Renault Clio: High pressure pump: Removal - Refitting
K9K, and 764 or 772
WARNING
Before starting work on the vehicle, obtain:
- a new plug kit (PART NO. 77 01 476 857),
- cleaning cloths (PART NO. 77 11 211 707),
- cleaning product (PART NO. 77 11 224 188).
WARNING
Parts always to be replaced:
- the high pressure pipe between the injector rail
and the high pressure pump.
REMOVAL
I - REMOVAL PREPARATION OPERATION
- Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 392, 02A, Lifting equipment).
IMPORTANT
Use the diagnostic tool before any operation is
carried out on the injection circuit to check:
- that the rail is not under pressure,
- that the fuel temperature is not too high.
It is essential to respect the safety and cleanliness
advice whenever work is carried out on this
system.
Working on the circuit with the engine running is
strictly forbidden.
- Disconnect the battery (see Battery: Removal - Refitting)
(MR 392, 80A, Battery).
- Remove:
- the engine protector,
- the engine undertray,
- the timing belt (see 11A, Top and front of engine, Timing belt:
Removal - Refitting, 11A-48).
- Remove the upper part of the turbocharging duct (1).
- Disconnect the inlet air pressure sensor (2)
- Loosen the clip (3).
- Move the inlet duct to one side (4).
- Unclip the clips (5) from the injector rail protector
cover.
- Remove:
- the injector rail protector cover mounting bolts (6),
- the injector rail protector cover (7),
- the dipstick,
- the dipstick tube mounting bolts (8).
- Move the dipstick duct to one side.
- Remove:
- the injector rail protector mounting bolts (9),
- the injector rail protector.
- Protect the alternator from fuel outflow.
- Pour cleaning product into a clean container.
IMPORTANT
Wear protective glasses when using cleaning
product.
- Soak a brush with cleaning product, then clean the
unions:
- of the fuel supply pipe fuel on the high pressure
pump,
- on the high pressure pump fuel return pipe, taking
care not to soak the diesel fuel temperature sensor,
- on the high-pressure pipe and the injector rail.
- Blow compressed air into the cleaned areas, then
wipe them with new wipes.
IMPORTANT
Wear protective glasses.
WARNING
To prevent impurities from entering, once the fuel
circuit is opened, it must not be blasted with compressed
air. Use wipes if necessary.
- Disconnect the high pressure pump from:
- the diesel fuel supply and return pipes (10),
- the fuel pressure regulating valve connector (11),
- the fuel flow regulating valve connector (12).
Note:
Make preparations for fuel outflow. Clean with
new cloths.
- Remove the high-pressure pipe between the high-pressure
pump and the injector rail and discard it.
Note:
Hold the intermediate nut between the pump-rail
pipe and the high pressure pump using a lock
wrench.
- Insert the blanking plugs.
- Remove the lower mounting bolt from the alternator.
- Undo the alternator's upper mounting bolt.
- Tip the alternator towards the front of the vehicle.
- Remove:
- the inner timing cover mounting bolts,
- the inner timing cover.
II - REMOVAL OF PART CONCERNED
- Remove:
- the high-pressure pump mounting bolts (13),
- the high pressure pump.
WARNING
If the high-pressure pump is to be reused, keep it
in a sealed plastic bag all the time it is disconnected.
Remove the high pressure pump pulley
WARNING
If the high-pressure pump is being replaced, take
the high-pressure pump pulley and refit it to the
new pump.
- Hold the high pressure pump in a vice, using the
lower securing point on the pulley side.
WARNING
Fix jaw covers onto the vice to protect the high-pressure
pump.
- Hold the high pressure pump pulley with a 32 mm
offset wrench then remove the mounting nut (14)
from the pulley.
Note:
The high pressure pump pulley can also be held
with a (Mot. 855).
- Fit the tool (Mot. 1768), as well as the tool Mot. 1525
without the spacer at the end of threaded rod, on the
high pressure pump pulley, then extract the pulley.
WARNING
Take care not to mark the high-pressure pump
when removing it.
A damaged high pressure pump pulley must
always be replaced.
REFITTING
I - REMOVAL PREPARATION OPERATION
WARNING
- Remove the blanking plugs only before reconnecting
the fuel circuit pipes.
- The plugs are single-use. Do not reuse them
and throw away the complete kit after opening.
Refitting the high pressure pump pulley
- Remove the injector rail from its plastic bag.
WARNING
If a high pressure pump is being replaced, only
remove the new one from its original packaging
when it is about to be fitted.
- Finger tighten the high-pressure pump pulley mounting
nut as far as possible.
- Hold the high-pressure pump pulley with the previously
used tool.
