Renault Clio: Flow actuator: Removal - Refitting

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Diesel Injection / Flow actuator: Removal - Refitting

K9K, and 750 or 752 or 766 or 768

IMPORTANT

Before carrying out any work on the injection system, check using the Diagnostic tool :

• that the injector rail is not under pressure,
• that the fuel temperature is not too high.

It is essential to respect the safety and cleanliness advice whenever work is carried out on this system.

Loosening a high pressure pipe union when the engine is running is strictly prohibited.

WARNING

Before starting work on the vehicle, obtain:

• a new blanking plug kit (part no. 77 01 206 804),
• cleaning cloths (part no. 77 11 211 707),
• cleaning product (part no. 77 11 224 188).

WARNING

Parts which must always be replaced:

• all the high pressure pipes which have been removed.

Note: Vehicles equipped with the K9K*768 engine may or may not be equipped with an intercooler.

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Disconnect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Remove the front engine cover.

• Disconnect the inlet air pressure sensor (1).

K9K, and 750 or 766 or 768

• Remove the upper section of the turbocharger air duct (2).
• Loosen the clip (3).
• Move the inlet air duct to one side (4).

• Remove:
  • the dipstick,
  • the dipstick duct bolts.
• Move the dipstick duct to one side.
• Unclip the upper section of the injector rail protector.
• Unscrew the upper section of the injector rail protector.
• Remove:
  • the injector rail protector,
  • Remove the high pressure pump protector plate.
• Protect the alternator from fuel outflow.
• Pour cleaning product into a container.

IMPORTANT

Wear protective gloves when using cleaning product.

• Soak the brush with cleaning product, then clean the diesel supply and return pipe unions on the high pressure pump.
• Blast the cleaned areas with compressed air then dry using new cloths.

IMPORTANT

Wear protective glasses.

WARNING

Do not blow compressed air once the fuel circuit is open, otherwise impurities may enter the system.

Use cloths if necessary.

• Disconnect:
  • the heater plugs on cylinders no. 3 and 4,
  • the injector connectors from cylinders no. 3 and 4 (5),
  • the diesel supply and return pipes (6),
  • the high pressure pump electrical connectors.
• Fit the correct blanking plugs on:
  • the high pressure pump,
  • the pipes.

• Disconnect:
  • the diesel temperature sensor,
  • the flow actuator.
• Remove the high pressure pipe (7) between the rail and injector no.4.
• Fit the correct blanking plugs on:
  • the rail,
  • the injector.

II - REMOVAL OF THE PART CONCERNED

• Loosen the two bolts (8) from the fuel flow actuator.
• Withdraw the fuel flow actuator (by hand using small successive turns).

WARNING

Do not use the electrical connector as a lever arm.

REFITTING

I - REFITTING PREPARATION OPERATION

WARNING

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

• Only unpack the new component when you are ready to fit it.

WARNING

Do not damage the seal when refitting.

Note: Do not lubricate the actuator seals with grease or used diesel oil. Use the applicator provided in the kit for the new part.

II - REFITTING PART CONCERNED

• Fit the actuator.
• Screw on the two actuator bolts without tightening them.
• Tighten to torque the two fuel flow actuator mounting bolts (5.5 N.m) using a torque wrench.

III - FINAL OPERATION

• Fit a new high pressure pipe to injector no. 4 and a new clip.
• Torque tighten the high pressure pipe unions (24 N.m) using the (Mot. 1566) or (Mot. 1746).
• Connect:
  • the high pressure pump electrical connectors,
  • the diesel supply and return pipe,
  • the injector connectors from cylinders no. 3 and 4,
  • the heater plugs.
• Refit:
  • the high pressure pump protector plate,
  • the upper section of the injector rail protector,
  • the dipstick pipe.
• Refit the air inlet duct.
• Connect the inlet air pressure sensor.

K9K, and 750 or 766 or 768

• Loosen the intercooler inlet air pipe nut on the alternator.
• Fit the air duct between the turbocharger and the intercooler air inlet pipe.
• Lock the air duct onto the turbocharger and the intercooler inlet air pipe.
• Tighten the bolt of the air duct on the rocker cover.
• Tighten the intercooler air inlet pipe nut on the alternator (8 N.m).

• Refit the engine cover.
• Connect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Check that there are no diesel leaks:
  • Check the sealing after repair (see 13B, Diesel injection, High pressure pipe: Check, 13B- 99).
  • Let the engine run at idle speed until the engine cooling fan starts to operate.
  • Accelerate several times at no load.
  • Switch off the ignition.
  • Check that there is no diesel fuel escaping.

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