change RENAULT KANGOO 2013 X61 / 2.G Diesel DCM 1.2 Injection Workshop Manual

1Engine and peripherals
V1 MR-376-X76-13B000$TOC.mif
V1
13B
"The repair procedures given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
The procedures may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from
which his vehicles are constructed."
V1
All rights reserved by Renault s.a.s.
Edition Anglaise
Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of
Renault s.a.s.
© Renault s.a.s. 2013
DIESEL INJECTION
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
Fault finding – Introduction 13B - 2
Fault finding – Cleanliness guidelines 13B - 7
Fault finding – System operation 13B - 10
Fault finding – Replacement of components 13B - 17
Fault finding – Configurations and programming 13B - 21
Fault finding – Fault summary table 13B - 22
Fault finding – Interpretation of faults 13B - 25
Fault finding – Conformity check 13B - 119
Fault finding – Status summary table 13B - 135
Fault finding – Interpretation of statuses 13B - 136
Fault finding – Parameter summary table 13B - 141
Fault finding – Interpretation of parameters 13B - 143
Fault finding – Command summary table 13B - 145
Fault finding – Customer complaints 13B - 148
Fault finding – Fault Finding Chart 13B - 150
Fault finding – Tests 13B - 186

13B-5V1 MR-376-X76-13B000$010.mif
DIESEL INJECTION
Fault finding – Introduction13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
4. FAULT FINDING PROCEDURE (continued)
Wiring check
Fault finding problems
Disconnecting the connectors and/or manipulating the wiring may temporarily clear the cause of a fault.
Electrical measurements of voltage, resistance and insulation are generally correct, especially if the fault is not
present when the analysis is made (stored fault).
Visual inspection
Look for damage under the bonnet and in the passenger compartment.
Carefully check the fuses, insulators and wiring harness routing.
Look for signs of oxidation.
Physical inspection
When handling the wiring, use the diagnostic tool to detect any change in the status of the faults from "stored" to
"present".
Make sure that the connectors are firmly secured.
Apply light pressure to the connectors.
Twist the wiring harness.
If there is a change in status, try to locate the source of the fault.
Inspection of each component
Disconnect the connectors and check the appearance of the clips and tabs, as well as the crimping (no crimping on
the insulating section).
Make sure that the clips and tabs are properly locked in the sockets.
Check that the clips or tabs have not been bent back during connection.
Check the clip contact pressure using an appropriate model of tab.
Resistance check
Check the continuity of entire lines, then section by section.
Look for a short circuit to earth, to + 12 V or with another wire.
If a fault is detected, repair or replace the wiring harness.

13B-13V1 MR-376-X76-13B000$030.mif
DIESEL INJECTION
Fault finding – System operation13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
Function: Air flow management
EGR valve control
The EGR system (Exhaust gas recirculation) comprises a proportional EGR valve, with a built-in valve position
feedback potentiometer. The EGR valve position is controlled by the potentiometer in a closed loop and/or by
changes in the estimated air flow.
Special feature of the K9K796 Euro 2 engine (Indonesia): The EGR solenoid valve is present on the vehicle, but not
used. It always remains closed. It must not be replaced on this vehicle (unless there is a mechanical fault).
Calculating the air flow
K9K 790 and 794 engines are not fitted with an air flowmeter. Instead, the amount of fresh inlet air is evaluated
based on the values supplied by the surrounding systems.
The (theoretical) air load is calculated using a model with various calculation parameters, which are:
– the inlet air temperature measured by a sensor located after the turbocharger and/or after the exchanger (if fitted),
– the turbocharging pressure,
– the atmospheric pressure (external air),
– the EGR valve position,
– the fuel flow,
– the engine speed.
The atmospheric pressure sensor is optional. If fitted, it sends back a signal relating to the atmospheric pressure to
an analogue port on the micro-controller. If not, atmospheric pressure is recovered based on the turbocharger
pressure and the engine field.
For K9K 792 and 796 engines, the flow of fresh air entering the engine is measured by a hot-wire ratiometric sensor.
This flowmeter is used to manage the amount of exhaust gas to be recirculated to ensure optimum recirculation
rates. A fresh air temperature sensor is integrated into the flowmeter. Air flow measurement allows closed-loop
control via the EGR valve.
Turbocharger control
K9K 796 engine:
The turbocharging system is made up of a solenoid valve which is used to control the wastegate to adjust the
absolute pressure of the inlet circuit.
K9K 790, 792, 794 engines:
The turbocharger system is controlled by the inlet pressure and does not need to be controlled by the computer.
Pre-postheating actuation
Pre-postheating actuation consists of controlling the heater plugs and the preheating warning light on the instrument
panel. The heater plugs are activated by a preheating unit (controlled by the injection computer), and the power is
supplied by the battery. After the ignition is switched on a preheating delay is activated. The indicator light comes on
for the activation period which is dependent on the battery voltage, atmospheric pressure and coolant temperature.
If the temperature is below a certain threshold, a postheating function can be used to improve the combustion
stability, and consequently engine operation (reducing unburnt particles and pollutant emissions).

