crankshaft pulley all have
six; when fitting the belt, therefore, ensure that
Disconnect the battery. tooth "E" is kept free.
Remove:
the accessories belt by swivelling the automatic
tension wheel to the right using a 16 mm wrench.
REFITTING
After refitting the accessories belt make sure to turn

the engine over twice fully to position the belt correctly.
For all other operations, refitting is the reverse of

removal.
07-3
VALUES AND SETTINGS
Tightening the cylinder head 07
CYLINDER HEAD TIGHTENING PROCEDURE
REMINDER: Use a syringe to remove any oil which

may have entered the cylinder head mounting bolt
holes to achieve correct tightening of the bolts.
All bolts must always be changed after removal.
Do not oil the new bolts.
All bolts must be tightened to a torque of 2.5 daN.m in

the order shown below.
Check that all the bolts are tightened to 2.5 daN.m,

then angle tighten (bolt by bolt in the order shown) by
255 10.
Do not retighten the cylinder head bolts after

performing this procedure.
07-4
210
ENGINE AND PERIPHERALS
Sump 10
Mot.1233-01 Threaded rods for lowering the sub-

frame
EQUIPMENT REQUIRED
8 Torx socket
Torque wrench
SPECIAL NOTES FOR VEHICLES FITTED WITH A

TIGHTENING TORQUES (in daN.m and/or) DRIVER'S AIRBAG
Sub-frame front mounting bolts 6.2
Sub-frame rear mounting bolts 10.5 WARNING:
Sump bolts 1.4 In order to eliminate any risk of damaging the
steering wheel rotary switch, observe the
Steering shaft yoke mounting bolts 3 recommendations below:
Engine tie bar bolts 6.2 Before the steering column and the steering
rack are disconected, the steering wheel
Wheel bolts 9 MUST be immobilised with the wheels straight
for the duration of the operation using a
REMOVAL steering wheel locking tool.
If there is any doubt regarding the correct
Put the car on a two-post lift. alignment of the rotary switch the steering
wheel must be removed so that the alignment
Disconnect the battery. procedure described in section 88 Air bag can
be applied.
Drain the engine.
REMINDER: in this case, only qualified
Remove: personnel who have received training may carry
the front wheels, out the operation.
the front right hand mudguard,
the front bumper mountings under the sub-frame,
the nut and the eccentric bolt of the steering shaft Remove:
yoke, after pushing back the guard. the lower ball joint mountings as well as the steering
ball joints,
10-1
Sump 10
the tie-rods between the sub-frame and body (3),
the gearbox control (on the gearbox side only),

the engine tie-bar bolt (1) and slacken the bolt
without removing it (2).
10-2
Sump 10
Remove the sub-frame mounting bolts, inserting the Mot. 1233-01 threaded rods as
you go.
Lower the sub-frame gradually using the Mot. 1233-01 threaded rods until dimensions
X1 = 11 cm are achieved.
Remove:
oil level sensor,
the oil level gauge guide on the sump,
the sump.
10-3
Sump 10
Apply RHODORSEAL 5661 at (A) (on either side of Refit the sump with a new seal by pretightening the
bearing No. 1), and at (B) on the crankshaft closure bolts to a torque of 0.8 daN.m, then tighten them (in a
panel. spiral) to a torque of 1.4 daN.m.
Top up the engine oil.
Proceed with refitting in the reverse order to removal
Take care to fit the oil anti-emulsion plate in the sump.
10-4
Oil pressure 10
Mot. 836-05 Oil pressure gauge kit

EQUIPMENT REQUIRED
22 mm long socket or pipe spanner
The oil pressure should be checked when the engine

is warm (approximately 80C).
Contents of kit Mot. 836-05.
USE
C+E+F
Connect the pressure gauge in place of the oil

pressure switch.
Tighten the oil pressure switch to a torque of

2.5 daN.m.
10-5
Identification 10
Cubic Bore Stroke Compression

Vehicle type Engine Gearbox
capacity (cc) (mm) (mm) ratio
XB07 K9K JB3 1461 76 80.5 18.25/1
Manual to consult: Mot. K9K
10-6
Engine and gearbox assembly 10
Mot.1040-01 Support cradle for removal/

refitting engine and gearbox unit
Mot. 1159 Engine support tool
Mot.1202-01
Pliers for large hose clips
Mot.1202-02
Mot. 1448 Remote operation pliers for hose
clip
Mot. 1453 Engine mounting support
Mot.1233-01 Rods for positioning the sub-
frame on the body
EQUIPMENT REQUIRED
Load positioner
Drain:
TIGHTENING TORQUES (in daNm and/or ) the refrigerant circuit (if fitted) using filling equipment,
the gearbox and the engine (if necessary),
Sub-frame front mounting bolts 6.2
the cooling circuit through the bottom hose of the
Sub-frame rear mounting bolts 10.5 radiator.
Mounting bolt for front right suspended
mounting cover to engine 3.7
Remove:
Mounting nut for rubber engine the front wheels as well as the right and left mud
mounting pad on front left-hand side flaps,
member support 6.2 the right and left brake calipers (as well as the ABS
sensors, if fitted) and secure them to the suspension
Shock absorber base bolts 18 springs,
Steering shaft yoke mounting bolts 2.1 the right and left base of the shock absorber
mountings,
Wheel bolts 9 the front fog light connectors,
the radiator grille,
Brake caliper mounting bolts 4
the front bumper,
the engine cover,
the air intake sleeve,
REMOVAL the upper cooling radiator mountings then attach the
radiator to the engine.
Put the car on a two-post lift.
Secure the vehicle to a lift with a strap to prevent the

body from overbalancing when the engine-gearbox
assembly is removed.
(See Technical Note 2988A for the procedure for

fitting a strap).
Remove the battery and the engine undertray.
10-7
the computer from its support at (A), Remove:
the battery tray (B). the clutch cable,
connector (A) from the accelerator pedal position
potentiometer.
Unclip the diesel filter from its support and disconnect

the diesel supply and return pipes from the filter and
the valve timing cover.
10-8
Remove the power assisted steering reservoir from its Remove:
support. the earth strap on the gearbox,
the nut and the eccentric bolt of the steering shaft
Remove: yoke, after pushing back the guard.
brake servo vacuum pipe,
the expansion bottle,
the connections between the passenger SPECIAL NOTES FOR VEHICLES FITTED WITH A
compartment wiring loom and the fuse box. DRIVER'S AIR BAG
WARNING:
In order to eliminate any risk of damaging the
steering wheel rotary switch, observe the
recommendations below:
Before the steering column and the steering
rack are disconnected, the steering wheel
MUST be immobilised with the wheels straight
for the duration of the operation using a
steering wheel locking tool.
If there is any doubt regarding the correct
alignment of the rotary switch the steering
wheel must be removed so that the alignment
procedure described in section 88 Air bag can
be applied.
REMINDER: in this case, only qualified

personnel who have received training may carry
out the operation.
Disconnect the hoses from the heater radiator.
Remove:
the exhaust bracket then the centre tube,
10-9
the gearbox control, Fit tool Mot. 1453 with the retaining straps.
the tie-rods (4).
Remove the engine suspension mounting-movement

limiter assembly.
Insert a wooden block between the gearbox and the

sub-frame.
Slacken the nut (1), then tap it with a copper hammer

to release the suspended engine mounting stud.
10-10
Fit tool Mot. 1159 between the sub-frame and the Lower the lift until the tool touches the ground.
cylinder block.
Remove the sub-frame mounting bolts and take out
Fit a wooden block between the multifunction support the engine and transmission assembly by lifting the
and the sub-frame. body.
NOTE: when undertaking work that requires the

engine and gearbox assembly to be removed from the
sub-frame, take care to note the engine position on the
sub-frame by marking the position of tool Mot. 1159
and the gearbox in relation to the sub-frame.
REFITTING
The alignment of the sub-frame with the body will be

made easier by positioning two threaded rods
Mot. 1233-01 in the two front mountings of the sub-
frame on the body.
Tighten the sub-frame mounting bolts to a torque of:

6.2 daN.m at the front,
10.5 daN.m at the rear.
Proceed with refitting in the reverse order to removal
Apply Loctite FRENBLOC to the brake calliper

Fit tool Mot. 1040-01 under the engine sub-frame. mounting bolts before fitting and tighten them to the
correct torque.
Press the brake pedal several times to bring the

pistons into contact with the brake pads.
Perform the following operations:

fill the engine and gearbox with oil (if necessary),
fill and bleed the cooling circuit (see section
19 "Filling - bleeding"),
fill the power assisted steering circuit (if fitted),
fill the refrigerant circuit (if fitted) using filling
equipment.
10-11
111FRONT
ENGINE TOP AND
Timing belt 11
Mot. 1430 Camshaft pulley timing pin

Mot. 1453 Adjustable engine support tool
Mot. 1489 Crankshaft TDC timing pin
Mot. 1505 Belt tension setting tool Hz
measurement
the accessories belt (see section 07 Accessories

TIGHTENING TORQUES (in daNm and/or ) belt tension),
Top dead centre cap 2
Position the engine support tool Mot. 1453 with the
Cylinder head suspended mounting retaining straps.
support 2.1
Timing tension wheel bolt 2.5
Crankshaft accessories pulley bolt 2+13015
Wheel bolt 9
Right-hand suspended mounting support
bolt 6.2
Suspended engine mounting support
cover nut 3.7
REMOVAL

NOTE: when doing this make sure that the feet of the
engine support tool are positioned on the rigid sections
of the wings.
Remove:
the engine undertray as well as the front right
mudguard,
11-1
ENGINE TOP AND FRONT
Timing belt 11
Remove:
the right-hand suspended
mounting support and cover,
the upper timing cover by
unclipping the two tabs (1),
the pulley-pump position sensor