- Torque tighten the high pressure pump pulley (55
N.m).
II - REFITTING PART CONCERNED
- Remove the injector rail from its plastic bag.
WARNING
If a high pressure pump is being replaced, only
remove the new one from its original packaging
when it is about to be fitted.
- Position the high-pressure pump on the cylinder
head.
- Finger tighten the high-pressure pump mounting
bolts as far as possible.
- Torque tighten the high pressure pump mounting
bolts (21 N.m).
III - FINAL OPERATION
- Fit the new high pressure pipe between the injector
rail and the high pressure pump.
Note:
If the new pipe kit does not contain an applicator,
lubrication of the high-pressure nut threads will
be unnecessary (as they are self-lubricating
pipes).
- Hand-tighten the nut on the high-pressure pipe on
the pump end, then the one on the rail end.
- Tighten to torque the high pressure pipe nuts (24
N.m) using the (Mot. 1746) or (Mot. 1566), starting
with the high pressure pump end.
- Disconnect the high pressure pump from:
- the fuel supply and return pipes,
- the fuel pressure regulating valve connector,
- the fuel flow regulating valve connector,
- Refit:
- the timing belt (see 11A, Top and front of engine, Timing belt:
Removal - Refitting, 11A-48),
- loosen the nut mounting the intercooler air inlet
pipe to 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
air inlet pipe.
- tighten the air duct bolt on the rocker cover,
- torque tighten the nut mounting the intercooler
air inlet pipe on the alternator (8 N.m),
- the engine undertray.
- Connect the battery (see Battery: Removal - Refitting)
(MR 392, 80A, Battery).
K9K, and 750 or 752 or 760 or 762 or 766 or 768
IMPORTANT
Consult the safety and cleanliness advice and operation
recommendations before carrying out any repair (see 13B, Diesel injection,
Diesel injection: Precautions for the repair, 13B-1).
REMOVAL
I - PARTS AND CONSUMABLES FOR THE REPAIR
- Consumables: (see 13B, Diesel injection, Diesel
injection: Precautions for the repair, 13B-1)
- Cleaning cloths,
- Set of K9K blanking plugs (injection DELPHI).
II - REMOVAL PREPARATION OPERATION
- Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
- Disconnect the battery (see Battery: Removal - Refitting)
(80A, Battery).
- Disconnect the inlet air pressure sensor (1)
K9K, and 750 or 766 or 768
- Remove the turbocharger outlet air pipe (2).
- Loosen the clip (3) on the intercooler outlet air pipe.
- Move the intercooler outlet air pipe to one side (4).
- Remove the dipstick.
- Remove the engine oil dipstick guide bolts (5).
- Put the engine oil dipstick guide (6) to one side.
- Remove the diesel fuel splash plate (7).
- Remove the high pressure pump protector (8).
- Disconnect:
- the heater plugs (9),
- the injectors (10).
- Disconnect the connectors on the high pressure pump (11).
- Protect the alternator from fuel outflow.
- Clean the union (12) on the diesel supply pipe high pressure pump (see
13B, Diesel injection, Diesel injection: Precautions for the repair, 13B-1).
- Disconnect the high pressure pump from:
- the diesel supply pipe,
- the diesel return pipe (13) to the fuel filter.
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
- Fit the appropriate blanking plugs on the high pressure
pump and on the pipes.
- Disconnect the diesel supply and return pipes from
the injection rail filler neck then move them away
from the high pressure pump.
- Disconnect:
- the diesel return pipe (14) on the venturi tube fitted
to the high pressure pump,
- the diesel return pipes (15) on the diesel injectors,
- the rail pressure sensor connector (16),
- the accelerometer connector (17),
- the oil level sensor connector (18),
- the cylinder reference sensor (19) connector on the
timing cover.
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
- Fit suitable blanking plugs on:
- the Venturi,
- the diesel injectors.
- Unclip and move aside the electric wiring on the injection
rail filler neck.
- Remove the filler neck on the injector rail.
- Clean the high pressure pipe unions (20) between the pump and the rail
(see 13B, Diesel injection, Diesel injection: Precautions for the repair,
13B-1).
- Remove the high pressure pipe between the pump
and the rail and discard it.
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
- Fit suitable blanking plugs on:
- the high pressure pump,
- the injector rail.
- Remove the right-hand suspended engine mounting
(see 19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, 19D-22) (19D, Engine mounting).
- Raise the vehicle.
- Remove the engine undertray.
- Remove the engine tie-bar.
- Lower the vehicle.
- Lift the engine a few centimetres using the (Mot.1453).
Note:
Do not disconnect the right-hand driveshaft when
raising the engine.