13B-28
AFTER REPAIRDeal with any faults declared by the diagnostic tool.
Clear the computer memory.
Carry out a road test followed by another check with the diagnostic tool.
V1 MR-376-X76-13B000$071.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
DF003
PRESENT
OR
STOREDATMOSPHERIC PRESSURE SENSOR CIRCUIT
CO.0: Open circuit or short circuit to earth
CC.1: Short circuit to +12 V
NOTESSpecial notes:
The atmospheric pressure sensor is built into the injection computer.
Use the Wiring Diagrams Technical Note for Logan, Sandero, Duster, Thalia 2/
Symbol 2 or Kangoo VLL.
Look for any wiring harness damage and check the condition and connection of the injection computer connectors,
component code 120.
Check the connection and condition of the injection locking relay connector.
If the connectors are faulty and if there is a repair procedure (see Technical Note 6015A (Renault) or Technical
Note 9804A (Dacia), Electrical wiring repair, Wiring: Precautions for repair), repair the connector, otherwise
replace the wiring.
Move the wiring harness between the injection computer and the battery, component code 107 to see if a change
of status occurs (Present  Stored).
Look for any damage to the wiring and check the connection and condition of the battery and its connections.
If the connector is faulty and there is a repair procedure (see Technical Note 6015A (Renault) or Technical Note
9804A (Dacia), Electrical wiring repair, Wiring: Precautions for repair), repair the connector, otherwise replace
the wiring.
Measure the battery voltage when the ignition is switched on.
If the battery voltage is less than 11 V, recharge the battery (see Technical Note 6014A (Renault) or Technical
Note 9859A (Dacia), Checking the charging circuit).
Check the condition and connection of the battery terminals and posts.
DCM1.2_V08_DF003

13B-69
AFTER
REPAIRDeal with any faults declared by the diagnostic tool.
Clear the computer memory.
Carry out a road test followed by another check with the diagnostic tool.
V1 MR-376-X76-13B000$072.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
DF047
PRESENT
OR
STOREDCOMPUTER SUPPLY VOLTAGE
1.DEF: Above maximum threshold
2.DEF: Below minimum threshold
NOTESConditions for applying the fault finding procedure to a stored fault:
The fault is declared present with the engine running at over 1000 rpm.
Special notes:
Use the Wiring Diagrams Technical Note for Logan, Sandero, Duster, Thalia 2/
Symbol 2 or Kangoo VLL.
Move the wiring harness between the injection computer, component code 120 and the battery, component code
107 to see if a change of status occurs (Present
 Stored).
Look for any damage to the wiring harness and check the connection and condition of the battery and its
connections.
If the connectors are faulty and if there is a repair procedure (see Technical Note 6015A (Renault) or Technical
Note 9804A (Dacia), Electrical wiring repair, Wiring: Precautions for repair), repair the connector, otherwise
replace the wiring.
Measure the battery voltage when the ignition is switched on.
If the battery voltage is less than 11 V, recharge the battery.
Check the condition and connection of the battery terminals and posts.
Check the charging circuit of the vehicle (see Technical Note 6014A (Renault) or Technical Note 9859A (Dacia),
Checking the charging circuit).
DCM1.2_V08_DF047