(4),
the fuel pipes from the lower
timing cover,
the lower timing cover by
unclipping the three tabs (2) and
pulling out the plastic bolt (3).
Lift up the engine to take out the
valve timing cover.
11-2
Timing belt 11
Remove:
the cylinder head suspended
mounting support,
the TDC pin cap.
11-3
Timing belt 11
Positioning the belt at the timing point. Turn the engine clockwise (timing side) until the
crankshaft comes to rest on the TDC pin Mot. 1489.
Position the hole (4) in the camshaft pulley almost
opposite the hole (5) in the cylinder head.
The pin Mot. 1430 must engage in the camshaft pulley

and cylinder head holes.
Screw in the TDC pin Mot. 1489.
Remove tools Mot. 1430 and Mot. 1489.
11-4
Timing belt 11
Remove the crankshaft accessories
pulley by blocking the flywheel using
a screwdriver.
Slacken the timing belt by loosening

the bolt (6) of the tension wheel,
then remove the timing belt.
11-5
Timing belt 11
REFITTING
IMPORTANT: it is essential to
degrease the end of the
crankshaft, the bore of the
crankshaft sprocket and the
bearing faces of the accessories
pulley to prevent any slip
between the timing and the
crankshaft which would risk
destroying the engine.
Ensure that the peg (7) of the

tension wheel is correctly
positioned in the groove (8).
Engage the TDC pin Mot. 1430 in

the camshaft and cylinder head
pulley holes.
Check that:
the mark on the high pressure
pump pulley (9) is opposite the
bolt head (10),
the crankshaft is resting on the
Top Dead Centre pin Mot. 1489
(the crankshaft groove (11) must
be facing upwards).
11-6
Timing belt 11
Fit the timing belt by aligning the belt markings with Tighten the tension wheel bolt to a torque of
those of the camshaft and the high pressure pump. 2.5 daNm.
Refit the crankshaft accessories pulley, tightening the

bolt to a torque of 2 daNm, then angle tighten to
130 15 (crankshaft resting on the Top Dead Centre
pin).
Remove the Top Dead Centre pin Mot. 1489 and the
camshaft pulley timing pin Mot. 1430
Turn the crankshaft two full turns in a clockwise

direction (timing side). Just before the hole (4) of the
camshaft pulley is opposite the cylinder head hole (5),
screw pin Mot. 1489 into the cylinder block. And move
the crankshaft slowly and without jolting it until it is
resting on the pin.
Using a 6 mm Allen key, move the movable index (1)

of the tension wheel into the position shown below, by
turning the key anticlockwise.
11-7
Timing belt 11
Check that the pin Mot. 1430 is properly engaged in Loosen the tension wheel bolt by a maximum of one
the camshaft pulley and cylinder head holes. turn while holding it using a 6 mm, Allen key, then
gradually bring the movable index (1) (by turning the
key clockwise) to the centre of the timing window (2)
and tighten the nut to a torque of 2.5 daNm.
Remove the Top Dead Centre pin Mot. 1489 and the
camshaft pulley timing pin Mot. 1430
Refit the cap of the Top Dead Centre pin, applying

RHODORSEAL 5661 to the thread and tightening to a
torque of 2 daNm.
11-8
Timing belt 11
Refit:
the cylinder head mounting,
tightening the bolts to a torque of
2.1 daNm,
11-9
Timing belt 11
the lower timing cover by
positioning the tab (1) into the
hole (2) on the inner timing cover,
11-10
Timing belt 11
the upper timing cover,
the accessories belt (see section 07 "Accessories belt tension"),
11-11
Timing belt 11
the right-hand suspended mounting support and
cover, tightening the bolts to a torque of 6.2 daNm,
Refitting is the reverse of removal.
11-12
ENGINE TOP AND111FRONT
Cylinder head gasket 11
Mot. 1159 Lower engine support

Mot.1202-01
Pliers for large hose clips
Mot.1202-02
Mot. 1505 Belt tension setting tool Hz
measurement
Mot. 1430 Camshaft timing pin
Mot. 1448 Remote operation pliers for hose
clip
Mot. 1453 Adjustable engine support tool
Mot. 1489 Crankshaft TDC pin
EQUIPMENT REQUIRED
Workshop crane
Load positioner
14 Torx socket
High pressure pipe wrench, for example, Facom
"DM19"
wrench
Torque wrench
Angular torque wrench
Cylinder head testing tool
Remove the timing belt (see the method described in

TIGHTENING TORQUES (in daNm and/or ) section 11 "Timing belt").
Injector high pressure pipes 4
Drain the cooling circuit through the lower radiator
High pressure pipes on the rail 4 hose.
Cylinder head cover bolts 1
NOTE: it is essential to fit the cleanliness plugs
Cylinder head bolts 2.5+25510
each time a diesel pipe is removed. Make sure that
Crankshaft pulley bolts 2+13015 you follow the safety instructions.
Refer to section 13 "Diesel-cleanliness
Gear tensioner bolts 2.5
equipment".
Right-hand suspended mounting support
bolt 6.2
Cylinder head suspended mounting bolts 2.1
TDC pin hole bolt 2
Wheel bolts 9
IMPORTANT: before carrying out any work, connect

the After-Sales diagnostic tool, set up communication
with the injection computer and check that the injection
rail is not under pressure.
Take note of the fuel temperature.
Order the special high pressure injection circuit plug

kit.
11-13
Remove the connectors from the sensors:
air intake temperature before turbocharger,
air intake temperature after turbocharger,
turbocharging pressure,
EGR valve control
the air filter unit.
Disconnect:
the fuel temperature sensor (1),
the connector from the low pressure flow adjuster (2).
11-14
Disconnect:
the injector connectors (A),
the pre-heater plug connectors (B),
11-15
the support from the wiring and the diesel fuel return the two struts (A),
pipe (1), the oxidation catalyser (B),
the oil fuel return pipe (C),
the hoses from the plenum chamber,

the timing gear tension wheel,
the coolant temperature sensor from the plenum
the accessories belt tensioner wheel,
chamber,
the inner timing housing,
the cylinder head cover,
11-16
NOTE: when removing and refitting the high the brake assistance pipe from the vacuum pump,
pressure pipes, a precise procedure must be the air filter support bracket (A),
followed to ensure the system operates correctly.
Refer to the method in section 13 "High pressure
pipes".
Remove:
the four high pressure pipes between the rail and the
injectors,
the fuel supply pipe from the rail,
the diesel pressure sensor connector from the rail in
(1),
fit plugs to maintain cleanness,
cylinder head bolts,

the cylinder head.
11-17
CLEANING CHECKING THE GASKET FACE
It is very important not to scratch the gasket faces Check for mating surface bow using a ruler and a set
of any aluminium component. of shims.
Maximum deformation: 0.05 mm.

Use the Dcapjoint product to remove the part of the
seal that is stuck down. No regrinding of the cylinder head is permitted.
Apply the product to the part to be cleaned, wait Test the cylinder head to detect possible cracks using
approximately 10 minutes, then remove it using a the cylinder head test tools (a container and a kit for
wooden spatula. the particular cylinder head, plug, sealing plate,
blanking plate). The approval number of the cylinder
head test container is 664000
Wear gloves whilst carrying out this operation.
REFITTING (special notes)

Please use great care during this operation, to
prevent any foreign bodies from being introduced Fit the cylinder head gasket. This is centred by two
into the oil galleries (ducts located in the cylinder dowels.
block and in the cylinder head).
Bring the pistons to mid-stroke position to prevent
Using a syringe, extract any oil which may have them from coming into contact with the valves as the
entered the cylinder head mounting holes. This is cylinder head is tightened.
necessary in order to obtain the correct tightening of
the bolts. Centre the cylinder head on the dowels.
Protect the oil outlet duct in order to prevent any Lubricate the threads and under the heads of the
foreign bodies from entering the oilways in the cylinder mounting bolts.
head.
Tighten the cylinder head using a wrench (see section
Failure to take this advice could lead to the 07 "Tightening the cylinder head").
blocking of the oilways, resulting in a rapid
deterioration of the camshaft. Refit using the same procedure as for removal in
reverse.
The cylinder head tightening studs must be replaced
each time they are removed and should not be oiled Refit the timing belt (see method described in section
before being fitted. 11 "Timing belt ").
Fill and bleed the cooling circuit, (see section 19

"Filling and Bleeding").
Consult section 13, "Fuel filter" for information on

how to reprime the diesel circuit.
Place the cylinder on the two centring dowels.
11-18
ADJUSTMENT OF VALVE ROCKERS (IF NECESSARY)
Adjustment values (in mm) cold engine:

inlet 0.20
exhaust 0.40
Open exhaust valve method:

Bring the exhaust valve of cylinder n 1 to the fully open position, then adjust the inlet valve clearance for cylinder
n 3 and the exhaust valve clearance for cylinder n 4.
Follow the same method for the other cylinders, in the order shown by the table.
Exhaust valve to be fully opened Inlet valve to be adjusted Exhaust valve to be adjusted
11-19
112
FUEL MIXTURE
Air intake 12
AIR INTAKE CIRCUIT DIAGRAM
1 Air inlet pipe

2 Air filter unit
3 Turbocharger
4 EGR unit
5 Air inlet metallic tube
A Air inlet
B Towards the inlet distributor
12-1
FUEL MIXTURE
Air filter 12
REPLACING THE FILTER ELEMENT
Remove the engine cover.
Disconnect the air aspiration sleeve (1) from the air

filter unit.
Release the electrical harness from the air filter unit.
Remove the four mounting bolts (2) from the air filter
unit.
Open the cover (3) of the air filter unit then remove the
filter element.
12-2
FUEL MIXTURE
Inlet manifold 12
TIGHTENING TORQUES (in daN.m)
Exhaust manifold mounting nuts 2.6

Exhaust cylinder head studs 0.9
Turbo mounting nuts on the exhaust
manifold. 2.6
EGR unit mounting bolts 2.1
REMOVAL
Remove the turbocharger (see relevant procedure).
Loosen the two clamps on the EGR metallic tube (1).
Remove:
the EGR tube,
the two mounting bolts (2) from the EGR unit,
the EGR unit,
the eight mounting nuts (3) from the manifold then
remove it.
12-3
FUEL MIXTURE
Inlet manifold 12
REFITTING
Replace the manifold gasket.
Refit the manifold then tighten the nuts, making sure to maintain the torque and order of tightening.
Fit the EGR unit and its new tube with two new clamps.
Tighten the new clamps using pliers Mot. 1567.
Tighten the two EGR unit mounting bolts on the cylinder head.
It is essential to replace all the disconnected air inlet plastic pipes.
For other operations, refitting is the reverse of removal.
12-4
FUEL MIXTURE
EGR unit 12
Disconnect:
TIGHTENING TORQUES (in daN.m) the EGR solenoid valve (4),
the downstream air temperature sensor (5),
EGR unit mounting bolts 2.1
the rubber tube (6) from the turbocharging pressure
Air inlet metallic tube mounting bolts 2.1 adjustment valve on the air duct.
Lifting ring mounting bolts (timing side) 2.1
Remove:
EGR solenoid valve heat shield mounting the air duct (7) between the EGR unit and the
bolts 1.2 turbocharger,
the lifting ring (8),
the mounting bolt from the air inlet metallic tube (9)
then pull it to remove it.
REMOVAL
Remove:
the engine cover,
the air filter unit, to do this:
Disconnect:
the air aspiration sleeve from the air filter unit,
the connector from the upstream air temperature
sensor (1).
Release, then disconnect the turbocharging pressure

sensor (2) from the air filter unit.
Loosen the air aspiration pipe clamp on the air filter

unit.
Remove the air filter unit (3).
12-5
FUEL MIXTURE
EGR unit 12
Remove the heat shield (10) from the EGR solenoid
valve.
Loosen the clamps (11) on the EGR tube.
Remove:
the EGR tube,
the two mounting bolts (12) from the EGR unit,
the EGR unit.
REFITTING
Replace the EGR tube with new clamps then tighten

them using pliers Mot. 1567.
Replace the air inlet tube O-rings.
It is essential to replace all the disconnected air inlet

plastic pipes.
Proceed in the reverse order to removal to complete

the operations.
You should follow the recommended tightening

torques.
12-6
TURBOCHARGING
Turbocharger 12
TIGHTENING TORQUES (in daN.m) unit.
Exhaust pipe clamp 2.1
Remove the air filter unit (3).
Catalytic converter rear mounting bolts 2.1
Catalytic converter side strut mounting
bolts 2.5
Engine side strut mounting bolts 4.4
Nuts securing catalytic converter to the
turbocharger 2.6
Air inlet metallic tube mounting bolts 2.1
Lifting ring mounting bolts (timing side) 2.1
Turbo mounting nuts on the exhaust
manifold. 2.6
EGR solenoid valve heat shield mounting
bolts 1.2
Turbocharger oil supply pipe union bolts 2.3
Turbocharger oil supply pipe union on the
cylinder head 2.3
Turbocharger oil return pipe on the
turbocharger 1.2
Turbocharger studs on the manifold 0.9
Turbocharger outlet studs 0.9
REMOVAL