- Unclip the upper timing cover tabs (21).
- Swivel the timing cover in the direction of the arrow.
- Remove the plastic bolt.
- Unclip the three tabs (22).
- Remove the timing cover.
- Remove the suspended mounting from the cylinder
head.
III - OPERATION FOR REMOVAL OF PART
CONCERNED
First fitting
Second fitting
- Position the engine at Top Dead Centre. The camshaft pulley hole (23)
should be opposite the cylinder head hole (24).
Note:
Never turn the engine against its operating direction.
- Insert the (Mot. 1430) (25) in the camshaft pulley
hole and in the cylinder head hole to check that the
engine operates correctly at top dead centre.
- Remove the (Mot. 1430) once the engine is in position.
- Fit the (Mot. 1606) (26) on the cylinder head.
Note:
If necessary, turn the engine slowly to adjust the
position of the (Mot. 1606) on the high pressure
pump pulley teeth.
- Immobilise the high pressure pump pulley with a 32
mm spanner then remove the nut (27) from the pulley.
- Fit the (Mot. 1525) (28) with the (Mot. 1525-02) on
the high pressure pump pulley.
Note:
If necessary, remove the spacer at the end pushrod
of the (Mot. 1525) to improve the positioning.
- Screw the (Mot. 1525) pushrod until it makes contact
with the high pressure pump shaft.
Note:
Check that the (Mot. 1525) pushrod is correctly
orientated and is pressing against the high pressure
pump shaft. adjust the tool if necessary.
- Remove:
- the bolts (29) from the high pressure pump on the
cylinder head,
- the air filter unit bracket (30).
- Gradually screw the pushrod of the (Mot. 1525) until
the high pressure pump becomes detached.
Note:
Guide and support the high pressure pump with
one hand as it is being removed using the (Mot.1525)
- Remove the high pressure pump from the engine
compartment.
Note:
If the high pressure pump is being reused, keep
it in a sealed bag during the removal operation.
- Remove the (Mot. 1525) and (Mot. 1525-02) from
the high pressure pump pulley.
REFITTING
I - PRECAUTIONS FOR REPAIR
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 - PARTS AND CONSUMABLES FOR THE REPAIR
- parts always to be replaced: High pressure pipe
between the pump and rail
III - REFITTING OPERATION FOR PART
CONCERNED
- Check that there is an indexing pin on the high pressure
pump shaft.
- Position the high pressure pump on the cylinder
head whilst inserting it in its pulley.
Note:
Check that the high pressure pump shaft is correctly
orientated in relation to the pulley.
- Fit the air filter unit bracket.
- Tighten the high pressure pump bolts until they
make contact with the cylinder head.
- Tighten to torque and in order the high pressure
pump bolts on the cylinder head (23 N.m).
- Fit the nut on the high pressure pump pulley.
- Torque tighten the high pressure pump pulley nut
(55 N.m) holding the high pressure pump pulley with
a 32 mm spanner.
Note:
Check that the timing belt is operating correctly
and in good condition.
- Remove the (Mot. 1606) from the cylinder head.
IV - FINAL OPERATION.
- Position the suspended mounting on the cylinder
head.
- Tighten the suspended mounting bolts onto the cylinder
head until they make contact.
- Tighten to torque and in order the suspended
mounting bolts on the cylinder head (25 N.m).
- Refit and clip on the lower timing cover.
Note: Make sure that the tab (31) is positioned opposite the mark (32).
- Refit:
- the plastic bolt on the lower timing cover,
- the cylinder position sensor,
- Torque tighten the camshaft position sensor bolt
(8 N.m).
- Refit and clip on the upper timing cover.
- Lower the engine using the (Mot. 1453).
- Fit the right-hand suspended engine mounting with
its bolts.
- Tighten the bolts on the straight suspended engine
mounting until they make contact.
- Torque tighten the right-hand suspended engine
mounting bolts (62 N.m).
- Raise the vehicle.
- Refit the engine tie-bar.
- Torque tighten the engine tie-bar bolts (105 N.m).
- Refit then tighten the protector under the engine.
- Remove tool (Mot. 1453) from the vehicle.
- Lower the vehicle.
WARNING
Before fitting a new high-pressure pipe, lightly
lubricate the nut threads with the oil from the
applicator provided in the new parts kit.
Be careful not to allow oil into the high-pressure
pipe.
Do not lubricate high-pressure pipes supplied
without an applicator, as these high-pressure
pipes are self-lubricating.
- Remove and discard the blanking plugs on:
- the high pressure pump,
- the injector rail.
- Fit a new high pressure pipe between the pump and
the rail.