13B-71
AFTER
REPAIRDeal with any faults declared by the diagnostic tool.
Clear the computer memory.
Carry out a road test followed by another check with the diagnostic tool.
V1 MR-376-X76-13B000$072.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
DF049
PRESENT
OR
STOREDREFRIGERANT SENSOR CIRCUIT
CO.1: Open circuit or short circuit to + 12 V
CC.0: Short circuit to earth
NOTESConditions for applying the fault finding procedure to a stored fault:
Apply the fault finding procedure below if the fault is present or stored.
Priority when dealing with a number of faults:
– DF113 Sensor supply voltage.
Special notes:
Use the Wiring Diagrams Technical Note for Logan, Sandero, Duster, Thalia 2/
Symbol 2 or Kangoo VLL.
Display PR037 Refrigerant pressure; if the value is less than 2 bar, top up the refrigerant fluid (see MR 388
(Logan/Sandero), MR 423 (Thalia 2/Symbol 2), MR 451 (Duster), or MR 374 (Kangoo VLL), Mechanical, 62A,
Air conditioning, Refrigerant circuit: Draining – Filling).
Move the wiring harness between the injection computer, component code 120 and the refrigerant pressure
sensor, component code 1202 to see if the status changes (present
 stored).
Look for any damage to the wiring and check the condition and connection of the refrigerant pressure sensor and
its connections.
If the connector is faulty and if there is a repair procedure (see Technical Note 6015A (Renault) or Technical
Note 9804A (Dacia), Electrical wiring repair, Wiring: Precautions for repair), repair the connector, otherwise
replace the wiring.
Check the connection and condition of the injection computer connector, component code 120.
If the connector is faulty and if there is a repair procedure (see Technical Note 6015A (Renault) or Technical
Note 9804A (Dacia), Electrical wiring repair, Wiring: Precautions for repair), repair the connector, otherwise
replace the wiring.
DCM1.2_V08_DF049

13B-74
AFTER
REPAIRDeal with any faults declared by the diagnostic tool.
Clear the computer memory.
Carry out a road test followed by another check with the diagnostic tool.
V1 MR-376-X76-13B000$072.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
DF052
PRESENT
OR
STOREDINJECTORS CONTROL CIRCUIT
CC.1: Short circuit to + 12 V
CC.0: Short circuit to earth
NOTESPriorities when dealing with a number of faults:
In the event of a combination of faults DF052,
– DF026 Cylinder 1 injector circuit control,
– DF027 Cylinder 2 injector circuit control,
– DF028 Cylinder 3 injector circuit control, and
– DF029 Cylinder 4 injector circuit control.
The fault finding procedure remains the same for DF026 to DF027 which is used to
identify the faulty injector.
Special notes:
When the fault appears, there is engine noise, unstable engine speed, reduced engine
performance and the level 2 warning light comes on.
Use the Wiring Diagrams Technical Note for Logan, Sandero, Duster, Thalia 2/
Symbol 2 or Kangoo VLL.
Switch off the ignition.
Check the condition and connection of the injector connectors, component codes 193, 194, 195 and 196.
Check the connection and condition of the injection computer connector, component code 120.
If the connectors are faulty and if there is a repair procedure (see Technical Note 6015A (Renault) or Technical
Note 9804A (Dacia), Electrical wiring repair, Wiring: Precautions for repair), repair the connector, otherwise
replace the wiring.
Switch off the ignition.
Disconnect the injectors (or the injector identified by DF026, DF027, DF028 and DF029) and switch on the ignition
again.
Using the diagnostic tool, check for changes to DF052.
Is DF052 present or stored?
DCM1.2_V08_DF052