Disconnect the battery then remove the front right hand
wheel.
From above:
Remove:
the engine cover,
Disconnect:
sensor (1).
Release, then disconnect the turbocharging pressure

sensor (2) from the air filter unit.
12-7
TURBOCHARGING
Turbocharger 12
Disconnect the connector from:
the downstream air temperature sensor (4),
the EGR solenoid valve (5),
the rubber tube (6) from the turbocharging pressure
adjustment valve on the air duct.
Remove:
the air duct (7) between the EGR unit and the
turbocharger,
the air duct (8) between the EGR unit and the
turbocharger,
From below:
Gently loosen the clamp from the exhaust pipe.
Remove:
the side strut from the catalytic converter (12),
the rear mounting bolt from the catalytic converter
(13).
Lower the catalytic converter.
the lifting ring (9),

the mounting bolt from the air inlet metallic tube (10)
then pull it to remove it.
the four nuts (11) securing the catalytic converter to
the turbocharger.
12-8
TURBOCHARGING
Turbocharger 12
IMPORTANT: before starting the engine, connect
the fault finding tool then inhibit the injection using
the VP005 "Injection inhibition" command located
in "Command modes/Set up".
Then activate the starter motor until the oil pressure
warning light extinguishes (persist for a few
seconds).
Stop the engine, cut off the ignition for about
15 seconds then restart the engine.
Run the engine at idle speed and check that there
are no leaks at the oil connections.
Special precautions
Ensure that no foreign bodies enter the turbine or

compressor during the refitting operation.
Check that the turbocharger oil return pipe is not
partially or completely blocked by scale. Also
check that it is perfectly sealed. If not, replace it.
From above:
Remove:
the heat shield from the EGR solenoid valve,
the oil supply pipe (14) from the turbocharger,
the lower turbocharger mounting nut on the exhaust
manifold.
the two upper mounting nuts 15).
Carefully remove the turbocharger and the oil return

pipe.
Remove the oil return pipe (16).
REFITTING
Proceed in the reverse order to removal.
Apply Loctite Frenetanch to the oil supply pipe union

threads of the turbocharger on the cylinder head.
IMPORTANT: it is essential to replace all the O-rings

and the two copper seals of the turbocharger oil supply
pipe.

plastic pipes.
Tighten all the mountings to the recommended

torques.
12-9
TURBOCHARGING
Pressure adjustment 12
TURBOCHARGING PRESSURE CONTROL VALVE Calibration pressure value
(WASTEGATE)
The turbocharging pressure limitation valve is Pressure value Rod movement (mm)
activated by a rod and is controlled by the (mbars)
turbocharging pressure applied to the LDA diaphragm.
Calibration pressure check 1300 2 1.95 0,6
Operation on the vehicle.
On the vehicle itself
When checking the calibration pressure it may be

necessary to adjust the wastegate rod length (A) (if it is
not within tolerance).
This adjustment is made with the turbocharger in

place.
First remove:
the lifting rings,
the mounting bolt from the air inlet metallic tube then
pull it to remove it.
Use a magnetic holder fitted with a gauge which

should be positioned at the end of the wastegate rod
(inserted as far as possible in the rod shaft).
Disconnect the pipe (1), then apply progressive Loosen the lock nut then loosen or tighten the
pressure to the wastegate using a manual pressure adjusting nut (B).
pump.
NOTE: It is essential to replace all the disconnected air
inlet plastic pipes.
12-10
113
DIESEL EQUIPMENT
Cleanliness 13
CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRESSURE
DIRECT INJECTION SYSTEM
Risks relating to contamination
The system is very sensitive to contamination. The risks caused by the introduction of contamination are:
damage or destruction of the high pressure injection system and the engine,
seizing or leaking of a component.
All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a
few microns in size) get into the system during dismantling or into the circuits via the fuel unions.
The cleanliness principle must be applied from the filter to the injectors.
WHAT ARE THE SOURCES OF CONTAMINATION?
Contamination is caused by:

metal or plastic chips,
paint,
fibres:
boxes,
brushes,
paper,
clothing,
cloths.
foreign bodies such as hair,
ambient air,
etc.
IMPORTANT: it is not possible to clean the engine using a high pressure washer because of the risk of damaging
connections. In addition, moisture may collect in the connectors and create electrical connection problems.
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYSTEM
Ensure that you have the plugs for the unions to be opened (bag of plugs sold at the Parts Stores - Part no. 77 01
206 804). Plugs are to be used once only. After use, they must be thrown away (once used they are soiled and
cleaning is not sufficient to make them reusable). Unused plugs must be thrown away.
Ensure that you have the hermetically resealable plastic bags for storing removed parts. Stored parts will therefore
be less subject to the risk of impurities. The bags must be used only once, and after use they must be thrown away.
Make sure that lint-free towelettes are available (part number 77 11 211 707). The use of a normal cloth or paper
for cleaning purposes is forbidden. These are not lint-free and may contaminate the fuel circuit of the system. Each
lint-free cloth should only be used once.
13-1
DIESEL EQUIPMENT
Cleanliness 13
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT
For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle.
For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).
Use a brush and thinners to clean the connections to be opened.
Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and injection
system zone). Check that no bristles remain adhered.
Wash your hands before and during the operation if necessary.
When wearing leather protective gloves, cover these with latex gloves.
INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION
As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. The
plugs to be used are available from the Parts Stores (part number 77 01 206 804). They must not, under any
circumstances, be reused.
Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries
contamination.
All components of the injection system that are removed must be stored in a hermetically sealed plastic bag once
the plugs have been inserted.
The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been opened.
These items are likely to allow impurities to enter the system.
A new component replacing an old one must not be removed from its packaging until it is to be fitted to the vehicle.
13-2
DIESEL EQUIPMENT
Cleanliness 13
FITTING INSTRUCTIONS FOR THE PLUGS KIT (part number 77 01 206 804)
13-3
DIESEL EQUIPMENT
Special features 13
The high pressure injection system is intended to deliver a specific quantity of diesel to the engine at a specific time.
DESCRIPTION
DELPHI and type "LVCR" flash EEPROM injection controlling 112 track computer.
The system consists of:

a priming bulb on the low pressure circuit,
a diesel filter,
a high pressure pump incorporating a low pressure pump (transfer pump),
a flow actuator attached to the pump,
an injector rail,
a pressure sensor located in the rail,
four solenoid injectors,
a diesel temperature sensor,
a coolant temperature sensor,
an upstream air temperature sensor,
a downstream air temperature sensor,
a cylinder reference sensor,
an engine speed sensor,
a turbocharging pressure sensor,
an accelerometer,
an EGR solenoid valve,
an accelerator pedal potentiometer,
an atmospheric pressure sensor,
and a computer.
The "common rail" direct high pressure injection system works sequentially (based on the operation of multipoint
injection for petrol engines).
This new injection system reduces operating noise, reduces the volume of pollutant gases and particles and
produces high engine torque at low engine speeds thanks to a pre-injection procedure.
The high pressure pump generates the high pressure sent to the injector rail. The flow actuator on the pump
controls the quantity of diesel engine fuel supplied according to the demand determined by the computer. The rail
supplies each injector through a steel pipe.
13-4
DIESEL EQUIPMENT
Special features 13
The computer:
determines the value of injection pressure necessary for the engine to operate well and then controls the pressure
regulator. It checks that the pressure value is correct by analysing the value transmitted by the pressure sensor
located on the rail,
determines the injection time necessary to deliver the right quantity of diesel and the moment when injection should
be started,
controls each injector electrically and individually after determining these two values.
The injected flow to the engine is determined by:

the duration of injector control,
the injector opening and closing speed,
the needle travel (determined by a constant for the type of injector),
the nominal hydraulic flow of the injector (unique to each injector),
the high pressure rail pressure controlled by the computer.
The computer runs:

the idle speed adjustment,
the exhaust gas flow reinjected into the inlet,
the fuel supply control (advance, flow and rail pressure),
the fan assembly control (GCTE function),
the heat adjustment of the coolant circuit (thermoplungers),
the pre/post heating control.
The high pressure pump is supplied at low pressure by an integrated low pressure pump (transfer pump). It supplies
the rail whose pressure is controlled for charge by the flow actuator and for discharge by the injector valves. Falls
in pressure can be compensated for in this way. The flow actuator allows the high pressure pump to provide just
the amount of diesel fuel necessary to maintain the pressure in the rail. Thanks to this element, heat generation is
minimised and engine output improved.
In order to discharge the rail using the injector valves, the valves are controlled by short electrical impulses:
short enough not to open the injector, (through the return circuit from the injectors),
long enough to open the valves and discharge the rail.
The injection computer controls the fan assemblies and the coolant temperature warning light on the instrument
panel (GCTE function).
13-5
DIESEL EQUIPMENT
Special features 13
IMPORTANT
The engine must not operate with:

diesel engine fuel containing more than 10% diester,
petrol, even in tiny quantities.
The system can inject the diesel into the engine at a pressure up to 1400 bars. Before carrying out any
work, check that the injector rail is not under pressure and that the fuel temperature is not too high.
You must respect the cleaning and safety advice specified in this document for any work on the high
pressure injection system.
Removal of the interior of the pump and injectors is prohibited. Only the flow actuator, the diesel
temperature sensor and the venturi can be replaced.
For safety reasons, it is strictly forbidden to slacken a high pressure pipe union when the engine is
running.
It is not possible to remove the pressure sensor from the fuel rail because this may cause circuit
contamination problems. If the pressure sensor fails, the pressure sensor, the rail and the five high
pressure pipes must be replaced.
It is strictly forbidden to remove any injection pump pulley marked number 070 575. If the pump is being
replaced, the pulley must be replaced.
It is forbidden to repair the wiring connecting the accelerometer and the engine speed sensor. If the wiring
should fail, it has to be replaced with new wiring.
Applying 12 volts directly to any component in the system is prohibited.
Ultrasonic carbon removal and cleaning are prohibited.
Never start the engine without the battery being connected correctly.
Disconnect the injection system computer when carrying out any welding work on the vehicle.
It is essential to replace all the disconnected air inlet plastic pipes.
13-6
DIESEL EQUIPMENT
Special features 13
There is a 16 character code on the injectors called C2I (individual injector correction). This code is specific
to each injector, and takes into account differences in manufacture and specifies the flow injected by each
of them.
When an injector is replaced, it is necessary to program the code of the new one into the computer.
When a computer is reprogrammed or replaced, it is necessary to program the codes of the four injectors.
There are two possibilities:
If it is possible to communicate with the computer:

