Renault Clio: Diesel return pipe: Removal - Refitting
K9K, and 764 or 772
IMPORTANT
Consult the safety instructions and cleanliness
advice and the operation recommendations before
carrying out any repairs (see Diesel injection:
Repair precautions).
IMPORTANT
Before carrying out any work on the injection system,
check using the Diagnostic tool :
- that the rail is not under pressure,
- that the fuel temperature is not too high.
Working on the circuit with the engine running is
strictly forbidden.
IMPORTANT
Be careful when removing the injectors or the injection
rail as there will be a quantity of fuel in the rail
and the union.
IMPORTANT
Loosening a high pressure pipe union when the
engine is running is strictly prohibited.
REMOVAL
I - REMOVAL PREPARATION OPERATION
- Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
- Switch off the ignition and wait 30 seconds before
starting work on the injection system.
- Disconnect the battery (see Battery: Removal - Refitting)
(80A, Battery).
- Remove the engine undertray.
- Remove the air inlet sleeve (1).
- Disconnect the inlet pressure sensor connector (2).
- Remove:
- the intercooler air outlet pipe,
- the air pipe at the intercooler inlet,
- the turbocharger outlet air pipe.
- Unclip the rail protector cover at (3).
- Remove:
- the rail protector cover bolts,
- the rail protector cover.
- Protect the alternator from fuel outflow.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
- Disconnect the diesel temperature sensor connector (4).
- Clean the diesel return union (5) on the high pressure pump (see 13B,
Diesel injection, Diesel injection: Precautions for the repair, 13B-1).
- Disconnect the diesel return union (5) from the high
pressure pump.
Note:
Make preparations for the fuel outflow.
- Fit blanking plugs to:
- the diesel return pipe,
- the high pressure pump.
- Clean the diesel return unions (6) on the injectors (see 13B, Diesel
injection, Diesel injection: Precautions for the repair, 13B-1).
First stage in removing the injector fuel return
unions
- Using a fine flat-blade screwdriver, push the lower
tabs (7) of the injector fuel return union clips towards
the rocker cover in order to unfasten them and fully
fit them on the rocker cover.
Note:
Take care not to dislodge the clip fully from its
housing in case it becomes damaged when
extracting the diesel return union.
Any clips that become completely separated
from a diesel injector that has not been removed
must always be replaced: to do this, it is essential
that the diesel injector in question is removed
(see 13B, Diesel injection, Diesel injector:
Removal - Refitting, 13B-83) (13B, Injection).
Second stage in removing the injector fuel return
unions
- Using a fine flat-blade screwdriver, push down (A)
on the lower tabs of the clips, which were first resting
on the rocker cover, without separating them fully
from their injectors.
- Manually remove the injector diesel return unions at
(B), while pressing (A) on the lower tabs of the
clips using a fine flat-blade screwdriver.
Note:
With sufficient force applied to the clip while
pressing continuously with the screwdriver, the
injector diesel return unions will come out effortlessly.
WARNING
Do not use the screwdriver as a lever on the
injector fuel return unions.
- Fit blanking plugs on:
- the diesel return unions on the injectors,
- the diesel return openings on the injectors.
- Unclip the diesel return pipe from the rocker cover at (8).
- Remove the diesel return pipe.
Note:
If the diesel return pipe is to be reused, keep it in
a sealed bag throughout the removal operation.
REFITTING
I - REFITTING PREPARATION OPERATION
WARNING
Only remove the blanking plugs from the protected
components at the last possible moment.
Also, do not remove the components from their
packaging until just before fitting them to the
vehicle.
II - REFITTING OPERATION FOR PART
CONCERNED
WARNING
Check the condition of the seals on the fuel
return unions on the injectors.
Check that they are not cut, crushed and have
not come out of their grooves.
Replace the entire diesel return pipe if one of the
components is damaged.
- Push the retaining clips for the diesel return unions
on the injectors towards the front of the vehicle until
they are in their original positions.
- Remove the blanking plugs from the injector fuel return
openings, and discard.
- Remove the diesel return pipe from its packaging.
- Lubricate the injector diesel return unions with SILICONE
FREE LUBRICANT (see Vehicle: Parts
and consumables for the repair) (04B, Consumables
- Products) so that the seals are completely
covered.
- Offer up the diesel return unions to the injector diesel return
openings, starting with injector number 4 (9).
- Clip the injector diesel return unions onto the injectors,
starting with injector number 4.
Note:
Check that the diesel return unions are clipped
on properly.
- Clip the fuel return pipe onto the rocker cover.
III - FINAL OPERATION.
- Connect the diesel temperature sensor connector.
- Refit:
- the rail protector cover,
- the intercooler air outlet pipe,
- the air pipe at the intercooler inlet,
- the turbocharger outlet air pipe.
- Torque tighten the intercooler inlet air pipe nut on
the alternator (8 Nm.)
- Refit the engine protector.
- Reprime the fuel circuit using the priming bulb.
- Connect the battery (see Battery: Removal - Refitting)
(80A, Battery).
- Check the high pressure circuit (see 13B, Diesel injection,
High pressure pipe: Check, 13B-99)
(13B, Injection).
READ NEXT:
K9K, and 764 or 772
WARNING
Before starting work on the vehicle, obtain:
a new blanking plug kit (part no. 77 01 476 857),
cleaning wipes (part no. 77 11 211 707),
cleaning product (part no. 77 1
K9K, and 764 or 772
WARNING
Before starting work on the vehicle, make sure you
have:
a new blanking plug kit (part no. 77 01 476 857),
cleaning wipes (part no. 77 11 211 707),
cleaning product (p
K9K, and 764 or 772
WARNING
Before starting work on the vehicle, have to hand:
a new blanking plug kit (part no. 77 01 476 857),
cleaning wipes (part no. 77 11 211 707),
cleaning product (part no
SEE MORE:
Once the engine is switched off, you
will see “Journey record” displayed on
the screen 3, enabling you to view information
relating to your last journey.
This indicates:
average fuel consumption;
number of miles/kilometres travelled;
number of miles/kilometres saved.
An over
LEFT-HAND DRIVE, and WITHOUT ANTI-LOCK BRAKING SYSTEM
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 392, 02A, Lifting equipment).
Remove:
the engine cover,
the engine undertray,
the air filter box air inlet pipe,
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