- Tighten the high pressure pipe unions between the
pump and the rail until contact is made.
- Using the (Mot. 1746), tighten to torque:
- the high pressure pipe unions between the
pump and the yellow rail (24 N.m),
- the high pressure pipe unions between the
pump and the silver rail (28 N.m),
- Refit the neck on the injector rail.
- Clip the wiring to the filler neck on the injector rail.
- Remove and discard the blanking plugs on:
- the Venturi,
- the diesel injectors.
- Connect:
- the cylinder position sensor connector on the timing
cover,
- the oil level sensor connector,
- the accelerometer connector,
- the rail pressure sensor connector,
- the diesel return pipes on the fuel injectors,
- the diesel return pipe to the Venturi attached to the
high pressure pump.
- Clip the high pressure pump diesel supply and return
pipes to the filler neck.
- Remove the blanking plugs from the high pressure
pump and the pipes and discard them.
- Connect to the high pressure pump:
- the diesel return pipe to the fuel filter,
- the diesel fuel supply pipe.
- Remove the protection on the alternator to prevent
fuel flowing out.
- Connect the electrical connectors to:
- the diesel temperature sensor,
- the flow actuator,
- the injectors,
- of the heater plugs.
- Remove the protection on the inlet opening of the oil
level dipstick guide.
- Refit the high pressure pump protection.
- Torque tighten the high pressure pump protection
bolts (21 N.m).
- Refit:
- the diesel splash plate cover,
- dipstick guide ,
- the oil dipstick guide nuts,
- the dipstick.
- Torque tighten the dipstick guide tube nuts (10
N.m).
- Refit the inlet duct.
- Connect the inlet air sensor connector.
K9K, and 750 or 766 or 768
- Loosen the intercooler inlet air pipe nut on the alternator.
- Fit the air pipe on the turbocharger outlet and the air
pipe on the intercooler inlet.
- Click the turbocharger outlet air pipe on the turbocharger
and on the exchanger inlet air pipe.
- Tighten the turbocharger outlet air pipe bolt on the
rocker cover.
- Torque tighten the exchanger inlet air pipe nut on
the alternator (8 N.m).
- Prime the fuel circuit with the manual priming pump
until the disconnected pipes are filled with fuel (automatic
degassing).
- Check that there are no fuel leaks.
- Connect the battery (see Battery: Removal - Refitting)
(80A, Battery).
- Check the high pressure circuit (see 13B, Diesel injection, High
pressure pipe: Check, 13B-99).
- Refit the engine cover.
- Using the diagnostic tool, check for stored faults;
deal with these and clear them as necessary.
V - REPLACING THE HIGH PRESSURE PUMP
- If replacing the high pressure pump, reprime the diesel
circuit using the Diagnostic tool.
Note:
For VDiag numbers before Vdiag 48, it is essential
to reprogram the injection computer. If the
computer is not reprogrammed, do not apply
the procedure described below but prime the
circuit using the manual priming pump.
Note:
Never start the engine until the pump has been
reprimed.
Also comply with the operation instructions provided
to prevent the high pressure pump from
being damaged internally, due to its running
empty and with no diesel lubrication.
- Connect the Diagnostic tool to the vehicle.
- Connect to the diesel injection computer.
- Run command AC212 "NEW PUMP HOUSING
FILLING".
- Follow the instructions on the Diagnostic tool until
the command is completed.
- Start the engine.
Note:
The starting phase can last up to 20 seconds.
- If the engine does not start or if the start-up sequence
is interrupted:
- switch off the ignition,
- wait 30s,
- restart the engine.
- Using the Diagnostic tool, clear any faults stored in
the injection computer.
READ NEXT:
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 temp
K9K, and 750 or 752 or 766 or 768
IMPORTANT
Before carrying out any work on the injection circuit,
check using the Diagnostic tool
that the injector rail is not under pressure,
that the fuel tempe
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).
IMPO
SEE MORE:
FRONT SIDE AIRBAG or FRONT SIDE + CURTAIN AIRBAG
IMPORTANT
Consult the safety and cleanliness advice and operation
recommendations before carrying out any
repair (see 88C, Air bag and Pretensioners, Airbag
and pretensioners: Precautions for the
repair, 88C-6).
REMOVAL
I - REMOVAL PREPARATION OPERAT
Wiping and washing: List and location of components
Passenger compartment
fuse and relay box
Protection and Switching
Unit
Power supply fuse board
UCH
Rain sensor
Wiper switch
Windscreen wiper motor
Rear screen wiper motor
Washer pump
Headlight washer pump
I - PASSENGER COMPARTMENT FUS