load the data from the computer into the diagnostic tool remotely
change the computer
transfer the data from the diagnostic tool to the computer.
using the diagnostic tool, ensure that the computer has not detected faults relating to the injector codes
and check that the instrument panel warning light is off.
If it is not possible to communicate with the computer:

change the computer
read the data on the injectors
enter the data in the computer using the diagnostic tool
reconfigure the different elements such as the power-assisted steering pump assembly and the
thermoplungers etc.
using the diagnostic tool, ensure that the computer has not detected faults relating to the injector codes
and check that the instrument panel warning light is off.
13-7
DIESEL EQUIPMENT
Special features 13
All the high pressure pipe removed must be Rail/injector pipes
systematically replaced along with the clips.
Undo the rail,
TIGHTENING THE HIGH PRESSURE PIPES Grease the threads of the high pressure pipe nuts,
Insert the high pressure pipe olive into the taper of
NOTE: fit the pump/rail pipe before the rail/injector the high pressure injector inlet,
pipes. Insert the high pressure pipe olive into the taper of
the high pressure rail outlet.
Pump/rail pipe Move the nut into position by hand, on the injector
side then the rail side,
Undo the rail, Tighten the rail,
Grease the threads of the high pressure pipe nuts, Ensure that the new clip, supplied with the new high
Insert the high pressure pipe olive into the taper of pressure pipe, is fitted,
the high pressure pump outlet, Tighten the nuts of the high pressure pipes on the
Insert the high pressure pipe olive into the taper of injector side first and then on the fuel rail side.
the high pressure rail inlet.
Move the nut into position by hand, on the rail side NOTE: before fitting a new high pressure pipe,
then the pump side, move back the nuts on the pipe then lightly
Tighten the rail, lubricate the nut threads with the oil from the
Tighten the high pressure pipe nuts on the rail side sachet (1) provided in the new parts kit.
then on the pump side.
13-8
DIESEL EQUIPMENT
Special features 13
CHECKING SEALING AFTER REPAIR
After any operation, check that there are no diesel leaks.
Reprime the circuit using the priming bulb.
Start the engine and allow to warm up at idle speed, visually inspecting for any fuel leaks.
Apply tracing fluid around the high pressure connections of the pipe that has been replaced.
Once the coolant temperature is above 50C and provided there are no faults present, carry out a road test, taking
the engine speed up to 4000 rpm at least once to check that there are no leaks.
Perform a visual inspection after the road test to make sure that there are no high pressure leaks.
Clean off the tracing fluid.
13-9
DIESEL EQUIPMENT
Special features 13
REPLACING OR REPROGRAMMING THE COMPUTER
The system can be reprogrammed at the diagnostic socket using the RENAULT NXR and CLIP fault finding
tools.
Before a computer is reprogrammed or replaced in after-sales, the following must be stored in the fault
finding tool: the C2I parameters (individual injector correction) and the configurations by command SC005.
If command SC005 has been taken into account, reprogram or replace the computer then run command SC008 to
restore the C2I and the different configurations then run a static / autoconfiguration test with command SC003 to
reposition the control of the fan assembly 2.
If the save command in the fault finding tool did not work, a static / autoconfiguration test should be run using
command SC003 to reconfigure the different elements such as the power-assisted steering pump assembly, the
climate control system and the thermoplungers and to re-enter the C2I codes manually (refer to injector
replacement).
REPLACING THE INJECTORS
NOTE: C2I (individual injector correction) is a factory calibration carried out on each injector to adjust the
flow of each one precisely, taking into account differences in manufacture.
The correction values are written on a label affixed to each injector then entered in the computer which can then
control each injector by taking account of their differences in manufacture.
The system can be programmed at the diagnostic socket using the RENAULT NXR and CLIP fault finding
tools.
The C2I parameters must be replaced after replacing an injector. To do this, reprogram the C2I code into the
computer using the following commands:
Entering the four C2Is, when replacing the computer, enter command SC004.
Entering an individual C2I, when replacing one or more injectors, enter command:
injector cylinder 1: command VP021 cylinder on the flywheel side
injector cylinder 2: command VP022
The technician uses the appropriate command to reprogram the new C2I for the replaced injector and erase the
old C2I.
13-10
DIESEL EQUIPMENT
Location of components 13
1 Camshaft sensor
2 Fuel filter
3 Injector
4 Air filter
5 Upstream air temperature sensor
6 Accelerometer.
7 Coolant temperature sensor
8 Spherical injector rail
9 Flow actuator
10 Diesel fuel temperature sensor
11 High pressure pump
12 Computer
13 Pre/postheating unit
14 Venturi
15 Rail pressure sensor
16 Priming bulb
17 Turbocharging pressure sensor
18 Accelerator pedal potentiometer
25 Impact sensor
13-11
DIESEL EQUIPMENT
1 Camshaft sensor 3 Injector
8 Injector rail
15 Rail pressure sensor
9 Flow actuator
10 Diesel temperature sensor 5 Upstream air temperature sensor
11 High pressure pump 6 Accelerometer
14 Venturi 17 Turbocharger pressure sensor
13-12
DIESEL EQUIPMENT
2 Fuel filter 7 Coolant temperature sensor
16 Priming bulb 19 Engine speed sensor
5 Downstream air temperature sensor

17 Turbocharger pressure sensor
21 EGR solenoid valve
18 Accelerator pedal potentiometer

12 Injection computer
13 Pre/postheating unit
13-13
DIESEL EQUIPMENT
22 Thermoplungers
23 Vehicle speed sensor
24 Injection locking relay

25 Impact sensor
13-14
DIESEL EQUIPMENT
Accelerator pedal potentiometer 13
The accelerator pedal potentiometer (1) is attached by Potentiometer connector:
a bracket under the injection computer.
1 Track 2 potentiometer signal
2 Track 1 potentiometer signal
3 5 volt supply track 2
4 Track 1 earth
5 Track 2 earth
6 5 volt supply track 1
No specific precautions need to be taken to remove it.

However, to access it, it is necessary to release it on
the side of:
the power assisted steering fluid reservoir,

the injection computer without disconnecting it.
13-15
DIESEL EQUIPMENT
Specifications 13
Engine
Gear-
Vehicles Emission
boxes Bore Stroke Compression Catalytic
Type Suffix Capacity control
(mm) (mm) ratio converter
standard
X B0 7 JB3 K9K 700 76 80.5 1461 18.25/1 228 EU 00
ENGINE SPEED (rpm) SMOKE OPACITY
IDLE SPEED Max. - no load Max. - under load Homologation Max. - legal
value
85050 4500 150 5000 150 2.26 m-1 (60 %) 3 m -1 (73 %)
DESCRIPTION MARQUE/TYPE SPECIAL NOTES
High pressure pump DELPHI 0 to 1400 bars continuous pressure
Fuel pump DELPHI Incorporated into the high pressure pump
Diesel rail pressure DELPHI Incorporated into the rail

sensor Non measurable resistance
Injectors DELPHI Solenoid injector

Maximum pressure 1400 bar
Non measurable resistance
Diesel flow actuator DELPHI Located on the high pressure pump

Resistance: 5.3 0.7 at 20C
Injection computer DELPHI 112-trackcomputer
Pre/postheating unit NAGARES BED With pre-postheating function controlled by the computer
7-12
Pre-heater plugs BERU Resistance: 0.6

connector disconnected
Accelerator pedal CTS Double track potentiometer

potentiometer Resistance:
track 1: 4 (earth) and 6 (+5 V): 1.7 0.9 k
track 2: 5 (earth) and 3 (+5 V): 2.4 1.2 k
Intake air temperature JAEGER CTN thermistor

sensors Resistance: 5000 6800 at - 40 C
9500 900 at - 10 C
2051 120 at 25 C
810 47 at 50 C
310 17 at 80 C
13-16
DIESEL EQUIPMENT
Specifications 13
DESCRIPTION MARQUE/TYPE SPECIAL NOTES
Diesel fuel temperature DELPHI Located on the high pressure pump

sensor CTN thermistor
Resistance: 2.2 k at 25C
Coolant temperature ELTH CTN thermistor

sensor Resistance: 76000 7000 at - 40 C
12500 1130 at - 10 C
2252 112 at 25 C
810 40 at 50 C
280 8 at 80 C
115 3 at 110 C
88 2 at 120 C
Engine speed sensor MGI Variable reluctance sensor

Resistance: 760
Atmospheric pressure DELPHI Incorporated into the computer

sensor
Turbocharging pressure DELCO Resistance

sensor ELECTRONICS tracks A and B: 9 k
tracks A and C: 4 k
tracks B and C: 5 k
Camshaft sensor SAGEM Hall effect sensor
Accelerometer. SAGEM Non measurable resistance
EGR solenoid valve PIERBURG Resistance:

tracks 1 and 5: 8 5 at 20 C
EGR valve position Incorporated into the EGR solenoid valve
potentiometer Resistance:
tracks 4 and 6: 1 0,5 K at 20 C
tracks 2 and 4: 4 1,6 K at 20 C
Thermoplungers BERU Resistance: 0.6 0.7 at 20C
13-17
DIESEL EQUIPMENT
Diesel filter 13
IMPORTANT: before carrying out any work, wait
for the fuel temperature to drop.
REMOVAL - REFITTING
Release the diesel fuel filter from its support.
Fit the new diesel fuel filter (do not remove the plugs
until the last moment).
Disconnect all the snap fasteners beginning with the

three vertical snap fasteners. Prevent the snap
fasteners from coming into contact with the
environment.
Disconnect the pump outlet snap fastener last of all;

reconnect it immediately when the new filter is
installed.
Reconnect the other snap fasteners.
Prime the system using the priming bulb (automatic

degassing).
Reconnect the battery.
13-18
DIESEL INJECTION
High pressure pump 13
IMPORTANT: It is strictly forbidden to remove
any injection pump pulley marked number 070
575. If the pump is being replaced, the pulley
must be replaced.
Mot. 1566 Tool for removing and refitting high

pressure pipes
EQUIPMENT REQUIRED
Low torque wrench
High pressure pipe wrench (for example, Facom
"DM19" wrench)
Pipe socket for tightening the injector-rail high
pressure pipes (for example, Facom Crowfoot 18-
17 wrench).
Pipe socket for tightening the pump-rail high
pressure pipe (for example, Facom Crowfoot 19-
17 wrench).
TIGHTENING TORQUES (in daNm)
High pressure pipe nuts 3.8