13B-91
AFTER
REPAIRDeal with any faults declared by the diagnostic tool.
Clear the computer memory.
Carry out a road test followed by another check with the diagnostic tool.
V1 MR-376-X76-13B000$072.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
DF113
PRESENT
OR
STOREDSENSOR SUPPLY VOLTAGE
1.DEF: At minimum stop
2.DEF: At maximum stop
NOTESSpecial notes:
If fault DF113 is present: immediate engine stop and restarting impossible. Level 2
warning light comes on.
Use the Wiring Diagrams Technical Note for Logan, Sandero, Duster, Thalia 2/
Symbol 2 or Kangoo VLL.
Check the condition and connection of the connectors on all sensors with a 5V feed:
– Refrigerant pressure sensor, component code 1202.
– Inlet manifold pressure and temperature sensor, component code 147 or temperature sensor only, component
code 272 and turbocharger pressure sensor, component code 1071.
– Rail pressure sensor, component code 1032.
– Pedal sensor gang 1 and 2, component code 921.
– Exhaust gas recirculation valve position sensor, component code 1460.
– Injection air flow sensor, component code 799.
If the connectors are faulty and if there is a repair procedure (see Technical Note 6015A (Renault) or Technical
Note 9804A (Dacia), Electrical wiring repair, Wiring: Precautions for repair), repair the connector, otherwise
replace the wiring.
Check the condition and connection of the injection computer connectors, component code 120.
If the connectors are faulty and if there is a repair procedure (see Technical Note 6015A (Renault) or Technical
Note 9804A (Dacia), Electrical wiring repair, Wiring: Precautions for repair), repair the connector, otherwise
replace the wiring.
To locate an internal fault on one of the sensors with a + 5 V feed (short circuit), disconnect each of the sensors in
the list above in turn, checking after each disconnection whether the fault changes status from present to stored.
If the faulty sensor is located, check its connections and that it is in order.
If necessary replace the sensor.
DCM1.2_V08_DF113

13B-98
AFTER
REPAIRDeal with any faults declared by the diagnostic tool.
Clear the computer memory.
Carry out a road test followed by another check with the diagnostic tool.
V1 MR-376-X76-13B000$072.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
DF122
PRESENT
OR
STOREDPEDAL POTENTIOMETER GANG 2 SUPPLY VOLTAGE
CO.1: Open circuit or short circuit to + 12 V
CC.0: Short circuit to earth
NOTESSpecial notes:
If fault DF122 is present: immediate engine stop and restarting impossible. Level 2
warning light comes on.
Use the Wiring Diagrams Technical Note for Logan, Sandero, Duster, Thalia 2/
Symbol 2 or Kangoo VLL.
Check the condition and the connection of the pedal sensor, component code 921.
Check the condition and connection of the injection computer connectors, component code 120.
If the connectors are faulty and if there is a repair procedure (see Technical Note 6015A (Renault) or Technical
Note 9804A (Dacia), Electrical wiring repair, Wiring: Precautions for repair), repair the connector, otherwise
replace the wiring.
To locate an internal fault on one of the sensors with a + 5V feed (short circuit), disconnect each of the sensors in
the list above in turn, checking after each disconnection whether the fault changes status from present to stored.
If the faulty sensor is located, check its connections and that it is in order.
If necessary replace the sensor.
Connect the bornier in place of the computer and check the insulation, continuity and absence of interference
resistance on the following connections:
●3LW between components 120 and 921,
●3LV between components 120 and 921,
●3LU between components 120 and 921.
If the connection(s) are faulty and if there is a repair procedure (see Technical Note 6015A (Renault) or
Technical Note 9804A (Dacia), Repairing electrical wiring, Wiring: Precautions for repair), repair the wiring,
otherwise replace it.
If the fault is still present, apply the fault finding procedure for each sensor with a 5 V supply.
DCM1.2_V08_DF122

13B-115
AFTER
REPAIRDeal with any faults declared by the diagnostic tool.
Clear the computer memory.
Carry out a road test followed by another check with the diagnostic tool.
V1 MR-376-X76-13B000$072.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
DF859
PRESENT
OR
STOREDINJECTOR PROGRAMMING CYCLE NOT DONE
NOTESConditions for applying the fault finding procedure to a stored fault:
The fault is considered present when the engine is running.
Priorities when dealing with a number of faults:
– Deal with all the other faults before fault DF859
Special notes:
This fault is activated when the injectors have not been reset for 1800 miles
(3000 km).
Leave the vehicle to run at idle speed until the engine is warm.
When the engine is warm (PR064 COOLANT TEMPERATURE above 77°C), carry out the following test drive:
– Drive at a speed of up to 30 mph (50 km/h) and change into 5th gear.
– Stay in this gear and perform 8 accelerations from 30 mph (50 Km/h) to 54 mph (90 Km/h).
– At the end of driving: without switching off the ignition, allow the vehicle to run at idle speed for at least
10 minutes.
– Switch off the ignition, and wait 30 seconds.
– switch on the ignition, check that the fault is stored and clear the fault.
DCM1.2_V08_DF859