Rail nuts 2.8 0.3
Filler neck nut on the rail 2.1
High pressure pump mounting bolts 1.2 2.2
IMPORTANT: before carrying out any work,

connect the After-Sales diagnostic tool, set up
communication with the injection computer and
check that the injection rail is not under pressure.
Wait until the fuel temperature drops.
kit.
13-19
DIESEL EQUIPMENT
REMOVAL
YOU SHOULD FOLLOW THE CLEANNESS INSTRUCTIONS CLOSELY
It is strictly forbidden to remove any injection pump pulley marked number 070 575 (see diagram). If the pump is
being replaced, the pulley must be replaced.
The high pressure pump may be removed after having first removed the timing belt (see section 11 " Timing belt")
Remove:
the neck (1) located on the fuel rail,
the dipstick guide and plug the hole.
Undo the mounting nuts of the rail (2) a few turns.
13-20
DIESEL EQUIPMENT
Carefully disconnect:
the connectors from the flow actuator (3) and diesel temperature sensor (4),
the pre-heater plugs and the injectors (5),
the return pipe (8) connecting the injector with the pump.
13-21
DIESEL EQUIPMENT
Remove the high pressure pipe (9) connecting the Refit the high pressure pipe, to do this:
pump to the rail. To do this:
remove the protective plugs,
undo the nut on the pump side then the nut on the rail insert the high pressure pipe olive into the taper of
side, the high pressure pump outlet,
move the nut along the tube keeping the olive in insert the high pressure pipe olive into the taper of
contact with the taper. the high pressure rail inlet.
Plug all the holes of the injection circuit. Finger tighten the nuts of the high pressure pipe
starting with the one located on the rail side.
Remove the three mounting bolts (10) from the
injection pump then remove it. Tighten the rail mounting nuts to a torque setting of
2.8 daNm).
IMPORTANT: do not touch the pipes with the

wrench when torque tightening.
Using the recommended tools, tighten the following in

the order and to the torques shown:
the nut on the rail side to 3.8 daN.m,

the nut on the pump side to 3.8 daN.m,
Tighten the mounting bolts (10) on the high pressure

pump to a torque of 2.1 daN.m.
REFITTING
Fit the pump then position the mounting bolts without

tightening them.
WARNING: all the high pressure pipes removed

must be systematically replaced.
Before fitting the new high pressure pipe, lightly

lubricate the nut threads with the oil from the sachet
provided in the new parts kit.
Refit in the reverse order to removal for the other

refitting operations.
Test the sealing of the high pressure after it has been

repaired (see section 13 "Special features").
13-22
DIESEL EQUIPMENT
Flow actuator 13
EQUIPMENT REQUIRED
Low torque wrench
Pipe socket for tightening the high pressure pipe
(for example, Facom Crowfoot 18-17 wrench).
Flow actuator mounting bolt 0.55 0.06

kit.
13-23
DIESEL EQUIPMENT
Flow actuator 13
REMOVAL
YOU SHOULD FOLLOW THE CLEANNESS

INSTRUCTIONS CLOSELY
Disconnect the connector from the flow actuator (1)

and from the diesel temperature sensor carefully (2).
Unscrew the two retaining bolts from the bracket (4).
Withdraw the flow actuator (by hand using small

successive turns. Do not use the electrical connector
as a lever arm).
REFITTING
Remove the new component from its packaging just

before fitting it.
NOTE: Do not lubricate the seals with grease or used

Disconnect the fuel return pipe (3). diesel oil. Use the applicator provided in the kit for the
new part.
Remove the high pressure pipe from injector no. 4
(see section on high pressure pipes). Position the actuator. (Important: when fitting the
regulator, do not mark the seal.)
Plug the holes in the injection circuit.
Position the two mounting bolts then torque tighten
Disconnect the pre-heater plug and the injectors from them.
cylinders 3 and 4.
Fit a new high pressure pipe to injector no. 4 plus a
new clip (see section on high pressure pipes).
Reconnect:
the diesel return pipe.
the electrical connectors.
13-24
DIESEL EQUIPMENT
Flow actuator 13
Test the sealing of the high pressure circuit after it has

been repaired (see section 13 "Special features").
13-25
DIESEL EQUIPMENT
Diesel fuel temperature sensor 13
EQUIPMENT REQUIRED
Low torque wrench
Diesel temperature sensor 1.5 0.15

kit.
13-26
DIESEL EQUIPMENT
Diesel fuel temperature sensor 13
REMOVAL REFITTING
Grease the O-ring with the lubricant from the sachet

provided with the new part.
Take care not to damage the O-ring when installing the
Disconnect the battery. sensor.
Remove the engine cover. Position the diesel fuel temperature sensor then
tighten to torque.
Disconnect the connector from the diesel temperature
sensor carefully (1). Reconnect:
the electrical connector.
Undo then remove the diesel temperature sensor. the battery.

13-27
DIESEL EQUIPMENT
Venturi 13
EQUIPMENT REQUIRED
Low torque wrench
Venturi mounting bolts 0.55 0.06

kit.
13-28
DIESEL EQUIPMENT
Venturi 13
REMOVAL REFITTING
Grease the O-ring with the lubricant from the sachet

provided with the new part.
Take care not to damage the O-ring when installing the
Disconnect the battery. venturi.
Remove the engine cover. Position the venturi then tighten it to torque.
Disconnect: Reconnect the different pipes.

the fuel return pipe on the pump (1).
the return pipe (2) connecting the injector with the Test the sealing of the high pressure after it has been
pump. repaired (see section 13 "Special features").
Remove the venturi mounting bolts (3) then take it out.
13-29
DIESEL EQUIPMENT
Injector rail 13

pressure pipes
EQUIPMENT REQUIRED
Low torque wrench
"DM19" wrench)
17 wrench).
17 wrench).

Rail nuts 2.8 0.3

kit.
IMPORTANT: the pressure sensor cannot be

separated from the rail.
13-30
DIESEL EQUIPMENT
Injector rail 13
REMOVAL
YOU SHOULD FOLLOW THE CLEANNESS INSTRUCTIONS CLOSELY
Carefully disconnect:
the connectors from the flow actuator(1),
the connectors from the diesel temperature sensor (2),
the injector connectors (3),
the heater plugs,
on the pump, the fuel supply (4) and return (5) pipes.
the return pipe (6) connecting the injectors with the pump.
Remove:
the neck (7) located on the fuel rail,
the dipstick guide and plug the hole.
Disconnect the pressure sensor connector from the rail (8).
13-31
DIESEL EQUIPMENT
Injector rail 13
Remove the clips connecting the high pressure pipes. Remove all the high pressure pipes (12).
Plug all the holes of the injection circuit.

IMPORTANT: when undoing the high pressure
pipes, it is essential to maintain the central union
Remove the rail (13).
of the injector (9).
IMPORTANT: do not damage the injector's leak

return duct (10).
NOTE: undo the nut on the pump side or the

injector side, then the nut located on the rail side.
Undo the nuts for each pipe in turn.
Move the nut along the pipe keeping the olive in
contact with the taper.
13-32
DIESEL EQUIPMENT
Injector rail 13
REFITTING insert the high pressure pipe olive into the taper of
the high pressure injector inlet,
insert the high pressure pipe olive into the taper of
IMPORTANT: all the high pressure pipes
removed must be systematically replaced.
finger tighten the nuts of the high pressure pipe
starting with the one located on the injector side.
Fit a new high pressure rail on the studs.
Fit the remaining high pressure pipes as you did
Finger tighten the nuts. previously.
Before fitting the new high pressure pipes, lightly

lubricate the nut threads with the oil from the sachet NOTE: The order in which the pipes are installed
provided in the new parts kit. is not important.
NOTE: fit the pump/rail pipe before the rail/injector Fit the clips supplied with the new pipes onto the high
pipes. pressure pipes:
insert the first half of the clip using adjustable pliers,
Fit the pump-rail high pressure pipe: Insert the second half of the clip using adjustable
pliers.
remove the protective plugs from the high pressure
pump outlet, the high pressure rail inlet and the pipe.
IMPORTANT: pay attention to the direction of
installation of the second clip. The tabs located
the high pressure pump outlet,
in the centre of the clip will only fit together in
one position.
Fit the rail-injector high pressure pipe:
IMPORTANT: when tightening the high pressure


rail outlet, the injector high pressure inlet and the
pipe.
13-33
DIESEL EQUIPMENT
Injector rail 13
Tighten the rail nuts to a torque of 2.8 daNm. Using the recommended tools, tighten the nuts on
the rail - injector high pressure pipes:
tighten the nut on the injector side to a torque of
3.8 daN.m.
tighten the nut on the rail side to a torque of
IMPORTANT: follow the order and tightening 3.8 daN.m.
torque of the high pressure pipes.
NOTE: Tighten one pipe fully before moving on to

Using the recommended tools, tighten the nuts on the next pipe.
the rail - pump high pressure pipe:
tighten the nut on the rail side to a torque of

3.8 daN.m.
tighten the nut on the pump side to a torque of
3.8 daN.m.


13-34
DIESEL EQUIPMENT
Pressure sensor 13
The pressure sensor (1) cannot be separated from the
fuel rail. If the pressure sensor fails, the pressure
sensor assembly - rail and high pressure pipes - must
be replaced (see fuel rail section).
13-35
DIESEL EQUIPMENT
Injectors 13

pressure pipes
EQUIPMENT REQUIRED
Low torque wrench
"DM19" wrench)
17 wrench).
17 wrench).

Rail nuts 2.8 0.3
Injector mounting 2.8 0.3

kit.
IMPORTANT: it is forbidden to open an injector. If you

open an injector by mistake, you will have to change it.
This is because of the manufacturing and installation
tolerances and because there is a risk of
contaminating the inside of the injector.
The rod filter of the injector must not be removed.
13-36
DIESEL EQUIPMENT
Injectors 13
REMOVAL
NOTE: it is possible to replace a single high pressure

pipe.

Remove:
the engine cover,
the neck (1) located on the high pressure rail,
the dipstick guide then plug the hole.
Disconnect:
the fuel return pipe (3),
the injector electrical connector.
Remove the clip (4) connecting the high pressure

pipes.

Undo the nut on the injector side, then the nut located
on the rail side of the high pressure pipe.
Move the nut along the tube keeping the olive in


return duct (6).
13-37
DIESEL EQUIPMENT
Injectors 13
REFITTING
NOTE: read the 16 digit code (C2I) on the new

injector before refitting it and programming the
code into the computer using the fault finding tool
(see section 13 "Special features, Replacing
injectors"). The C2I code is unique to each injector,
it specifies the flow.
Clean the injector sockets and the injector bodies, as

well as their brackets using a lint-free cloth (use the
wipes recommended for this purpose, part
no. 77 11 211 707) dipped in clean solvent.
Dry off using a different new wipe.
Replace the flameshield washer with a new one.
Position the injector.
* 16 digit code Tighten its mounting clamp to a torque of 2.8 daN.m.
Remove the high pressure pipe (7).

Disconnect the diesel return pipe on the injector. removed must be systematically replaced.

Before fitting the new high pressure pipe, lightly
Unscrew the injector bracket (8).
lubricate the nut threads with the oil from the sachet
provided in the new parts kit.
Remove the injector.
Pull off the flameshield washer.
13-38
DIESEL EQUIPMENT
Injectors 13
Fit the high pressure pipe: Tighten the rail nuts to a torque of 2.8 daNm.
Remove the protective plugs from the rail, the

injector inlet and the pipe.
the injector inlet,
the rail outlet. IMPORTANT: when tightening the high pressure
Move the nut into position by hand, injector side first of the injector.
then the rail side.
Fit a new clip supplied with the new pipes onto the
high pressure pipes: Using the recommended tools, tighten the following in
insert the first half of the clip using adjustable pliers, the order and to the torques shown:
Insert the second half of the clip using adjustable the nut on the injector side to a torque of 3.8 daN.m.
pliers. the nut on the rail side to a torque of 3.8 daN.m.
IMPORTANT: pay attention to the direction of

installation of the second clip. The tabs located
in the centre of the clip will only fit together in
one position.


13-39
DIESEL EQUIPMENT
High pressure pipes 13

pressure pipes
EQUIPMENT REQUIRED
Low torque wrench
DM19 wrench).
17 wrench).
17 wrench).

Rail nuts 2.8 0.3

kit.
13-40
DIESEL EQUIPMENT
REMOVAL
NOTE: it is possible to replace a single high pressure

pipe.

Remove:
the engine cover,
the neck (1) located on the high pressure rail,
the dipstick guide then plug the hole.
Undo the nut on the pump side or the injector side,

then the nut located on the rail side.
Move the nut along the tube keeping the olive in


return duct (5).
Remove the clip (3) connecting the high pressure

pipes.

13-41
DIESEL EQUIPMENT
Remove the high pressure pipes(s). Fit the remaining high pressure pipes as you did
previously.
REFITTING
removed must be systematically replaced.
NOTE: fit the pump/rail pipe before the rail/injector
pipes.
Before fitting the new high pressure pipes, lightly Fit a new clip supplied with the new pipes onto the
lubricate the nut threads with the oil from the sachet high pressure pipes:
provided in the new parts kit. insert the first half of the clip using adjustable pliers,
insert the second half of the clip using adjustable
Fit the pump-rail high pressure pipe: pliers.

pump outlet, the high pressure rail inlet and the pipe. IMPORTANT: pay attention to the direction of
insert the high pressure pipe olive into the taper of installation of the second clip. The tabs located
the high pressure pump outlet, in the centre of the clip will only fit together in
insert the high pressure pipe olive into the taper of one position.
Fit the rail-injector high pressure pipe:

rail outlet, the injector high pressure inlet and the
pipe.
the high pressure injector inlet,
starting with the one located on the injector side.
13-42
DIESEL EQUIPMENT
Tighten the rail nuts to a torque of 2.8 daNm.. NOTE: tighten one pipe fully before moving on to
the next pipe.


the nut on the pump - rail high pressure pipe starting
with the one located on the rail side to a torque of
3.8 daN.m.
the nut on the pump side to a torque of 3.8 daN.m.


IMPORTANT: when tightening the high pressure


the nut on the injector side to a torque of 3.8 daN.m.
the nut on the rail side to a torque of 3.8 daN.m.
13-43
DIESEL EQUIPMENT
Computer 13
NOTE: when replacing or reprogramming a computer, it is necessary to program the C21 parameters
(individual injector correction) and the other vehicle configurations using the RENAULT NXR and CLIP fault
finding tools.
There are two possible ways of doing this:
An automatic method which can be done if it is possible to read out the information contained in the old computer.
A manual method which is to be used if it is not possible to read out the information contained in the old computer.
REPLACING OR REPROGRAMMING THE COMPUTER
Before a computer is reprogrammed or replaced in after-sales, the following must be stored in the fault
finding tool: the C2I parameters (individual injector correction) and the configurations by command SC005.
If command SC005 has been taken into account, reprogram or replace the computer then run command SC008 to
restore the C2I and other configurations then run a static / autoconfiguration test with command SC003 to
reposition the control of the fan assembly 2.
If the save command in the fault finding tool did not work, a static / autoconfiguration test should be run using
command SC003 to reconfigure the different elements such as the power-assisted steering pump assembly, the
climate control system and the thermoplungers and to re-enter the C2I codes manually (see section13 "Special
features, Replacing injectors").
13-44
DIESEL EQUIPMENT
Computer 13
REMOVAL REFITTING
Disconnect: Fit the new computer, taking care to engage the

the battery, positioning tab, then fit the computer on its mounting
the computer connectors. studs.
Unclip the power steering reservoir and attach it to the Tighten the computer mounting nuts.
front bulkhead.
Clip the power steering reservoir back in.
Remove the mounting nuts from the computer (1) on
the battery tray. Reconnect the computer.
Tilt the computer slightly to the rear to free up the Connect the battery.
studs and pull it out upwards to free the positioning
tab. Turn the engine on and read the fault codes using the
fault finding tool.
If necessary repair the faults that appear then delete

them.
Check that the vehicle is operating correctly.
13-45
DIESEL EQUIPMENT
Computer 13
COMPUTER ALLOCATION OF TRACKS
CONNECTOR A
H1 .... Not used
H2 Accelerator pedal potentiometer signal track 1
H3 --- Accelerator pedal potentiometer earth track 1
H 4 .... Not used
G1 .... Not used

G2 --- Accelerator pedal potentiometer supply track 1
G3 .... Not used
G4 .... Not used
F1 Electronic On Board Fault finding warning light control

F2 --- Accelerator pedal potentiometer supply track 2
F3 Accelerator pedal potentiometer signal track 2
F 4 --- Accelerator pedal potentiometer earth track 2
E1 Coolant temperature warning light control

E2 Air conditioning on/off signal
E3 .... Not used
E4 Stop light switch signal
D1 --- +after ignition supply

D2 .... Not used
D3 .... Not used
D4 Comsumption signal (computer)
C1 .... Not used

C2 .... Not used
C3 .... Not used
C4 .... Not used
B1 Injection fault control

B2 Engine speed signal
B3 Software lock signal
B4 Fault finding line: K
A1 Pre-heating warning light control

A2 .... Not used
A3 .... Not used
A4 .... Not used
13-46
DIESEL EQUIPMENT
Computer 13
CONNECTOR B
M1 .... Not used
M2 .... Not used
M3 .... Not used
M4 Flow actuator control
L1 .... Not used

L2 .... Not used
L3 EGR solenoid control
L4 .... Not used
K1 .... Accelerometer shielding

K2 Upstream air temperature sensor signal
K3 --- Upstream air temperature sensor earth
K 4 .... Not used
J1 .... Not used

J2 Downstream air temperature sensor signal
J3 --- Downstream air temperature sensor earth
J4 .... Not used
H1 .... Not used

H2 Coolant temperature sensor signal
H3 --- Coolant temperature sensor earth
H4 Control - injector N2
G1 .... Accelerometer earth

G2 Diesel temperature sensor signal
G3 --- Diesel temperature sensor earth
G4 Control + injector N2
F1 Accelerometer signal
F2 Engine speed sensor signal
F3 --- Engine speed sensor earth
F4 Control - injector N4
E1 .... Not used

E2 Camshaft sensor signal
E3 --- Camshaft sensor earth
E4 Control + injector N4
D1 --- Rail pressure sensor supply

D2 Rail pressure sensor signal
D3 --- Rail pressure sensor earth
D4 Control - injector N3
C1 --- Turbocharging pressure sensor supply

C2 Turbocharger pressure sensor signal
C3 --- Turbocharger pressure sensor earth
C4 Control + injector N3
B1 --- EGR solenoid valve potentiometer supply

B2 EGR solenoid valve potentiometer signal
B3 --- EGR solenoid valve potentiometer earth
B4 Control - injector N1
A1 .... Not used

A2 .... Not used
A3 .... Not used
A4 Control + injector N1
13-47
DIESEL EQUIPMENT
Computer 13
CONNECTOR C
A1 .... Not used
A2 .... Not used
A3 .... Not used
A4 .... Not used
B1 Fan assembly relay control 1

B2 Fan assembly relay control 2
B3 .... Not used
B4 .... Not used
C1 Power-assisted steering pump assembly relay control

(according to fittings)
C2 Thermoplunger relay control 1
C3 .... Not used
C4 .... Not used
D1 Thermoplunger relay control 3

D2 Thermoplunger relay control 2
D3 Pre-heater plug fault finding signal
D4 Stop light switch signal
E1 Vehicle speed sensor signal

E2 .... Not used
E3 .... Not functioning
E4 Signal for output absorbed by the air conditioning
F1 Injection locking relay control

F2 Pre-postheating relay unit control
F3 .... Not used
F4 .... Not used
G1 --- Power earth

G2 --- battery + after relay
G3 .... Not used
G4 .... Not used
H1 --- Power earth

H2 --- battery + after relay
H3 .... Not used
H4 .... Not used
13-48
DIESEL EQUIPMENT
Injection warning light 13
Vehicles that operate with the high pressure diesel system Delphi LVCR are fitted with three warning lights,
dependent on the level of seriousness of the fault detected, to inform the customer and determine the diagnostic.
These warning lights are used during the preheating phase and in case of an injection fault or engine overheating.
PRINCIPLE FOR LIGHTING UP OF THE WARNING LIGHTS
Pre/postheating and injection fault orange warning light (severity level 1)
This warning light is used as an operating indicator light and as a system fault indicator light.
The orange preheating warning light comes on when the ignition is switched on, remains lit during the preheating
phase and then goes out (see section 13 Pre/post-heating control).
After the preheating phase and an automatic timed 3 second stop, a severity level 1 problem is indicated by
flashing. It indicates reduced level operation and a limited safety level. The driver should carry out repairs as soon
as possible.
These faults are connected to:

the engine immobliser,
a C2I code error (individual injector correction),
an injector,
the injector controls,
the fuel supply (injector leak etc.),
an engine speed sensor fault,
the injection locking relay
the EGR solenoid valve (short circuit or open circuit),
the accelerator pedal potentiometer (tracks 1 and 2),
the accelerator pedal potentiometer supply,
the turbocharger pressure sensor (in the event of overpressure).
Coolant temperature red warning light (severity 2)
This warning light is used as an operating indicator light and as a system fault indicator light.
When the ignition is switched on, the coolant temperature warning light lights up for 3 seconds then goes out.
13-49
DIESEL EQUIPMENT
Injection warning light 13
When there is a serious fault, the coolant temperature warning light lights up continuously and signals a fault
linked to the injection system or engine overheating.
In the event of an injection system fault, the engine is automatically switched off after 1 minute 30 seconds or
immediately.
In the event of engine overheating, it is the driver's choice to stop the car or continue driving.
These faults are connected to:

Timed stop
the flow actuator (loop deviation and overpressure),
Immediate stop
the engine speed sensor (no signal),
the diesel flow actuator,
the rail pressure sensor,
the supply of all the injectors,
the sensor supply voltage,
an internal computer fault.
Excess pollution orange warning light "OBD" (On Board Diagnostic)
This warning light, depicted by an engine, lights up for about 5 seconds when the engine is switched on then goes
out. It is never visible when the engine is running (not operational).
13-50
DIESEL INJECTION
Immobiliser function 13
This vehicle is fitted with an engine immobiliser system which is controlled by a key recognition system.
REPLACING THE INJECTION COMPUTER
The injection computers are supplied without a code but they must all be programmed with one.
If a computer is replaced, it must be programmed with the code of the vehicle and the correct operation of the engine
immobiliser function must be checked.
To do this, switch on the ignition for a few seconds without starting the engine, then switch it off. With the ignition off,
the engine immobiliser function comes into operation after approximately 10 seconds (the red engine immobiliser
warning light flashes).
WARNING:
These vehicles have a special injection computer which does not function unless it is coded.
Consequently, it is strongly recommended that you do not carry out tests using computers borrowed from the
warehouse or on another vehicle to prevent coding and uncoding problems which may leave the computer useless.
UNCODING PROCEDURE
If the injection computer has learnt a code and must be returned to the workshop it is imperative that you uncode it
before removing it. (See the repair manual or engine immobiliser Technical Note ).
13-51
DIESEL INJECTION
Idle speed adjustment 13
The computer takes over calculation of the idle speed to maintain the idle speed at the recommended level and
to compensate for any variation in the mechanical or electrical couple as regards:
the coolant temperature,
battery voltage,
the gear selected on the gearbox,
the electrical consumers (thermoplungers, climate control system, fan assembly etc.),
any faults found.
At the engine operating temperature, without high electrical consumer, the idle speed is 850 rpm.
IDLE SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE
X. Engine speed in rpm

Y. Temperature in C
SPEED ADJUSTMENT WHEN THERE IS AN ACCELERATOR PEDAL POTENTIOMETER FAULT'
If one or both tracks of the accelerator pedal potentiometer are faulty, the computer overrides the idle speed to
maintain it at 1100 rpm. This defect mode limits performance. The orange injection warning light lights up and
flashes.
If the potentiometer is blocked, is no longer being supplied, or is not transmitting an output signal, the
computer overrides the idle speed to maintain it at 1300 rpm. This mode limits performance. The orange injection
warning light lights up and flashes.
In both cases, when the brake pedal is depressed, the idle speed is stabilised at the recommended speed.
If the information from the accelerator pedal position potentiometer and the brake switch information does
not correspond, the speed is changed to 1100 rpm.
13-52
DIESEL INJECTION
Idle speed adjustment 13
IDLE SPEED ADJUSTMENT WHEN THERE IS AN INJECTOR C21 CODE FAULT
When there is an injector C21 code fault, the computer overrides the idle speed to maintain it at 1300 rpmn . This
mode limits performance. The orange injection warning light lights up and flashes.
CORRECTION OF THE IDLING SPEED ACCORDING TO THE GEAR RATIOS
The idling speed is modified according to the gear engaged in the gearbox:
in neutral, 1st and 2nd gear, the speed is (at the engine operating temperature) 850 rpm (graph A),
for the other gears, the speed is (at the engine operating temperature) 900 rpm (graph B).
X. Engine speed in rpm

Y. Temperature in C
13-53
DIESEL INJECTION
Injection/air conditioning management 13
INJECTION COMPUTER / AIR CONDITIONING COMPUTER CONNECTION
The compressor is a variable displacement type.
The injection computer and the air conditioning computer are connected by three wires:
the signal for output absorbed by the compressor passes through track E4 of connector C. It is possible to see
the output absorbed using the diagnostic tool. With air conditioning switched on, the reading should be between
250 and 5000 watts.
the compressor is activated or deactivated via track E2 of connector A.
track E3 of connector C, is not operational.
When the air conditioning switch is activated, the injection computer authorises the clutch compressor according to
the parameters and adopts a fast idling speed. In this case, the engine speed can reach 900 rpm depending on how
much power is absorbed by the compressor.
IMPORTANT: the value for the parameter "PR power absorbed by the AC compressor" (PR044) is never equal
to 0, whatever the status of the compressor. The minimum value read is approximately 250 watts.
COMPRESSOR OPERATION PROGRAMMING
During certain stages of operation, the injection computer stops the compressor from functioning.
Engine starting program
The compressor is prevented from operating for 4 seconds after the engine has started.
Thermal protection program
The compressor is not engaged when the engine temperature is higher than 115 C or from 110 C at high speed,
4500 rpm for more than 3 seconds.
Fan assembly control program
At idling speed and when driving, with the air conditioning activated, the speed of the fan assembly is determined
according to the refrigerant fluid pressure and the vehicle speed.
13-54
DIESEL INJECTION
Injection/air conditioning management 13
Recovery of performance
When pressure is applied to the accelerator pedal above 70 %, the compressor is disengaged for 5 seconds.
Recovery of output when the vehicle starts moving
In order to help the vehicle move off, the air conditioning compressor is disengaged if the position of the accelerator
pedal is above 35 % and the idling speed less than 1250 rpm.
Anti-stall protection
The compressor is disengaged if the engine speed is lower than 750 rpm.
Engine overspeed timed protection program
The compressor is disengaged when the speed reaches 4500 rpm for more than 3 seconds.
NOTE: the time between the compressor being disengaged twice is always greater than 10 seconds.
13-55
DIESEL INJECTION
Pre/postheating control 13
The pre/postheating function is controlled by the preheating unit.
PRE/POSTHEATING OPERATING PRINCIPLE 2) "Post heating" with the engine running
1) Ignition on "preheating" During this phase the plugs are supplied continuously
according to coolant temperature.
a) Variable preheating
The time period for the warning light to light up and
the feed to heater plugs depends on the coolant
temperature and the battery voltage.
X. Time in seconds
Y. Temperature in C
For idle speed without pressing the accelerator pedal.

X. Time in seconds
Y. Temperature in C
Whatever the situation, the preheating warning

light cannot be lit for more than 15 seconds
(except in the event of a coolant temperature
sensor fault).
b) Fixed preheating
After the warning light goes out the plugs remain
supplied for a fixed period of 5 seconds.
13-56
DIESEL EQUIPMENT
Pre-heater plugs 13
The resistance of a heater plug is 0.6 .
TIGHTENING TORQUE (in daNm)
Heater plug 1.5
Plugs may be removed without having to open the

high pressure circuit.
REMOVAL
Unclip the plug connector.
Clean the outside of the plug to avoid any dirt entering

the cylinder.
Loosen and remove the plugs.
To undo the plug on cylinder 4 use a 10 mm long radio

socket attached to a universal joint. Once the plug is
loosened use a hose to unscrew it completely.
REFITTING
Proceed in the reverse order to removal.
13-57
DIESEL INJECTION
Coolant temperature management (GCTE) 13
The fan unit is controlled by the injection computer.
FAN ASSEMBLY OPERATION WITH THE ENGINE RUNNING
The fan assembly is controlled:
at slow speed if the coolant temperature exceeds 99C or if there is a coolant temperature sensor fault, and is
switched off when the temperature falls below 96C.
at high speed if the coolant temperature exceeds 102 C or if there is a low speed fault, and is switched off when
the temperature falls below 99C.
The fan assembly low and high speeds are controlled when the air conditioning function is selected on the
instrument panel.
If the low speed setting is faulty, the high speed setting operates under low speed conditions.
OPERATION OF THE TEMPERATURE WARNING LIGHT
The temperature warning light remains lit if the coolant temperature exceeds 114 C. It goes out when the
temperature falls below 111 C.
13-58
DIESEL INJECTION
Thermoplungers 13
The three or four thermoplungers are located on a Control strategy
water unit (1), attached to the gearbox by a retaining
bracket. When the thermoplungers are operating the idle speed
is brought to 900 rpm.
The system is designed to reheat the coolant intended
for the passenger compartment heating system. Thermoplungers cannot operate in the case of:
preheating,
The thermoplungers are supplied with 12 volts by two post-heating,
or three relays. engine speed below 700 rpm.
When there are two relays: one relay controls one If the conditions mentioned above apply, the
thermoplunger and the other controls two thermoplungers are controlled according to a mapping
thermoplungers. This enables control of one, two or related to the air and coolant temperature.
three thermal plungers.
When there are three relays: two relays control one

thermoplunger each and the other controls two
thermoplungers. This enables control of one, two,
three or four thermoplungers.
The resistance of the thermoplungers is:
0.6 0.05 at 20 C
Unhatched area: thermoplunger not supplied

Shaded zone: Thermoplunger supplied
13-59
DIESEL EQUIPMENT
Thermoplungers 13
3 OR 4 RELAY THERMOPLUNGER CONTROL PROGRAM
If the battery voltage is > 13 volts
If not then
Thermoplungers not supplied One thermal plunger supplied
If, after 20 seconds, the battery

voltage is > 13 volts
If not then
Thermoplungers not supplied Two thermoplungers supplied

If not then
Thermoplungers not supplied Three thermoplungers supplied

If not then
Thermoplungers not supplied Four thermoplungers supplied

while the battery voltage is
> 13.5 volts and if the conditions
mentioned above are met.
13-60
114
ANTI-POLLUTION
Oil vapour rebreathing 14
CIRCUIT DIAGRAM
A. When there is a low charge, the vacuum in the air
intake duct is below the spring set point. The oil
vapours are extensively rebreathed by the
vacuum in the air intake duct.
B. When there is a medium or high charge, the

pressure in the air intake duct exhausts the valve
diaphragm, the oil vapours are breathed in small
quantities via a calibrated hole.
CHECKING
To ensure the correct operation of the anti-pollution

system, the oil vapour rebreathing circuit must be kept
clean and in good condition.
1 Cylinder head cover

2 Oil vapour rebreathing duct
3 Oil vapour recirculation valve
4 Air intake duct
5 Turbocharger
Ap Atmospheric pressure
14-1
ANTI-POLLUTION
Exhaust gas recirculation (EGR) 14
CIRCUIT DIAGRAM
1 Engine
2 Air filter unit
3 Air distributor
4 Exhaust manifold
5 EGR unit with solenoid valve
6 Turbocharger
7 Injection computer
A Air inlet
B Exhaust gas outlet
PURPOSE OF THE EGR SYSTEM
Exhaust gas recirculation is used to reduce the nitrogen oxide (NOx) content of the exhaust gases.
The computer authorises gas to pass by controlling a solenoid valve.
14-2
ANTI-POLLUTION
Exhaust gas recirculation (EGR) 14
OPERATING PRINCIPLE In this case, the fault finding tool can read an RCO
value of the position of the EGR valve equal to 16 %.
The valve is controlled by an RCO (Opening Cyclic
Ratio) signal sent by the injection computer. The RCO EGR function is disabled if:
signal modulates the opening of the valve and the battery voltage is less than 9 volts,
consequently the quantity of exhaust gas directed engine speed is below 500 rpm.
back to the inlet manifold. the mapping (engine speed/load) exceeds a given
threshold,
The computer continuously carries out a test to detect the air conditioning compressor is activated.
the position of the EGR valve.
The EGR solenoid valve is not supplied after the
NOTE: the position of the EGR valve is determined by engine starts for 2 seconds.
the calculation of the amount of air taken in by the
engine. If there is a fault in:
the EGR valve,
OPERATING CONDITIONS the turbocharging pressure sensor,
the supply to the EGR solenoid valve is cut.
The parameters which determine the activation of the
EGR solenoid valve are as follows:
coolant temperature,
air temperature,
atmospheric pressure,
accelerator pedal position,
injected diesel flow,
the engine speed.
Operating point for the EGR valve test:
The EGR valve is activated when:

the air temperature is > 15 C and the coolant
temperature is > 70 C,
or the air temperature is > 50 C and the coolant
temperature is > 40 C,
the engine speed is between 850 and 1000 rpm,
the injected diesel flow is between 2 and
5 mg/stroke,
the atmospheric pressure is between 980 et
1000 mb.
1 Solenoid feed
2 Position potentiometer feed
3 Not used
4 Position potentiometer earth
5 Solenoid earth control
6 Position potentiometer signal
14-3
716
STARTING - CHARGING
Starter 16
REMOVAL Disconnect the two electrical connectors from the
starter motor.
Remove the two mountings from the starter motor (B).
Remove:
the front right driveshaft,
the air filter unit,
the oxidation catalyser mountings,
the two mounting struts of the oxidation catalyser,
the driveshaft (on the right side only),
the oxidation catalyser,
REFITTING
Refit in reverse order to removal.
Position the starter motor correctly with the centring

device.
the two mounting bolts on the support of the

thermoplunger unit (A),
16-1
STARTING - CHARGING
Starter 16
Type Engine Starter
XB07 K9K Mitsubishi MOT. 86181
16-2
STARTING - CHARGING
Alternator 16
IDENTIFICATION:
Type Engine Alternator Current
Mitsubishi: A002TB6481 110 A

XB07 K9K
Valo: SG12B038 125 A
CHECKING
After 15 minutes warming up with a voltage of 13.5 volts.
Rpm 110 amps 125 Amps
800 - 64
1000 57 -
2000 94 81
3000 105 -
4000 82 118
6000 - 123
16-3
STARTING - CHARGING
Alternator 16
REMOVAL
Disconnect the battery and all electrical connections on the alternator.
Remove:
the accessories belt (see section 07 "Accessories belt tension"),
the alternator mounting bolts.
NOTE: the lower bolt cannot be completely released, you have to swivel the alternator towards the front to
remove it.
REFITTING
Refitting is the reverse of removal.
Refer to section 07 "Accessories belt tension" for the belt tensioning procedure.
NOTE: the inner tooth (on the engine side) of the air conditioning compressor and crankshaft pulleys must
remain free.
16-4
819
COOLING SYSTEM
Radiator 19
Mot. 1448 Remote operation clip pliers for

cooling system hose clips
The removal and refitting of the radiator presents no REFITTING

particular difficulty.
Refit in reverse order to removal.
REMOVAL NOTE: ensure that the fins of the radiator or of the

condenser (if fitted) are not damaged when
Put the car on a two-post lift. removing-refitting, and protect them if necessary.
Disconnect the battery. Fill and bleed the cooling circuit (see section 19
"Filling - bleeding").
Remove the engine undertray.
Drain the cooling circuit through the lower radiator

hose.
Unclip the diesel filter unit and remove it.
Remove:
the air intake sleeve,
the connectors of the fan unit,
the fan assembly support wiring,
the upper radiator hose,
the radiator grille,
the upper radiator mountings,
the radiator.
19-1
COOLING SYSTEM
Filling and bleeding 19
There is no heater matrix water control valve.
Coolant flow is continuous in the heater matrix, which

contributes to the cooling of the engine.
FILLING
Check the tightening of the drain plugs.
Open the two bleed screws.
Fill the circuit through the expansion bottle opening.
Close the bleed screws as soon as the liquid starts to

flow in a continuous stream.
Start the engine (2 500 rpm).
Adjust the level by overflow for a period of about

4 minutes.
Close the bottle.
BLEEDING
Allow the engine to run for about 10 minutes at

2500 rpm, until the fans operate (time necessary for
automatic degassing).
Verify that the liquid level is at or near the "Maximum"

marker.
DO NOT OPEN THE BLEED SCREW(S) WHILE THE

ENGINE IS RUNNING.
RE-TIGHTEN THE EXPANSION BOTTLE CAP

WHILE THE ENGINE IS WARM.
19-2
COOLING SYSTEM
K9K
Diagram 19
1 Engine
2 Radiator 9 Coolant pump
3 Hot bottle with degassing after thermostat
4 Heater matrix 10 Thermostat
5 Thermostat mounting
6 Fitting 3 mm 11 Bleed screw
12 Temperature switch
The expansion bottle valve rating is 1.2 bar (colour

brown).
19-3
EXHAUST
Exhaust pipe 19
DIAGRAM OF THE EXHAUST PIPE AND LOCATION OF THE CUTTING AREA
K9K engine
1 Silencer
ZC Pipe cutting area
19-4
EXHAUST
Catalytic converter 19
TIGHTENING TORQUES (in daN.m)
Exhaust pipe clamp 2.1

Exhaust downpipe mounting nuts 2.1
Exhaust downpipe mounting studs 1
Catalytic converter rear mounting bolts 2.1
Catalytic converter side strut mounting
2.5
bolts
Engine side strut mounting bolts 4.4
Nuts securing catalytic converter to the
2.6
turbocharger
Turbocharger outlet studs 0.9
REMOVAL
Disconnect the battery then remove the front right

hand wheel.
Remove:
the engine undertray
the engine cover,
Disconnect:
sensor (1).
Release the turbocharging pressure sensor (2) from

the air filter unit.

unit.
Remove:
the air filter unit (3),
the four nuts (4) securing the catalytic converter to
the turbocharger.
19-5
EXHAUST
Catalytic converter 19
From the side Remove:
the side strut from the catalytic converter (6),
Remove the front right driveshaft, to do this: the mounting bolt (7) from the catalytic converter on
remove the clip from the mudguard screen to gain the rear strut,
access to the ABS sensor connector, catalytic converter.
disconnect the ABS sensor connector,
remove the brake caliper then hang it in the wheel
arch,
uncouple the steering ball joint,
remove the lower ball joint bolt,
remove the bolts of the shock absorber base,
remove the driveshaft.
From below:
Remove the exhaust pipe, to do this:

loosen the clamp,
remove the two mounting nuts (5) from the catalytic
converter,
release the exhaust pipe.
REFITTING
Fit the catalytic converter then position the lower

mounting bolts.
Torque tighten:
the nuts securing the catalytic converter to the
turbocharger
the lower mountings.
Replace:
the exhaust pipe clamp,
the exhaust bracket seal.

plastic pipes.
For the rest of the refitting operation, refitting is the

reverse of removal.
Tighten all the mountings to the recommended

torques.
19-6
ENGINE MOUNTING
Suspended engine mountings 19
A 2.1
B 3.7
C 6.2
D 10.5
19-7

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T.N.

Special features of Clios fitted with K9K

This note cancels and replaces Technical Note 3458A

77 11 301 382 JUNE 2001 EDITION ANGLAISE

07 VALUES AND SETTINGS 13 DIESEL EQUIPMENT

19 COOLING - EXHAUST - FUEL TANK

SPECIAL TOOLING REQUIRED

Mot. 1505 Belt tension setting tool

NOTE: the accessories belt has five Vs, while the

The tension value is 233 5 Hertz.

For all other operations, refitting is the reverse of

REMOVAL NOTE: the accessories belt has five Vs whilst the

After refitting the accessories belt make sure to turn

For all other operations, refitting is the reverse of

REMINDER: Use a syringe to remove any oil which

All bolts must always be changed after removal.

Do not oil the new bolts.

All bolts must be tightened to a torque of 2.5 daN.m in

Check that all the bolts are tightened to 2.5 daN.m,

Do not retighten the cylinder head bolts after

Mot.1233-01 Threaded rods for lowering the sub-

SPECIAL NOTES FOR VEHICLES FITTED WITH A

the gearbox control (on the gearbox side only),

Top up the engine oil.

Proceed with refitting in the reverse order to removal

Take care to fit the oil anti-emulsion plate in the sump.

Mot. 836-05 Oil pressure gauge kit

The oil pressure should be checked when the engine

Contents of kit Mot. 836-05.

Connect the pressure gauge in place of the oil

Tighten the oil pressure switch to a torque of

Cubic Bore Stroke Compression

XB07 K9K JB3 1461 76 80.5 18.25/1

Manual to consult: Mot. K9K

Mot.1040-01 Support cradle for removal/

Secure the vehicle to a lift with a strap to prevent the

(See Technical Note 2988A for the procedure for

Remove the battery and the engine undertray.

Unclip the diesel filter from its support and disconnect

REMINDER: in this case, only qualified

Disconnect the hoses from the heater radiator.

Remove the engine suspension mounting-movement

Insert a wooden block between the gearbox and the

Slacken the nut (1), then tap it with a copper hammer

NOTE: when undertaking work that requires the

The alignment of the sub-frame with the body will be

Tighten the sub-frame mounting bolts to a torque of:

Proceed with refitting in the reverse order to removal

Apply Loctite FRENBLOC to the brake calliper

Press the brake pedal several times to bring the

Perform the following operations:

Mot. 1430 Camshaft pulley timing pin

the accessories belt (see section 07 Accessories

Put the car on a two-post lift.

the pulley-pump position sensor

the TDC pin cap.

The pin Mot. 1430 must engage in the camshaft pulley

Remove tools Mot. 1430 and Mot. 1489.

Slacken the timing belt by loosening

Ensure that the peg (7) of the

Engage the TDC pin Mot. 1430 in

Refit the crankshaft accessories pulley, tightening the

Turn the crankshaft two full turns in a clockwise